Exploitation of rubbery electrospun nanofibrous mat for fracture toughness improvement of structural epoxy adhesive bonded joints

The improvement of the fracture toughness of adhesive joints is a key factor in many structural applications. The ability of nylon electrospun nanofibrous mat to act as an adhesive carrier and reinforcing web in adhesive bonding has been demonstrated by the Authors in previous works. It has been shown that the impregnation method developed and refined during the previous studies allow generating high-quality pre-preg nanomats out of a 2k unfilled epoxy resin. By applying this methodology, in the present work, rubbery nanofibrous mats have been adopted for the first time to reinforce and increase the fracture toughness of adhesive joints. Rubbery nanofibers were produced by electrospinning of nitrile butadiene rubber (NBR) and poly(ε-caprolactone) (PCL). The addition of the semi-crystalline polymer (PCL) is exploited to maintain the nanofibrous morphology, which the rubber alone (NBR) would not be able to ensure due to its low glass transition temperature (Tg). The nanofibers thus obtained have been integrated into a two-component high strength epoxy resin for structural applications. S235 steel adherends for Double Cantilever Beam (DCB) tests have been manufactured and sandblasted to improve adhesion. An optimization of the sandblasting parameters (distance, pressure, angle and time) has been carried out evaluating the shear strength and the fracture surfaces on S235 steel Single Lap Joints (SLJ). Finally, DCB tests have been performed to compare the mode I fracture toughness with and without the rubbery electrospun nanomats.