KTF - 5 - Fügeteilwerkstoffe StBo Final PDF

Adhesive Manufacturing Processes
Chapter 5: Joint Element Materials
Univ.-Prof. Dr.-Ing. Prof. h.c. Stefan Böhm

Fachgebiet Trennende und Fügende Fertigungsverfahren (tff)
Universität Kassel
Quelle: Wikipedia
Agenda
 Introduction
 Adhesive Properties - Metal
 Adhesive Properties – Synthetic Materials
 Adhesive Properties - Glass
 Adhesive Properties – Wood
 Adhesive Proerties - FVK-Materials
 Material Combinations
 Conclusion
2
Introduction
 Surface Layers of Metalic Materials
Foreign Substance
Layer
Adsorption Layer
Reactionary Layer
Metallic
Basic Material Boundary Layer
Schematic depiction of the surface layers of metallic material
(Source: Habenicht)
3
Introduction
Depiction of the relevant layer thickness in relation to each other
Adsorption Layer
Reactionary Layer
Metallic Base Material Boundary Layer
– Adsorption Layer
– Reactionary Layer
– Boundary Layer
● The foreign substance layer (dirt) has no defined thickness.

(Source: Habenicht) 4
Introduction
Foreign Substance
Boundary Layer Layer
Adsorption Layer
Reactionary Layer
 Layer Thickness: 0.1-100μm Metallic Nase Material Boundary Layer
 The boundary layer is formed by deformation processes and/or through cutting

and is very strong.
(Source: Habenicht, S.2965ff)

5
Introduction
Foreign Substance
Reactionary Layer Layer
Adsorption Layer
Reactionary Layer
Thickness: 0.01-0.1 µm Metallic Base Material Boundary Layer
The reactionary layer is formed by chemical changes within the boundary layer.
● This reaction can be natural or can be caused intentionally
This layer is connected strongly to the boundary layer through primary valence
bonds
The reactionary layer is primarily responsible for the formation of
adhesion forces
(lSource: Habenicht)
6
Introduction
Foreign Substance
Adsorption Layer Layer
Adsorption Layer
Reactionary Layer
Thickness: 0.001-0.01µm Metallic Base Material Boundary Layer
The adsorption layer is formed through the intake of molecules from the
environment.
● The formation processes are mostly reversible.
(Source: Habenicht)
7
Introduction
Foreign Substance
Dirt Layer
Adsorption Layer
Reactionary Layer
Layer thickness cannot be defined

The foreign substance layer (dirt) can be made of:
● Oil
● Dust
● Greases
● Humididty
(Source Habenicht)
8
Introduction
Foreign Substance
Metallic Coatings Layer
Adsorption ayer
Reactionary Layer
Further surface layers can be created by adding metallic coatings.

● for example in galvanized/ tinned plates,
● plated aluminium alloys or
● metallised plastics
These layers lie between the boundary layer and the reactionary layer.
(Source: Habenicht)
9
Introduction
 As described in the chapter regarding the adhesive forces, the surface
energies are significant for the adhesive bonding possibilities
Surface Energy [mN/m]
Iron 2550
Titanium 2050
… …
Silver 1250
…
PVC 40
… …
PTFE (Teflon) 19
 The surface energy has a direct impact on the quality of the wetting, which
again is the prerequisite for an optimal adhesion
10
Introduction
 This allows the general conclusion that, as regards surface energies, metal
bonds are unproblematic.
● Surface energies > 1000 mN/m
 Difficulties occur when the surface has negative properties:
● Oiled surface (protection against corrosion)

● not very solid oxide layer
● roughness (viscosity of the adhesive)
● …
11
Introduction
 Synthetics have much lower surface energies, which limits the possibilities, if
bonding adhesively without prior treatment.
● Surface energies between 19 mN/m and 47 mN/m
 Depending on the synthetic, further negative properties can influence the

adhesive bonding properties.This is very important to regard concerning the
ageing resistance:
● contained softeners
● separating agents on the surface
12
Introduction
 Apart from metallic and synthetice surfaces, there is another surface structure
that is especially porous
● This includes:
– wood, plywood, balsa wood, chipboards, veneers, cork
– paper, cardboard, carton
– textiles, felt, leather
– porcelain, ceramic, terracotta, concrete, marble, artificial stones
– plastic foam
 Speciality: micro-mechanical form lock, mechanical adhesion
13
Agenda
 Introduction
 Adhesive Properties – Synthetic Material
 Adhesive Properties – Wood and Ceramics
 Adhesive Properties – FVK-Materials
 Conclusion
14
Adhesive Properties - Metal
Corrosion Resistant Steels – Stainless Steel
15
Characteristics
● After formation of passive layer very good corrosion resistance
● high-strength and wear-resistant

● weldable
● temperature-resistant
● hygenic
● conductive
16
Fields of Application
● When a high resistance to weather is needed, especially in long-term conditions.
● Chemical Industry
● Medical Industry
althammer.de
● Food Industry
UNIPACK
17
Corrosion Resistant Steels – Stainless Steels
The most important corrosion resistant steels
● V2A - X5 Cr Ni 18 10 (WNr.: 1.4301)

– food industry, chemical machiners... (33% of the production)
● V4A - X2 Cr Ni Mo 17 13 2 (WNr.: 1.4404)

– pharmaceutics, medicine und dentistry… (highly resitant to chlorine containing media)
● V4A - X6 Cr Ni Mo Ti 17 12 2 (WNr.: 1.4571)

– chemical machinery, submarine constructions…
● As well as austenitic Cr Ni-steels 1.4376 and 1.4377
18
Adhesive Properties of the Surface
● The steels form a passive layer at the surface

– this is mainly based on the amount of containeds chrome which reacts with the
surrounding oxygene.
● The passive layer leads to a chemically hardly reacting surface
● This strongly limits intermolecular bonds and bonds created through

chemisorption
19
Corrosion Resitant Steels – Stainless Steel
Possible Surface Treatments:
Degreassing and cleaning
SACO
● Sufficient resistance to ageing
Mechanical Pretreatments (grinding, brushing, blasting)

● Good starting hardness
● Adhesive bond that is sensitive to the materials
20
Adhesive Properties of Steels
Steels, Construction Steel in General
21
Steels, Construction Steels in General
Material Properties I
● Density 7850 kg/m³

● Modulus of Elasticity 210 kN/mm²
● Thermal Conductivity 40 bis 60 W/m·K
● Spec. Heat Capacity 0,46 bis 0,48 kJ/kg·K
● Heat Accumulating Capacity 3611 kJ/m³·K
● Coefficient of Thermal Expansion 12·10-6/K
22
Material Properties II
● Yield Strength (Re σS) 185 - 355 MPa

● Tensile Strength (Rm, σB) 310 - 630 MPa
● Elongation at Break (δ) 18 - 26 %
● Shear Modulus 81000 MPa
● Poisson´s Ration 0,30
23
Adhesive Properties of the Surface
● High surface energy, reactive surface
● Rust Formation
– Pretreatment necessary to bond according to the specific needs
– Mechanical surface pretreatment
● Basically very good adhesive properties
24
 Adhesive Bonding on Oiled Surfaces
● Usage of oil-tolerating adhesives
● Epoxy Resin Adhesive, Plastisols, Butyle Rubber
● Often with support of heat
 Adhesive Bonding on Varnished Surfaces

● Examination of the bond of the varnish to the
underground, i.e. cross cutting test
● Compatibility of adhesive and varnish
25
Adhesive Properties of Metal
Aluminium and Aluminium-Alloys
26
Adhesive Properties of Aluminium/-Alloys
Material Properties I
● Density ρ = 2,7 • 103 kg/m-3
● Melting Point Ts = 666 °C
● Boiling Temperature Tv ≈ 2060 °C
● Specific Heat Capacitiy cp = 896 J kg-1 K-1
● Thermal Conductivity λ = 230 W m-1 K-1
● Coefficient of Thermal Expansion α (0…100 °C) = 23,86 • 10-6 K-1
● Specific Electrical Conductivity χ = 37,74 m Ω-1 mm-2
● Specific Electrical Resistance ρ = 0,0265 Ω mm2 m-1
● Yield Strength (soft) (Re, σS) Re = 9,81… 24,5 MPa (weich);
● Yield Strength (hard) (Re, σS) Re = 68,67 … 98,1 (hart) MPa
27
Material Properties II
● Yield Strength (soft) (Re, σS) Re = 9,81… 24,5 MPa (weich);

● Yield Strength (hard) (Re, σS) Re = 68,67 … 98,1 (hart) Mpa
● Tensile Strength (soft) (Rm, σB) Rm= 39,2 … 49,1 MPa (weich);
● Tensile Strength (hard) (Rm, σB) Rm= 88,3… 17,7 (hart) MPa
● Elongation at Break (soft) (δ) A = 30 … 45 %
● Elongation at Break (hard) (δ) A= 1 … 3 %
● Modulus of Elasticity E = 68,67 GPa
● Shear Modulus G = 26,49 GPa
28
Fields of Application I
● Many areas of application in aviation and astronautics

– Usage since beginning of the 20th Century (for over 100 years)
● Strong increase in use in car constructions

– Within the last 50 years
● The main features, why aluminium and aluminium alloys are used in these
areas, are:
– degree of hardness nearly the same as steel
– low density
– quite high modulus of elasticity
29
Fields of Application II
● Conductor material in form of wires and sheet metals

– (cables, over-head electrical power lines)
● Aluminium foils as packaging materials in the food industry

– (hidden, printed, varnished)
● Cladding and/ or thermal insulation in the building industry

● Container and machinery constructions
● Engines
● Electro-Technical Industry
30
Forms of Corrosion
Surface Corrosion
● no corrosion when attacked with acids or bases
● only when alloy carries a lot of copper
Pitting
● when exposed to salt
● in aggressive atmosphere
● in sensitive alloys the holes can be deep, can also lead to surface corrosion when
alloy not so sensitive
31
Adhesive Properties of Aluminium/-Allyos
Forms of Corrosion
● Intercristalline Corrosion
– mainly in AlMg-Alloys with > 3% Mg-amount when under thermal stress
● Stress Corrosion Cracking

– AlZnMg-alloys from 6% alloy content
● Contact Corrosion
– possible problems in material combinations with steel, copper and copper alloys
– Ni-basic alloys
– Ti-alloys (not with pure titanium) carbon

32
Adhesive Properties of Alumninium/-Alloys
 Problem of infiltration with corrosion
● Have bigger influence on very strong bonds (with EP), than on weaker, elastic
bonds (with PUR)
 Surface Treatment
● Blasting with fine sand
● Etching in an chromo-sulphuric acid bath
● Conversion layer
● SACO (Sandblast Coating)
 With growing Mg-amount

● decrease in strength of the bond
 Adhesives: Epoxy Resin, Polyurethane

33
Copper
34
Adhesive Properties of Copper
Material Properties
Density ρ = 8,93 • 103 kg/m-3

Melting Point Ts = 1083 °C
Boiling Temperature Tv ≈ 2600 °C
Specific Thermal Capacity cp = 385,2 J kg-K
Thermal Conductivity λ = 394 W m-1 K-1
Coefficient of Thermal Expansion α = 16,4 • 10-6 K-1
Specific Electrical Conductivity χ = 58 m Ω-1 mm-2
Specific Electrical Resistance ρ = 0,017241 Ω mm2 m-1
35
Material Properties
Yield Strength (Re, σS) Re = 39,2 … 78,5 Mpa

Tensile Strength (Rm, σB) Rm gegossen = 147,2 - 196,2 Mpa
Elongation at Break (δ) A= 38 … 40 %
Modulus of Elasticity E = 122,6 Gpa
Shear Modulus G = 38,3 … 47,1 GPa
36
Chemical Properties
In contact with air, copper forms a strongly adherent, light-green oxide layer
(patina)
Good resistance to corrosion

Copper only dissolves in oxidating acids
www.uni-kassel.de
Copper roof with typical green colour
37
Technological Properties
● Castability, bad because of the high intake of gas, bubbles and porosity
● Copper can be formed chiplessly in a cold and warm state (car grid), except in
temperatures between 350 … 650 °C
● When cutting copper, the high toughness has to be considered
● Copper and its alloys can be soldered in a cold and hard condition (usage of Cu-,
Ag- und brass solders)
● Adhesive bonding can only take place after surface treatment
38
Adhesive Characteristics (with pretreatment)
● basically quite good for adhesive bonding

● Low e-module has to be considered
– Expansion of joint elements
● To avoid re-cristallisation, work-hardened copper needs a cold-hardening

system.
● Adhesives: Epoxy Resins, Polyurethanes, MS-Polymers
39
Surface Pretreatment for Copper
 Degreasing of the joint connection surfaces

● Roughening through blasting with fine sand (grindig stones or hard cast gravel)
● Post-cleaning
 Pickling of the joint surface at 20°C

● Solution: - water 50l
- iron(III)P-chloride (42% of the solution)
- Nitric Acid (ρ=1,42g/l)
40
Magnesium and Magnesium Alloys
41
Adhesive Properties of Magnesium
 Infiltration with corrosion problematic, in analogy to aluminum
 Pretreatment
 Direct adhesive bonding or sealing of the surface to prevent new corrosion
 Adhesive: Epoxy Resin
42
Matrial Properties
Density ρ = 1,738 • 103 kg/m3

Specific Heat Capacity cp = 1023 J kg-1 K-1
Heat Conductivity λ = 160 W m-1 K-1
Tensile Strength (Rm, σB) Rm = 160 … 250 Mpa
Modulus of Elasticity E = 45 Gpa
Shear Modulus G = 17,7 GPa 43
Surface Pretreatment Methods for Magnesium:
Flourzirkonat Procedure (Fa. Chemetall)
● NP-Bonder C4740
NH 35-Procedure (Fa. Norsk Hydro)

● Cleaning (solvent / alkaline baths)
● Rinsing
● Chromating with NH 35 (20s-30s)
● Rinsing
● Drying
Possible Adhesives: Polyurethanes, Epoxy Resins

44
Titanium and Titanium Alloys
45
Adhesive Properties of Titanium/-Alloys
Material Properties
Density ρ = 4,505 • 103 kg/m3

Specific Heat Capacity cp = 523,4 J kg-1 K-1
Thermal Conductivity λ = 17,2 W m-1 K-1
Specific Electrical Conductivity χ = 2,08 m Ω-1 mm-2
Specific Electrical Resistance ρ = 0,49 Ω mm2 m-1
46
Material Properties
Tensile Strength (Rm, σB) Rm = 300 … 1400 Mpa

Modulus of Elasticity E = 111,8 Gpa
Shear Modulus G = 40,2 GPa
47
Chemical Properties
● In contact with air, titanium forms a thin oxide covering layer

● Resistant to oxidasing materials, solutions with chlorine
● Titanium is sensitive as regards hydrofluoric acid (HF) and solutions with fluorine
ions and is attacked strongly
● High affinity towards hydrogen
● Inorganic acids (esp. nitric acid HNO3) strongly attack titanium
● Good chemical resistance against sea water and sweat
48
Titanium Alloys (Selection)
● Pure Titanium Ti or TiPd 0,15

● Single-phase α-alloy TiAl5Sn2,5, TiAl8Mo1V1
● Single-phase β-alloy TiV13Cr11Al3
● α + β-alloys TiAl6V4 F89, TiAl6V6Sn2,
TiAl7Mo4
● Casted pure titanium G-Ti2
● High-strength cast alloy G-TiAl5Fe2,5
49
Technological Properties
● Can be cold-formed chiplessly or welded (hdP-Grid)

● Can be cut well (Drilling, Rotating, Milling)
● Good formability (Casting)
● Good weldability (Laser, WIG- and MIG-welding with Argon)
● Good adhesive bonding qualities after specific pretreatment
● Soldering, good when doing soft-soldering with the help of fluxes
50
● Chemical Industry
– In systems for chlorine chemistry
● Aviation and Astronautics

– Highly strong wiht low weight
www.stern.de
Medical Technology- Titanium Implants
● Biomedical Engineering (Implants)
51
Adhesive Characteristics
● Surface treatment necessary
● Infiltration with corrosion problematic
Adhesives: highly temperature resistant poly condensation adhesives and hot-

curing epoxy resin systems (mainly examined through usage in aviation)
52
Possible Surface Treatments:
Joint surface has to be cleaned before, inbetween and after all surface
treatments
Removal of oxide layers and roughening
● Chemically
– Pitching with non-oxidising acids (hydrofluoric acid, hydrochloric acid, sulphuric acid
diluted)
● Mechanical
– Blasting (aluminium oxide or sand) or with abrasive cloth
– roughening wiht rotating steel brushes
After the pretreatment, either the adhesive bonding process must start
immidiately or primers have to be applied to avoid new oxidation
53
Agenda
 Introduction
 Adhesive Properties – Synthetice Materials
 Adhesive Properties - FVK-Materials
 Conclusion
54
Adhesive Properties of Synthetic Materials
Basic problem when using adhesive technology on synthetic

materials:
 Low Surface Energy

 Changeable Compositions
 Softeners
 Release Agents
55
Differentiation between:
 Adhesion Bonding
● Basically for all synthetic materials
● Mostly no formations of stress cracks
● Good gap bridging qualities
 Diffusion Bonding
● The surface can be dissolved or swelled with the proper solvents
● This makes the molecules more mobile and they can diffuse into the joint counterpart
● Polyvinyl chloride (hard/soft) (PVC), perspex (PMMA), acrylnitrile-butadiene-styren-
copolymer (ABS), polystyrene (PS), polycarbonate (PC)
● Solvents: THF, MEK
56
Classifications of the Synthetics
Thermoplastic Synthetics
● Solvable/swellable in organic solvents
– Diffusion and adhesion bonding possible
● Not solvable/not swellable in organic solvents

– Adhesion bonding
Duromers
● Only adhesion bonding
57
Diffusion Bonding Diffusion Bonding

(Advantages) (Disadvantages)
+ Quick starting hardness  Low bridge gapping
+ Easy to use  Solvents

 Tension crack formation
+ Good optical qualities
 Bond cannot be put under
+ Low influence of the surface, much load
softeners and release agents
 Tempering, 60°C - 80°C
1h - 3h
58
Classification According to Bonding Qualities
unpolar / soluble polar / hardly soluble unpolar / hardly soluble

polar / soluble polar / non-soluble unpolar / non-soluble
Polystyren (PS) Polyamide (PA) Polyethylene (PE)
Polyvinyl chloride (PVC) Polyterephtal acid ester Polypropylene (PP)

(PETP)
Polymethylmethacrylate Polytetrafluorethylene
(PMMA, Plexiglas) (PTFE, Teflon)
Good Bonding Qualities* Limited Bonding Qualities* No Bonding Qualities*

* without surface pretreatment
59
Surface Treatment Methods for Synthetic Materials
 Cleaning
 Roughening
 Etching
 Flame Treatment
 Primer
 Fluorinating
 Corona
 Plasma-Treatment
 SACO
 Laser-Treatment
60
Polyvinyl Chloride (PVC)
61
 Polyvinyl Chloride (PVC)
PVC-U (hart) PVC-P (weich)

Density 1,38-1,40 g/cm³ 1,20-1,35 g/cm³
E-Modulus 1000-3500 MPa k. A.
Tensile strength 50-75 MPa 10-25 MPa
Melting Point Decomposition >180 °C Decomposition >180 °C

Solubility Soluble in organic solvents Soluble in organic solvents
(Acetone, Ester…) (Acetone, Ester…)
-50 °C - +60 °C
Temp. Area
62
Fields of Application (PVC)
● Pipes (hard)
● Packages (hard/soft)
● Food Packaging (soft)
http://www.mcm-systeme.de
● Hoses/Tubes (soft)
● Floor Covering (soft)
obi.de
63
Bonding Qualities of Polyvinyl Chloride (PVC-U, hard)
The surface is polar and soluble

● Surface Energy: 40 mN/m
Hard PVC is easy to bond

● Solubility allows diffusion bonding
● Adhesion bonding is possible after easy surface pretreatments
Adhesives: Reactive Adhesives
64
Bonding Qualities of Polyvinyl Chloride (PVC-P, soft)

● Surface energy: 40 mN/m
Soft PVC is only bondable to a certain degree

● When doing adhesion bonding, the amount of softeners has to be considered
● Softeners can diffuse into the adhesive layer and reduce the strength of the
bond
● Adhesives: Cyanacrylate, NBR-Contact Adhesives, reactive PUR-Hotmelt
Adhesives
65
Polystyrene (PS)
66
Material Properties of Polystyrene (Thermoplastic)
Standard Foamed
Density 1,040 - 1,090 kg/cm3 0,015 - 0,090 kg/cm3
Melting Temperature 110 °C 110 to 120 °C
Continuous Operating -60 to 80 °C -180 to 75 °C

Temperature
unstable unstable
UV-Resistance
unstable unstable
Resistance to the Weather
soluble soluble
Solubility 67
Standard
● Packaging
● Household Objects
● Toys
● Electro-Technology http://www.chemgapedia.de
Foamed (PS-E)
● Building (Insulation)
● Packaging Industry
www.bauen.de
68
Adhesive Characteristics of Polystyrene

● Surface energy: 31-33 mN/m
Polystyrene can be bonded very well

– When polystyrene is foamed, it is important to regard that even small amounts of
solvents make big holes (material is dissolved).
● Surface Treatments: Flame Treatment, Corona, Low Pressure Plasma, Etching,
Dissolving
69
Polymethyl Methacrylate (PMMA)
70
Material Properties of Polymethyl Methacrylate (PMMA) (Thermoplastic)
● Gross Density 1180.00 kg/m³

● Elasticity Modulus: 3200.00 N/mm²
● Continuous Operating Temperatures -40.00 bis 70.00 °C
● Melting Point 105.00 °C
● Resistance to the Weather Resistant
● Resistance Alcohol and solvents lead to
tension cracks
71
Fields of Application (Plexiglass)
● Optics
● Electro-Technology
● Vehicle-Constructions
● Building Industry
● Construction of Fairs and Exhibitions
● Protection Glazing
● Sanitary Systems
http://www.koenig-kunststoffe.de
72
Adhesive Characteristics of Polymethyl Methacrylate (PMMA)
Polymethyl Methacrylate can be bonded easily

● Diffusion bonding is possible, if PMMA is not interlinked
– If PMMA is interlinked, then tension cracks can occur, caused by the solvent
● Adhesion bonding is possible after easy surface pretreatment
Adehsives: mainly Reactive Adhesives (MMA, CA, UV-curing Acrylates,

Solvent-Based Adhesives, MS-Polymers)
73
Polyamide (PA)
74
Material Properties of Polyamide (PA, Nylon) (Thermoplastic)
● Elasticity Modulus 3300.00 N/mm2

● Gross Density [ρ] 1140 kg/m3
● Resistance to Alkalines unstable
● Resistance to Acids unstable
● UV-Resistance unstable
● resistance to the Weather unstable
● Continuous Operating Temperature -30.00 to 95.00 °C
● Melting Point 260.00 °C
75
Fields of Application for Polyamide (PA, Nylon) (Thermoplastic)
● Maschine Constructions
– Slide Bearings, Gears…
● Vehicle Constructions
● Electro-Technolog
● Clothing
thyssenkrupp-plastics.de
76
Adhesive Characteristics of Polyamide
The surface is polar and hardly soluble
Polyamides are only suitable for adhesive bonding to a limited degree

● Due to the solubility, diffusion bonding is basically possible (formic acid)
Adhesives: Reactive Adhesives (PUR, EP)
77
Polyethylene Terephthalate (PET)
78
Material Properties of Polyethylene Terephthalate (PET) (Thermoplastic)
● Elasticity Modulus 2 300.00 N/mm2

● Gross Density [ρ] 1 200.00 kg/m3
● Resistance to Alkalines limited resistance

● Resistance to Acids limited resistance
● UV-Resistance limited resistance
● Resistance to the Weather limited resistance
● Continuous Operation Temperature-30.00 to 70.00 °C
79
about 6,5% of the world-wide production of synthetics is that of PET
● Packaging Industry
– PET-bottles
● Construction of Exhibitions
● Maschine Constructions
www.dew-stahl.com
80
Adhesive Characteristics of PET
The surface is polar and not soluble

PET can only be used for adhesive bonding to a limited degree

● Non-solubility prevents diffusion bonding
● Adhesion bonding is possible after easy surface treatments (etching wih NaOH,
roughening)
81
Polypropylene (PP)
82
Material Properties of Polypropylene (PP) (Thermoplastic)
● Elasticity Modulus 1300 N/mm²

● Gross Density [ρ] 906 kg/m³
● Resistance to Alkalines resistant

● Resistance to Acids resistant
● Continuous Operation Temperature 0 to 100 °C

● Melting Point 163 °C
83
Fields of Application for Polypropylene (PP)
About 20% of the world wide production of synthetics contains polypropylene
● Building Industry
– Pipes
● Vehicle Constructions
– Interior of cars
● Electro-Technology
● Packaging
84
Adhesive Characteristics of Polypropylene (PP)
The Surface is unpolar and hardly soluble

Polypropylene is hard to bond adhesively

● Adhesion bonding is possible after surface treatment
● Possible surface treatments: flame treatment, Corona, SACO, low pressure
plasma, primering
Adhesives: Reactive Adhesives, i.e. Cyanacrylates
85
Polytetrafluorethylene (PTFE)
86
Material Characteristics of Polytetrafluorethylene (PTFE) (Thermoplastic)
● Elasticity Modulus 500 N/mm²

● Gross Density [ρ] 2170 kg/m³
● Resistance to Alkalines resistant
● Resistance to Acids resistant
● UV-Resistance resistant
● Resistance to the Weather resitant
● Continuous Operating Temperature-200.00 to 260.00 °C
● Melting Point 327 °C
87
Fields of Application for Polytetrafluorethylene (PTFE, Teflon)
– Anti-adhesive coatings for frying pans
● Engineering www.castan-elastomere.de
PTFE-seals
– statically and dynamically stressed loads
● Medical Technology
– artificial veins and arteries
www.herzzentrum.ch
Stent, PTFE coated
88
Adhesive Characteristics of PTFE
The surface of PTFE is unpolar and not soluble

PTFE cannot be bonded adhesively without prior treatment

● Diffusion bonding cannot happen, due to lack of solubility
● Adhesion bonding: Due to the very low surface energy, a sufficient wetting
cannot take place without prior surface treatment
● Possible surface pretreatment: special primers
● Adhesives: Cyanacrylates
89
Group: Thermosetting Plastics
90
Chemical Properties of Duromers (also Thermosetting Plastics)
Synthetic Charcteristics: Not soluble/not-swellable in organic solvents

● Therefore: only adhesion bonding possible
● Surface energies have to be increased with the help of suitable surface
treatments
– This allows the conclusion that it has a good chemical resistance
Synthetics
● Epoxy Resins (EP), Phenolic Resins (PF), Urea Resins (UF), Melamine Resins
(MF), different Polyurethanes (PUR)
91
Mechanical Properties of Duromers (also Thermosetting Plastics)
Duromers do not turn soft any more after being heated

● this means that when they are completely hardened, they cannot be melted or
welded any more
Duromers are much harder and more porous than thermoplastics
● Duromers do not deform when under tensile stress, they rather break
Adhesives: mainly Epoxy Resins, Polyurethanes
92
Survey
Adhesion Bonding Diffusion Bondingsklebung

Polyethylene (PE) Polyvinyl Chloride (hard/soft) (PVC)
Epoxy Resin (EP) Plexiglass (PMMA)
Different Polyester Acrylnitriel-Butadiene-Styrene-Copolymers
Polyurethanes (PUR) (ABS)
Polypropylens (PP) Polystyrene (PS)
Teflon (PTFE) Polycarbonaet (PC)
Phenolic- (PF) Different Types of Rubber
Urea- (UF)
Melamine Resins (MF)
> Pretreatment necessary! > Possible without pretreatment
93
Agenda
 Introduction
 Adhesive Properties – Hybrid Materials
 Conclusion
94
Adhesive Properties of Glass
Mechanical/ Chemical Properties of „Normal Glass“
Physically, glass is an undercooled liquid

● At about 1.400 °C to 1.650 °C glass melts and turns liquid
● Density
● Thermal Expansion
● Inert Surface
● Resistant to Media
● Can Take High Temperatures
95
Adhesive Properties of Glass
Surface Properties of Glass
Because of its chemical composition, glass has the chracteristic that it can bind
humididty at its surface.
● This layer of humidity can prevent bonding forces to a certain extent.
Aim of the surface pretreatment must therefore be to remove the layer of
humididty from the surface. (Temporarily for the time of the application of the
adhesive)
– heating of the surface leads to the evaporization of the humidity and at the same time
quickens the reaction of the adhesive
Adhesives: Polyurethanes (PUR), suitable Epoxy Resins
96
Agenda
 Introduction
 Adhesive Properties - FVK-Materials
 Conclusion
97
Adhesive Properties of Wood and Ceramics
Wood
98
Adhesive Properties of Wood
General Properties of Wood
As a natural product, wood has a more or less strongly developed porous
structure.
● Mechanical Adhesion (micro-mechanical form lock)
It has the characteristic to absorb humidity from the environment (hygroscopic
characteristic)
● Changes in the amount of humidity lead to a change in the cross-section

● The amount of humidity and its effect on the adhesive and the curing process has
to be taken into consideration
99
Hygroscopic Characteristics
As wood takes humidity from its environment, it has no high dimensional
stability
● If the surrounding climate and the humidity are constant, then the dimensions stay
constant
● Under the fibre saturation range (about 25-35% moisture), the wood either
swells or shrinks due to the change in humidity
– Coefficient for shrinkage or swelling shows the change in size per percent change in
wood moisture
100
Anisotropy
For wood, three directions need to be distinguished as they have different
properties, depending on their direction
Example Shrinkage:
● Axial
– Coefficient for shrinkage: ~0,3%*
● Radial (parallel to wood rays)

– Coefficient for shrinkage: ~5%*
● Tangential (parallel the tree-rings)

– Coefficient for shrinkage: ~10%*
* Mittlerer Wert für europäisches Nutzhölzer
101
Mechanical Properties – Soft Wood
Coefficient for
Strength (N/mm²)
Shrinkage
Gross E-
Tyoe of
Density Modulus
Wood Tensile Pressure Bending( Shear
(kg/m³) radial tang. (N/mm²)
(axial) (axial) quer) (axial)
Spruce 470 0,15 0,32 80 40 68 7,5 10.000

Pine 520 0,15 0,30 100 45 80 10 11.000
Larch 590 0,20 0,44 105 48 93 9 12.000
102
Mechanical Properties - Hardwood
Coefficient for
Strength (N/mm²)
Shrinkage
Gross E-
Tyoe of Wood Density Pressur Modulus
(kg/m³) Tensile Bending Shear (N/mm²)
radial tang. e
(axial) (quer) (axial)
(axial)
Birch 650 — — 137 60 120 12 14.000

Beech 690 0,19 0,34 135 60 120 10 14.000
Oak 670 0,15 0,26 110 52 95 11,5 13.000
Ash 690 0,19 0,34 130 50 105 13 13.000
Robinia 730 — — 148 60 130 16 13.500
Sipo 590 0,22 0,25 110 58 100 9,5 11.000

Azobé 1060 0,32 0,42 180 95 180 14 17.000
103
Fields of Application for Wood + Bonding
Plywood, Veneer and cross-laminated timber

 Flat materials such as chipboards
Plywood, www.holzland-stoellger.de
Medium-dense fibreboard, MDF
OSB- Boards (oriented strand board)
Laminated Timber (BSH) from bonded boards,
using pressure and, if necessary, heat
…
MDF, bcwest.pfleiderer.com
104
Influence of the Degree of Moisture
The degree of moisture at the time of the adhesive bonding process is very
important for the quality of the bond.
● The highest possible, acceptable degree of moisture depends on the specific
adhesive in use
If the degree of moisture is exceeded, this leads to:
● when using dispension adhesives, the diffusion of water might be obstructed,
which leads to longer hardening periods. It can also lead to a dilution of the
adhesive.
● when using condensation adhesives, water can be locked in, which can lead to
shrinkage.
● when applying hotmelt adhesives, it can lead to the formation of steam, which
weakens the bonding forces.
105
Agenda
 Introduction
 Adhesive Properties - Wood
 Adhesive Properties- FVK-Materials
 Conclusion
106
Adhesive Properties of FVK-Materials
 GFK – Glass Fibre Reinforced Plastics

 CFK – Carbon-Fibre Reinforced Plastics
 As material for the matrix, the following material can be used:

– Duromers (Polyester Resin or Epoxy Resin)
– Thermoplastics (i.e. Polyamide, PTFE)
 The adhesive properties are those of the matrix material
107
 Fields of Application
● GFK- and CFK-materials are very important for leight-weight constructions
● Examples
– Shipbuilding
– Aviation
– Cycling
Bicycle frameout of CFK
– Vehicle Constructions
www.produktion.de
CFK and GFK – Components in the A380
CFK-car body i3, Source: BMW Group

108
 Pretreatment should harm the fibres as little as possible
 Degreasing
 Peel-Ply allows the formation of pure, undamaged joint areas
 Corona
 Low pressure plasma
 Laser teatment (defined surface modification)
 Mechanical Pretreatment (grinding, brushing, blasting) (danger of damaging
the fibres)
109
Agenda
 Introduction
 Conclusion
110
Material Combinations
In General
The advantage of adhesive bonding in contrast to other methods is that

basically every material combination is possible.
● The different adhesive properties of the joint elements must be taken into
consideration.
● To ensure durability after hardening of the bond, the coefficients for the thermal
expansion of all components must be considered.
– To big differences in the expansion lead to tensions in the adhesive layer, which can then
lead to cracks in the bond.
111
Metal-Plastic-Bonds
112
Metal-Plastic-Bonds
The bond must be joined through adhesion bonding

● Diffusion bonding cannot be done with metals as they are not soluble.
A surface pretreatment is necessary
Thermal Expansion
● The relation of the expansion of metal to plastic is about 1:5
– The bigger the bonding area, the more important the expansion is
– If the bonding area is small, the influence is not critical
113
Metal-Plastic-Bonds
For the general selection of adhesives this means:
● For small bonds and/or low stress through heat

– 2C-Epoxy Resin Adhesive
● Bigger bonding areas and/or higher stress through heat

– 2C-Polyurethane Adhesive
● Also possible:
– Methacrylate Adhesive, Contact Adhesive , Foamed Adhesive Tapes
114
Metal-Plastic-Bonds
Special Case: Bonding of translucent plastics to metals

● Usage of an additional radiation hardening adhesive
Not suitable Adhesives

● Dispersion Adhesives
● Hotmelt Adhesives (Thermal Stress)
● Hot-Hardening Reactive Adhesives (Thermal Stress)
115
Glass-Metal-Bonds
116
Glass – Metal – Bonds
Material combination needs adhesion bonding

● No solubility
Surface Pretreatment
Thermal Expansion
● Relation 1:10:2 Glass:Plastic:Metal (KM 5:1, KG 10:1)
– Adhesive needs high deformation properties
– Unnecessary stress through heat should be avoided
117
Adhesive Selection
● Preferably cold-hardening systems
– avoid heat
● Adhesive with good deformation qualities

– to compensate tensions that result from the different expansions.
Suitable Adhesives
● Polyurethane, Contact Adhesives and specially flexible adjusted Epoxy
Resin
118
Special Situation must be taken into consideration

● i.e. UV-exposure of the adhesive layer (i.e. windscreen)
– suitable black primers should be used to protect the adhesive layer
Unsuitable Adhesives
● Basically all adhesives that are hard and porous
119
Agenda
 Introduction
 Conclusion
120
Conclusion
 Looking at the adhesive properties of the materials, or the material
combinations, results in:
● Choice of suitable adhesive system

– i.e. Adhesion bonding, diffusion bonding, (special autohesion)…
● Choice of suitable adhesive

– i.e. Epoxy resin, Cyanacrylate, pressure sensitive adhesive, certain solvent-based
adhesives …
● Choice of suitable surface pretreatment
– mechanicsl, physical or chemical
 The environment of the joint elements must also be considered!

121

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Adhesive Manufacturing Processes

Chapter 5: Joint Element Materials

Univ.-Prof. Dr.-Ing. Prof. h.c. Stefan Böhm

 Adhesive Properties - Metal

 Adhesive Properties – Synthetic Materials

 Adhesive Properties - Glass

 Adhesive Properties – Wood

 Adhesive Proerties - FVK-Materials

Schematic depiction of the surface layers of metallic material

Metallic Base Material Boundary Layer

● The foreign substance layer (dirt) has no defined thickness.

 Layer Thickness: 0.1-100μm Metallic Nase Material Boundary Layer

 The boundary layer is formed by deformation processes and/or through cutting

(Source: Habenicht, S.2965ff)

Thickness: 0.01-0.1 µm Metallic Base Material Boundary Layer

Thickness: 0.001-0.01µm Metallic Base Material Boundary Layer

Metallic Base Material Boundary Layer

Layer thickness cannot be defined

Metallic Base Material Boundary Layer

Further surface layers can be created by adding metallic coatings.

 Difficulties occur when the surface has negative properties:

● Oiled surface (protection against corrosion)

 Depending on the synthetic, further negative properties can influence the

– paper, cardboard, carton

– textiles, felt, leather

– porcelain, ceramic, terracotta, concrete, marble, artificial stones

 Speciality: micro-mechanical form lock, mechanical adhesion

 Adhesive Properties - Metal

 Adhesive Properties – Synthetic Material

 Adhesive Properties - Glass

 Adhesive Properties – Wood and Ceramics

 Adhesive Properties – FVK-Materials

Corrosion Resistant Steels – Stainless Steel

● After formation of passive layer very good corrosion resistance

● high-strength and wear-resistant

● V2A - X5 Cr Ni 18 10 (WNr.: 1.4301)

● V4A - X2 Cr Ni Mo 17 13 2 (WNr.: 1.4404)

● V4A - X6 Cr Ni Mo Ti 17 12 2 (WNr.: 1.4571)

● As well as austenitic Cr Ni-steels 1.4376 and 1.4377

● The steels form a passive layer at the surface

● The passive layer leads to a chemically hardly reacting surface

● This strongly limits intermolecular bonds and bonds created through

Mechanical Pretreatments (grinding, brushing, blasting)

Steels, Construction Steel in General

● Density 7850 kg/m³

● Yield Strength (Re σS) 185 - 355 MPa

● High surface energy, reactive surface

– Mechanical surface pretreatment

● Basically very good adhesive properties

 Adhesive Bonding on Varnished Surfaces

Aluminium and Aluminium-Alloys

● Yield Strength (soft) (Re, σS) Re = 9,81… 24,5 MPa (weich);

● Many areas of application in aviation and astronautics

● Strong increase in use in car constructions

– quite high modulus of elasticity

● Conductor material in form of wires and sheet metals

● Aluminium foils as packaging materials in the food industry

● Cladding and/ or thermal insulation in the building industry

● Stress Corrosion Cracking

– Ti-alloys (not with pure titanium) carbon

 With growing Mg-amount

 Adhesives: Epoxy Resin, Polyurethane

Density ρ = 8,93 • 103 kg/m-3