TASK 70-48-03-220-010

TENSILE BOND TEST

1. General.
A. This test determines the average value of the
coating-to-base metal bond strength.
B. The test consists of spraying the coating to be checked on
the face of a cylinder test specimen, and bonding a second
cylindrical test specimen to the coating. The test
specimen is then tested using a tensile testing machine.
C. One of 4 possible test specimen variants is selected by
the user for testing a given base material/coating
combination. Once selected, the variant must always be
used for testing this material/coating. The 4 test
specimens are as follows:
(1) On type 1 coated specimens, the test coating is
applied directly to one side of the test specimen.
(2) On type 2 uncoated specimens, the test coating is
applied to a test button sandwiched between the test
specimen.
(3) On version A specimens, the test specimen is attached
to the tensile testing machine by a plain pin.
(4) On version B specimens, the test specimen is attached
to the tensile testing machine by an internally or
externally threaded pin.
D. A new test specimen must be coated each time one of the
following parameters is changed for initial coating
qualification (100% frequency):
(1) Material of the repaired part.
(2) Nature of the coating.
(3) Particle size of the powders.
(4) Spraying equipment.
(5) Setting of the spraying equipment.
(6) Surface preparation of the parts.
(7) Personnel carrying out the spraying operation.

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 NOTE: Depending upon experience and practice, the frequency
of producing test specimens required for metallographic
examination, may be lowered as follows:
As spraying continues, passing data should be gathered
and analized by an acceptable statistical process control
(SPC) system. The frequency of testing may then be
reduced (or the time intervals between quality control
increased) based on the statistical analysis if
consistent results are obtained. The frequency intervals
should all be based on requirements documented in the
repair shops internal Quality Assurance System.

2. Test Equipment.
A. Equipment.
(1) Tensile Testing Machine.
(2) Bonding Fixture.
B. Test Specimens. See figures 1 and 2.
(1) Dimensions.
Dimensional requirements of the test specimens are
shown in figures 1 and 2.

(2) Material.
Part Material Test Specimen Material
Commercial Designation Specification Ref.
Austenitic steel
Martensitic steel AISI 321 or AMS 5510, (Z10CNT18)
Nickel alloy HASTELLOY X AMS 5536, (NC22FeD)
Cobalt alloy
Titanium alloy A 40 or T40, AMS 4902
A 110 AT or TA5E, AMS 4910
Ti 6-4 TA6V, AMS 4911
TA6V, AMS 4928
Aluminum alloy 5052 or AG3, AMS 4015
6061 AG1, AMS 4025

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 (a) Consumable products.
___________________________________________________________________
Materials Product No.
___________________________________________________________________
EC 1386 Scotch Weld CP2186
FM 1000 Film Adhesive (NOTE) CP2192
___________________________________________________________________
R NOTE: Imposed for Cu-Ni-In (CP6003)

It is always best to follow the suppliers

instructions which accompany their product.
With respect to extension of shelf life, the
particular adhesive should be tested to determine
if the physical properties or curing
characteristics are still within the nominal
values for new materials. If the test results
confirm this, then it is appropriate and
acceptable to extend the shelf life for a period
of time equal to 50% of the original shelf life.
This procedure for extension of shelf life may be
used indefinitely or until the product no longer
meets the minimum acceptance limits for the
tested characteristic. If further assitance is
required with this procedure, please contact your
local CFMI representative.

(3) Preparation of type 1 test specimens. See figure 1.

(a) Prepare surface of test specimens to be coated

as follows:
R 1 Solvent Degrease test specimens of all materials
R per 70-21-11.
2 Abrasive blast side A of test specimens using
medium grain size corundum per 70-51-12.
3 Blow with dry and oil free compressed air.

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Tensile Test Specimen - Type 1A
Figure 1 (Sheet 1 of 2)

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Tensile Test Specimen - Type 1B
Figure 1 (Sheet 2 of 2)

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 4 For single coating, thermal spray so as to
obtain a thickness of 0.006 to 0.010 inch (0,15
to 0,25 mm) for 10 to 45 micron powders, (type
1) and 0.008 to 0.010 inch (0,20 to 0,25 mm) for
45 to 90 micron powders (type 2).
In case of double coating, thermal spray so as
to obtain a thickness of 0.002 to 0.005 inch
(0.05 to 0.13 mm) for under coat, and 0.005 to
0.010 inch (0.13 to 0.25 mm) for top coat.

R (b) Prepare surface of loading fixtures as follows:

R 1 Solvent Degrease loading fixtures of all
R materials per 70-21-11.
R 2 Abrasive blast side B of loading fixtures
R using medium grain size corundum per 70-51-12.
R 3 Blow with dry and oil free compressed air.

(c) Bond both test specimens using either epoxy

resin or film adhesive as follows.
1 Bond with epoxy resin as follows:
a Apply a coat of epoxy resin (CP2186) over
side A of the uncoated test specimen.
b Position the test specimens in bonding
fixture taking care not to entrap air
bubbles.
c Polymerize the resin at 330-365F
(165-185C) for one hour. Keep a pressure
of 29-36 PSI (0.2 to 0.25 MPa).
NOTE: The pressure must not be released
after polymerization until test
specimens have cooled to ambient
temperature.
d Remove the excess resin with abrasive
cloth.

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 2 Bond with film adhesive as follows:
a Cut disk of film adhesive (CP2192) to the
same dimensions as test specimens.
b Insert one epoxy disc between test
specimens.
c Position the test specimens in bonding
fixture.
d Polymerize the resin at 350-400F
(177-204C) for 2 hours. Keep a pressure
of 5-50 PSI (0.03 to 0.34 MPa).
NOTE: The pressure must not be released
at the end of polymerization until
test specimens have cooled to
ambient temperature.
e Remove the excess resin with abrasive
cloth.
(d) Mark the test specimens per 70-10-12.
(4) Preparation of type 2 test specimens. See figure 2.
(a) Prepare surface of test buttons as follows:
R 1 Solvent Degrease test buttons of all materials
R per 70-21-11.
2 Abrasive blast side D of test buttons using
medium grain size corundum per 70-51-12.
3 Blow with dry and oil free compressed air.
4 For single coating, spray so as to obtain a
thickness of 0.006 to 0.010 inch (0,15 to
0,25 mm) for 10 to 45 micron powders, (type 1)
and 0.008 to 0.010 inch (0,20 to 0,25 mm) for
45 to 90 micron powders (type 2).

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Tensile Test Specimen - Type 2A
Figure 2 (Sheet 1 of 2)

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Tensile Test Specimen - Type 2B
Figure 2 (Sheet 2 of 2)

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 5 In case of double coating, thermal spray so
as to obtain a thickness of 0.002 to 0.005
inch (0.05 o 0.13 mm) for under coat, and 0.005
to 0.010 inch (0.13 to 0,25 mm) for top coat.
R 6 Solvent Degrease test buttons of all materials
R per 70-21-11.
7 Abrasive blast side C of test buttons using
medium grain size corundum per 70-51-12.
8 Blow with dry and oil free compressed air.
(b) Prepare surface of loading fixtures as follows:
R 1 Solvent Degrease loading fixtures of all
R materials per 70-21-11.
2 Abrasive blast side B of loading fixtures
using medium grain size corundum per 70-51-12.
3 Blow with dry and oil free compressed air.
(c) Bond both test specimens using either epoxy
resin or film adhesive as below.
1 Bond with epoxy resin as follows:
a Apply a coat of epoxy resin (CP2186) over
side 4 of the loading fixtures.
b Position the test button between the 2
loading fixtures and place the assembled
test specimen in the assembly fixture,
taking care not to entrap air bubbles.
c Polymerize the resin at 330-365F
(165-185C) for one hour. Keep a pressure
of 29-36 PSI (0.2 to 0.25 MPa).
NOTE: The pressure must not be released
after polymerization until test
specimens have cooled to ambient
temperature.
d Remove the excess resin with abrasive
cloth.

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 2 Bond with film adhesive as follows:
a Cut disc of film adhesive (CP2192) to the
same dimensions as button.
b Insert one epoxy disc on each side of
button between button and loading fixture.
c Position the test button between the 2
loading fixtures and place the assembled
test specimen in the assembly fixture.
d Polymerize the resin at 350-400F
(177-204C) for 2 hours. Keep a pressure
of 5-50 PSI (0.03 to 0.34 MPa).
NOTE: The pressure must not be released
after polymerization until test
specimens have cooled to ambient
temperature.
e Remove the excess resin with abrasive
cloth.
(d) Mark the test specimens per 70-10-12.

3. Method of Test.

NOTE: The test specimens shall be at room temperature and the

test carried out using 3 test specimens.

A. Mount and align the test specimen in the tensile testing

machine without any bending or twisting.
B. Apply tensile load at a rate of 0.040 inch per minute
(1 mm/min) until test specimen rupture occurs.
C. Record rupture points for each of the three (or more) test
specimens. The tensile bond strength average shall be
determined from the property values of three coated specimens
tested. The average shall be calculated using the following
procedure.
(a) Identify the highest result as T1, psi (Mpa).
(b) Identify the median result as T2, psi (Mpa).
(c) Identify the lowest result as T3, psi (Mpa).

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 (d) Use the identified values of T1, T2 and T3 in the
equation show in figure 3 to evaluate the specimens.
D. The prescribed values for bond strengths are shown in the
Table below:
___________________________________________________________________
Nature of the Coating Tensile Bond Strength
Code No. Description psi MPa
___________________________________________________________________
CP6001 Tungsten Carbide, 6520 45
Cobalt Powder
CP6002 Cobalt, Chromium, 5070 35
Nickel, Tungsten
Powder
CP6003 Copper, Nickel, 3600 25
Indium Powder
CP6004 Tungsten Carbide, 7250 50
Cobalt Powder
CP6005 Nickel, Aluminum 5000 35
Powder
CP6006 Nickel, Chromium, 4350 30
Aluminum Powder
CP6007 Nickel, Aluminum 4350 30
Powder
CP6008 Tungsten Carbide, 6500 45
Cobalt Powder
CP6009 Aluminum Oxide 2175 15 (type 2)
Powder
CP6010 Aluminum Silicon, 800 5.5
Polyester Powder
CP6011 Aluminum, Bronze 2000 14
CP6017 Chromium Carbide, 5000 35
Nickel Chromium Powder
CP6019 Molybdenum Powder 3000 20
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___________________________________________________________________
Nature of the Coating Tensile Bond Strength
Code No. Description psi MPa
___________________________________________________________________
CP6020 Cobalt Molybdenum 2500 17
Chromium Silicon Powder
CP6021 Triballoy T800 4000 28
CP6023 Nickel Chromium 5000 35
Aluminum Yttrium Powder
CP6024 Zirconium Oxide Ytrium 2175 15
Powder
CP6025 Nickel Chromium Iron 5000 35
Molybdenum Powder
CP6026 Tungsten Carbide Powder 7250 50
CP6027 Copper Nickel Indium 3600 25
Powder
CP6028 Aluminum Powder 3000 20
CP6029 Cobalt, Chromium, Nickel 5000 35
Tungsten Powder
CP6030 Aluminum Oxide Titanium 3600 25
Dioxide Powder
CP6031 Tungsten Carbide, 5500 38
Cobalt Powder
CP6032 Nickel Chromium Iron 9500 65
Molybdenum Powder
(INCO 718-HVOF)
CP6033 Chrome Carbide Nickel 9500 65
Chromium HVOF Powder
CP6041 Cobalt Chromium Aluminum 3000 20
Ytrium Silicium Boron nitride
HVOF Powder
___________________________________________________________________

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Calculating Tensile Bond Strength Average
Figure 3

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