The bonding strength of metal-metal single-lap joints with different adhesives applied on steels and aluminum alloys were studied. The bonding strength is found to be related to the type of adhesives and the backing metal, the surface roughness, the surface scratch orientations, the adhesive layer thickness, and the loading conditions (static vs. cyclic and loading rate). SEM observation of fractured surfaces reveals some common feature of bonding strength enhancement, fracture paths and the mechanisms of fracture. The direction of the adhesive joint design is suggested.

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