Three-Point Bending Properties of Hybrid Multi-Materials Using Adhesive Bonding Dependent on Strength Difference between Steel and Aluminum

The mechanical behaviors of two multi-materials, DP590 (steel sheet)–A356 (cast aluminum alloy) and SS330 (steel sheet)–A5052 (aluminum sheet), were studied. A structural adhesive was used for the joining of steel and aluminum at adhesion strengths of 10, 22, and 30 MPa. To demonstrate that the three-point bending properties depend on the difference in strength between steel and aluminum and adhesion strength, optical microscopy (OM), scanning electron microscopy (SEM), and finite-element analysis (FEA) were performed. According to the results of the bending tests on both multi-materials under the same stacking conditions, the flexural stress increased with the improvement in the adhesion strength until interface separation or aluminum fracture. At the same adhesion strength, the DP590 (lower)–A356 (upper) and SS330 (upper)–A5052 (lower) configurations exhibited a tendency to decrease in the sudden stress drop due to aluminum fracture and interface separation. The bending results were analyzed through the FEA and the stress distribution as a function of the stacking and adhesion strength was confirmed.