In this research, a generalized machine learning (ML) framework is proposed to estimate the fatigue life of epoxy polymers and additively manufactured AlSi10Mg alloy materials, leveraging their failure surface void characteristics. An extreme gradient boosting algorithm-based ML framework encompassing Synthetic Minority Over-sampling TEchnique (SMOTE), categorical data encoding, and external loop cross-validation is developed to evaluate the fatigue life across materials. The influence of different training strategies based on materials, input features, encoding method, and data standardization on the model performance is explored. Additionally, the importance of anti-data-leakage and anti-overfitting measures over the ML model performance is addressed. The result shows that the data-leakage-free, external loop cross-validated model can estimate the fatigue life of selective epoxy polymers and metal alloys with an average R² of 0.71 ± 0.06 using a mere 12 to 27 experimental data points per material category. Whereas the model trained with data-leakage and overfitting results in high R² of 0.9.

The development of new adhesives has allowed to expand the application of bonding into the most diverse industrial fields. This review article presents the commonly used experimental methods for the investigation of mechanical performance of adhesively bonded joints in the aerospace, wind energy, automotive and civil engineering sectors. In these sectors, due to their excellent intrinsic properties, composite materials are often used along with conventional materials such as steel, concrete and aluminium. In this context, and due to the limitations that the traditional joining techniques present, adhesive joints are an excellent alternative. However, standardized experimental procedures are not always applicable for testing representative adhesive joints in these industries. Lack of relevant regulations across the different fields is often overcome by the academia and companies’ own regulations and standards. Additional costs are thus mitigated to the industrial sectors in relation with the certification process which effectively can deprive even the biggest companies from promoting adhesive bonding. To ensure continuous growth of the adhesive bonding field the new international standards, focusing on actual adhesive joints’ performance rather than on specific application of adhesive joints are necessary.