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

Adhesive Bonding
Increasing use of composites
1980s A310 B767 5-6% 2000s A380 23%

1990s A320 B777 10-15%

2010s A350 B787 50%+

Adhesive Bonding
Attaching bows to slippers Instant Adhesive replaced stitching

Adhesive Bonding
Gas Tanker Bonding and Sealing of internal panels

Outer Hull Insulation Wooden Block Tank Skin Adhesive (up to 80mm thk) Inner Hull

Types of Adhesive

Adhesive Bonding
Adhesive is the only option to join the two materials

Surface Irregularity
Micrograph showing surface irregularity Adhesive fully fills the joint

Surface wetting

Dynes/cm2

Avoid / reduce stress peaks

Avoid / reduce stress peaks

Adhesive Bonding
Adhesive is the only option to join the two materials

Fatigue Strength
Fatigue Strength
2000

Failure Load (MPa)

1500
Adhesive

1000
Spot weld

500

0
103 104 105 106 107

Adhesive & Cylindrical Bonding

Fatigue Resistance

Cylindrical bonding
Bell crank bearing Slip fit saves assembly time No distortion reduces friction Smoother operation

Adhesive Bonding
Ski Bonding

Adhesive Bonding
Typical Loudspeaker structure

Loudspeaker Assembly
Gasket Ring (ABS plastic) Surround (Rubber) Dust Cap (Paper or polypropylene) Water or solvent based adhesive Water or solvent based adhesive Cyanoacrylate with Primer Cyanoacrylate Cyanoacrylate or UV Adhesive

Cone (Paper or Polypropylene)

Coil (Copper windings on Kevlar former) Suspension (Polyester/Cotton) Chassis (Polycarbonate or plated steel) Top Plate (Plated Steel) Magnet (Ferrite) Pole Piece (Plated steel)

Cyanoacrylate
Rivets with sealant to prevent buzz

Structural Anaerobic
Structural Anaerobic

Adhesive Bonding
Aluminium car chassis bonding Lotus Elise

Joint Stiffness
Box Section Relative Stiffness
150% Relative Stiffness to Steel Joint 100%

Aluminium Adhesively Bonded Steel Joint Performance

50%

Aluminium SpotWelded
Relative Mass Al/Steel

0% 1.00

34%

41% 1.20

52%

69% 2.00

1.40 1.60 1.80 Alum inium Up-Gauge Factor

Adhesive Bonding
Automotive composite bonding

Adhesive Bonding
Aluminium Jaguar XJ Bonded & Riveted

Cylindrical bonding
Ring gear for differential

Cylindrical bonding
Ring gear for differential

Cylindrical bonding
Scania Truck Gearbox

Press Bonded Gear Set onto Countershaft

Video

Cylindrical Assembly
Traditional methods of retaining coaxial components

Adhesive Bonding
Critical bonding of brake shoes Strength must exceed the substrate strength at extreme temperatures

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

Adhesive Bonding
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

Cylindrical bonding
Golf club head to carbon fibre shaft

Cylindrical bonding
GRP paddles to carbon fibre shaft

Cylindrical bonding
Composite Propshaft Bonding

Cylindrical bonding
Composite drive shaft end couplings

Cylindrical bonding
Mountain bike forks Composite to titanium

Cylindrical assemblies
Recumbent Tricycle Frame

Adhesive Bonding
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

Cylindrical bonding
Bonding aluminium fittings to polymeric body Fuel system for an F1 car

Adhesive Bonding
Structural Insulation Laminate

Adhesive Bond Lines

Glass/Polyester Laminate Plywood Laminate

Insulation Foam Painted Aluminium Sheet

Adhesive Bonding
Panel and Window bonding on Coaches

Adhesive Bonding
Table tennis bats

Adhesive Bonding
Shock absorbing on cricket bats Rubber to manilla cane

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

Adhesive Bonding
Dental tool bit into handle Must withstand high loads! Standardised components

Adhesive Bonding
UV Cure Adhesives in General Industry Optical Instruments Glass Assemblies Sports Equipment

Adhesive Bonding
UV Cure Adhesives in the Automotive Industry Bonding & sealing electrical connectors

Adhesive Bonding
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

Joint Durability
Effect of surface pre-treatment on the durability of Aluminium Alloy/Toughened Epoxy Joints subjected to accelerated ageing in water at 50C
50 40
Phosphoric Acid Anodised

Lap Joint Strength (MPa)

30 20 10 0 0 200 400 600 800 1000 1200 1400 Time in Water at 50C (Hours)
Grit Blasted Solvent Degreased

Adhesive Bonding
Long term outdoor loading

Adhesive Bonding
Double Lap Joint

Double Lap Joint

Skin Bonding
Adhesive Replaces Stitches Minimises Scarring Prevents Infection
After 3 Weeks

Wound Bonding

In conclusion
Adhesives used in all aspects of Life: