Adhesive Bonding: Materials, Applications and Technology

Adhesive Bonding Materials, Applications and Technology......Page 2
Contents......Page 8
Preface......Page 18
List of Contributors......Page 20
1 Adhesive Bonding as a Joining Technique......Page 22
2 The Historical Development of Adhesive Bonding......Page 26
3.1 Introduction......Page 32
3.2 Classical Adhesion Theories......Page 35
3.2.1 Polarization Theory......Page 38
3.2.2 Diffusion Theory......Page 41
3.2.3 Chemical Reactions......Page 42
3.3 Adhesion in Real Systems......Page 45
3.3.2 Polyethylene and Polypropylene......Page 46
3.4 New Concepts in the Field of Adhesion......Page 47
3.5 Conclusions......Page 49
4.1 Noncuring (Pressure-Sensitive) Adhesives......Page 50
4.2.1 Contact Adhesives......Page 54
4.2.3 Hot-Melt Adhesives......Page 55
4.3.1 Two-Part Adhesives......Page 56
4.3.3 Cold-Setting, One-Part Adhesives......Page 57
4.4 Primers......Page 58
4.5 General Handling Instructions......Page 59
5 Chemistry and Properties of Adhesives and Primers......Page 60
5.1.2 Chemistry of Pressure-Sensitive Adhesives......Page 61
5.1.3 Physical Properties of Pressure-Sensitive Adhesives......Page 64
5.1.4 Properties of Pressure-Sensitive Adhesives as a Function of  Temperature......Page 65
5.1.7 Creep......Page 66
5.1.8.2 Typical Formulation of Block Copolymer PSAs......Page 67
5.2.1 Composition of Contact Adhesives......Page 68
5.2.2 Properties and Fields of Application of Contact Adhesives......Page 69
5.3 Hot Melts......Page 70
5.3.1 Thermoplastic Hot Melts......Page 71
5.3.3 Plastisols......Page 72
5.3.6 Epoxy Resin-Based Reactive Hot Melts......Page 73
5.4.1 Chemistry of Phenolic Resins......Page 74
5.4.2 Formulation of Phenolic Resin Adhesives......Page 77
5.4.3 Behavior and Applications of Phenolic Resin Adhesives......Page 78
5.5.1 Chemistry of Epoxy Resin Adhesives......Page 79
5.5.2 Reactions of Epoxy Resins......Page 80
5.5.3 Properties of Epoxy Resin Adhesives......Page 81
5.5.4.1 Epoxy Resins......Page 84
5.5.4.4 Flexibilizers and Additives That Improve Impact Toughness......Page 85
5.5.4.7 Typical Epoxy-Resin Adhesive Formulations......Page 86
5.6.1 Chemistry of Polyurethanes......Page 87
5.6.2.1 Isocyanates......Page 88
5.6.2.2 Polyols......Page 89
5.6.3.1 One-Part Polyurethane Adhesives......Page 90
5.6.4 Formulations of Polyurethane Adhesives......Page 91
5.7.2 Chemically Setting Acrylates......Page 92
5.7.2.1 Monomers......Page 94
5.7.2.2 Two-Part Acrylates/Methacrylates......Page 95
5.7.2.4 Examples of Application......Page 96
5.7.2.5 Anaerobic Acrylates......Page 97
5.7.2.6 UV-Setting Acrylates......Page 98
5.7.2.7 Cyanoacrylate Adhesives......Page 104
5.7.3.2 Formulations of UV-Setting Acrylate Adhesives......Page 105
5.8.1 One-Part Silicone Adhesives......Page 106
5.8.2.1 Condensation Crosslinking......Page 107
5.8.2.2 Addition Crosslinking......Page 108
5.9.1 Introduction......Page 109
5.9.2 Natural Raw Materials......Page 110
5.9.3 Modern Adhesives Based on Natural Raw Materials......Page 112
5.9.3.2 Casein Glues......Page 113
5.9.3.4 Natural Material-Based Pressure-Sensitive Adhesives......Page 114
5.10 Chemistry of Primers and Adhesion Promoters......Page 115
5.10.1 Primers......Page 116
5.10.2 Adhesion Promoters......Page 117
5.11 Fillers......Page 120
6.1.1 Interaction of Polymer Behavior and State of Stress......Page 122
6.1.2 Design of Adhesive Bonded Joints......Page 124
6.1.3 Dimensioning of Adhesive Bonded Joints......Page 125
6.2 Surface Preparation......Page 129
6.2.1.1 Grit Blasting......Page 130
6.2.1.3 Brushing......Page 131
6.2.3.2 Microplasma Treatment......Page 132
6.2.4 The Preconditions of Adhesion......Page 133
6.2.5 Protection of Prepared Surfaces......Page 135
6.3.1.1 Processing of Two-Part Adhesive Systems......Page 136
6.3.1.2 Processing of One-Part Adhesive Systems......Page 140
6.3.1.4 Film Adhesives......Page 142
6.3.1.5 Hybrid Bonding......Page 143
6.3.2 Quality Assurance......Page 144
7 Adhesives and Adhesive Joints: Test Methods and Properties......Page 146
7.1.1 Stress–Strain Analysis of Bulk Specimens......Page 147
7.1.2 Determination of Tg by Dynamic Mechanical Analysis or Differential Scanning Calorimetry......Page 148
7.2.1 Tensile Stress (e.g. Butt Joints)......Page 149
7.2.2 Shear Stress (e.g. Single Lap Shear Specimen)......Page 151
7.2.3 Cleavage (e.g. Wedge Test)......Page 153
7.2.5 Wedge Test......Page 154
7.2.6 Peel Test......Page 155
7.3.1 Long-Term Static Tests (e.g. Creep Experiments Under Dead Load)......Page 158
7.3.2 Impact Tests (e.g. Impact Wedge Test to Evaluate Crash Performance)......Page 159
7.4 Assessment of Durability and Service Life of Adhesive Joints......Page 160
7.5.2 Open Time and Working Life......Page 164
7.5.5 Volatile Organic Compound (VOC) Emissions......Page 165
7.6 Nondestructive Testing Methods......Page 166
7.6.3 Magnetic, Electrical and Chemical Techniques......Page 167
7.6.4.1 Impulse-Induced Resonance......Page 168
7.6.4.2 Pulse Echo......Page 169
7.6.5.1 Optical and Ultrasonic Lockin Thermography......Page 170
7.6.5.2 Ultrasound Burst Phase Thermography......Page 172
7.6.5.3 Excitation Mechanisms for Active Thermography......Page 174
7.6.6 Assessment of Nondestructive Testing Methods......Page 176
7.7 Applications of Test Methods in Structural Adhesive Bonding......Page 177
7.7.1 Tensile Shear Strength Under Short-Term Loading......Page 178
7.7.2 Tensile Shear Strength Under Long-Term Static and Alternating Loading......Page 183
7.7.3 Peel Strength......Page 185
7.7.4 Impact Behavior......Page 186
7.7.5 Durability of Bonded Joints......Page 187
7.7.6 Adhesive Bonding of Aluminum......Page 189
7.7.7 Adhesive Bonding of Steel......Page 204
7.7.8 Adhesive Bonding of Glass......Page 209
7.8 Experiences and Learning from Damage Cases......Page 212
7.8.1 Delamination of Bonded Rotor Blade Pockets......Page 214
7.8.2 Total Separation of a Rotor Blade Prole......Page 215
7.8.3 Bond-Line Corrosion in Wing Honeycombs......Page 217
7.8.4 Delamination of the Outer Cover Sheet of Tail Units of Aircraft......Page 218
7.8.5 Temperature-Induced Damage on a Tail Rotor Blade......Page 220
7.8.6 Temperature-Induced Delamination of a Bonded Glass Fiber Patch......Page 221
7.8.7 Incorrect Design of Bonded Filter Elements......Page 222
7.8.8 Deciencies of the Peel Ply Treatment......Page 223
8.1 Introduction......Page 226
8.2 Transportation......Page 227
8.2.1 Aircraft Manufacture......Page 228
8.2.1.1 Historical Development......Page 230
8.2.1.2 Advantages of Bonding in Aircraft Manufacture......Page 234
8.2.1.3 Adhesives Used in Aircraft Manufacture......Page 237
8.2.1.4 Surface Preparation......Page 238
8.2.1.6 Quality Control of Bonding in Aircraft Manufacture......Page 239
8.2.1.7 Conclusions......Page 240
8.2.2 The Automotive Industry......Page 241
8.2.2.1 Bonding in Passenger Car Bodywork Construction......Page 244
8.2.3 Bonding in Rail Vehicle Manufacture......Page 255
8.2.4 Shipbuilding......Page 256
8.3.1.1 Adhesive Mortars for Tiling......Page 258
8.3.2.1 Adhesive Anchor Systems......Page 259
8.3.2.2 Adhesives......Page 261
8.3.4 Structural Bonding in Structural Steel and Facade Engineering......Page 262
8.4.1 Introduction......Page 264
8.4.2.1 The Molecular Structure of Wood......Page 266
8.4.3.1 Strength, Swelling and Shrinking......Page 267
8.4.5 Adhesive Systems......Page 268
8.4.6 Adhesives Based on Renewable Resources......Page 269
8.4.7.2 Chemically Setting Adhesives......Page 270
8.4.8 Wood Composites......Page 272
8.4.9.2 Laminated Wood Constructions Today......Page 274
8.4.10 Prefabricated Elements......Page 276
8.5.1 Introduction......Page 278
8.5.2.1 Corrugated Board and Paperboard Containers......Page 279
8.5.2.3 Folder Gluer......Page 280
8.5.2.5 Flexible Packages......Page 281
8.5.2.6 Bags, Pouches and Sacks......Page 284
8.5.3.2 Carton Closing......Page 285
8.5.4 Pallet Securing......Page 288
8.5.5.1 Pressure-Sensitive Labels......Page 290
8.5.5.2 Inline Labeling......Page 291
8.5.5.3 Tamper-Evident Bottle Closures......Page 294
8.5.7 Manufacture of Tissue Paper Products......Page 295
8.5.7.1 Core Winding......Page 296
8.5.7.2 Lamination......Page 297
8.5.7.4 Tail Tie Adhesives......Page 298
8.5.8.1 Unsewn Binding......Page 299
8.5.8.3 Unsewn Binding with Hot Melts......Page 300
8.5.8.4 Unsewn Binding with Reactive Polyurethane Hot Melts......Page 301
8.5.8.5 Multilayer Unsewn Binding......Page 303
8.5.8.6 Side Gluing......Page 304
8.5.8.8 Book Manufacture......Page 305
8.5.8.10 Casing-In......Page 306
8.5.9 Envelopes and Advertising Mail......Page 307
8.5.10.1 Reuse......Page 308
8.5.10.3 Recycling of Paper Products......Page 309
8.5.10.5 Compostable Products......Page 312
8.5.12 Perspectives......Page 313
8.6.1 Joining......Page 314
8.6.1.1 Structural Adhesives......Page 315
8.6.1.2 Cyanoacrylate Adhesives......Page 316
8.6.1.4 Hot-Melt Adhesive Systems......Page 317
8.6.1.6 Dispersion Adhesives......Page 318
8.6.1.8 High-Performance Acrylic PSA Tapes......Page 319
8.6.1.9 Reclosable Fasteners......Page 321
8.6.2 Protecting, Splicing and Masking......Page 322
8.6.3 Damping......Page 325
8.6.4 Labeling, Marking and Coding......Page 326
8.7.1 Thermally Conductive Adhesives......Page 328
8.7.2 Electrically Conductive Adhesives......Page 329
8.7.4 Functional PSA Tapes......Page 331
8.7.6 Labeling......Page 332
8.8.1 General Requirements for Adhesives in Optical Industry......Page 333
8.8.2 Optical Adhesives for the Temporary Fixture of Optical Elements......Page 334
8.8.3 Optical Cementing......Page 335
8.8.4 Bonding Optical Elements to Mounts......Page 336
8.9.1 Mechanical Engineering......Page 337
8.9.3 Manufacture of Internal Combustion Engines and Transmission Manufacturing......Page 338
8.9.4 Stainless Steel Structures......Page 340
8.10.1 The Early History of Fabric-Reinforced Rubber Materials......Page 341
8.10.2 How Textile Fibers Contribute to the Living Standards of the Industrial World......Page 342
8.10.2.2 Textiles as Rubber Reinforcements......Page 343
8.10.3 General Properties of Elastomers (Rubber)......Page 344
8.10.4.2 Adhesive Systems Used to Treat Textiles......Page 345
8.10.4.3 Effect of the Fiber Type on the Adhesive System......Page 347
8.10.5 Adhesion Mechanisms......Page 349
8.10.6 Aging of RFL-Dipped Textiles......Page 351
8.11 Footwear Industry......Page 353
8.12 Road and Highway Engineering......Page 354
8.12.1 Trafc Signs......Page 355
8.12.2 Pavement Markings......Page 356
8.13.1 Surface Design and Surface Protection......Page 358
8.13.3 Public Transport Advertising......Page 359
8.13.4 Building and Floor Graphics......Page 361
8.14 Tamper-Indicating Labels......Page 362
8.15.2 Medical Devices with Several (up to 30) Days Body Contact......Page 364
8.15.3 Medical Devices with Long-Term (Over 30 Days) Body Contact......Page 365
8.16.1 Design Principles of Biological Attachment Devices......Page 367
8.16.2 Gluing Under Water......Page 368
8.16.2.1 Byssus Adhesion in Mollusks......Page 369
8.16.2.2 Tube Feet of Starsh......Page 372
8.16.2.3 Adhesion in Barnacles......Page 374
8.16.3.1 Permanent Adhesion in Insects and Spiders......Page 375
8.16.4 Adhesion in Plants......Page 376
8.17.1 Foils for the Rotors of Wind Turbines......Page 377
8.17.1.1 Erosion-Protection......Page 378
8.17.2 Adhesive Elastomer Composites......Page 379
8.17.3 Light Bulbs......Page 380
8.17.4.1 Art......Page 382
8.17.4.2 Jewelry Making......Page 384
8.17.4.3 Archeology......Page 385
8.17.5.1 Commercially Available Removable Adhesive Systems......Page 386
8.17.5.2 High-Strength Removable Adhesives......Page 388
9.2 Technical Trends......Page 392
Appendix......Page 396
References......Page 414
Index......Page 424