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I
nterference fits, commonly referred
to as press fits and shrink fits, are
traditional methods for joining
cylindrical parts. In an interference
fit, the inner partsuch as a shaft,
bearing or bushingis machined
to be bigger than the mating hole
of the outer partsuch as a gear or
housing. The larger part is then forced
into the smaller part. Both
parts deform slightly to
fit together and extremely
hi gh fri ct i on resul t s
between them. The friction
is so great that even large
amounts of torque cannot
separate the parts. They
operate as one.
For maximum joint
strength and optimal
performance, interference
fits must be highly precise.
Engineers go to great pains
to calculate and achieve the
appropriate allowance that
will provide maximum friction between
the parts. This dimensional precision
increases both the cost and the time
required for component production.
A reliable interference fit puts
high levels of stress on the joined
components, which limits substrate
selection. Only certain materials can
withstand the stresses of machining
and the forces required to merge the
parts. For example, an engineer may
not be able to select powdered metal
or aluminum for a component because
steel is required to achieve the target
joint strength.
Adhesives called retaining com-
pounds enable engineers to design
robust, lightweight joints at less cost
than traditional interference fits by
reducing dimensional precision and
increasing the selection of viable sub-
strate materials. Retaining compounds
provide strength and reliability and are
commonly used to secure bearings,
bushings, gears and cylindrical parts
onto housings or shafts.
Retaining Compounds
Retaining compounds are anaerobic
structural adhesives that polymerize
when the liquid is confined without air
between close-fitting metal surfaces. The
first and best-known use for anaerobic
adhesives is thread-locking, in which a
drop of adhesive applied to the threads
of a nut and bolt bonds the assembly,
prevents vibrational loosening, seals
the threads against fluids and moisture,
and prevents corrosion and rusting.
Manufacturers embraced anaerobic
threadlockers as a chemical solution to
the mechanical problem of loosening.
Engineers soon discovered another
use for anaerobic adhesives: assembling
cylindrical metal parts. The retaining
compound fills the empty space
between the mating surfaces and cures
to chemically unitize the assembly. The
combination of an interference fit and
a retaining compound is much stronger
than an interference fit alone.
The cured adhesive fills the inner
space between the components and
provides a physical and chemical barrier
that eliminates fretting, oxidation and
galvanic corrosion. The adhesive also
seals the interference fit joint against
leakage.
Retaining compounds are used in
three ways for interference fit joints:
M added to existing interference t
designs to increase joint strength and
reliability.
Increasing Strength and
Reliability of Interference Fits
ASSEMBLY Adhesive Bonding
Retaining compounds enable
engineers to design robust,
lightweight joints at less cost
than traditional interference
fits.
By Doug Lescarbeau
Anaerobic Technology Manager
Rob Dunkel
Technical Service Director
Henkel Corp.
Rocky Hill, CT
To reduce stress concentrations and prevent
premature failure, a slip-fit bonded with an
anaerobic retaining compound replaced an
interference fit on fit on a brushless motor.
Photo courtesy Henkel Corp.
Reprinted with permission from
ASSEMBLY
www.assemblymag.com
Adhesive Bonding
M engineered into new interference t
designs to create smaller, lighter weight
assemblies. The parts can be made with
relaxed tolerances requiring lower cost
machining.
M used to structurally bond a slip t
that eliminates the need for an inter-
ference t. The parts do not need to be
machined to tight tolerances, and the
joint is as reliable and effective as an
interference t.
Retaining compounds increase the
strength and reliability of a traditional
interference fit. Interference fits generate
strength from the metal to metal contact
of surface peaks, which represent only
15 percent of the total surface area of
the joint. The liquid retaining compound
fills the surface irregularities and clear-
ance gaps between the two parts. It then
cures to create a dense, high-strength
bond that increases joint strength and
achieves maximum load transmission.
The cured resin increases the area of
surface contact so stress distribution is
improved. This enhances joint reliabil-
ity, reduces equipment downtime and
increases part life.
Whether its an interference fit or
a slip fit, components bonded with
retaining compounds do not require
precise dimensions or a fine surface
finish. Bonded interference and slip
fits allow relaxed tolerances that are
ideal for joining dissimilar metals and
translate into lower-cost processing
for components. Bonded assemblies
experience less stress in the joint and are
more robust under differential thermal
expansion. So when different substrates
are bonded, the assembly maintains its
strength better, since the joint does not
depend on the interference fit alone.
Retaining compounds prevent fret-
ting corrosion in interference fits.
Fretting corrosion results when micro-
movement occurs between a bearing
and a shaft or housing, causing small
sections of the assembly to weld togeth-
er. When the assembly moves the next
time, these small welded sections rip
off and result in a cratered surface. By
filling the inner space between inter-
ference-fit parts, retaining compounds
prevent this micro-movement.
Retaining compounds also serve
as a sealant that prevents corrosion
and leakage and provides a physical
and chemical barrier to oxidation and
galvanic corrosion. These adhesives are
often used to seal core plugs into an
engine block and to close off the outer
diameter of a rotary seal installed into
a housing.
Retaining compounds can replace
brazing and welding with a quick and
simple process that does not require
specialized equipment or skilled
operators. Unlike brazing and welding,
retaining adhesives do not produce
hazardous fumes. Bonding is also faster
than brazing or welding.
Application and Removal
In their liquid form, retaining
compounds may be applied using
manual, semiautomatic and fully
automatic dispensing equipment.
An example of a fully automatic
dispenser is the Rotospray applicator.
This device applies a metered amount
of adhesive in a 360-degree bead or
band onto a predefined location in the
bore of a part. Application is precise and
repeatable. The applicator can be posi-
tioned in any axis and operated in either
semiautomatic or fully automatic mode.
Hand pumps are precision applica-
tors for manual dispensing that con-
trol the volume and location of adhe-
sive. The heart of the hand pump is an
adjustable-stroke peristaltic pump that
dispenses a metered amount of adhesive
each time it is manually actuated.
Parts assembled with retaining com-
pounds come apart with the standard
disassembly methods for press- and
shrink-fit components. These methods
range from gear pullers to hydraulic
oil injection to hydraulic presses. No
special processing steps are required to
break the adhesive bond.
Retaining compounds are available
in medium- and high-strength formu-
lations. A medium-strength retaining
compound may be preferred for a joint
designed for routine disassembly.
Advancements in
Chemical Retaining
Recent advancements have made
retaining compounds more robust
for todays process and performance
requirements. Formulated for simplified
processing, the latest compounds do
not require primers or activators to
Retaining compounds can be used to augment press fits, slip fits and shrink fits.
Illustration courtesy Henkel Corp.
On industrial radiators, a time-consuming and costly brazing process on heat exchanger tubes was
replaced with a slip-fit bonded with retaining compound. Photo courtesy Henkel Corp.
enhance cure speed or strengthen
bonds. Once assembled, they resist
higher temperatures than earlier
formulations.
Surface cleaning and preparation
processes continuously evolve as a
result of environmental, safety, regula-
tory and cost-saving initiatives. While
clean bonding surfaces deliver the best
results for any assembly, the newest
oil-tolerant retaining compounds are
formulated to cut through light oils
and surface contaminants. The result is
consistent bond strength despite varia-
tions in the cleaning process.
Engineers employ a wide range of
substrates and coatings when designing
interference or slip fit assemblies. For
example, aluminum is used for weight
reduction and stainless steel for chemi-
cal resistance. Historically, a chemical
activator or primer had to be applied to
nonferrous parts to cure the retaining
compound. The newest primerless com-
pounds cure on these surfaces as well as
they cure on steel. The primer is no lon-
ger required to achieve polymerization,
making the process more robust and
eliminating an assembly step.
Size, weight and efficiency are key
parameters for most new interference
or slip fit designs, targets that drive
assemblies to higher operating
temperatures. The latest heat-resistant
retaining compounds can withstand
continuous operating temperatures to
180 C. Even when high temperature
capability is not required, these
formulations increase the safety and
robustness of the assembly.
Typical Applications
Manufacturers use retaining com-
pounds to lower costs, increase perfor-
mance and improve reliability. These
are just a few real-world examples of
their use in industrial applications.
To reduce stress concentrations and
potential premature failure, a slip-fit
bonded with an anaerobic retain-
ing compound replaced an interfer-
ence fit on the lobe of the eccentric
shaft of a brushless motor. The new
design enhances overall strength of
the assembly and helps it operate over
a sufficient temperature range, resist
lubricating oils and withstand torsional
stress. Loctite 7649 primer cleans the
surface, accelerates cure and allows
larger gaps to be filled. Loctite 620
high-temperature retaining compound
grips the metal and locks the parts
together. The new design relaxes toler-
ances and reduces part costs, simplify-
ing alignment and reducing stress.
On large air bearings, steel threaded
inserts are bonded to the 18-guage
galvanized steel bearing surface using
a retaining compound. This eliminated
spot welding and the extra cleaning step
to remove oxides from the surfaces.
Loctite 638 retaining compound made
the assembly process simpler and
faster, lowered overall production costs,
increased process safety and reduced
work in process.
On industrial radiators, a time-
consuming and costly brazing process on
heat exchanger tubes was replaced with a
slip-fit bonded with retaining compound.
To eliminate leaks in the welded seams
and resulting loss of static pressure, the
heat exchanger tubes are inserted into the
tubing sheets using a slip fit. Loctite 635
retaining compound is applied to the outer
diameter of the tubes. The tubes are then
expanded into the tube sheet. The new
process is faster than brazing and does not
require specialized labor.
In a steel roller conveyor application,
Loctite 638 retaining compound seals
the bearing housing and eliminates cor-
rosion from water intrusion around the
housing. Since the adhesive replaced
welding, it saves labor by eliminat-
ing the need to grind the weld seam
on every bearing housing. Production
speed could be further improved by
automating the process of dispensing
the adhesive and assembling the parts.
A bonded slip fit replaces the press
fit in a gear box. The new bonded
design meant that tolerances for the
parts could be relaxed, lowering the
overall cost of the assembly while
doubling torque performance. A
The combination of an interference fit and a
retaining compound is much stronger than an
interference fit alone.
The latest heat-resistant retaining compounds
can withstand continuous operating tempera-
tures to 180 C. Graph courtesy Henkel Corp.
While clean surfaces deliver the best results for
any assembly, the newest oil-tolerant retaining
compounds are formulated to cut through oils and
contaminants. This graph shows the difference in
bond strength between old and new compounds
when bonding surfaces contaminated with oil.
Graph courtesy Henkel Corp.
In a steel roller conveyor application, a retaining
compound seals the bearing housing and prevents
water intrusion around the housing. Photo courtesy
Henkel Corp.
Adhesive Bonding
Gold Medal Retaining
Mike Schulz lost part of his left leg
during a professional snowmobiling race
in 2008. When he lost control of his sled,
his foot hit the ground so hard that his
knee hyperextended almost all the way
in the wrong direction. His joint shattered
and doctors had to amputate just above
the knee.
As a professional snowmobiler,
motocross rider and snowboarder,
Mikes career was over unless he could
find a prosthetic leg that could withstand
the impacts and stresses required by his
extreme sports and give him the control
he needed to perform. But nothing was
available on the market. So Mike, whose
two passions are athletic competition
and creative engineering and building,
decided to create his own prosthetic leg.
Less than a year later, Mike had founded
Biodapt Inc., a company that manufactures
cutting-edge performance prosthetics
for action sports. His above-the-knee
prosthetic leg is used by professional
amputee athletes competing in extreme
sporting events like the X Games and
amateur adaptive athletes who enjoy
high-impact sports like skateboarding,
horseback riding, cycling and skiing.
Designed to withstand extreme
impacts and repetition, the prosthetic
leg has two critical joints. The Moto
Knee uses a linkage coupled with an
adjustable pneumatic shock absorber
from a mountain bike to regulate the
joints stiffness. For sports requiring
critical toe pressure and ankle tension,
the Versa Foot foot-ankle assembly
uses a similar pneumatic shock absorb-
er to emulate joint resistance.
The specialized joints create an
impact-resistant, waterproof prosthetic
that can be customized for a range of
high-performance activities. Schultzs
linkage system provides resistance when
the Moto Knee is flexed as far as 135
degreesthe position of a leg squatting
on a motorcycle or snowmobile
compared with 80 or 90 degrees for
traditional artificial legs.
For safety and reliability, the bearings
and bushings on the Moto Knee and Versa
Foot must stay in place. Repetitive, high-
impact conditions and thermal cycling
can cause press-fit components to loosen
and slip out of position.
With no seats or shoulders to stop
bushings from sliding in and out, Mike
trusts a retaining compound to keep
joint parts in place. Loctite 680 retaining
compound and Loctite 7649 Primer secure
multiple Ampco 45 bushings and keep the
stainless steel ball bearings in place.
The spray-on primer cleans contact
surfaces and speeds anaerobic cure. The
bearing joints are then assembled using
Loctite 680 to provide 100 percent contact
within the joint, evenly distributing load
and stress. The material seals the bearing
seats, prevents corrosion and erosion of
the fit, locks the components in place,
and increases safety and durability.
It didnt take long for Schultz to return
to competition. Since 2009, he has won
silver and gold medals in the Summer
X Games Adaptive Super X and three
consecutive gold medals in adaptive
SnoX at the Winter X Games.
Schultz competed in the 2013 X
Games in Los Angeles and won the
gold in adaptive motocrosshis second
consecutive gold in Moto X Adaptive
and fifth gold in X Games competition.
During this years games, Mike and two
other amputee riders competed wearing
Biodapts prosthetic leg.
Biodapt has sold 75 Moto Knees so far,
mostly to athletes and wounded veterans.
This whole project started because I
wanted to allow myself to do the things
I wanted to do, but its evolved way
past that, Schultz explains. Im helping
people do things they havent done since
they had two good legs and thats worth
it right there.
This prosthetic leg is designed for high-
impact sports, such as motocross. A retaining
compound keeps the legs bushings and
bearings in place. Photo courtesy Henkel Corp.


www.loctiteretaining.com
1-800-LOCTITE (562-8483)
LT6795