GROUP NO:6

Group Members
1.Manjith Manohar
2.Manu S S
3.Manu M S
4.Alex Mathew
5.Amarnath H V
 Adhesive Bonding

Joining process in which a filler material is

used to hold two (or more) closely spaced parts
together by surface attachment.

It is used in a wide range of bonding and

sealing applications for joining similar and
dissimilar materials such as metals, plastics,
ceramics, wood, paper, and cardboard.
 Terminology in Adhesive
Bonding

Adhesive :- Filler material, nonmetallic,

usually a polymer.
Adherends :- Parts being joined.
Structural adhesives :- They have greate
interest in engineering, capable of forming
strong, permanent joints between strong,
rigid adherends.
 Adhesive Bonding Procedures

There are three essential steps required to be

followed to make an adhesive joint.They are,

1.Preparation of the surfaces.

2.Application of the adhesive on to the mating
surfaces.
3.Assembly of workpieces
 .
1 Preparing the surface

The workpiece surfaces are cleaned by

chemical etching or mechanical abrasion like
Grinding, filing, wire brushing, sanding and
abrasive blasting.

The prepared surfaces are tested by their

affinity to be wetted by water. It is called water-
break test. Smooth spread of water is an
indication that the surface is chemically clean
while the collection of droplets indicates the
possibility of oil film in the surface.
 .
2 Application of the Adhesive to the
Surface
Adhesives are applied on to the workpiece
surface by hand brushing, spraying, roller
casting, knife coating and dipping.

They are also applied as sheet or tape type

coating to the surface.

The adhesive are either applied as one thick

layer on one of the workpiece surface, or as a
thin layer on surfaces of both the workpiece.
 3 . Assembly of Workpieces
The workpieces are held together by means
of clamps, tools, tack welds, or other fixtures.
During the assembly process, sufficient care
should be taken so that the open time of the
adhesive is not exceeded, the parts are put
together in the proper sequence, the bonding
is performed under specified environmental
conditions, and the parts are held together
until cured.
 3.1 . Curing the Joint
Process by which physical properties of the
adhesive are changed from liquid to solid,
usually by chemical reaction, to accomplish
surface attachment of parts.
Curing often aided by heat and/or a catalyst.
Curing takes time,it is a disadvantage in
production.
Pressure sometimes applied between parts to
activate bonding process.

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 Classification of Adhesives

1.Based on load carrying capacity.

Adhesives

Structural Adhesives Non Structural Adhesives

Structural Non-structural
adhesives are adhesives are
having high load having low load
carrying carrying capacity.
capacity.
 Structural adhesives

Structural adhesives

Thermoplastic Thermosetting Plastics

 Thermoplastic Adhesives

The thermoplastic adhesives get soften at

high temperatures.
The most commonly used thermoplastic
adhesives include polyamides, vinyls and
non-vulcanizing neoprene rubber.
Polyvinyl acetate is used to form strong
bonds with metals, glass and porous
materials.
 Thermosetting Plastic Adhesives

The thermosetting adhesives usually do not get

soften at high temperature. Once they harden,
these adhesives cannot be remelted and a broken
joint cannot be rebounded by heating.
Thermosetting adhesives are mainly available in
two variants phenolic resin and the epoxy resin.
Phenolic resins are the best bonding materials
for waterproof plywood.
Epoxy resins produce the joint with high
strength, toughness, chemical inertness, and low
shrinkage.
 2.Based on Reactiveness

Adhesives

Non Reactive Adhesives Reactive Adhesives

Drying Adhesives. Multi Part Adhesives.
Pressure Sensitive One Part Adhesives.
Adhesives.
Contact Adhesives.
Hot Adhesives.
 Non Reactive Adhesives

1.Drying Adhesives
Drying adhesives hardens by drying.
There are two types of drying adhesives
Solvent based adhesives and Polymer
dispersion adhesives (Emulsion adhesives).
Solvent based adhesives are a mixture of
ingredients dissolved in a solvent.
Emulsion adhesives are milky white
dispersions often based on polyvinyl
acetate.
2.Pressure Sensitive Adhesives
It forms a bond by the application of light
pressure.
Pressure sensitive bonds are designed to
have a balance between flow and resistance
to flow.
Eg:- Acrylate based polymers
3.Contact Adhesives
Contact adhesives are used in strong bond
with high shear resistance.
Natural rubber and Polychloroprene
(Neoprene) are commonly used contact
adhesives.
Contact adhesives must be applied to both
surfaces and allowed some time before
pushed togather.
4.Hot Adhesives
Hot adhesives also known as hot melt
adhesives.
These are thermoplastics applied at molten
form which on cooling forms strong bonds.
Etylene vinyl acetate based hot melts are
commonly used because of ability to form
bonds with wide range of commonly used
materials.
 Reactive Adhesives

1.Multi Part Adhesives

Multi part adhesives harden by mixing two
or more components which chemocally
react.
The individual components of a multi part
adhesives are not adhesive in nature.
Commonly used multi part adhesives are,
Polyester resin-Polyurethane resine,
Polyols-Polyurethane resine and
Acrylic polymers-Polyurethane resines.
2.One Part Adhesives
One part adhesives harden via a chemical
reaction with an external energy source.
Light curing adhesives are popular due to
rapid hardenig of the adhesives. UV lights
are used in hardening purpose.
 3.Based on Origin
Adhesives

Natural Adhesives Synthetic Adhesives

Made from organic Based on elastomers,
sources such as thermoplastics,
vegitable starch, emulsions and
natural resins and thermosetting
animals. plastics.
 Natural Adhesives

Natural adhesives derived from natural

sources, including gums, starch, dextrin,
soya flour, collagen.
Inorganic adhesives based principally on
sodium silicate and magnesium oxychloride.
Low cost, low strength
Low-stress applications: cardboard cartons,
furniture, bookbinding, plywood.
 Synthetic Adhesives
Synthetic adhesives Includes various
thermoplastic and thermosetting polymers.
Synthetic adhesives cured by various
mechanisms:
1. Mixing catalyst or reactive ingredient with
polymer prior to applying.
2. Heating to initiate chemical reaction.
3. Radiation curing, such as UV light.
4. Curing by evaporation of water.
 Durability of a Bonded Joint

The durability (the long-term performance) of

a bonded joint depends on the properties
both of the adhesive and of the materials
being joined.
The adhesive and joint will be affected by
high temperatures, by powerfuf solvents or
by water.
 Structure of Adhesive Joint

Adhesive bonding uses a variety of

chemicals that are applied as a liquid and
solidify to form a bond.
 Adhesive joint generally consists of two substrate
surfaces with the adhesive material filled the gap
between them. However the adhesive layer is not
uniform. Besides the part of the adhesive layer,
properties of which are not affected by the
substrate, there are two boundary layers, which
have been changed by impurities and products of
reactions at the substrate surfaces.
 Theory
The various theory's associated with adhesive
bonding are;
The mechanical interlock theory
The adsorption theory
The chemisorption theory
The electrostatic theory
The diffusion theory
The weak boundary layer theory
 Equipments Used in Adhesive Bonding

To make a successful bond, the adhesive

must wet the material to be joined, fill the
gap between the surfaces, and then fully
harden.
With a two-part adhesive this means that
resin and hardener must be correctly
proportioned and thoroughly mixed together.
The right amount of mixed adhesive needs to
be placed and spread onto the bond area.
Both these steps are aided by using
automatic equipment.
 1.Handgun Operated by Compressed Air

In this type of
handgun compressed
air is used to pump
required amount of
adhesive.
It is commonly used in
adhesive bonding
using thermoplastics,
where adhesive
contains only one
component.
 2.Metering and Mixing Machine

These are
volumetric
proportioning
equipment, which
meters, mixes and
dispenses two-part
epoxy adhesives.
It contains two
pistons which helps
to attain different
mixing ratios.
 3.Hot air ovens

This is a practical method only when a

large number of assemblies are in the
oven at the same time or for continuous
production lines.
Heat transfer is relatively slow and
affected by the assembly type and
thickness.
Infa-red ovens can also be used.
 Types of Adhesive Joints

Single lap (unsupported) joint

Balanced double lap adhesive joint

 Unbalanced double lap joint

Scarf Joint
 Butt Joint

Cylindrical Joint

Ofset Lap Joint

 Design Parameters

1. Lap Joints
Lap joints are the most practical design and
applicable in bonding thin materials. Lap joints
are used to enhance joint strength by reducing
its potential to peel stress.
2. Butt Joints
In tension, the straight butt joint is
impractical for load bearing assemblies. To
minimize this stress, the angle design applies
compression. Compressive loading will not
affect the joint unless bucking of the vertical
component occurs.
 Process Parameters

The most important process parameters for

achieving a high bonding strength are,

1.Adhesive material
2.Coating thickness
3.Bonding temperature
4.Processing time
5.Chamber pressure
6.Tool pressure
 Protection

The aim of health protection is to protect

people against hazards and exposure.
Work protection is used to describe
protection in commercial and industrial work
environments while consumer protection
refers to private users.
 Work Protection

Industrial and commercial users of adhesives

require special protection because they work
on daily basis with adhesives.
In addition to hazards associated with the
physical properties of adhesives such as
flammability, explosiveness and burns when
using hot melts, it is in particular chemical
effects such as toxicity, skin irritation, acid
burns and allergies which have to be
avoided.
 These hazards can be avoided by,
1. Equipping the workplace with properly
designed air replenishment and ventilation
systems.
2. Providing workers with personal protection
equipment like work clothing, gloves, and
safety glasses.
3. Ensuring that hygiene regulations like
washing of the skin before breaks and at the
end of work.
 Consumer Protection

For private individuals using adhesives at

home where no special protective measures
are taken.
Private users, unlike industrial users,
generally have no knowledge of the
properties and potential hazards of
products.
Only relatively few of all the known types of
adhesives are available to private users, and
even then only small amounts are made
available in the form of tubes, cartridges and
tins.
 private users do not use adhesives every day,
so the protective measures described for
industrial users are generally neither
possible nor necessary for private users.
It is nevertheless essential that the safety
information given on the small packages is
observed, as well as basic principles of work
hygiene.
 Health Risks

The area of toxicology is concerned with

issues relating to the effects of chemical
compounds and mixtures of chemicals.
The risk assessment determines whether,
and to what extent, there is a health risk to
people as a result of the relevant hazard
potential of the substance and the nature and
degree of exposure.
 The hazard potential generally decreases when
the fraction of hazardous material present is
lower.
Small amounts of a hazardous substance can
often be present without the product having to be
labeled accordingly.
The physicochemical properties of the substance,
the nature and degree of exposure, and the ability
of the substance to get into the body determine
the relevant amount and the resulting dose that
can be taken up by the body.
 The dose level
determines whether,
and to what degree, a
substance can harm a
persons health.
The risk to human
health is determined
from the hazard
potential of the
substance and the
exposure, or
opportunity for contact.
 Advantages

Fast and cheap joining technique

The adherents are not affected by heat
Uniform stress distribution
Possibility to join large structures
Ability to join different materials
Possibility to join very thin adherents
 Advantages(cont)

Gas proof and liquid tight joints

No crevice corrosion
No contact corrosion
Good damping properties
High dynamic strength
 Disadvantages

Limited stability to heat

High strength adhesives are often brittle
Long term use may alter the properties
Cleaning and surface preparation of the
adherents is necessary in many cases
Specific clamping devices are often required
to fix the joint
Difficult disassembly of joined parts
 Applications

Bonding of metal to non-metals especially

plastics is the major application of adhesive
bonding.
Used as an alternative to riveting for aircraft
structures.
Widely applicable in fastening of stiffeners to
the aircraft skin and in assembling
honeycomb structures in aircraft.
 Applications (cont.)
Using extensively in the fabrication of
aircraft internal structures and providing the
smooth surface for supersonic planes.
Useful in automobile industry for attaching
brake lining to shoes, automatic
transmission bands, and stiffeners.
Find applications in the fabrication of railway
coaches, boats, refrigerators, storage tanks,
and microwave reflectors for radar and space
communications.