LOCTITE Webinar Series Structural Bonding

Transcription

1 LOCTITE Webinar Series Structural Bonding

2 Meet Your Presenter Darryl earned a B.S. in Mechanical Engineering with an emphasis in design from Worcester Polytechnic Institute in Darryl Small Application Engineer Darryl started as a regional application engineer with Loctite Corporation, later acquired by Henkel, in October He has held several positions throughout the years, including: Laboratory Manager, Tech Info Service Manager, Electronics Application Engineer, and Special Equipment Engineer. Darryl.Small@Henkel.com 2

3 Agenda 1. Who is Henkel? 2. Intro to Structural Bonding 3. Joint Design Principles 4. Surface Preparation Fundamentals 5. Qualification Testing 6. Bonding Durability & Solutions 7. Loctite 4090 Hybrid Structural Adhesive 8. Technology Overview 9. Application Case Histories 10. Resources 11. Questions 3

4 Agenda 1. Who is Henkel? 2. Intro to Structural Bonding 3. Joint Design Principles 4. Surface Preparation Fundamentals 5. Qualification Testing 6. Bonding Durability & Solutions 7. Loctite 4090 Hybrid Structural Adhesive 8. Technology Overview 9. Application Case Histories 10. Resources 11. Questions 4

5 Who We Are Global Leading Positions in Consumer and Industrial Businesses Consumer Businesses Laundry & Home Care Beauty Care Industrial Business Adhesive Technologies 5

6 Who We Are Henkel at a Glance 2014 Almost 50,000 employees worldwide Employees in more than 120 different nations Around 16.4 bn sales, 3.4% organic sales growth 17 major R&D facilities around the world 169 manufacturing sites globally 138 years of brand success 1 Adjusted for one-time charges/gains and restructuring charges. 6

7 Adhesive Technologies Business Units Business Units General Industry Packaging & Consumer Goods Automotive & Metals Aerospace Electronics Consumer & Craftsmen Top Brands 7

8 Adhesive Technologies Leading solution provider in adhesives, sealants & functional coatings Customer Partnership Innovation Leader Deep industry expertise Leading brands for industrial customers and consumers Best-in-class quality and service Global presence and customer proximity Comprehensive portfolio of leading technologies Innovation driver in the industry Shaping industry megatrends (e.g. sustainability, lightweight) 8

9 Agenda 1. Who is Henkel? 2. Intro to Structural Bonding 3. Joint Design Principles 4. Surface Preparation Fundamentals 5. Qualification Testing 6. Bonding Durability & Solutions 7. Loctite 4090 Hybrid Structural Adhesive 8. Technology Overview 9. Application Case Histories 10. Resources 11. Questions 9

10 Structural Bonding HENKEL and the HENKEL logo are trademarks and/or registered trademarks of Henkel and its affiliates in the U.S. and elsewhere. All other marks are the property of their respective owners. 10

11 Intro to Structural Bonding What Is a Structural Adhesive? Structural adhesives unify parts that endure high loads or stress to provide mechanical integrity and durability to an assembly or joint 11

12 Intro to Structural Bonding What Is a Structural Adhesive? Structural adhesives unify parts that endure high loads or stress to provide mechanical integrity and durability to an assembly or joint 12

13 Intro to Structural Bonding What Is a Structural Adhesive? Structural adhesives unify parts that endure high loads or stress to provide mechanical integrity and durability to an assembly or joint 13

14 Intro to Structural Bonding Why Use a Structural Adhesive? Seals, bonds and protects in one step Distributes stress evenly Resists impact, peel, and shear forces Weight reduction Improves aesthetics Joins dissimilar substrates Reduces NVH (anti-flutter) Prevents corrosion Simplifies designs Improves part performance Use lower-cost materials Adapts to surface and gap tolerance Easy to apply / automate More versatile / less inventory Reduces assembly time Reduces need for skilled labor / welders 14

15 Intro to Structural Bonding Where Are Structural Adhesives Being Used? 15

16 Agenda 1. Who is Henkel? 2. Intro to Structural Bonding 3. Joint Design Principles 4. Surface Preparation Fundamentals 5. Qualification Testing 6. Bonding Durability & Solutions 7. Loctite 4090 Hybrid Structural Adhesive 8. Technology Overview 9. Application Case Histories 10. Resources 11. Questions 16

17 Joint Design Principles Types of Forces Shear Compression Tensile Cleavage on rigid parts Peel on flexible parts 17

18 Joint Design Principles Distribution of Stresses for Bolts, Welds and Adhesives Different joint methods lead to different stress distribution Bolting Welding Bonding Very irregular stress distribution Stress concentration at holes Uneven stress distribution Concentration within small welding line Reasonable even stress distribution Distribution over a large area 18

19 Joint Design Principles Types of Peel/Cleavage Joints and Ways to Improve Them Pure peel force Stiffening Tensile/peel forces Transformation into tensile and pressure forces Roll and peel forces Transformation into tensile shear forces 19

20 Joint Design Principles Adhesion vs. Cohesion Adhesion Cohesion Adhesion 20

21 Joint Design Principles Adhesion Ability of the adhesive to bond to the surface depends on Surface polarity Surface roughness Surface contamination Surface energy / wettability Surface activity Surface stability Corrosion (oxidation) Leaching (phthalates) Sacrificial layer (galvanized) Reliable adhesion needs reliable surface conditions 21

22 Peak Shear Strength, [psi] Average Peel Strength, [lbf/in] Joint Design Principles Gap Control Tape Zone Spacer Beads Products containing glass beads Loctite Product Bulk Size (mil) AA H3151 AA AA H4710 AA AA H4720 AA AA H8010 AA AA H8500 / AA 8510 AA AA H8600 AA AA H HHD AA H8501 AA AA H9030 AA AA AA AA mil 30 mil 50 mil 80 mil Induced Gap Shear Strength Peel Strength 0 Increased bond gap 22

23 Joint Design Principles Types of Failure Mode Cohesive Adhesive Substrate 23

24 Agenda 1. Who is Henkel? 2. Intro to Structural Bonding 3. Joint Design Principles 4. Surface Preparation Fundamentals 5. Qualification Testing 6. Bonding Durability & Solutions 7. Loctite 4090 Hybrid Structural Adhesive 8. Technology Overview 9. Application Case Histories 10. Resources 11. Questions 24

25 Surface Preparation Fundamentals Surface Wetting In order for the liquid adhesive to maximize surface area it must have a lower surface tension than the surface energy of the substrate Limited contact/wetting Liquid stays off the surface Optimum contact/wetting Liquid smooths onto the surface The liquid adhesive has to be in optimum contact to the surface through surface preparation, e.g., cleaning, pretreatment 25

26 Surface Preparation Fundamentals Surface Treatment Options Primer acts as a chemical bridge between substrate and adhesive Part of primer reacts with substrate Part of primer has an affinity for the adhesive Surface roughening Simple, low-cost method Abrade surface of substrate Increase the number of mechanical interlocking sites Corona / plasma treatment Electrical discharge in presence of air Creates a plasma field Roughens the surface provides interlocking sites Increases reactivity and wettability of the surface 26

27 Surface Preparation Fundamentals Surface Energy After Plasma Treatment Typical surface energy of various substrates before and after plasma treatment Table 1: Surface energy (dynes/cm) 4 Substrate Initial Surface Energy Surface Energy following Plasma Polypropylene 29 >73 Polyethylene 31 >73 PTFE, FEP Polycarbonate 46 >73 Polysulfone 41 >73 Silicone 24 >73 Polyurethane 38 >73 Adhesive N/A N/A 27

28 Agenda 1. Who is Henkel? 2. Intro to Structural Bonding 3. Joint Design Principles 4. Surface Preparation Fundamentals 5. Qualification Testing 6. Bonding Durability & Solutions 7. Loctite 4090 Hybrid Structural Adhesive 8. Technology Overview 9. Application Case Histories 10. Resources 11. Questions 28

29 Qualification Testing Structural Bonding Adhesion Strength Shear, peel and cleavage strength High-speed impact resistance Surface treatment effects Conditioning Static and dynamic fatigue testing Heat, cold and humidity resistance Salt fog testing Cataplasma Properties Fixture and cure time Sag resistance Smoothability and appearance Read-through (profilometer) Paintability 29

30 Agenda 1. Who is Henkel? 2. Intro to Structural Bonding 3. Joint Design Principles 4. Surface Preparation Fundamentals 5. Qualification Testing 6. Bonding Durability & Solutions 7. Loctite 4090 Hybrid Structural Adhesive 8. Technology Overview 9. Application Case Histories 10. Resources 11. Questions 30

31 Bonding Durability Structural Bonding Fatigue Aging Constant vibration, different dynamic loads Frequencies Load changes in direction and intensity Relative movements of counterparts Not only bond line but also substrate deterioration Outside weathering conditions UV Rain Dust Temperature changes Humidity changes Corrosion (salt) Polymer destruction by cleaners 31

32 Bonding Solutions Structural Adhesive Technologies Epoxies Acrylics Polyurethane Silane Modified Polymers Silicones Rigid bonding 1- or 2-component solution Excellent gap filling Very high strength For small to medium surfaces Outstanding chemical resistance Rigid to slightly flexible bonding 2-component solution Very high strength For small surfaces Good chemical resistance Slightly flexible bonding 1- or 2-component solution Excellent gap filling (2C) High strength For medium to large surfaces Good chemical resistance Flexible bonding 1- or 2-component solution Wide primerless adhesion on many substrates High impact strength Good UV and weather resistance Flexible bonding 1- or 2-component solution Outstanding temperature and UV resistance Excellent chemical resistance 32

33 Shear strength [N/mm 2 ] Bonding Solutions Structural Adhesive Technologies 1KEP 2KEP ACR PU Flexible bonding PU SMP Elongation [%] 33

34 Agenda 1. Who is Henkel? 2. Intro to Structural Bonding 3. Joint Design Principles 4. Surface Preparation Fundamentals 5. Qualification Testing 6. Bonding Durability & Solutions 7. Loctite 4090 Hybrid Structural Adhesive 8. Technology Overview 9. Application Case Histories 10. Resources 11. Questions 34

35 Loctite 4090 The First Hybrid Structural Adhesive Speed and Strength in One Unique hybrid technology patent protected* Highest combination of critical attributes in one product First instant adhesive suitable for structural applications Opens new application areas * U.S. patent granted. 35

36 Speed Characteristics Ambient (21 C) Cold Temp (5 C) Zero gap fixture Time seconds seconds Gap fixture time: minutes 3-6 minutes (0.04 ) Nozzle life Approx. 4 minutes Gap filling Up to

37 Bonds to a Wide Range of Substrates Substrate N/mm 2 psi Steel Aluminum Rubber Steel 17 2,420 Stainless 15 2,120 Aluminum 7.6 1,100 Nitrile ABS ABS Polycarbonate Acrylic Polycarbonate 6.9 1,000 Epoxy 9.1 1,320 Wood (Oak)

38 In.-lbs. Impact Resistance Side Impact Results Mild steel Aluminum Generic CA product 38

39 strength (psi) Heat Resistance 1000 hours heat aging on GBMS F 300 F 360 F CA = 0 Generic CA product 39

40 % Retention Moisture Resistance 150 F / 95% relative humidity aging GBMS % strength retention Lap shears of grit-blasted mild steel (GBMS) are bonded and then exposed to 150 F and 95% relative humidity for times shown. Then lap shears are pulled apart and the % of the original strength is shown ~85% 4090 ~62% ~37% 0% Generic CA CA = 0 After 1,000 hours, a generic CA-bonded GBMS lap shear fell apart. 500 hrs 1000 hrs 40

41 Agenda 1. Who is Henkel? 2. Intro to Structural Bonding 3. Joint Design Principles 4. Surface Preparation Fundamentals 5. Qualification Testing 6. Bonding Durability & Solutions 7. Loctite 4090 Hybrid Structural Adhesive 8. Technology Overview 9. Application Case Histories 10. Resources 11. Questions 41

42 Technology Overview Epoxy Adhesives Pros Heat cure and ambient 2k options High shear and impact strength on metal Oily surface adhesion (heat cure) Excellent moisture barrier / resistance High modulus and hardness Excellent heat resistance (up to C) Wide range of cure speeds Weld-through compatible Cons Slow fixture / cure times (2k) Requires mixing and/or fixturing during cure Poor elongation and damping Below-average oil tolerance as 2k Poor adhesion to plastics 42

43 Technology Overview 2-Part Polyurethane Adhesives (2k PU) Pros Ambient cure Excellent flexibility Great for noise and vibration reduction Great adhesion on plastics and metals Great on dissimilar materials Clear options available Excellent paintability after cure up to 7 days Cons Limited temp. resistance (1 140 C) Poor adhesion to bare and oily metal Poor corrosion resistance Contains isocyanates Moisture-sensitive before cure Requires mixing and/or fixturing during cure 43

44 Technology Overview Activator (2-Step) Acrylic Adhesives Pros No mixing, cure-on-demand Heat, light and ambient cure options Long on-part life Good corrosion resistance High strength on wide range of substrates Light oily surface adhesion High heat resistance ( C) Cons Activator may contain solvents Resin has moderate odor Low cure-through depth (~1 mm) Fillets remain uncured Not weld-through capable 44

45 Technology Overview 2-Part (2k) Acrylic (MMA) Adhesives Pros Ambient cure Excellent adhesion on plastics and metals High peel and impact resistance Wide range of open / fixture times May contain spacer beads to induce gap Great oily surface adhesion Good corrosion resistance More flexible than epoxies High heat resistance ( C) Cons Requires mixing and/or fixturing Refrigerated storage Strong odor (MMA) Not weld-through capable (flammable) May create read-through on thin metals 45

46 Technology Overview Silyl Modified Polymers (SMP) Adhesives Pros Primerless adhesion to most substrates Ambient-cure 1k RTV and 2k options No read-through on thin gauge metals Excellent anti-flutter material Great UV stability Elastic behavior No solvent, isocyanates or silicone Good paintability after cure (up to 3 days) Cons Poor adhesion on oily metal Maximum temperature resistance (1 177 C) May require mixing and/or fixturing Low cohesive strength Slow fixture and cure speed Moisture sensitive 46

47 Technology Overview Silicone Adhesives Pros Excellent temperature resistance up to 400 F (600 F intermittent) Exceptional flexibility Ambient-cure 1k RTV and 2k options Good resistance to polar solvents Excellent UV and moisture resistance Contains no solvents or isocyanates Fast fixture and high tensile and cohesive strength with 2k options Cons May require mixing and/or fixturing Low cohesive strength with 1k Slow fixture and cure speed with 1k Moisture sensitive Non-paintable May foul paint systems 47

48 Agenda 1. Who is Henkel? 2. Intro to Structural Bonding 3. Joint Design Principles 4. Surface Preparation Fundamentals 5. Qualification Testing 6. Bonding Durability & Solutions 7. Loctite 4090 Hybrid Structural Adhesive 8. Technology Overview 9. Application Case Histories 10. Resources 11. Questions 48

49 Application Case Histories #1 Skin-to-Frame Bonding Product: Loctite AA H8700 2k MMA Advantages: Eliminated warping and rework caused by welding Better customer support than other adhesive suppliers Improved aesthetics Product: Loctite AA H8500 2k MMA Advantages: Ultra-high impact resistance Reduced labor and assembly time to install rivets Eliminated leak paths and corrosion issues Created more aesthetically pleasing surface Hinge to Door Skin Frame to Door Skin 49

50 Application Case Histories #2 Cabin Assembly Application Bonding body side panels and floor Adhesion semi-structural and sealing Teroson stat mixer Consumption per cabin = g L M N K Q J I R A B C D H G F R S E T O P Q Product s Advantages Fast cure Sealing Filling out high gaps Paintable High resistance No adhesion failure detected U 50

51 Application Case Histories #3 Dry Freight Box Truck Application Bonding galvanized steel e-tracks to FRP side walls Replace self-sealing through-bolts Loctite AA H stat mixer Product s Advantages Eliminated pre-drilling of bolt holes Eliminated costly through-bolts Improved aesthetics Reduced labor costs now only one operator required Reduced assembly time by 20% 51

52 Application Case Histories #4 PING Golf Club Assembly Application Bonding steel shafts to stainless steel heads Withstand impact from 120+ mph swings Loctite EA 10C epoxy adhesive Product s Advantages High impact resistance Long-term durability Grey color matches parts Removable by pro shops Proven 30-year track record HENKEL, the HENKEL logo and LOCTITE are trademarks and/or registered trademarks of Henkel and its affiliates in the U.S. and elsewhere. All other marks are the property of their respective owners. 52

53 Agenda 1. Who is Henkel? 2. Intro to Structural Bonding 3. Joint Design Principles 4. Surface Preparation Fundamentals 5. Qualification Testing 6. Bonding Durability & Solutions 7. Loctite 4090 Hybrid Structural Adhesive 8. Technology Overview 9. Application Case Histories 10. Resources 11. Questions 53

54 Henkel Adhesive Resources The Adhesive Sourcebook Plastic, rubber and metal Bonding Guides Application assistance LOCTITE ( ) Over-the-phone assistance Technical Information Services team 8 a.m.-5 p.m. Eastern time In-person assistance Local Adhesive & Sealant Specialists Technical Customer Service department Testing services Process development Authorized Loctite Industrial Products Distributors ~ 5,000 branches in USA 54

55 U.S. industrial site The Adhesive Sourcebook Product categories Market segments Equipment website Product # search TDS, MSDS & RoHS Distributor locator How-to videos Literature, Case Histories, Quality Certifications Plastic, Rubber and Metal Bonding Guides 55

56 Why Henkel? Adhesive Supplier Considerations Breadth & depth of product offering Technical service / support Quality standards / industry certifications Testing capabilities Global reach and resources Process knowledge / dispensing equipment Industry expertise / innovativeness Overall value of offering 56

57 Agenda 1. Who is Henkel? 2. Intro to Structural Bonding 3. Joint Design Principles 4. Surface Preparation Fundamentals 5. Qualification Testing 6. Bonding Durability & Solutions 7. Loctite 4090 Hybrid Structural Adhesive 8. Technology Overview 9. Application Case Histories 10. Resources 11. Questions 57

58 Thank You! Except as otherwise noted, all marks used are trademarks and/or registered trademarks of Henkel and its affiliates in the U.S. and elsewhere. All other marks and logos are trademarks of their respective owners. = registered in the U.S. Patent and Trademark Office Henkel Corporation. All rights reserved. This material has been visually improved with the help of our team at the Graphic Design Center in SSC Manila. To know more about this service, please visit in the Henkel portal.