Adhesive joining technology

AMT 2503
Shanmuga Raja .B (BVB0912004)

Module leader

: Mr. K.N. Ganapati

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Introduction
Adhesive joining is an interfacial (Surface) bonding technique of two similar or dissimilar material. Two principle bonding types are,
Structural bonding Capable of transmitting stresses without integrity loss.

Non-structural bonding Support by holding material in place without loading criteria

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Terminology & requirements

Adhesive composition: Adhesive base or binder. Hardener (Promote curing) Solvent (improve viscosity) Diluents (reduce concentration) Fillers (electric characteristics) Reinforcements (strength) Requirements for good bond are, Proper choice of adhesive (film, paste, etc., performance based) Good joint design (ability to withstand loads and stresses) Cleanliness of surface (efficiency of adhesion) Wettability (spreadability and remove trapped air) Proper adhesive bonding process (physical, chemical method)
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Adhesion theory
Electrostatic theory: Noticed from electrical discharges while peeling adhesive from substrate. Diffusion theory: Chemically similar material soluble in one another Mechanical theory: Through penetration into pores or surface asperities. Chemical bonding theory: Promoting formation of covalent, ionic or hydrogen bond.
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Classification
Adhesives Natural Organic
Cassein Gellatin Asphalt

Synthetic

Thermoplastic
- Acrylic - Polyvinyl chloride - Polyamide

Thermosetting
- Epoxy - Polyester - Melamine formaldehyde

Inorganic
- Sodium silicate - Magnesium oxychlodide

Elastomeric
- Polyurethane - Nitrile rubber - Silicone

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Adhesive selection factors

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Processing
Surface Preparation (Clean surface, strong bond) Solvent cleaning Chemical etching Mechanical abrasion Corona treatment Brushing Spraying Flowing Roll coating Automatic applicators Ovens Heaters Autoclave
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Adhesive application (Paste, film, powder)

Curing (Temperature, pressure)

Adhesive joint failure mode

The failure mechanism occurring in the joints are, Cohesive failure Inability of adhesive material to resist internal separation. Adhesive failure Inability of adhesive material to stick to the adherent.
Cohesive Adhesive

Load applied on joint causing failure

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General design considerations

Provide maximum bonding area possible to minimize stress on adhesives. Shear stress is constant along the scarf joint.

Taper the adherent to reduce peel stress.

Choose ductile adhesive, which can perform along with the adherent modulus. Design the joint to counter the loading direction. Design the joint for easy adhesive application, curing and inspection.
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Joint design

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Quality control
Adhesive: Incoming material with shelf life is tested for, Physical properties (percent flow, gel time, percent volatiles) Mechanical properties (shear, flexural, fatigue) Surface preparation: The degree of cleanliness can be checked by, Water break test (laminar flow of water without break) Contact angle test (wettability of surface) Bonding: The defects such as debond,, voids, poor adhesion and cohesion can be tested by, Fokker bond tester (debond, cohesion) Ultrasonic (voids, adhesion) Thermography (voids, debond)
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Safety
Adhesive contain many chemical agents and is specified by manufacturer in MSDS. NFPA rating for hazard

PPE proposed based on severity and application.

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Pros and Cons

Pros: + Stress distribution is uniform with larger stress bearing area. + Reduce or prevent electrochemical corrosion between dissimilar material. + Resistance to fatigue or cyclic loads. + Act as a sealant against various environment. + Insulate against heat transfer and electrical conductance. + Provides dampening against shock. Cons: Careful surface preparation is required to ensure quality bond. Long cure time with temperature control is required in thermoset. Holding jig, presses, autoclaves are required for the process. Rigid process control ensuring cleanliness is mandatory. Service life is dependent on the environment exposure. Natural adhesive are susceptible to microbial attack.
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References
Unknown (n.d.,) Adhesive Bonding, [online] available from <http://www.scribd.com/doc/98786479/Adhesive-Bonding-2> [08 Aug 2013] Ed, Sina Ebnesajjad (2008) Adhesives technology Handbook, 2nd edn, USA: William Andrew Inc, Dr. S. Srikari (2013) Module notes Cutting, Machining and Joining of Plastics and Composites, Bengaluru: MSRSAS Raja Hussain (2013) Module notes Brazing, Soldering and Adhesive bonding, Bengaluru: MSRSAS

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