Cavitation and crack nucleation in thin hyperelastic adhesives

The present study investigates in the failure of adhesive bondings with structural silicone sealants. Point connectors of two circular metal adherends bonded with DOWSIL™  TSSA are subjected to tensile loading. We formulate and use a constitutive law that captures volumetric softening owing to the formation of cavities. Therein, cavitation is considered a process of elastic instability which is homogenized with a pseudo-elastic approach. Ultimate failure initiating from the free edges is predicted employing the framework of finite fracture mechanics. The concept requires both a strength-of-materials condition and a fracture mechanics condition to be satisfied simultaneously for crack nucleation. For the former, we use a novel multiaxial equivalent strain criterion. For the latter, we employ literature values of the fracture toughness of DOWSIL™  TSSA . The predicted onset of cavitation and ultimate failure loads are in good agreement with our experiments. The proposed model provides initial crack lengths that allow for the derivation of simple engineering models for both initial designs and proof of structural integrity while simultaneously extending the range of usability of the structural silicone compared to standardized approaches.