PSI - Issue 82

Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2026) 000–000 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2026) 000–000

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ScienceDirect

Procedia Structural Integrity 82 (2026) 206–212

© 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSID organizers © 2026 The Authors. Copy from the contract: Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSID organizers Single-lap bonded joints are widely used in structural applications that require lightweight design, efficient load transfer, and material compatibility. This study investigates the fatigue performance of adhesively bonded DC01 steel and unprocessed aluminum plates with adhesive thicknesses of 1 mm, 2 mm, and 3 mm. A cataphoresis (KTL)-coated DC01 steel plate was bonded to unprocessed aluminum using a structural adhesive under controlled conditions. Fatigue tests were conducted to compare the influence of adhesive thickness on joint durability. Load levels, number of cycles to failure, and failure modes were systematically examined. Although the fatigue lives across specimens with different adhesive thicknesses were relatively close, distinct differences in fracture behavior were observed. The variation in adhesive thickness significantly influenced crack initiation and propagation mechanisms. These findings underscore the importance of adhesive thickness in the design optimization of joints, highlighting how variations in joint geometry and adhesive layer can significantly influence fatigue resistance. © 2026 The Authors. Copy from the contract: Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSID organizers Single-lap bonded joints are widely used in structural applications that require lightweight design, efficient load transfer, and material compatibility. This study investigates the fatigue performance of adhesively bonded DC01 steel and unprocessed aluminum plates with adhesive thicknesses of 1 mm, 2 mm, and 3 mm. A cataphoresis (KTL)-coated DC01 steel plate was bonded to unprocessed aluminum using a structural adhesive under controlled conditions. Fatigue tests were conducted to compare the influence of adhesive thickness on joint durability. Load levels, number of cycles to failure, and failure modes were systematically examined. Although the fatigue lives across specimens with different adhesive thicknesses were relatively close, distinct differences in fracture behavior were observed. The variation in adhesive thickness significantly influenced crack initiation and propagation mechanisms. These findings underscore the importance of adhesive thickness in the design optimization of joints, highlighting how variations in joint geometry and adhesive layer can significantly influence fatigue resistance. Keywords: DC01 steel; fatigue performance; single-lap joints; adhesive bonding; aluminum bonding; hybrid joints; adhesive thickness Keywords: DC01 steel; fatigue performance; single-lap joints; adhesive bonding; aluminum bonding; hybrid joints; adhesive thickness 8th International Conference on Structural Integrity and Durability (ICSID2025) * Influence of Adhesive Thickness on The Fatigue Performance of Single-lap Bonded DC01–Aluminum Joints Celalettin Baykara a , Ibrahim T. Teke b, c *, Mustafa Akbulut d , Ahmet H. Ertas c a Department of Mechanical Engineering, Sakarya University of Applied Sciences, Sakarya, Türkiye b Department of Mechanical Engineering, Haliç University, Istanbul, Türkiye 8th International Conference on Structural Integrity and Durability (ICSID2025) * Influence of Adhesive Thickness on The Fatigue Performance of Single-lap Bonded DC01–Aluminum Joints Celalettin Baykara a , Ibrahim T. Teke b, c *, Mustafa Akbulut d , Ahmet H. Ertas c a Department of Mechanical Engineering, Sakarya University of Applied Sciences, Sakarya, Türkiye b Department of Mechanical Engineering, Haliç University, Istanbul, Türkiye c Department of Mechanical Engineering, Bursa Technical University, Bursa, Türkiye d Department of Mechanical Engineering, Istanbul Aydin Universiy, Istanbul, Türkiye c Department of Mechanical Engineering, Bursa Technical University, Bursa, Türkiye d Department of Mechanical Engineering, Istanbul Aydin Universiy, Istanbul, Türkiye Abstract Abstract

* Corresponding author. E-mail address: ibrahimtalhateke@halic.edu.tr, ibrahimtekeiu@gmail.com * Corresponding author. E-mail address: ibrahimtalhateke@halic.edu.tr, ibrahimtekeiu@gmail.com

2452-3216 © 2026 The Authors. Copy from the contract: Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSID organizers 2452-3216 © 2026 The Authors. Copy from the contract: Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSID organizers

2452-3216 © 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSID organizers 10.1016/j.prostr.2026.04.032