Modern Engineering Adhesives

Presentation objective

1. Illustrate a wide range of real applications

2. Explain why adhesives have been used

3. Describe how work

4. Discuss the main types available

• Increasing use of composites1980s A310 B7675-6%

1990s A320 B77710-15%

2000sA380 23%

2010s A350 B78750%+

Adhesive Bonding

• Attaching bows to slippers

• Instant Adhesive replaced stitching

Adhesive Bonding

Adhesive Bonding

• Gas Tanker

• Bonding and Sealing of internal panels

Types of Adhesive

Adhesive Bonding

• Adhesive is the only option to join the two materials

• Micrograph showing surface irregularity

• Adhesive fully fills the joint

Surface Irregularity

Surface wetting

Dynes/cm2

Avoid / reduce stress peaks

Avoid / reduce stress peaks

• Adhesive is the only option to join the two materials

Adhesive Bonding

Fatigue Strength

Fatigue Strength

0

500

1000

1500

2000

Failu

re L

oad

(MP

a)

103 106

Adhesive

Spot weld

104 107105

• Fatigue Resistance

Adhesive & Cylindrical Bonding

• Bell crank bearing

• Slip fit saves assembly time

• No distortion reduces friction

• Smoother operation

Cylindrical bonding

• Ski Bonding

Adhesive Bonding

Typical Loudspeaker structure

Adhesive Bonding

Loudspeaker Assembly

Structural Anaerobic

Structural Anaerobic

Gasket Ring (ABS plastic)

Surround (Rubber)

Cone (Paper or Polypropylene)

Coil (Copper windings on Kevlar former)

Chassis (Polycarbonate or plated steel)

Top Plate (Plated Steel)

Magnet (Ferrite)

Pole Piece (Plated steel)

Dust Cap (Paper or polypropylene)

Suspension (Polyester/Cotton)

Cyanoacrylate or UV Adhesive

Rivets with sealant to prevent buzz

Cyanoacrylate

Cyanoacrylate with Primer

Cyanoacrylate

Water or solvent based adhesiveWater or solvent based adhesive

• Aluminium car chassis bonding

• Lotus Elise

Adhesive Bonding

Joint StiffnessBox Section Relative Stiffness

0%

50%

100%

150%

1.00 1.20 1.40 1.60 1.80 2.00Aluminium Up-Gauge Factor

Relative Stiffness to Steel Joint

34% 41% 52% 69%

Aluminium Adhesively Bonded

Aluminium Spot-Welded

Relative Mass Al/Steel

Steel Joint Performance

• Automotive composite bonding

Adhesive Bonding

Adhesive Bonding

•Aluminium Jaguar XJ•Bonded & Riveted

• Ring gear for differential

Cylindrical bonding

Cylindrical bonding

• Ring gear for differential

• Scania Truck Gearbox

• Press Bonded Gear Set onto Countershaft

Cylindrical bonding

Video

• Traditional methods of retaining coaxial components

Cylindrical Assembly

• Critical bonding of brake shoes

• Strength must exceed the substrate strength at extreme temperatures

Adhesive Bonding

Threadlocking

• Camming Unit (Mountaineers Friend)

• Critical threaded components locked

Threadlocking

• Wheel studs on formula student car from the University of Hertfordshire

Threadsealing

• Threadsealing on petrol forecourt pumps

• Safety critical

• Wing roots bonded on Hornet aircraft

Adhesive Bonding

• Aeroplane Wing Skins

Adhesive Bonding

• Bullet-proof vest bonding

• Potting of delicate components with UV adhesives in police radio

Adhesive Bonding

• Wind Turbine Blades

Adhesive Bonding

• Golf club head to carbon fibre shaft

Cylindrical bonding

• GRP paddles to carbon fibre shaft

Cylindrical bonding

Cylindrical bonding

• Composite Propshaft Bonding

• Composite drive shaft end couplings

Cylindrical bonding

Cylindrical bonding

• Mountain bike forks

• Composite to titanium

• Recumbent Tricycle Frame

Cylindrical assemblies

• Honeycomb Sandwich

• Aircraft Floor

• Interior Panels

Adhesive Bonding

• Helicopter Seat

• Bonded assembly uses less parts

Adhesive Bonding

• Laying Up Carbon Fibre– Prepreg

– Film Adhesive

– Honey Comb

– Film Adhesive

– Prepreg

Adhesive Bonding

• Bonding aluminium fittings to polymeric body

• Fuel system for an F1 car

Cylindrical bonding

Glass/Polyester Laminate

Plywood Laminate

Insulation Foam

Painted Aluminium Sheet

Adhesive Bond Lines

Structural Insulation Laminate

Adhesive Bonding

• Panel and Window bonding on Coaches

Adhesive Bonding

• Table tennis bats

Adhesive Bonding

• Shock absorbing on cricket bats

• Rubber to manilla cane

Adhesive Bonding

Gasketing

• Tradition gaskets

• Disadvantages

• Compressible

• Storage

• Automation

• Inventory

Gasketing

• How do they work?

Tradition Liquid gaskets

Gasketing

• Hot air powder drier manifold

• Alternatives?

Gasketing

• K Series Engine

• Liquid Gaskets used throughout (except cylinder head & exhaust manifold)

Gasketing

• Differential cover

• Cast Aluminium

• Screen printing of anaerobic gasket

Threadlocking

• Variable pitch propeller

• Locking & sealing threads

Threadsealing

• Compressor reservoir pipework sealing

• Dental tool bit into handle

• Must withstand high loads!

• Standardised components

Adhesive Bonding

• Optical Instruments

• Glass Assemblies

• Sports Equipment

Adhesive BondingUV Cure Adhesives in General Industry

• Bonding & sealing electrical connectors

Adhesive BondingUV Cure Adhesives in the Automotive Industry

UV Cure Adhesives for the Medical Industry

• Blood Filter (Polycarbonate)

• Face Mask (Silicone rubber) Bonding

• Needle Bonding

Adhesive Bonding

• Attaching wads to container lids

Adhesive Bonding

• Bridge Construction

• Enhancing mechanical joints

Adhesive Bonding

•Bonding GRP bridge in Aberfeldy Scotland

Adhesive Bonding

• Concrete structure reinforcement

Adhesive Bonding

• Concrete Dam

Adhesive Bonding

• Petrol powered chainsaw

• Fuel tank & Carburettor

• Bonds must resist petrol

Adhesive Bonding

Joint Durability

• Effect of surface pre-treatment on the durability of Aluminium Alloy/Toughened Epoxy Joints subjected to accelerated ageing in water at 50°C

0

10

20

30

40

50

0 200 400 600 800 1000 1200 1400

Time in Water at 50°C (Hours)

Lap

Jo

int

Str

eng

th (

MP

a)

Phosphoric Acid Anodised

Grit Blasted

Solvent Degreased

• Long term outdoor loading

Adhesive Bonding

• Double Lap Joint

Adhesive Bonding

Double Lap Joint

• Adhesive Replaces Stitches

• Minimises Scarring

• Prevents Infection

Skin Bonding

• After 3 Weeks

• Wound Bonding

In conclusion

Adhesives used in all aspects of Life: