Adhesive Bonding in Five Steps: Achieving Safe and High-Quality Bonds

393 Pages·2022·11.681 MB·English

by  Jürgen Klingen

AdhesiveBondinginFiveSteps
ThisbookisdedicatedtoProf.Dr.WalterBrockmann,agreatscientist,teacher,and
promoterofadhesive-bondingtechnology,whounfortunatelypassedawayfartoo
earlyinJune2011attheageof72.
Invariouspositions,Prof.Brockmannsignificantlyadvancedthecorresponding
researchandapplicationengineeringactivitiesinGermanyandEuropeoverdecades.
Beforehisdeath,hehadheadedtheMaterialsandSurfaceEngineeringGroup
(AWOK)attheUniversityofKaiserslautern,Germany,since1990.Priortothat,he
workedformorethan20yearsasascientistanddepartmentheadattheFraunhofer
InstituteforAppliedMaterialsResearch(IFAM)inBremen,Germany.
Asaco-founderofthe“EuropeanAdhesionConference”(EURADH),hehas
significantlypromotedEuropeanandinternationalcooperationinthefieldof
adhesive-bondingtechnologyandwithhissignificantinvolvementintheinitiationof
the“WorldCongressonAdhesionandRelatedPhenomena”(WCARP)Prof.
Brockmannstronglysupportedtheglobalizationofresearchinadhesive-bonding
technology.
Hisopen,uncomplicated,andfriendlymanner,coupledwithhisboundlessknowledge
andexperience,hasenabledProf.Brockmanntoconveythemanyaspectsand
advantagesofadhesive-bondingtechnologytomeandmanyothers,includingR&D
managers,scientists,students,andusersinindustry.Inmycase,hetriggeredagreat
enthusiasmforthistechnologythatremainsunbrokentothisday.
Adhesive Bonding in Five Steps
Achieving Safe and High-Quality Bonds
Jürgen Klingen
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10 9 8 7 6 5 4 3 2 1
v
Contents
Preface xv
AuthorBiography xvii
1 Introduction 1
1.1 TheArtofAdhesiveBonding 1
1.2 Adhesives 1
1.3 AdhesiveBonds 2
1.3.1 MetalBonds 3
1.3.2 PlasticBonds 4
1.3.3 GlassBonds 4
1.3.4 WoodBonds 5
1.4 AdhesiveBondinginIndustryandCraft 6
1.5 AnExampleforAdhesiveBondinginNature 7
2 HistoryofAdhesive-BondingTechnology 9
2.1 FirstAdhesives 9
2.2 Adhesive-BondingTechnology:1845–1930 10
2.3 Adhesive-BondingTechnology:1930–1960 14
2.4 Adhesive-BondingTechnologyfrom1960UntilToday 18
References 20
3 Wetting,Adhesion,andCohesion 21
3.1 Introduction 21
3.2 WettingofSurfaces 21
3.2.1 Young’sEquationandSurfaceTension 21
3.2.2 SurfaceTensionofLiquids 23
3.2.3 SurfaceEnergyofSolids 23
3.2.4 DeterminationoftheCriticalSurfaceTension 24
3.2.5 PolarandDispersiveInteractions 24
3.3 AdhesiontoSurfaces 26
3.3.1 IntermolecularInteractions 26
vi Contents
3.3.2 SummaryAdhesion 28
3.4 CohesionofAdhesiveLayers 29
3.4.1 SummaryWetting,Adhesion,andCohesion 29
References 30
4 AdhesiveBondinginIndustryandCraft 31
4.1 Introduction 31
4.1.1 RoleofAdhesiveBondinginProductionToday 31
4.1.2 LimitationsofAdhesiveBonding 32
4.2 ThePerformanceofStandardAdhesivesToday 32
4.2.1 VespaisHeldbya1cm2AdhesiveLayer 32
4.3 AdvantagesandDisadvantagesofAdhesiveBonding 33
4.4 StructuralandElasticBonding 36
4.4.1 StructuralBonding 38
4.4.1.1 LimitsofStructuralBonding 39
4.4.2 ElasticBonding 39
4.4.2.1 ElasticBondingforHeavierLoads 39
4.5 SelectedAdhesiveSystemsusedinIndustryandCraft 40
4.5.1 “High-Speed”CyanoacrylateAdhesivesforSmallBondingAreas 41
4.5.2 “Easy-to-Use”HotmeltAdhesivesforRapidFurtherProcessing 41
4.5.3 “All-Purpose”AdhesivesforNumerousApplications 42
4.5.4 The“All-Rounders”forStructuralApplications 43
4.5.5 “User-Friendly”ConformableHigh-PerformancePSAFoamTapes 44
4.5.6 PSATapesfor“QuickConnectandDisconnect” 46
4.5.6.1 High-StrengthFasteners 46
4.5.6.2 Hook-and-LoopFasteners 46
4.5.7 “TheStrongPSATape”forAllCases 47
References 48
5 The5StepsforAchievingSafeandHigh-QualityBonds
(Overview) 49
5.1 Introduction 49
5.2 RequirementsfortheSpecialProcess 49
5.3 QualityStandards 50
5.4 The5-StepProjectManagementSystem 51
5.4.1 Introduction 51
5.4.1.1 ProcessMap 52
5.4.2 Planning,Concept,andFeasibility(Part1) 52
5.4.3 DevelopmentandLaunch(Part2) 53
5.5 GateReviews 53
5.5.1 TheGatekeeper 54
5.5.2 ColorCoding 54
5.6 QualityRequirementsAccordingtoDIN2304 55
5.6.1 Part1–ClassificationofAdhesiveComponentsintoSafetyClasses 55
5.6.2 Part2–AssignmentoftheResponsibleSupervisors(SIC) 57
Contents vii
5.6.3 Part3–ProofofAppliedLoad<Load-BearingCapacityoftheAdhesive
Layer 57
5.6.3.1 Measurements 57
5.6.3.2 ComponentTesting 58
5.6.3.3 DocumentedExperience 58
5.6.3.4 Combinationsof1–3 58
References 58
6 Planning(Step1)–PreparingthePlanandtheProject
Contract 59
6.1 Introduction 59
6.2 TheProjectPlanandContract 59
6.3 RolesofProject-RelevantPeople 60
6.3.1 ProjectSponsor(Client) 60
6.3.2 ProjectManager(Planner) 61
6.3.3 ProjectChampion(Advocate) 61
6.3.4 SupervisorInCharge(SIC) 61
6.3.5 OperatingStaff 62
Reference 62
7 Concept(Step2a)–Substrates,theirSurfaces,andtheir
Treatment 63
7.1 IntroductiontoChapters7and8 63
7.2 SubstratesandtheirSurfaces 64
7.2.1 Introduction 64
7.2.1.1 Metals 64
7.2.1.2 PlasticMaterials 65
7.2.1.3 Glasses 66
7.2.1.4 Wood 66
7.2.2 FerrousMaterials 67
7.2.2.1 Introduction 67
7.2.2.2 MechanicalPropertiesofFerrousMaterials 68
7.2.2.3 ClassificationofSteel 69
7.2.2.4 SurfaceImprovementofSteel 71
7.2.3 AluminumandtheirAlloys 74
7.2.3.1 Introduction 74
7.2.3.2 PropertiesofAluminum 74
7.2.3.3 ApplicationsofAluminum 75
7.2.3.4 SurfaceImprovementofAluminum 75
7.2.4 PlasticMaterials 76
7.2.4.1 Introduction 76
7.2.4.2 Properties 76
7.2.4.3 ChemistryofPlasticMaterials 78
7.2.4.4 ThermomechanicalPropertiesofPlasticMaterials 80
7.2.4.5 ViscoelasticPropertiesofPlasticMaterials 82
viii Contents
7.2.4.6 PlasticMaterialsUsedinIndustryandCraft 85
7.2.5 Glass 93
7.2.5.1 Introduction 93
7.2.5.2 ClassificationofGlass 94
7.2.5.3 ManufactureofGlass 94
7.2.6 Wood 95
7.2.6.1 Introduction 95
7.2.6.2 PropertiesofWood 95
7.2.6.3 WoodSurfaces 96
7.3 SurfaceCleaningandTreatment 96
7.3.1 Introduction 96
7.3.1.1 ImportanceofSurfaceTreatment 97
7.3.2 SurfaceCharacteristics 100
7.3.2.1 Metals 100
7.3.2.2 Plastics 102
7.3.2.3 Glasses 105
7.3.3 SurfaceCleaning 105
7.3.3.1 CleaningwithOrganicSolvents 105
7.3.3.2 CleaningwithAqueousSystems 108
7.3.3.3 CleaningofMetalSurfaces 108
7.3.3.4 CleaningofPlasticSurfaces 109
7.3.3.5 CleaningandDegreasingProcesses 109
7.3.4 SurfaceTreatment 110
7.3.4.1 MechanicalSurfaceTreatment 111
7.3.4.2 ChemicalSurfaceTreatment 115
7.3.4.3 PhysicalSurfaceTreatment 118
7.3.4.4 Summary:PhysicalSurfaceTreatmentMethods 125
References 127
8 Concept(Step2b)–Adhesives,theirSelection,andDefinition
ofConcepts 129
8.1 Introduction 129
8.2 AdhesivesforIndustryandCraft 129
8.2.1 Introduction 129
8.2.1.1 AdhesiveClassificationbyCuringMechanism 130
8.2.1.2 AdhesiveClassificationbyNumberofComponents 132
8.2.2 1KAdhesiveSystems 132
8.2.2.1 CyanoacrylateAdhesives 133
8.2.2.2 1KPUAdhesives 137
8.2.2.3 1KSiliconeAdhesives(RTV-1) 143
8.2.2.4 HotmeltAdhesives 146
8.2.2.5 PhotoinitiatedAdhesives 155
8.2.2.6 AnaerobicAdhesives 161
8.2.2.7 1KEpoxyAdhesive 164
8.2.2.8 Solvent-BorneandDispersionAdhesives 169
Contents ix
8.2.2.9 Pressure-SensitiveAdhesives(PSAs) 174
8.2.3 2KAdhesiveSystems 189
8.2.3.1 Introduction 189
8.2.3.2 CuringandProcessingof2KAdhesives 190
8.2.3.3 Applicationsof2KAdhesives 190
8.2.4 2KEpoxyAdhesives 190
8.2.4.1 Overview 190
8.2.4.2 ChemistryandComposition 190
8.2.4.3 Curing/Processing 191
8.2.4.4 Properties 192
8.2.4.5 Applications 192
8.2.5 2KAcrylateAdhesives 193
8.2.5.1 Overview 193
8.2.5.2 Chemistry/Composition 193
8.2.5.3 Processing 193
8.2.5.4 Properties 194
8.2.5.5 Applications 194
8.2.6 2KPUAdhesives 195
8.2.6.1 Overview 195
8.2.6.2 Curing/Processing 195
8.2.6.3 Properties/Applications 196
8.3 AdhesiveBondingonMetal,Plastic,Glass,andWoodSurfaces 196
8.3.1 AdhesiveBondingonMetals 196
8.3.1.1 AdhesiveBondingonSteelSurfaces 197
8.3.1.2 BondingonSteelSheet 197
8.3.1.3 BondingonOilySteelSheet 198
8.3.1.4 BondingonGalvanizedSteel 199
8.3.1.5 SurfaceTreatmentofGalvanizedSteel 200
8.3.1.6 BondingonStainlessSteel 200
8.3.1.7 SurfaceTreatmentofStainlessSteel 201
8.3.1.8 BondingonAluminumSurfaces 202
8.3.1.9 SurfaceTreatmentofAluminum 202
8.3.1.10 SurfaceTreatmentforLong-termAging-resistantBonds 203
8.3.2 AdhesiveBondingonPlasticMaterials 204
8.3.2.1 RoleofDiffusionandSolubilityCharacteristics 205
8.3.2.2 BondingonRecycledPlastic 205
8.3.2.3 Long-termResistanceofPlasticBonds 206
8.3.3 AdhesiveBondingonGlass 207
8.3.3.1 SelectionofAdhesiveforGlassBonding 207
8.3.3.2 GlassBondswithLong-termResistance 208
8.3.3.3 SurfaceTreatmentofGlass 208
8.3.3.4 AdhesivesforGlassBonding 210
8.3.4 AdhesiveBondingonWood 210
8.3.4.1 RequirementsforWoodBonding 211
8.3.4.2 PVACDispersions(WhiteGlue) 212
x Contents
8.3.4.3 HotmeltAdhesives 212
8.3.4.4 FormaldehydeResinDispersions 213
8.3.4.5 Post-curingPVACDispersions 213
8.3.4.6 Moisture-curing1KPUAdhesives 213
8.3.4.7 BondingWoodtoOtherMaterials 213
8.4 LoadsonAdhesiveBonds 214
8.4.1 Introduction 214
8.4.2 Long-termBehaviorofAdhesiveBonds 214
8.4.3 MechanicalLoads 215
8.4.3.1 ExternalLoads 215
8.4.3.2 InternalLoads 215
8.4.4 EnvironmentalLoads 219
8.4.4.1 TemperatureChanges 219
8.4.4.2 WaterDiffusion 220
8.4.4.3 CorrosiveMediaImpact 220
8.5 AdhesiveSpecification 222
8.5.1 Introduction 222
8.5.2 DefinitionofSubstrates 223
8.5.3 DeterminationofLoadsontheJoint 223
8.5.4 DefinitionofAdhesiveRequirements 224
8.5.5 DefinitionofSurfaceTreatmentMethod 225
8.5.6 DefinitionofManufacturingProcess 226
8.5.7 AdhesiveSpecification 228
8.5.8 SomePracticalGuidelinesforAdhesiveSelection 229
8.6 DefinitionofConcepts 230
References 231
9 Feasibility(Step3)–DemonstratingFeasibilityand
ValidationofthePreferredConcept 235
9.1 Introduction 235
9.2 ProductionofBondedJointsintheLaboratory 236
9.2.1 PreparationsBeforeStartingWorkintheLaboratory 236
9.2.1.1 ProvisionofPersonalProtectiveEquipment 237
9.2.1.2 PreparationoftheWorkplace 239
9.2.1.3 PreparationoftheAdhesive 241
9.2.2 ExecutionoftheWorkfortheProductionofaBondedJointinthe
Laboratory 241
9.2.2.1 SurfaceTreatment 241
9.2.2.2 BondedJointswith1KAdhesives 244
9.2.2.3 BondedJointswith2KAdhesives 256
9.3 TestMethodsforAdhesiveBonds 263
9.3.1 Introduction 263
9.3.1.1 TechnologicalandPhysicalTests 263
9.3.2 TechnologicalTestMethodsforAdhesiveBonds 264
9.3.2.1 ShearTest 265