Prezentare Adhes Bond

Joining in Car Body Engineering 2011
Tutorial 1: Adhesive bonding

technologies
Lucas F M da Silva
Faculty of engineering of the University of Porto
Department of Mechanical Engineering
Lucas da Silva
JCBE2011 Adhesive bonding technologies
Contents
Introduction
Theory of adhesion
Adhesive selection
Joint design
Surface treatment
Joint fabrication methods
Control (destructive and non-destructive
tests))
Applications in the automotive industry
Lucas da Silva
Introduction Applications
Aeronautical industry
de Bruyne (1957)
De Havilland Comet
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Aeronautical industry
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Aerospace industry
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Dsagulier (2010)
Automotive industry
Lotus Elise
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Automotive industry
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Rail industry
Hexcel Composites
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Marine industry
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Civil industry
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Electrical industry
Shoe industry
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Introduction Technologies involved
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Introduction Technologies involved

Petrie (2000)
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Introduction Advantages
Uniform stress distribution
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Uniform stress distribution better fatigue strength
Vibration damping better fatigue strength
Powis (1968)
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Kinloch (1997)
Ability to joint dissimilar
materials
Ability to join thin-sheet
material efficiently
Frequently represent
the most convenient
and cost effective
joining technique
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An increase in design flexibility (e.g. honeycomb structures)

Smooth shapes (no bolt or rivet or weld)
Continuous contact between surfaces
In general, reduce costs
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Introduction Disadvantages
Peeling loads
Peel (one substrate is flexible)
Cleavage (the
Cl
(th ttwo substrates
b t t
are rigid)
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Avoid localised stress
Best solution load in shear
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Limited resistance to extreme conditions such as heat and
humidity.
Need to fixing tools to keep the substrates in position until cure
is complete important economic disadvantage.
To obtain good results, a surface treatment is often required.
Adhesives are frequently cured at high temperatures.
Quality control more difficult but recent developments in NDI
techniques.
No universal failure criterion.
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10
Theory of adhesion Forces involved
Primary bonds
e- are transferred or shared
strong: 100-1000
100 1000 kJ/mol
Ionic
Covalent
Metallic
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Secondary bonds
no e- transferred or shared
interaction of atomic/molecular dipoles
weak < 100 kJ/mol
van der Waals
London forces or dispersion
(induced dipoles)
Debye forces (permanent
dipole and induced
dipole)
Keesom forces (permanent
dipoles)
Hydrogen
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11

All the bonds are forces acting in very short distances (some
angstroms (1 A = 10-10 m = 0.0001 m)
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Theory of adhesion Surface roughness
1
R = h( x) dx
Ra
d
L0
0.5 m
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12
Theory of adhesion Surface roughness

Roughness = 1000 x distance of action of the
bonding forces
But if liquid...
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Theory of adhesion Phase change

Good wetting but without strength
Liquid
Hardening...
Solid
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13
Theory of adhesion Phase change

Hardening process (cure)
L
Loss off solvent
l
t (e.g.
(
white
hit glue
l ffor wood)
d)
Cooling from the molten state (hot melts)
Chemical reaction (most of structural
adhesives)
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Theory of adhesion Wetting
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14
Contact
angle,
l
SV = SL + LV cos
cos 1
Spreading
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Complete wet.
Partial wet.
Young (1805)
90
180
-1
SL= SV
Low wetting
No wetting
29
Surface energy,
Unbalance of atraction forces at the surface
surface energy
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15
Surface energy,
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Surface energy of liquids

Wilhelmy plate, weight of a drop, capillarity, etc.
L =
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F
2l
32
16

Surface energy of solids
Critical surface tension, C
Zisman (1950)
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Surface energy of solids
Dispersion and polar components
Fowkes (1963)
= d + p
L ( 1 + cos )
=
1/ 2
2 ( LD )
( )
P 1/ 2
S
( )
( )
P
LD
L
1/ 2
1/ 2
D
+ S
( )
1/ 2
Watts (2010)
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17
Theory of adhesion Spreading
Principle of minimum energy

L < S
L > S
the liquid spreads

the liquid does not spread
Surfaces of high energy S = 500 ~ 5000 mJ m-2

(metals and their oxides, glass and ceramics; generally hard
materials with high melting points)
Surfaces of low energy S = 5 ~ 100 mJ m-2
(most of organic solids and polymeric materials; generally soft
materials with low melting points)
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18
How can the user intervene?

Increase the surface energy of the solid
Contamination of surfaces (powders, greases, oils,
adsorbed gases, humidity, etc.) low surface energy
The surface treatments can eliminate the
contaminants and modify the chemistry of surfaces of
low energy (polymers)
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Theory of adhesion Theories of adhesion
Mechanical
Adsorption
Diffusion
Electrostatic
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19
Mechanical
But...
Smooth surface
Example: rubber with textile

Increase of surface area
Elimination of weak boundary layers
Better wetting
More energy dissipation
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Adsorption
Physical adsorption
Surface forces
Good
G d wetting
tti
Most important
Occurs in all bonds
Chemical adsorption
Chemical
Ch i l b
bond
d
Acid-base
Primary
Bonding agents
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20
1. Adhesive selection
2. Joint design
3. Surface treatment
4. Fabrication
5. Control
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Adhesive selection Classification

Function (structural and non-structural)
Chemical composition (thermoplastics, thermosets,
elastomers hibrids)
elastomers,
Hardening mechanism (chemical reaction, loss of
solvent or water, hardening from the melt)
Physical form (liquid, paste, solid)
Cost
Substrates
Method of application
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21

Function
Adhesives
Structural
Epoxies
Polyurethanes
y
Acrylics
Phenolics
Aromatics
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Non-structural
Rubbers
Polyesters
y
Hot melts
Inorganic
43

Chemical composition
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22

Kinloch (1997)
Hybrids (e.g. thermoset + rubber)
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Hybrids (e.g. thermoset + rubber)
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da Silva & Adams (2005)
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23
Adhesive selection Composition
Base or binder
Hardener and catalyst
S l
Solvents
t
Diluents
Fillers
Carriers or reinforcements
O
Other
additives
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Adhesive selection Hardening

1. Chemical reaction
a.
b.
c.
d.
e.
f.
Two parts
One part, cure by catalyst or hardener
Cure by humidity
Cure by radiation (light, UV, electrons beam, etc.)
Catalized by the substrate
Adhesives in solid form (tape, film, powder, etc.)
2. Loss of solvent or water

a. Resinous solvent adhesives
b. Reactivatable adhesives
c. Contact adhesives
3. Hardening from the melt
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24
Adhesive selection Hardening
Chemical reaction
VULCANIZAO
(CROSS-LINKING)
Condensation reaction (polyimides,

polybenzimidazole,
p
y
phenolics))
p
Addition reaction (epoxies, urethanes, acrylics)
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Adhesive selection Epoxies
Most important
Strong but brittle
Low shrinkage
1 or 2 parts
Exothermic cure
Can be B-staged
Diglycidyl ether of bisphenol A
(DGEBA)
Cured with amines (room temp.)
Most are hybrid epoxies
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25

Two part epoxy
Form
Cure
Service temperature
Advantages
Disadvantages
Environment
resistance
Water
Solvent
Oil
Health and safety

Applications
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2 parts in paste
Manual mixture
Mi t
Mixture
andd automated
t
t d application
li ti
Room temperature (can be
accelerated at high temperature)
40 to 100C
Strength and durability
Slow curing
Mixture (voids)
Good
Good
Good
Dermatosis
Breathing problems
Aircraft, helicopters, cars, trains,
sport equipment, etc.
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One part epoxy
Form
Cure
Service temperature
Advantages
Disadvantages
Environment
resistance
Health and safety
Applications
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Water
Solvent
Oil
Film, paste
Manual
Temperature (~150C)
40 to 180C
Strength and durability
Storage
Cures at high temperature
Excellent
Excellent
Excellent
Dermatosis
Breathing problems
Aircraft, helicopters, cars, trains,
sport equipment, etc.
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26

Hexcel Composites
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Toughened epoxies
Inclusions of CTBN
Increased toughness
Lower Tg
Lower strength
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Kinloch (1997)
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27

Epoxy-phenolic
Epoxy resin + phenolic resin

High temperature resistance
Continuously until 175C
Very good strength to environment, oil, solvents
Low toughness
Aeronautical applications
Bonding honeycomb sandwich composites
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Kinloch (1997)
Epoxy-nylon
Improved toughness and
peel strength
Limited resistance to the
environment
Max temperature 80C
Good filleting capacity
Bond
B d aluminium
l i i
skins
ki tto
honeycomb core
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28

Epoxy-polysulfide
Excellent toughness, peel strength and flexibility,
chemical resistance
Max temperature 50-80C
2 parts paste
Room temperature cure
High deformation applications
C t i
Cotronics
Bond concrete in floors and roads
Sealants, glass bonding, bond rubber to metals
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Adhesive selection Polyurethanes

Form
Cure
Service temperature
Advantages
Disadvantages
Environment
resistance
Health and safety
Applications
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Water
Solvent
Oil
Solutions, pastes
Cartridge
Room temperature and moisture (1
part)
Can be accelerated with temperature
(2 parts)
200 to 120C
Good strength at low temperatures
Toughness
Wetting ability
Moisture cure
Limited temperature resistance
Fair
Fair/Good
Fair/Good
Avoid physiological risks
Cryogenic applications
Automotive industry
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29
Adhesive selection Polyurethanes

Total / Le joint Franais
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Adhesive selection Acrylics
Anaerobics
Cyanoacrylates
Modified acrylics
Cure rapidly
Bond many substrates, including plastics
Fast assembly operations
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Adhesive selection Acrylics Anaerobics

Form
Cure
Service temperature
Advantages
Disadvantages
Environment
resistance
Water
Solvent
Oil
Health and safety

Applications
1 part liquid or paste

Small container or automatic
application
By absence of oxygen
Cures in min or h at 25C or in 10
min at 120C
55 to 150C
Little surface preparation
Thin bondlines
Good
Depends on formulation
Good
No major problems
Liquid lock washer
Small assembly works
Loctite
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Adhesive selec. Acrylics Cyanoacrylates

Form
Cure
Service temperature
Advantages
Disadvantages
Environment
resistance
Health and safety
Applications
Water
Solvent
Oil
1 part liquid
application
Substrate moisture
Cures in sec or min at 20C
30 to 80C
Fast cure
Cannot bond large areas due to fast
cure
Brittle
Bad gap filling
Weak
Fair/good
Good
Can bond to skin due to fast cure
Rapid assemble of light structures
Optical and electronic industry
Loctite
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31
Adhesive selec. Acrylics Modified acrylics

Form
Cure
Service temperature
Advantages
Disadvantages
Environment
resistance
Health and safety
Applications
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Water
Solvent
Oil
2 parts
application
pp
Catalysed by an initiator that allows
a fast cure
40 to 120C
Fast cure
Can bond unprepared surfaces
Good environment resistance
Lower strength and stiffness than
epoxies
Good
Good
Good
No major problems
Rapid assemble of structures
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Adhesive selection Phenolics

Cure at high temperature (140C)
and pressure
g cure
Volatiles released during
porous bondlines
Good resistance to environment
and temperature
Wood bonding
Cheap
Brittle and low peel strength
Hybrid phenolics generally used
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32

Form
Cure
Service temperature
Advantages
Disadvantages
Environment
resistance
Water
Solvent
Oil
Health and safety

Applications
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Solutions, powder, films

Manual, brush, film
Temperature and pressure
40
40 to 180C
Good strength to fire
Cheap
Difficult processing
Brittle
Porous bondlines
Excellent
Good
Good
Low smoke and low level of
toxicity
Wood
Metal (hybrid phenolics)
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Nitrile-phenolics
Vinyl-phenolic
Neoprene-phenolic
N
h
li
http://en.wikipedia.org/wiki/Brake_lining
http://www.boardtek.com.tw/Metal.htm
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Adhesive selection Polyaromatics

Polyimide, bismaleimide,
polybenzimidazole
Ladder structure
High temperature adhesives
Expensive
Difficult processing
Brittle and low peel strength
Difficult to toughen
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Form
Cure
Service temperature
Advantages
Disadvantages
Environment
resistance
Health and safety
Applications
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Water
Solvent
Oil
Supported film
Sandwich assembly
Temperature
p
(250C)
(
) and pressure
p
40 to 280C
Strength at high temperatures
Very difficult processing
Brittle at room temperature
Porous bondlines
Expensive
Excellent
Excellent
Excellent
No major problems
Applications at high temperature
Aeronautical and aerospace industry
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Hexcel Composites
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Adhesive selection Selection process

Substrate
Production
requirements
Adhesive
selection
Experimental
validation
Design and
loading
Service
environment
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35

Substrate
Spreading condition principle of minimum energy
L < S
L > S
the liquid spreads

the liquid does not spread
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Modifiied acrylic
Cyanoaacrylate
Anaeroobic
Polyurrethane
Polyestter
Polyaromatic
Urea foormaldehyde
Melam
mine formaldehyde
Neopreene-phenolic
Phenoll formaldehyde
Vinyl-p
phenolic
Shields (1984)
Resorccinol formaldehyde
Nitrile--phenolic
Metals
Ceramics
Wood
Paper
Leather
Textile
Elastomers
Neoprene
Silicone
Polyurethane
y
Thermoplastics
PVC (flexible)
PVC (rigid)
Cellulose acetate
PE (film)
PE (rigid)
PP (film)
PP (rigid)
PC
Teflon
Epoxy
Substrate
72
36

Substrate
Residual thermal stresses
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Production requirements
Adhesive form
Working time
Cure conditions (temperature, pressure, time)
Holding time
Shelf life
Safety and health issues
Cost
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37
Petrie (2000)
Presssure not required
Presssure required
Highh temperature
Room
m temperature
Processing
conditions
Chem
mical reaction
solution,
Cure
method
Solvent
emullsion
Liquuid
Film
m
Pastee
Solidd
Epoxy (polyamine)
Epoxy (polyanhydride)
Epoxy (polyamide)
Epoxy-phenolic
Epoxy-nylon
Epoxy-polysulfide
Nitrile-phenolic
Vinyl-phenolic
Neoprene-phenolic
Resorcinol formaldehyde
Phenol formaldehyde
y
Melamine formaldehyde
Urea formaldehyde
Polyimide
Bismaleimide
Polybenzimidazole
Polyester + isocyanate
Polyester + monomer
Polyurethane
Cyanoacrylate
Acrylic
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Common forms
available
Solvent release
Type of adhesive
Production
requirements
75

Design and loading
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38

Service environment
Adhesive
da Silva et al. (2007)
Epoxies
Toughened
g
epoxy
p y
Epoxy phenolic
Epoxy nylon
Epoxy polysulfide
Phenolics
Nitrile phenolic
Vinyl phenolic
Neoprene phenolic
High temperature adhesives
Bismaleimide
Polyimide
Polyurethanes
Anaerobics
Cyanoacrylates
Modified acrylics
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Tg (C)
50-150
200
50
50
120
70
70
210-280
340-430
20-50
120
80
60-120
77
Experimental validation
Physical and chemical properties
Colour viscosity,
Colour,
viscosity shelf life
life, working life
life, density
density, Tg,
etc...
Mechanical properties
Failure strength tests (shear, tension, compression),
fracture tests (mode I, II)
D bilit
Durability
Temperature, moisture
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39
Tensile test
EN ISO 527-2
BS 2782
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Tension vs
vs. compression
c = 1.2 to 1.4 t
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40
ASTM D 695
Compression test
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Thick Adherend Shear Test (TAST)
ISO 11003
11003-2,
2 ASTM D 5656
ISO 11003-2
ISO 11003-2, ASTM D 5656

da Silva et al.(2008)
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41

Shear test (Arcan)
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Shear test (Torsion)
Chen et al. (2010)
Gali et al. (1981)
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42

Toughness (Double cantilever beam (DCB) test)
6 .3 5
25.4
6.35
1 2 .7
ASTM D 3433
a 0 = 51
356
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Tljsten (2005)
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43

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Adhesive
Epoxies
Araldite AV138
Hysol EA 9394
Hysol EA 9321
Supreme 10HT
Araldite AV 119
Hysol EA 9150
Hysol EA 9359.3
Hysol EA 9330
Hysol EA 9628f
Araldite 2015
Redux 810
02 Rapid
Hysol EA 9361
Polyurethanes
Araldite 2026
Sikaflex 256
Bismaleimides
Redux HP655f
Redux 326f
Modified acrylics
DP-8005
Araldite 2024
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Manufacturer
Tension
E
y
(MPa) ((MPa))
((MPa))
((%))
Huntsman
Loctite
Loctite
Master Bond
Huntsman
Loctite
Loctite
Loctite
Loctite
Huntsman
Hexcel Comp.
Delo
Loctite
4590
4420
3870
3240
3450
2852
2650
2646
2377
1850
1730
1000
670
41.0
59.8
46.0
45.5
67.1
79.0
42.5
38.6
51.7
22.5
40.0
24.0
7.99
1.30
4.64
3.80
2.00
4.10
5.00
4.50
2.40
7.50
4.40
5.53
20.0
44.0
Huntsman
Sika
200
18.0
50.00
Hexcel Comp.
Hexcel Comp.
3620
4850
80.7
50.9
2.39
1.28
3M
Huntsman
590
760
13.0
20.0
5.30
42.5
41.0
31.0
22.0
25.0
67.1
42.5
80.7
50.9
Compression
((MPa))
((MPa))
35.9
34.0
68.9
99.9
145
53.1
79.3
Shear
G
(MPa)
GIc
(J/m2)
GIIc
(J/m2)
345.9
3000
40.3
1401
525.7
4700
8.26
330
2901
37.9
37.9
3.70
5.3
8.40
180
((MPa))
((MPa))
r (%)
1559
1140
1030
1460
1260
1056
660.0
965.0
624.0
560.0
25.0
25.0
20.0
37.1
47.0
30.2
40.4
33.0
37.1
47.0
5.50
8.36
6.35
16.1
50.7
35.3
35.3
63.0
14.0
20.0
1.351
8.26
1615
178.6
0.30
0.37
0.35
0.37
694.0
1360
88
44

Tg
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89

Tg DMA
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45

Temperature
70
-55C
55C
Shear stress (MPa)
60
50
40
22C
30
100C
20
10
200C
0
0
0.1
0.2
0.3
0.4
0.5
Shear strain
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Humidity
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Bordes et al. (2009)
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2. Joint design
4. Fabrication
5. Control
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Joint design Stress analysis
Two possibilities:
Analytical methods design
Numerical methods (finite element
method) research
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47
Simple analysis
=
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P
bl
95
Volkersen (1938)
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48
Volkersen (1938)
Load balance of upper adherend:

d
1bt1 + bdx = ( 1 + d 1 ) bt1 1 =

d
dx
t1
Load balance of lower adherend:

2bt2 = ( 2 + d 2 ) bt2 + bdx
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d 2
=
dx
t2
97
Volkersen (1938)
Joint equilibrium:
P = 1bt1 + 2bt2
Shear deformation in the adhesive:
Ga
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1
d
1 d 1 du1 du2 1 1 2
=
( u1 u2 ) =
=
ta
dx Ga dx ta dx dx ta E1 E2
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49
Volkersen (1938)
d 2
d 1
1 d 1 1 2
=
=
=
+
+
dx
t2
Ga dx ta E1 E2
dx t1
1 d
t d 2 1
t2 d 2 2
d 2 1 Ga 1 2
= 1
=
=
t

1
Ga dx Ga dx 2
Ga dx 2
dx 2
ta E1 E2
P
t1
P = 1bt1 + 2bt2 2 = bt 1 t
From
1
2
t1
Substituting in
d 2 1 Ga 1 2
=

dx 2
ta E1 E2
d 2 1
2 1 + C0 = 0
2
dx
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with
2 =
Ga
ta
1
1
+
E
t
E
2 t2
11
C0 =
Ga P
ta bE2t2t1
99
Volkersen (1938)
1 =
From
= t1
C0
C
P sinh ( x ) C0
+ 2
cosh ( x ) + 02 cosh ( l ) 1 +
bt
1 sinh ( l )
d 1
=
dx t1
Ct
d 1
P cosh ( x )
C t
= 021 sinh ( x ) + 021 cosh ( l ) 1 +
dx
l sinh ( l )
Substituting C0 and 2 and using =
P
bl
( x)
l
( k 1) cosh ( ( l x ) ) + cosh ( x )
=
k sinh ( l )
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2 =
k=
Ga
ta
1
1
+
E
t
E
2t2
11
E1t1
+1
E2 t 2
100
50
Goland & Reissner (1944)
Bending moment M = Ft/2

Not deformed
Deformed
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Bending moment M = kFt/2

k<1
101
Goland & Reissner (1944)
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51
Hart-Smith (1973)
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Hart-Smith (1973)
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52
Finite element method
KD = R
9 Any geometry
9 All stresses
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Parametric studies
more difficult
105
Joint design Failure modes
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53
Joint design Failure criteria
In the adhesive
Brittle adhesive maximum stress ((Volkersen or

G&R)
Ductile adhesive maximum strain (Hart-Smith)
Very ductile adhesive (> 20% in shear) global
yielding
Fracture mechanics
Damage mechanics
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Global yielding
Crocombe (1989)
Pmax = bl p
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Global yielding
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Metals
Hart-Smith (1973)
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55
Metals
Adams et al. (1997)
Adherend yielding
t = P bt
sup = 6M bt 2 and M = kPt 2 (G & R)
Pmax = bl p
Pmax = bt y
sup = 3kP bt
max = sup + t = P(1 + 3k ) bt
Pmax = y bt (1 + 3k )
Pmax = bt y 4
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For low loads and short overlaps,

k=1
For joints which are long
compared to the adherend
thickness (l/t = 20), k = 0
111
Composites
Hart-Smith (1973)
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112
56
Singularities
Lucas da Silva
113

Singularities
adherend
rounding
Zhao et al. (2010)
Lucas da Silva
114
57
Fracture mechanics
To solve proble of singularities
But...
Crack
Difficult to relate K with

experimental results
Difficult
Diffi lt when
h there
th
is
i
plastic deformation
Groth (1985)
Lucas da Silva
115
Damage mechanics
de Moura et al. (2002)
= utop ubottom
i
i > u ,i
u,i
u ,i i Softening
u ,i 0,0 i
i = u ,i
o,i
Lucas da Silva
Initiation
u,i
1
Gic = u ,i u ,i Propagation
2
116
58
Damage mechanics
Lucas da Silva
Loureiro et al. (2010)
117
Joint design Optimisation

Fillets
Lucas da Silva
118
59

Fillets
Lucas da Silva
Grant et al. (2009)
119

Adherend shaping
Cherry & Harrison (1970)

Adams et al. (1986)
Hildebrand (1994)
Rispler et al. (2000)
Sancaktar & Nirantar (2003)
Kaye & Heller (2005)
Lucas da Silva
120
60
Failure load (kN)
Adherend shaping
50
45
40
35
30
25
20
15
10
5
0
Basic design
Taper and adhesive fillet
-55C 22C -55C 22C -55C 22C

Supreme
10HT
Lucas da Silva
AV119
Adams et al
(1986)
121

Mixed adhesive joint
Sancaktar & Kumar (2000)

Pires et al. (2003)
Temiz (2006)
Bouiadjra et al. (2007)
das Neves et al. (2009)
Marques & da Silva (2008)
da Silva & Lopes (2009)

Lucas da Silva
122
61

da Silva & Lopes (2009)
Lucas da Silva
123

Lucas da Silva
124
62

Hybrid joints
Liu & Sawa (2001)
Liu et al. (2004)
G
Grassi
i ett al.l (2006)
Pirondi & Moroni (2009)
Lucas da Silva
125

Hybrid joints
Pirondi & Moroni (2010)
Lucas da Silva
126
63
Joint design Tubular joints
Lucas da Silva
127
Joint design T joints

Adams et al. (1997)
Apalak (2002)
Marcadon et al. (2006)
Lucas da Silva
128
64

12
12
Failure load (kN)
10
10
Base thickness
1.5 mm
10 mm
4
2
0
(a)
Lucas da Silva
(b)
(c)
(d)
129

(a) Observed locus of failure
(b) Apalak et al FE stress prediction
Locus of failure
Progressive failure
Yield
Maximum stresses
Locus of failure
Sudden failure
Maximum stresses
Lucas da Silva
130
65
Joint design Corner joints
Adams et al. (1997)

Apalak and Davies (1993)
Feih and Shercliff (2005)
Lucas da Silva
131
Joint design
http://ni.fe.up.pt/~rteixeira/rjoints
Lucas da Silva
132
66
2. Joint design
4. Fabrication
5. Control
Lucas da Silva
133
Surface treatment
Hagemaier (1990)
Lucas da Silva
134
67
Surface treatment
Characteristics that affect adhesion
Contamination
Oils, greases, fingerprints, mold release
agents etc.
agents,
etc low surface energy
decrease adhesion
Lucas da Silva
135
Surface treatment
Characteristics that affect adhesion
Weak boundary layer

Contaminant films, oxide layers, rust,
corrosion scale
corrosion,
scale, and loose surface particles
particles,
etc.
Lucas da Silva
136
68
Surface treatment General principles
In surface treatment, the following

operations can occur:
1- Material removal
2- Chemical modification of the surface
3- Change of the surface topography
Lucas da Silva
137
Surface treatment Importance

Aluminium joints bonded with an epoxy adhesive
Kinloch (1987)
Lucas da Silva
138
69
Surface treatment Assessment
Water-break test
Lucas da Silva
139
Surface treatment Assessment
Destructive test
Adhesive failure
Bad treatment
Cohesive failure
G d treatment
Good
t t
t
Lucas da Silva
140
70
Surface treatment Selection
1.
2.
3.
4.
Initial strength
Durability
Initial condition of the substrates
Type of substrate and nature of the
surface
5. Production factors (cost, time, etc.)
Lucas da Silva
141
Surface treatment Methods

Passive processes
No chemical alteration
Clean the surface
Remove substances that are weakly attached
Active processes
Chemical transformation
Metals formation of a well defined oxide or structure
Polymers formation of polar groups that increase
surface energy and adhesion
Last treatment when high strength and durability are
required
Lucas da Silva
142
71

Passive processes
Abrasive methods
Solvents
Chemical cleaning
Active processes
Acid etching
Anodizing (metals)
Flame treatment, corona discharge, plasma
(polymers)
Lucas da Silva
143

Steel (shot-blasted)
Lucas da Silva
144
72

Al (acid etching)
Lucas da Silva
Critchlow et al. (2006)
145

Loctite
Metals
Lucas da Silva
146
73

Loctite
Polymers
Lucas da Silva
147
2. Joint design
4. Fabrication
5. Control
Lucas da Silva
148
74
Fabrication Steps
Adhesive application
pp
Storage
Fixturing of parts
Metering and mixing
Hardening
Lucas da Silva
149
Fabrication Storage
Adhesives degrade
with
ith lilight,
ht h
humidity,
idit etc.
t
Viscosity increases
with time determines
the shelf-life
Van Twisk & Aker (1990)

Lucas da Silva
150
75
Fabrication Storage
Ambient temperature
Low temperature
L
(fridge or freezer)
Lucas da Silva
151
Fabrication Storage
Effect of ambient conditions

Van Twisk & Aker (1990)
Lucas da Silva
152
76
Fabrication Storage
Refrigerated or frozen products
Lucas da Silva
Hexcel Composites
153
Fabrication Metering and mixing
Lucas da Silva
154
77
Fabrication Adhesive application
Liquid
Brush, simple rollers, syringes, squeeze
b ttl
bottles,
pressurized
i d glue
l guns, etc.
t
Easy to apply
A lot of waste
Any geometry
Good wetting
Lucas da Silva
155
Paste
Guns, spatula
Simple
Low waste
Lucas da Silva
156
78
Paste
Application pattern to avoid air entrapment
Translation
Lucas da Silva
Rotation
157
Paste
Lucas da Silva
Sika (2009)
158
79
Film
Minimum waste
N mixing
No
i i
Easy
Good reproducibility
Uniform thickness
Flat surfaces
Expensive
Lucas da Silva
159
Fabrication Fixturing of parts
Keep surfaces in contact

Avoid adhesive thickness variations
Allow good wetting of the surface
Avoid formation of voids and porosity
(adhesives that cure by condensation such as
phenolics and p
p
polyimides)
y
)
Lucas da Silva
160
80
Equipment
ARIANE 5 satellite adaptor
Clamps
Dsagulier (2010)
Lucas da Silva
161
Equipment
Moulds
Lucas da Silva
162
81
Equipment
Press
Lucas da Silva
163
Equipment
Autoclave
NPL
Aschome
Lucas da Silva
164
82
Equipment
Vacuum-bag
Lucas da Silva
165
Adhesive thickness
Influence on joint strength (0.1 to 0.2 mm)
G t ett al.l (2009)
Grant
Lucas da Silva
166
83
Adhesive thickness
Microspheres or carriers (films)
Lucas da Silva
167
Adhesive thickness
Shims
Shim (controls the thickness and filet)

Lucas da Silva
168
84
Adhesive thickness
TWI
Wires
Lucas da Silva
169
Fabrication Hardening
Chemical reaction (most of structural
adhesives)
Loss of solvent or water (e.g. white glue of
wood)
Hardening from the melt (hot melts)
Lucas da Silva
170
85
Chemical reaction
Depends on adhesive, room temperature or high
temperature
May need pressure (e. g. phenolics)
Examples:
Epoxy 120C, 1h
Bismaleimide (for high temperatures) 175C, 2h +
230C, 2h
Cure is accelerated with temperature

Tg increases with the cure temperature but beware of
degradation of adhesive
Lucas da Silva
171
Chemical reaction
Time depends on temperature
Permabond
ESP 110
Lucas da Silva
172
86
Equipment
Temperature of adhesive
Ovens (g
(good air circulation))
Hot press
Lucas da Silva
173
Equipment
Local heating (induction or dielectric)
Lucas da Silva
174
87
Equipment
Hexcel Composites
Local heating
Lucas da Silva
175
Fabrication Safety and environment
Use gloves and masks

Well ventilated area with
air e
extraction
traction
Safety equipment
Keep in a safe place
solvents
Exothermic
E th
i reaction
ti
use thin bondlines
Lucas da Silva
Schindel Bidinelli
Schindel-Bidinelli
176
88
2. Joint design
4. Fabrication
5. Control
Lucas da Silva
177
Control Destructive tests
Lap joints
Peel
Impact
Fatigue
Creep
Environment
Lucas da Silva
178
89
Single lap joints

ASTM D 1002
Lucas da Silva
179
Modified lap joints

Laminated lap shear specimen
ASTM D 3165
Double lap specimen

ASTM D 3528
Lucas da Silva
180
90
Peel
ASTM D 1781
ASTM D 3167
ASTM D 1876
T-peel
Lucas da Silva
Floating roller peel

Climbing drum peel

181
Peel
Lucas da Silva
Blackman (2010)
182
91
Peel
Adhesive thickness
Rider (1964)
Lucas da Silva
183
Impact
ASTM D 950
Lucas da Silva
184
92
Impact
Harris & Adams (1985)
Lucas da Silva
185
Impact (wedge impact peel)

ISO 11343
Lucas da Silva
186
93
Impact (Split Hokinson Pressure Bar)

Goglio (2010)
Strain gauges
a)
Projectile
First (incident) bar
Second (transmitter) bar
Specimen
distance
Incident pulse
b)
Reflected pulse
Transmitted pulse
time
Lucas da Silva
187
Impact (Inertial wheel impact)

Loureiro et al. (2010)
Load cell
Swing arm
Impactor
Inertia wheel
AC Motor
Specimen
Anvil
Lucas da Silva
188
94
Fatigue
ASTM D 3166
Lucas da Silva
Banea et al. (2009)
189
Fatigue
Fernndez et al. (2010)
G Imax/G Ic
0.1
0.1
da e/dN (CBBM) = 0.0058x
1.7956
0.01
dae/dN
0.001
da/dN
da /dN (BEFM)= 0.0046x
da/dN (mm/cycle) sss
S i
Specimen
2
1.4131
0.0001
Lucas da Silva
190
95
Creep
ASTM D 2294
Lucas da Silva
191
Creep
Lucas da Silva
ASTM D 2294
192
96
Environment
ASTM D 896
Lucas da Silva
193
Environemnt (Boeing wedge test)

ASTM D 3762
Lucas da Silva
194
97
Control Non-destructive tests
Defects
Poor adhesion
Porr cohesive strength
Voids,
V id di
disbonds
b d or porosity
it
Lucas da Silva
195

Visual inspection
Hart-Smith (2010)
Porosity, misalignments, non-uniform adhesive

thickness, etc.
Lucas da Silva
196
98
Tap test
Tapping on the bonded joint

Sh
Sharp
clear
l
ttone good
d adhesion
dh i
Dull hollow tone void or unattached area
Can be instrumented (solenoid operated
hammer and microphone pickup)
Lucas da Silva
197
Ultrasonic method
Lucas da Silva
Petrie (2000)
198
99
Ultrasonic method
Lucas da Silva
Assler (2006)
199

Acoustic emission
Joint must be loaded (semi-destructive)
Stress waves emitted by crack propagation or micro-cracking
are recorded
d d with
ith piezoelectric
i
l t i ttransducers
d
The only method that can detect poor adhesion
Magalhes (1999)
Lucas da Silva
200
100

Radiography
Voids or discontinuities
p
with metal p
powder or other suitable
Contrast improved
filler
Magalhes (1999)
Lucas da Silva
201
Thermal methods
Lucas da Silva
Petrie (2000)
202
101
Control Post-fracture tests
Optical microscopy
Failure mechanism
S f
Surface
analysis
l i
Lucas da Silva
203
Scanning electron microscopy
Surface analysis
da Silva & Adams ((2005))
Failure surface of a
toughened adhesive
Lucas da Silva
Failure surface of an
untoughened adhesive
204
102
Scanning electron microscopy
Surface analysis
Lucas da Silva
Banea & da Silva (2010)
205
Atomic force microscopy
Surface analysis
Lucas da Silva
206
103
X-ray Photoelectron Spectroscopy (XPS)
Chemical composition of the surface

Surface of a
bi
bismaleimide
l i id
Lucas da Silva
207
Fourier transform infrared (FTIR)
Identification of a material
Suarez (2010)
FTIR spectrum of vulcanized styrene-butadiene rubber

Lucas da Silva
208
104
Applications in the automotive industry

Requirements
Areas of application
Adhesives
Strength
Durability
y
Repair
Lucas da Silva
209
Automotive industry Requirements

Bonding of multi-materials
Mangino (Fiat)
Dune Buggy 1970s
Renault Espace 1984-1996

Volvo V70 XC AWD 2000
Fiat 8V 1954
Ferrari Enzo 2003
Aston Martin V12 Vanquish 2002
Chevrolet Corvette 1953
BMW M3 Sport Coup 2003

Ford Thunderbird 2002
Lucas da Silva
210
105

Bonding of multi-materials in S-Class Coup of
DaimlerChrysler
Flegel (2002)
Lucas da Silva
211
Automatic application
Good filling capacity (~1 mm)
Fast hardening
Flexible and tough
Crash test
Reduce cost
D bilit ((~15
Durability
15 years))
Repair
Lucas da Silva
Cognard
212
106
Automotive industry Areas of application

Body shop
Hem flange bonding
Burchardt (2010)
Lucas da Silva
213

Body shop
Anti-flutter bonding
Burchardt (2010)
Lucas da Silva
214
107

Body shop
Hybrid bonding
Lucas da Silva
215

Assembly line
Direct glazing
Lucas da Silva
Sika
216
108
Lucas da Silva
217

Norton (2010)
Aston Martin DB9 Coupe
1C epoxy
Lucas da Silva
218
109
Automotive industry Adhesives
Tljsten (2005)
Lucas da Silva
219
Automotive industry Strength

Increase in stiffness compared to welded structures
Flegel (2002)
Lucas da Silva
220
110

Plastic deformation of the adherend controls failure
(see joint design)
Grant et al. (2009)
Lucas da Silva
221

Use flexible and ductile adhesives (crash suitable)
Burchardt (2010)
Lucas da Silva
222
111
Impact
Droste (2006)
Lucas da Silva
223

Impact
Jost (2000)
Lucas da Silva
224
112
Automotive industry Durability

Fatigue strength
Dilger (2005)
Lucas da Silva
225

Temperature (-30 to +80C)
Burchardt (2010)
Structural adhesive
1C PU
Lucas da Silva
226
113

Humidity
Davies (2010)
Lucas da Silva
227
Automotive industry Repair

Dismantable adhesives
Lucas da Silva
Sato (2010)
228
114
Bibliography
Lucas da Silva
229
230
Bibliography
Lucas da Silva
115

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Joining in Car Body Engineering 2011

Tutorial 1: Adhesive bonding

JCBE2011 Adhesive bonding technologies

JCBE2011 Adhesive bonding technologies

JCBE2011 Adhesive bonding technologies

JCBE2011 Adhesive bonding technologies

JCBE2011 Adhesive bonding technologies

JCBE2011 Adhesive bonding technologies

JCBE2011 Adhesive bonding technologies

JCBE2011 Adhesive bonding technologies

JCBE2011 Adhesive bonding technologies

JCBE2011 Adhesive bonding technologies

JCBE2011 Adhesive bonding technologies

Introduction Technologies involved

JCBE2011 Adhesive bonding technologies

Introduction Technologies involved

JCBE2011 Adhesive bonding technologies

JCBE2011 Adhesive bonding technologies

JCBE2011 Adhesive bonding technologies

JCBE2011 Adhesive bonding technologies

An increase in design flexibility (e.g. honeycomb structures)

JCBE2011 Adhesive bonding technologies

JCBE2011 Adhesive bonding technologies

Avoid localised stress

Best solution load in shear

JCBE2011 Adhesive bonding technologies

JCBE2011 Adhesive bonding technologies

Theory of adhesion Forces involved

JCBE2011 Adhesive bonding technologies

Theory of adhesion Forces involved

JCBE2011 Adhesive bonding technologies

Theory of adhesion Forces involved

JCBE2011 Adhesive bonding technologies

Theory of adhesion Surface roughness

JCBE2011 Adhesive bonding technologies

Theory of adhesion Surface roughness

JCBE2011 Adhesive bonding technologies

Theory of adhesion Phase change

JCBE2011 Adhesive bonding technologies

Theory of adhesion Phase change

JCBE2011 Adhesive bonding technologies

Theory of adhesion Wetting

JCBE2011 Adhesive bonding technologies

Theory of adhesion Wetting

JCBE2011 Adhesive bonding technologies

Theory of adhesion Wetting

JCBE2011 Adhesive bonding technologies

Theory of adhesion Wetting

JCBE2011 Adhesive bonding technologies

Theory of adhesion Wetting

Surface energy of liquids

JCBE2011 Adhesive bonding technologies

Theory of adhesion Wetting

JCBE2011 Adhesive bonding technologies

Theory of adhesion Wetting

JCBE2011 Adhesive bonding technologies

Theory of adhesion Spreading

Principle of minimum energy

the liquid spreads

Surfaces of high energy S = 500 ~ 5000 mJ m-2

JCBE2011 Adhesive bonding technologies

Theory of adhesion Spreading

JCBE2011 Adhesive bonding technologies

Theory of adhesion Spreading