Amts Standard Workshop Practice

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Adhesive Bonding AMTS-SWP-0012-A-2008
AMTS STANDARD WORKSHOP PRACTICE

_________________________________________
Adhesive Bonding
Reference Number:
AMTS_SWP_12_2008
Date:
June 2008
Version:
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5/21/2018 AMTSAdhesiveBonding-slidepdf.com
Contents
1 Technical Terms...................................................................................................3
2 Scope....................................................................................................................3
3 Primary References..............................................................................................4
4 Adhesive Selection...............................................................................................5
4.1 Criteria for selecting adhesives ...................................................................5
4.2 Types of bonding adhesives........................................................................6
4.2.1 Bonding Epoxy 2 component.........................................................6
4.2.2 Polyurethane 2 component............................................................6
4.2.3 Film strips adhesives .....................................................................6
4.2.4 Laminating epoxy with additives....................................................6
5 Surface Preparation ............................................................................................. 7
5.1 Introduction .................................................................................................. 7
5.2 Degreasing Methods....................................................................................8

5.3 Abrading methods........................................................................................8
5.4 Chemical pre-treatment ............................................................................... 9
6 Bonding process...................................................................................................9
6.1 Preparation of an Adhesive ......................................................................... 9
6.2 Ensure that the surfaces are correctly aligned............................................9
6.3 Surface preparation ................................................................................... 10
6.4 Priming the surface....................................................................................11
6.5 Applying the adhesive................................................................................11
6.6 Clamping .................................................................................................... 12
6.7 Removal of excess adhesive.....................................................................13
6.8 Adhesive Curing.........................................................................................13
7 Quality Control....................................................................................................14
7.1 Adhesive quality determination..................................................................14
7.1.1 Preparing a test specimen ...........................................................14
7.1.2 Visual inspection of the bond.......................................................15
1 Technical Terms
Acid etched: The release of weak metal scale from the surfaces of metals to form an
oxidation layer.
Bond line thickness: The thickness of the adhesive at a given point in a bond.
Chemical Chemically altering the properties of a surface.

pre-treatment:
Composite: A material that consists of two or more materials joined to form a matrix.
Conductor metals: Metals that conduct electricity.
Cure temperature: The temperature that the adhesive need to reach in order to form
covalent bonds.
Curing: A chemical reaction whereby the polymer chains interlink to form a three-
dimensional network of covalent bonds.
Film adhesives: Adhesives in the form of sheets.
Maximum service The maximum temperature that the component will be exposed to.
temperature:
Polythene-interleaves: Interleaves found on film adhesives to protect them from environmental

influences.
Pot life: The time the adhesive takes to gel and become unusable.
Resin: Synonymous with thermosetting matrix.
Tackiness: The measure of an adhesive to stick to the surface of a material.
Thermo couple: Temperature sensitive material used to determine the temperature at a

point.
Thermo set: Polymer whose molecular chains form a three-dimensional cross-linked

structure of covalent bonds.
Viscosity: A measure of the resistance of a fluid to flow.
2 Scope
This procedure describes the preparation of materials and the application of adhesives
used in adhesive bonding. The following sections are discussed with references to other
applicable SWPs were applicable.
Adhesive Selection
Criteria for selecting adhesives
•
Bonding types
Bonding of composite components using liquid adhesives
•
Bonding of composite components using laminating resin with additives

•
Bonding of composite components using film adhesives

•
Preparation for adhesive bonding:

• Preparation of the surfaces using chemical and mechanical methods.
• Preparation of the adhesive (accurate mixing procedures and quality
control)
Assembly of the components

Use of jigs and clamps to accurately align components
•
Alignment pins and holes used in moulds.

•
Curing of bonded components:

• General guidelines when composites are cured are given.
• SWP 009 – Curing of Composites gives a more in depth discussion for
the curing of composites.
3 Primary References
RGU 034b: Redux Bonding Technology, December 1997.
th
D – 71111 Waldenbuch: Composite Materials Handbook, 8 Ed.
Composite Materials in Aircraft Structures, Donald H. Middleton
4 Adhesive Selection
A large variety of bonding adhesives are available for various applications. It is necessary to
select the appropriate adhesive for the required application. This section gives criteria for
selecting adhesives and gives the most common types of adhesives available.
4.1 Criteria for Selecting Adhesives
When choosing an adhesive the following must be taken into account:
1. Maximum operating temperature:

The maximum operating temperature of the component should not exceed the
maximum allowable operating temperature of the adhesive being used. This will
lead to severe weakening of the bond which will lead to joint failure.
2. Elasticity
The properties of the adhesive after curing should match the properties of the
components that are bonded together for example if two highly elastic
components are bonded and the adhesive is not elastic after curing, the bond will
fail when load is applied.
3. Viscosity
A lower viscosity will create resistance against sagging.
4. Shrinkage during curing

An adhesive that has a tendency to shrink when cured will cause deformation of
the components when large areas are bonded.
5. Cure temperature:
Film adhesives typically fall in a cure temperature of 120 – 180 °C. This
temperature should not exceed the maximum temperature that the component
can resist.
6. Bond line thickness control:

Some adhesives contain micro-spheres to maintain the optimum bond thickness
for the adhesive being used. This prevents the adhesive from being pushed out
and the bond thickness becoming too small.
7. Compatibility:
The adhesive should be compatible with both of the materials being used. If an
adhesive is not available, one or both of the surfaces can be pre-treated to
conform to the specifications of the adhesive. The manufacturer should be
consulted on the best course of action in this regard.
8. Pot life:
This is the time the adhesive will take to set. If it the bonding procedure is
complicated and needs a long time to complete, an adhesive with a long pot life
should be used. This will prevent the adhesive from hardening before the bond
has been completed.
9. Cost:
When joining materials it is necessary to research alternatives in order to lessen
the cost of the bond. An example of this is the use of a laminating resin with
additives which provides a good quality bond. This is discussed in section 4.2.4
4.2 Types of bonding adhesives
4.2.1 Bonding Epoxy 2 component
Epoxies are available for most bonding applications. The above mentioned criterion is used to
determine the correct system for the application.
Epoxies are supplies in two components called the resin and the hardener. The components
are mixed according to the manufacturer data sheet in the correct ratios. Note that the
manufacturer will specify if the ratios are by weight or by volume.
The low viscosity of bonding epoxies enables easy application without having to use additives
and normally have good gap filling properties.
4.2.2 Polyurethane 2 component
Poly-urethanes are good bonding adhesives similar to epoxies. Polyurethanes are designed for
bonding of a wide variety of materials.
4.2.3 Film strips adhesives
Film strip adhesives are pre-prepared adhesives which are easily used when bonding flat areas.
These adhesives usually consist of precatalysed modified epoxies, often with a synthetic rubber
additive, which forms a toughened dispersion of fine rubber particles upon curing. The adhesive
consist of two covering sheets with the bonding material enclosed between them. After the two
components have been assembled heat must be applied to both the components to initiate the
bonding process and be kept at a raised temperature during the curing process.
A serious disadvantage of precatalysed film adhesives is that the cure reaction will slowly
progress – even under refrigeration to -20 C˚. For this reason the shelf life is only 6-12 months
for most film adhesives.
Because of the low storage temperature film adhesives should be allowed to heat up to room
temperature before use to prevent moisture from forming on the bonding surfaces through
oxidation. The moisture will prevent the adhesive from bonding with the surface of the
components and lead to a low quality bond.
4.2.4 Laminating epoxy with additives
Laminating epoxies normally have properties that make it unsuitable for bonding composite
components. By adding additives, e.g. Cotton flocks, Cab-o-sil (Fused Quartz) and Glass Micro
balloons the viscosity and gap filling properties can be improved. Laminating epoxies with
additives is a highly cost effective bonding adhesive, but requires accurate mixing procedures to
ensure consistency.
The effect of the additives on the resin is as follows:
Cotton flocks:
• Improves the mechanical properties (shear strength)
Cab-o-sil (Fused Quartz):

• Increases viscosity (More sag resistant)
• Improves the mechanical properties (shear strength)
Glass Micro balloons:

• Increases volume
• Low mechanical strength – good for bonding foam cores and non-structural surface
filling.
By using a combination of additives, the properties can be manipulated to suit the required
application. Refer to SWP xxx Laminating Resins with Additives (Fillers)
5 Surface Preparation
5.1 Introduction
A clean, dry surface is a prerequisite for the effective joining of components. The adhesive will
either adhere to the surface of the components or to any foreign materials that are present at
the timeand
smaller of bonding.
will lead toIf aforeign materials
weakened bond.are present the area to which the adhesive adheres is
The most common methods in preparing a surface for bonding are:
1. Degrease only.
2. Degrease, abrade and degrease again.
3. Degrease and chemically pre-treat.
The methods mentioned above are dependant on the materials being bonded and the adhesive
being used.
When bonding epoxy laminates, the use of a suitable peel ply as the last layer in their
manufacture is recommended, otherwise prepare as above. Trials may be required to test peel
ply and it is usually advisable to provide an additional light sanding and solvent wipe once the
peel ply has been pulled off.
5.2 Degreasing Methods
The surface is cleaned using a solvent to remove any materials from the bonding surface. The
solvent should be compatible with the adhesive and the material being bonded. Using the
wrong solvent will adversely affect the bond and the manufacturer should be consulted in this
regard.
Note: These methods are most commonly used in practice but the manufacturer of the
adhesive should be consulted on the most effective solvent to use on the surface.
Test for a clean surface:
The most common test is the water break test. A drop of distilled water is applied to the
prepared surface and the contact angle noted. The reason for using this test is to check
whether the fluid wets the surface. If the fluid spreads out over the surface, a large contact
angle is formed. This means the fluids does wet the surface and the surface preparation was
successful.
Figure 5.2-1: Water Break Test
The image on the right shows a surface with a large contact angle.
5.3 Abrading methods
Abrading a polished surface will help the adhesive to form a better bond with the surface. The
surface can be mechanically abraded or sandblasted. A general rule is not to abrade the
surface
bonding more than 0.1 microns. This will trap air bubbles in the bond which will lessen the
surface.
Usually a composite surface finished with peel ply will give a good bond after removing the peel
ply. However better results are achieved by abrading and cleaning the surface with a suitable
solvent (e.g. acetone).
Caution: Sanding composites laminates gives off a fine dust that may cause skin and/or
respiratory irritation unless suitable skin and respiratory protection is used. Sanding also
creates static charges that attract dirt or other contaminants.
5.4 Chemical pre-treatment
The chemical pretreatment of surfaces is the most effective method for achieving a high quality
bond with a long bond life.
Etching metals with acids removes the weak metal scale from the surface, producing an
oxidation layer where the adhesive can bond. Typical treatments are: chromium acid for
aluminum and hydrochloric acid for stainless steel. Some metals require an alkaline treatment
such as alkaline peroxide for titanium.
For bonding Ferro cement, etch with a 5% solution of hydrochloric acid, wash with fresh water,
then dry.
6 Bonding process
6.1 Preparation of an Adhesive
Preparation of the adhesive is a critical step in the bonding procedure. Inaccuracy during the
mixing process can be the single contributing factor to bond failure and all steps must be taken
to ensure that the adhesive is prepared according to manufacturer specifications.
When
before using laminating
adding epoxy with
the additives. additives,
It is best tothe resin and
measure thethe hardeneraccurately
additives is mixed thoroughly
to ensure
consistency.
6.2 Ensure that the surfaces are correctly aligned
Before applying any adhesive to surfaces it is important to check the alignment. This is done to
ensure that the bond line thickness is maintained. The bondline thickness can be controlled by
calculating the volume of the adhesive that is required to complete the bond and applying it
evenly on the surface.
The manufacturer should be consulted on the optimum bond line thickness for the adhesive in
use.
Figure 6.2-1: Checking the alignment of the two surfaces.
6.3 Surface preparation
Ensure that the surfaces are degreased, abraded and cleaned before applying the adhesive.
Also ensure surfaces are moisture free and that all peel ply is removed form the bonding
surfaces. (Peel ply must have a trace lining to make it more visible.)
Using a vacuum cleaner on the bonding areas will suck sanding dust from small cavities,
enlarging the bonding area.
Figure 6.3-1: Mechanically abraded composite surface.
10
6.4 Priming the surface
Priming the surface helps to remove air to ensure maximum bonding surface. The adhesive is
prepared to a lower viscosity, making it flow easier. This adhesive is then applied using a
brush.
The priming adhesive or liquid may sometimes be a different bonding material with lower
viscosity that is compatible with the materials being bonded. Consult with the manufacturer to
ensure compatibility.
Figure 6.4-1: Applying adhesive using a brush.
6.5 Applying the adhesive
The next step in the bonding process is the application of the adhesive. Various tools for the
application of adhesives are available commercially. A very effective and easy alternative is the
use of a clean plastic bag as shown in figure 6.5-1. The bag is cheap and can be disposed of
afterwards unlike a glue gun that has to be cleaned after each application.
11
Figure 6.5-1: Use of plastic bag to apply the adhesive.
The adhesive should be spread evenly along the surface. Using an excess amount of adhesive
will ensure that all the air is pushed out of the bond.
Figure 6.5-2: Application of the adhesive.
6.6 Clamping
When joining components it must be ensured that the components are positioned or aligned
correctly. Accurate aligning of components can be achieved by:
• Jigs
12
• Alignment holes / pins

• Component shape when designed for accurate bonding (puzzle-like shape)
Clamping is normally required to ensure that the components stay in position during the curing
process. Clamping methods that can be used are:
• Clamps, pegs with spring clamp action

• Clamping or bolting jigs in position
• Vacuum clamping (with vacuum bag)
• Gravity (applying weights on the parts)
• Riveting parts together
• Bolt parts together
• Jigs
6.7 Removal of excess adhesive
Excess adhesive should be removed after components have been clamped. Stress
concentrations are minimized by leaving a fillet along the edge of the components.
Figure 6.7-1: Excess Adhesive
6.8 Adhesive Curing
The curing process is dependent on the type of adhesive being used. The manufacturer should
be consulted on the most effective method of curing. For a more in depth discussion refer to
SWP009 – Curing of Composites
13
General guidelines:
• The specified temperature is for the adhesive. The temperature of the adhesive should
be monitored and not that of the oven. The use of thermocouples is handy in this
application. They should be positioned along the bond line to ensure that the correct
temperature is maintained in the adhesive.
• During the curing process the components must not be moved as this may disturb the
bond.
• Heating of the oven should be done gradually to allow the components time to adjust to
the temperature. If the oven is heated too quickly, deformation of the components may
occur. A generally accepted rate is 1 – 5 °C/min.
• After the curing process is completed, pressure on the components should be

maintained to prevent them from deforming when cooling. This may occur as a result of
the materials not cooling at the same rate.
7 Quality Control
The best measure of quality control is the repeatability of a process. If the same conditions can
be created uniformly throughout a process, the quality of the product will remain consistent.
Best consistency is achieved in a controlled environment, like moisture and temperature control
in a room.
7.1 Adhesive quality determination
Ensuring the quality of an adhesive bond requires that consistent methods are followed.
Preparing test specimens is required to determine the quality of the bond.
7.1.1 Preparing a test specimen
A test specimen should be prepared during the actual bonding process. The reference number
on each of the specimens should be traceable to the following:
• By whom the batch was mixed.

• Where the adhesive was used (e.g. which part of the assembly).
•
When the batch was mixed.
These can then be subjected to a destructive test to establish the quality of the adhesive bond.
The specimens must be assembled with the same adhesive batch mixture and subjected to
curing pressure, -temperature and -time identical to the actual bonded part. Refer to SWP001
on Test Specimens.
14
7.1.2 Visual inspection of the bond
Visual inspection of the bond will reveal any discontinuities or voids in the bond line.
Discontinuities will increase the chance of bond failures as the contact area of the adhesive with
the component is reduced.
Figure 7.1-1 Shows a good bond line (top) and a bad bond line (bottom)
15
Appendix I: Fault Diagnostics of bond failure.
Fault Cause Remedy

Bond fails leaving bear, 1. Surface not properly 1. Check pre-treatment
clean surface. pre-treated. procedures.
2. Protective layering not 2. Ensure surfaces are not

removed. contaminated after pre-
treatment.
3. Remove protective
covers before bonding.
Adhesive soft after cure. 1. Adhesive not properly 1. Check curing
cured. procedures.
2. Inaccurate mixing of 2. Quality control of

components. mixing procedures
Voids in bond-line and thick 1. Bonding pressure too 1. Increase pressure.
bond-line. low.
2. Initial poor fit of parts. 2. Check alignment before

bonding.
16

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Adhesive Bonding AMTS-SWP-0012-A-2008

Adhesive Bonding AMTS-SWP-0012-A-2008

5.2 Degreasing Methods....................................................................................8

Adhesive Bonding AMTS-SWP-0012-A-2008

Bond line thickness: The thickness of the adhesive at a given point in a bond.

Chemical Chemically altering the properties of a surface.

Conductor metals: Metals that conduct electricity.

Film adhesives: Adhesives in the form of sheets.

Polythene-interleaves: Interleaves found on film adhesives to protect them from environmental

Resin: Synonymous with thermosetting matrix.

Tackiness: The measure of an adhesive to stick to the surface of a material.

Thermo couple: Temperature sensitive material used to determine the temperature at a

Thermo set: Polymer whose molecular chains form a three-dimensional cross-linked

Viscosity: A measure of the resistance of a fluid to flow.

Adhesive Bonding AMTS-SWP-0012-A-2008

Bonding of composite components using laminating resin with additives

Bonding of composite components using film adhesives

Preparation for adhesive bonding:

Assembly of the components

Alignment pins and holes used in moulds.

Curing of bonded components:

Adhesive Bonding AMTS-SWP-0012-A-2008

4.1 Criteria for Selecting Adhesives

When choosing an adhesive the following must be taken into account:

1. Maximum operating temperature:

4. Shrinkage during curing

6. Bond line thickness control:

Adhesive Bonding AMTS-SWP-0012-A-2008

4.2 Types of bonding adhesives

4.2.1 Bonding Epoxy 2 component

4.2.2 Polyurethane 2 component

4.2.3 Film strips adhesives

4.2.4 Laminating epoxy with additives

Adhesive Bonding AMTS-SWP-0012-A-2008

The effect of the additives on the resin is as follows:

Cab-o-sil (Fused Quartz):

Glass Micro balloons:

The most common methods in preparing a surface for bonding are:

Adhesive Bonding AMTS-SWP-0012-A-2008

5.2 Degreasing Methods

Test for a clean surface:

Figure 5.2-1: Water Break Test

5.3 Abrading methods

Adhesive Bonding AMTS-SWP-0012-A-2008

5.4 Chemical pre-treatment

6.1 Preparation of an Adhesive

6.2 Ensure that the surfaces are correctly aligned

Adhesive Bonding AMTS-SWP-0012-A-2008

Figure 6.2-1: Checking the alignment of the two surfaces.

6.3 Surface preparation

Figure 6.3-1: Mechanically abraded composite surface.

Adhesive Bonding AMTS-SWP-0012-A-2008

6.4 Priming the surface

Figure 6.4-1: Applying adhesive using a brush.

6.5 Applying the adhesive

Adhesive Bonding AMTS-SWP-0012-A-2008

Figure 6.5-1: Use of plastic bag to apply the adhesive.