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Master Bond Inc. 154 Hobart Street, Hackensack, NJ 07601 USA Phone +1.201.343.8983 | Fax +1.201.343.2132 | WhitePaper@masterbond.com
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Surface Preparation
Surface preparation is critical in achieving high-strength structural bonds. In order to get the best adhesion, substrates must be properly prepared, cleaned, and roughened. Substrates with oils, greases, dirt, moisture, and other contaminants on their surfaces must be carefully cleaned prior to adhesive application. Certain forms of oxidation (notably loose rust) must be completely removed. Physical abrasive treatments and/or appropriate chemical cleaning are essential manufacturing steps to achieve the desired performance characteristics with most metallic substrates. Specially formulated primer coats are also useful in some applications.
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Common Pretreatments Pretreatments for Bonding & Assembling Structural Components Substrate
Aluminum & its alloys Chromium Copper & its alloys Magnesium & its alloys Nickel & its alloys Stainless steel
Recommended pretreatments
Degrease and clean followed by rigorous abrasion or acid etching (96% sulfuric acid with sodium dichromate) Degrease and clean followed by rigorous abrasion or acid etching (37% hydrochloric acid and distilled water @ 80C) Degrease and clean followed by rigorous abrasion or acid etching (69% nitric acid based solution) Degrease and clean followed by rigorous abrasion or acid etching (chromic acid solution) Degrease and clean followed by rigorous abrasion or acid etching (69% nitric acid based solution) Degrease and clean followed by rigorous abrasion or acid etching (69% nitric acid based solution) Degrease and clean followed by rigorous abrasion or acid etching (69% nitric acid/60% hydrofluoric acid blend) Degrease and clean followed by rigorous abrasion or acid etching (37% hydrochloric acid and distilled water @ 20C) Solvent clean and light abrasion, if possible Solvent clean and light abrasion, if possible Solvent clean, acid etch (sulfuric acid based solution); abrasion minimally effective Solvent clean and abrasion, if possible Solvent clean and abrasion, if possible Solvent clean and abrasion, if possible Solvent clean, chemical etching required. Contact Master Bond for additional information Solvent clean, abrasion somewhat effective, chemical etching preferred (phenol based solution) Solvent clean, possible abrasion or primers. Plasma or corona treatments preferred Solvent clean and light abrasion, if possible Solvent clean, abrasion minimally effective, flame treatments, chemical etching (sulfuric acid), corona treatment preferred Solvent clean and abrasion, if possible Corona or plasma treatments, or special chemical etching Solvent clean and abrasion, if possible Special primers
Polymer Types
Structural adhesive bonding offers significant technical and economic advantages over mechanical fasteners, as well as joining techniques such as soldering, brazing, or welding for many demanding assembly constructions. Due to their unmatched processing versatility, high strength, low weight, and wide service temperature capabilities (even when exposed to hostile environmental conditions), epoxy polymerbased resin systems have become the driving force for the growth of structural bonding. Their strength properties can be further improved by compounding with glass, carbon, or polyimide reinforcing fibers. Additionally, both thermally conductive and electrically conductive adhesive formulations are available and are widely used in the design of many electrical, mechanical, and medical devices. Fiber reinforced epoxy resin composites can compete economically with steadily increasing success against conventional metal constructions, both on the basis of a more favorable strength-to-weight ratio and enhanced corrosion resistance over the service life of the assembly. Their industrial success is demonstrated by the fact that some 60% of todays aerospace structures are manufactured with epoxy resin adhesive systems. The workhorses of the structural adhesives field are bisphenol A-type epoxy resins and amine-type hardeners. Epoxy resins and hardeners can be either liquid or solid, with liquids generally preferred. They are also available in supported and unsupported semi-cured films. A polymers overall performance profile and cure requirements are mainly determined by the choice of base resin and hardener.
Titanium
Zinc Acrylic plastics ABS plastics Acetal resins & copolymers Ceramics Diallylphthalates Epoxy resins & epoxy phenolics Fluoropolymers e.g Teflon, viton Polyamides (nylons) Polyesters, thermoplastics (PET, PBT) Polycarbonates Polyolefins
Performance Properties
Structural epoxy adhesive systems feature the highest tensile strengths of all commercially available bonding agents. Resistance to moisture, fuels, oils, acids, bases, and many other aggressive chemicals is of a very high order over a wide temperature range. They can safely be operated at service temperatures from as high as 300C to cryogenic conditions. Polysulfones, polyether Thermoplastic elastomers such as EPDM Carbon & carbon fibers Silicones
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Conclusion
As technology has advanced and assemblies have become smaller, traditional mechanical fastening methods have become increasingly difficult to use. For example, joining components that are small and thin, such as sheet metal less than 0.01 inches thick, proves problematic for traditional fastening methods. In addition, specialized methods such as welding, brazing, and soldering require expensive skilled labor without yielding any clear advantage over adhesive bonding. The contiguous contact between substrates afforded through the use of adhesive bonding serves as a metaphor for the incredible attention that adhesive manufacturers bring to the needs of industry. When the needs of one industry are met through the creation of new bonding systems, many others reap the spoils as well. For instance, the high-tech demands of aerospace and defense have lead to the development of lighter weight, high strength, and heat resistant formulas that are now used in many other industries. The relationship between the adhesive industry and those industries to which it caters is symbiotic. Time and time again, adhesive formulators have risen to the challenges that these other fields present -- not just meeting their needs, but advancing their industries. With each improvement, new challenges arise and new solutions are created by the adhesives industry. The cycle does not just continue onward, but forward as well.
Types of Cures
The most widely used epoxy adhesives are one and two component liquids or pastes. The two component systems may be cured at ambient temperatures or more quickly at
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