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Agenda
Introduction
Material Combinations
Conclusion
2
Introduction
Surface Layers of Metalic Materials
Foreign Substance
Layer
Adsorption Layer
Reactionary Layer
Metallic
Basic Material Boundary Layer
(Source: Habenicht)
3
Introduction
Depiction of the relevant layer thickness in relation to each other
Adsorption Layer
Reactionary Layer
– Adsorption Layer
– Reactionary Layer
– Boundary Layer
Adsorption Layer
Reactionary Layer
Adsorption Layer
Reactionary Layer
The reactionary layer is formed by chemical changes within the boundary layer.
● This reaction can be natural or can be caused intentionally
This layer is connected strongly to the boundary layer through primary valence
bonds
The reactionary layer is primarily responsible for the formation of
adhesion forces
(lSource: Habenicht)
6
Introduction
Foreign Substance
Adsorption Layer Layer
Adsorption Layer
Reactionary Layer
The adsorption layer is formed through the intake of molecules from the
environment.
● The formation processes are mostly reversible.
(Source: Habenicht)
7
Introduction
Foreign Substance
Dirt Layer
Adsorption Layer
Reactionary Layer
Adsorption ayer
Reactionary Layer
These layers lie between the boundary layer and the reactionary layer.
(Source: Habenicht)
9
Introduction
As described in the chapter regarding the adhesive forces, the surface
energies are significant for the adhesive bonding possibilities
Surface Energy [mN/m]
Iron 2550
Titanium 2050
… …
Silver 1250
…
PVC 40
… …
PTFE (Teflon) 19
The surface energy has a direct impact on the quality of the wetting, which
again is the prerequisite for an optimal adhesion
10
Introduction
This allows the general conclusion that, as regards surface energies, metal
bonds are unproblematic.
● Surface energies > 1000 mN/m
11
Introduction
Synthetics have much lower surface energies, which limits the possibilities, if
bonding adhesively without prior treatment.
● Surface energies between 19 mN/m and 47 mN/m
● contained softeners
● separating agents on the surface
12
Introduction
Apart from metallic and synthetice surfaces, there is another surface structure
that is especially porous
● This includes:
– wood, plywood, balsa wood, chipboards, veneers, cork
– plastic foam
13
Agenda
Introduction
Material Combinations
Conclusion
14
Adhesive Properties - Metal
15
Corrosion Resistant Steels – Stainless Steel
Characteristics
16
Corrosion Resistant Steels – Stainless Steel
Fields of Application
● When a high resistance to weather is needed, especially in long-term conditions.
● Chemical Industry
● Medical Industry
althammer.de
● Food Industry
UNIPACK
17
Corrosion Resistant Steels – Stainless Steels
The most important corrosion resistant steels
18
Corrosion Resistant Steels – Stainless Steel
Adhesive Properties of the Surface
19
Corrosion Resitant Steels – Stainless Steel
Possible Surface Treatments:
Degreassing and cleaning
SACO
● Sufficient resistance to ageing
20
Adhesive Properties of Steels
21
Steels, Construction Steels in General
Material Properties I
22
Steels, Construction Steels in General
Material Properties II
23
Steels, Construction Steels in General
Adhesive Properties of the Surface
● Rust Formation
– Pretreatment necessary to bond according to the specific needs
24
Steels, Construction Steels in General
Adhesive Bonding on Oiled Surfaces
● Usage of oil-tolerating adhesives
● Epoxy Resin Adhesive, Plastisols, Butyle Rubber
● Often with support of heat
25
Adhesive Properties of Metal
26
Adhesive Properties of Aluminium/-Alloys
Material Properties I
● Density ρ = 2,7 • 103 kg/m-3
● Melting Point Ts = 666 °C
● Boiling Temperature Tv ≈ 2060 °C
● Specific Heat Capacitiy cp = 896 J kg-1 K-1
● Thermal Conductivity λ = 230 W m-1 K-1
● Coefficient of Thermal Expansion α (0…100 °C) = 23,86 • 10-6 K-1
● Specific Electrical Conductivity χ = 37,74 m Ω-1 mm-2
● Specific Electrical Resistance ρ = 0,0265 Ω mm2 m-1
● Yield Strength (soft) (Re, σS) Re = 9,81… 24,5 MPa (weich);
● Yield Strength (hard) (Re, σS) Re = 68,67 … 98,1 (hart) MPa
27
Adhesive Properties of Aluminium/-Alloys
Material Properties II
28
Adhesive Properties of Aluminium/-Alloys
Fields of Application I
● The main features, why aluminium and aluminium alloys are used in these
areas, are:
– degree of hardness nearly the same as steel
– low density
29
Adhesive Properties of Aluminium/-Alloys
Fields of Application II
30
Adhesive Properties of Aluminium/-Alloys
Forms of Corrosion
Surface Corrosion
● no corrosion when attacked with acids or bases
● only when alloy carries a lot of copper
Pitting
● when exposed to salt
● in aggressive atmosphere
● in sensitive alloys the holes can be deep, can also lead to surface corrosion when
alloy not so sensitive
31
Adhesive Properties of Aluminium/-Allyos
Forms of Corrosion
● Intercristalline Corrosion
– mainly in AlMg-Alloys with > 3% Mg-amount when under thermal stress
● Contact Corrosion
– possible problems in material combinations with steel, copper and copper alloys
– Ni-basic alloys
Copper
34
Adhesive Properties of Copper
Material Properties
35
Adhesive Properties of Copper
Material Properties
36
Adhesive Properties of Copper
Chemical Properties
In contact with air, copper forms a strongly adherent, light-green oxide layer
(patina)
www.uni-kassel.de
Copper roof with typical green colour
37
Adhesive Properties of Copper
Technological Properties
● Castability, bad because of the high intake of gas, bubbles and porosity
● Copper can be formed chiplessly in a cold and warm state (car grid), except in
temperatures between 350 … 650 °C
● When cutting copper, the high toughness has to be considered
● Copper and its alloys can be soldered in a cold and hard condition (usage of Cu-,
Ag- und brass solders)
38
Adhesive Properties of Copper
Adhesive Characteristics (with pretreatment)
39
Surface Pretreatment for Copper
40
Adhesive Properties of Metal
41
Adhesive Properties of Magnesium
Pretreatment
Direct adhesive bonding or sealing of the surface to prevent new corrosion
42
Adhesive Properties of Magnesium
Matrial Properties
45
Adhesive Properties of Titanium/-Alloys
Material Properties
46
Adhesive Properties of Titanium/-Alloys
Material Properties
47
Adhesive Properties of Titanium/-Alloys
Chemical Properties
48
Adhesive Properties of Titanium/-Alloys
Titanium Alloys (Selection)
49
Adhesive Properties of Titanium/-Alloys
Technological Properties
50
Adhesive Properties of Titanium/-Alloys
Fields of Application
● Chemical Industry
– In systems for chlorine chemistry
51
Adhesive Properties of Titanium/-Alloys
Adhesive Characteristics
52
Adhesive Properties of Titanium/-Alloys
Possible Surface Treatments:
Joint surface has to be cleaned before, inbetween and after all surface
treatments
Removal of oxide layers and roughening
● Chemically
– Pitching with non-oxidising acids (hydrofluoric acid, hydrochloric acid, sulphuric acid
diluted)
● Mechanical
– Blasting (aluminium oxide or sand) or with abrasive cloth
After the pretreatment, either the adhesive bonding process must start
immidiately or primers have to be applied to avoid new oxidation
53
Agenda
Introduction
Material Combinations
Conclusion
54
Adhesive Properties of Synthetic Materials
55
Adhesive Properties of Synthetic Materials
Differentiation between:
Adhesion Bonding
● Basically for all synthetic materials
● Mostly no formations of stress cracks
● Good gap bridging qualities
Diffusion Bonding
● The surface can be dissolved or swelled with the proper solvents
● This makes the molecules more mobile and they can diffuse into the joint counterpart
● Polyvinyl chloride (hard/soft) (PVC), perspex (PMMA), acrylnitrile-butadiene-styren-
copolymer (ABS), polystyrene (PS), polycarbonate (PC)
● Solvents: THF, MEK
56
Adhesive Properties of Synthetic Materials
Classifications of the Synthetics
Thermoplastic Synthetics
● Solvable/swellable in organic solvents
– Diffusion and adhesion bonding possible
Duromers
● Only adhesion bonding
57
Adhesive Properties of Synthetic Materials
58
Adhesive Properties of Synthetic Materials
Classification According to Bonding Qualities
61
Adhesive Properties of Synthetic Materials
Polyvinyl Chloride (PVC)
-50 °C - +60 °C
Temp. Area
62
Adhesive Properties of Synthetic Materials
Fields of Application (PVC)
● Pipes (hard)
● Packages (hard/soft)
● Food Packaging (soft)
http://www.mcm-systeme.de
● Hoses/Tubes (soft)
● Floor Covering (soft)
obi.de
63
Adhesive Properties of Synthetic Materials
Bonding Qualities of Polyvinyl Chloride (PVC-U, hard)
64
Adhesive Properties of Synthetic Materials
Bonding Qualities of Polyvinyl Chloride (PVC-P, soft)
Polystyrene (PS)
66
Adhesive Properties of Synthetic Materials
Material Properties of Polystyrene (Thermoplastic)
Standard Foamed
Density 1,040 - 1,090 kg/cm3 0,015 - 0,090 kg/cm3
unstable unstable
UV-Resistance
unstable unstable
Resistance to the Weather
soluble soluble
Solubility 67
Adhesive Properties of Synthetic Materials
Fields of Application
Standard
● Packaging
● Household Objects
● Toys
● Electro-Technology http://www.chemgapedia.de
Foamed (PS-E)
● Building (Insulation)
● Packaging Industry
www.bauen.de
68
Adhesive Properties of Synthetic Materials
Adhesive Characteristics of Polystyrene
70
Adhesive Properties of Synthetic Materials
Material Properties of Polymethyl Methacrylate (PMMA) (Thermoplastic)
71
Adhesive Properties of Synthetic Materials
Fields of Application (Plexiglass)
● Optics
● Electro-Technology
● Vehicle-Constructions
● Building Industry
● Construction of Fairs and Exhibitions
● Protection Glazing
● Household Objects
● Sanitary Systems
http://www.koenig-kunststoffe.de
72
Adhesive Properties of Synthetic Materials
Adhesive Characteristics of Polymethyl Methacrylate (PMMA)
The surface is polar and soluble
● Surface Energy: 46 mN/m
73
Adhesive Properties of Synthetic Materials
Polyamide (PA)
74
Adhesive Properties of Synthetic Materials
Material Properties of Polyamide (PA, Nylon) (Thermoplastic)
75
Adhesive Properties of Synthetic Materials
Fields of Application for Polyamide (PA, Nylon) (Thermoplastic)
● Maschine Constructions
– Slide Bearings, Gears…
● Vehicle Constructions
● Electro-Technolog
● Clothing
thyssenkrupp-plastics.de
76
Adhesive Properties of Synthetic Materials
Adhesive Characteristics of Polyamide
77
Adhesive Properties of Synthetic Materials
78
Adhesive Properties of Synthetic Materials
Material Properties of Polyethylene Terephthalate (PET) (Thermoplastic)
79
Adhesive Properties of Synthetic Materials
Fields of Application
● Packaging Industry
– PET-bottles
● Construction of Exhibitions
● Maschine Constructions
www.dew-stahl.com
80
Adhesive Properties of Synthetic Materials
Adhesive Characteristics of PET
81
Adhesive Properties of Synthetic Materials
Polypropylene (PP)
82
Adhesive Properties of Synthetic Materials
Material Properties of Polypropylene (PP) (Thermoplastic)
83
Adhesive Properties of Synthetic Materials
Fields of Application for Polypropylene (PP)
● Household Objects
● Building Industry
– Pipes
● Vehicle Constructions
– Interior of cars
● Electro-Technology
● Packaging
84
Adhesive Properties of Synthetic Materials
Adhesive Characteristics of Polypropylene (PP)
85
Adhesive Properties of Synthetic Materials
Polytetrafluorethylene (PTFE)
86
Adhesive Properties of Synthetic Materials
Material Characteristics of Polytetrafluorethylene (PTFE) (Thermoplastic)
87
Adhesive Properties of Synthetic Materials
Fields of Application for Polytetrafluorethylene (PTFE, Teflon)
● Household Objects
– Anti-adhesive coatings for frying pans
● Engineering www.castan-elastomere.de
PTFE-seals
– statically and dynamically stressed loads
● Medical Technology
– artificial veins and arteries
www.herzzentrum.ch
Stent, PTFE coated
88
Adhesive Properties of Synthetic Materials
Adhesive Characteristics of PTFE
89
Adhesive Properties of Synthetic Materials
90
Adhesive Properties of Synthetic Materials
Chemical Properties of Duromers (also Thermosetting Plastics)
Synthetics
● Epoxy Resins (EP), Phenolic Resins (PF), Urea Resins (UF), Melamine Resins
(MF), different Polyurethanes (PUR)
91
Adhesive Properties of Synthetic Materials
Mechanical Properties of Duromers (also Thermosetting Plastics)
92
Adhesive Properties of Synthetic Materials
Survey
93
Agenda
Introduction
Material Combinations
Conclusion
94
Adhesive Properties of Glass
Mechanical/ Chemical Properties of „Normal Glass“
● Density
● Thermal Expansion
● Inert Surface
● Resistant to Media
● Can Take High Temperatures
95
Adhesive Properties of Glass
Surface Properties of Glass
Because of its chemical composition, glass has the chracteristic that it can bind
humididty at its surface.
● This layer of humidity can prevent bonding forces to a certain extent.
Aim of the surface pretreatment must therefore be to remove the layer of
humididty from the surface. (Temporarily for the time of the application of the
adhesive)
– heating of the surface leads to the evaporization of the humidity and at the same time
quickens the reaction of the adhesive
96
Agenda
Introduction
Material Combinations
Conclusion
97
Adhesive Properties of Wood and Ceramics
Wood
98
Adhesive Properties of Wood
General Properties of Wood
As a natural product, wood has a more or less strongly developed porous
structure.
● Mechanical Adhesion (micro-mechanical form lock)
It has the characteristic to absorb humidity from the environment (hygroscopic
characteristic)
99
Adhesive Properties of Wood
Hygroscopic Characteristics
As wood takes humidity from its environment, it has no high dimensional
stability
● If the surrounding climate and the humidity are constant, then the dimensions stay
constant
● Under the fibre saturation range (about 25-35% moisture), the wood either
swells or shrinks due to the change in humidity
– Coefficient for shrinkage or swelling shows the change in size per percent change in
wood moisture
100
Adhesive Properties of Wood
Anisotropy
For wood, three directions need to be distinguished as they have different
properties, depending on their direction
Example Shrinkage:
● Axial
– Coefficient for shrinkage: ~0,3%*
Coefficient for
Strength (N/mm²)
Shrinkage
Gross E-
Tyoe of
Density Modulus
Wood Tensile Pressure Bending( Shear
(kg/m³) radial tang. (N/mm²)
(axial) (axial) quer) (axial)
102
Adhesive Properties of Wood
Mechanical Properties - Hardwood
Coefficient for
Strength (N/mm²)
Shrinkage
Gross E-
Tyoe of Wood Density Pressur Modulus
(kg/m³) Tensile Bending Shear (N/mm²)
radial tang. e
(axial) (quer) (axial)
(axial)
104
Adhesive Properties of Wood
Influence of the Degree of Moisture
The degree of moisture at the time of the adhesive bonding process is very
important for the quality of the bond.
● The highest possible, acceptable degree of moisture depends on the specific
adhesive in use
If the degree of moisture is exceeded, this leads to:
● when using dispension adhesives, the diffusion of water might be obstructed,
which leads to longer hardening periods. It can also lead to a dilution of the
adhesive.
● when using condensation adhesives, water can be locked in, which can lead to
shrinkage.
● when applying hotmelt adhesives, it can lead to the formation of steam, which
weakens the bonding forces.
105
Agenda
Introduction
Material Combinations
Conclusion
106
Adhesive Properties of FVK-Materials
107
Adhesive Properties of FVK-Materials
Fields of Application
● GFK- and CFK-materials are very important for leight-weight constructions
● Examples
– Shipbuilding
– Aviation
– Cycling
Bicycle frameout of CFK
– Vehicle Constructions
www.produktion.de
CFK and GFK – Components in the A380
109
Agenda
Introduction
Material Combinations
Conclusion
110
Material Combinations
In General
● To ensure durability after hardening of the bond, the coefficients for the thermal
expansion of all components must be considered.
– To big differences in the expansion lead to tensions in the adhesive layer, which can then
lead to cracks in the bond.
111
Material Combinations
Metal-Plastic-Bonds
112
Material Combinations
Metal-Plastic-Bonds
Thermal Expansion
● The relation of the expansion of metal to plastic is about 1:5
– The bigger the bonding area, the more important the expansion is
113
Material Combinations
Metal-Plastic-Bonds
● Also possible:
– Methacrylate Adhesive, Contact Adhesive , Foamed Adhesive Tapes
114
Material Combinations
Metal-Plastic-Bonds
115
Material Combinations
Glass-Metal-Bonds
116
Material Combinations
Glass – Metal – Bonds
Surface Pretreatment
Thermal Expansion
● Relation 1:10:2 Glass:Plastic:Metal (KM 5:1, KG 10:1)
– Adhesive needs high deformation properties
117
Material Combinations
Glass – Metal – Bonds
Adhesive Selection
● Preferably cold-hardening systems
– avoid heat
Suitable Adhesives
● Polyurethane, Contact Adhesives and specially flexible adjusted Epoxy
Resin
118
Material Combinations
Glass – Metal – Bonds
Unsuitable Adhesives
● Basically all adhesives that are hard and porous
119
Agenda
Introduction
Material Combinations
Conclusion
120
Conclusion
Looking at the adhesive properties of the materials, or the material
combinations, results in: