+Composites - LCS Adhesive Bonding bvba (B) Luxembourg - 26-09-2013

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« Les Adhésifs comme Méthode Alternative pour l’Assemblage des

Matériaux Composites ».

Luxembourg - 26 septembre 2013

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Oh, yes !

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Repair of Glove Box Lock

VW Golf – Bondmaster E32 – 2K EP… Collage, Bricolage ! ???

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History

• Genghis Khan : laminated bows

• Romans : – Helmets– Animal glue - bones– Tar: waterproofing ships– Glue based on blood, eggs, milk, etc. …

• 1644-1737 Stradivarius : violins

• 1750 first patent• 1910 Bakelite : phenolic resins

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NASA – Spaceshuttle - Heatshield

Now ARES-1-X 28-10-2009 NASA - Constellation project – Orion-cabine & Altair-maanlander

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Automotive Applications

Sun Roof

Tire Pressure Sensors

Turbo Charger Windscreen

Radiator Headlamps

Loudspeakers

Brake Linings

Mirrors

Seats

Chassis

Relais

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Advantages of Adhesives• Easy & Fast: less rework

• Also for dissimilar materials– e.g. metal-plastic & thick-thin

• Higher Strength: uninterrupted joint– No or less weak points

• Improved Stress-distribution & -reduction– Higher fatiguestrength

• Sealing: corrosion prevention– Liquid- & gastight

• Damped Vibrations – less Noise S&R

• Light: weight reduction

• Esthetic: invisible

• Bonding also “Thin” & “Small” components

• Less components

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Pseudo -disadvantages of Bonding

• It’s “Chemistry” ! It’s a mess !?

• Environmental aspects– Water based adhesives– recycling of adhesive and cleaners

• Cleanliness of substrates• Design flexibility: is manageable

• Speed: adhesive type dependent

• Dangers: exothermic reactions, H&S

• Difficult Disassembly: recycling

• Limited Strength & Temperature Resistance

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Sticking as a Gecko

www.wildeyereptiles.com

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What’s “Bonding” ? Definition

Joining of

two substratesby means of a

third medium

= the adhesive

Adhesion vs Cohesion

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But what’s really on the ‘Surface’ ?!

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Why Surface Treatment ?

• Strength: adhesion - cohesion ( rupture )• Wetting ( > 40 Dyne/cm)• ‘Contact Angle’ measurement• Watertest

+Composites - LCS Adhesive Bonding bvba (B) Luxembourg - 26-09-2013

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Pretreatment of substrates

• Degreasing: cloth, vapour, ultrasonic

• Grinding: roughen = > surface

• Blasting: grit-, ice- . NON-recirculating !

• Primers: silanes – thickness = µm

• Chemical etch: bv Aluminium

• Flame & Corona: foil & sheet

• Plasma: vacuum & atmospheric – CA!

• Laser: surface structure change

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Failure Types

• Cohesive failure: in the adhesive

• Adhesive failure: on the surface of at least one of the substrates

• Material Failure: one of both substrates

• Mixed Failure: a combination of the above

K07M01R32C.mov

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Surface Treatment with Atmospheric Plasma

• Benkiser Labels• Mint Cards• Rottaler Bottles• Hella BMW

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Surface Treatment with Atmospheric Plasma

Effects on Bonding Results

KB 4552

KB 4552

KB 4571

KB 4571

KB 45952

KB 45952

0

2

4

6

8

10

12

14

16

18

20

cleaned plasma-treated

com

pre

ssio

n sh

ear s

tren

gth

[MP

a]

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Surface Testing

• Test ink for Surface Tension Measurement: 38mN/m

• Also available in bottles. Wait 30 seconds !!!

• Containing Formamid ! Toxic

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External Influences

• Time: aging – degradation in function of time

• Temperature: -change en thermoshock– under the hood: -55°C tot +125°C

• Vibrations & Shock: noise - S&R

• Chemical: salt + humidity = corrosion

• Radiation: X-ray, α-, β-, γ-radiation

– Radioactive

– Light: UV degradation – color permanency

• Medical: USP Class VI – ISO 10993 – sterilisation, biocompatibility, citotoxicity

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Adhesive Types

• Epoxy : highest performance, chemical resistant• Polyurethane : humidty sensitive, cheap• Silicone : flexible, price ↑, Mix-Ratio, Visc ≠ f(T)• Phenolics: high temperature applications• UV & light - curing: fast, price ↑, light sensitive• Acrylates : highest strength, smell, initiators• Cyanoacrylates : moisture cure• Anaerobics : thread lock – metal+ & air cut off• Hybrids : EP/Si, PU/EP, UV + moisture or T …• Exotics : polybutadiene, MS-polymer, PSA, …• Hotmelts: cheap, reactive types, performance• Tapes: single and double sided• Ceramic : HT - Waterglass

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Adhesive Types

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Windmill blades

SIEMENS B75 Rotor blade - 75m length - 5-10 rpm - 25t - 6 MW

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Composites

2K Epoxy

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Composites

Rivetless Nutplates

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Adhesive Types - PHENOLICS

• Phenolics applications• Braking pads for automotive

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Adhesive Types - ACRYLATES

• Toughened Acrylics applications– Hinges for mirrors – shower doors– Bank terminals - security– Car sunroof– Bus panels

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Turtle Surgery - Nanocomposites

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Dental Surgery - Nanocomposites

Amalgam Restoration

Cavity Composite Restoration

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Adhesive Types - Casein

Cork for (wine)bottles & knife handles

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Adhesive Types - Tapes

• Tapes: single and double sided

8609 Wind Tapes Blade Protection

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Podotactile Domes – Dual Bonding System

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Safety

Campuskrant KULeuven

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Health & Safety – H&S – NEW !

It kills = T & T+ New

It pollutes

R&S phrases: Risk & Safety

New

New since september 2008 – Obligatory by 2017

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That’s why there are Safety Measures …

Specific for Adhesive Bonding Operations

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Stress Resistance

Tensile vs

Compression

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Stress Resistance

Shear

Best for Bonding !

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Stress Resistance

Cleavage

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Stress Resistance

Peel

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Bewegende Belastingen

• Tensile - Trekbelasting

• Shear – Afschuiving L&R

• Cleavage - Splijtbelasting

• Peel - Afpelbelasting

• K07M03R21C.mov Cfr Video

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Belasting van lijmnaden

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Anti-Peel solutions

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Bonding Composite Profiles

• Pultrusion profiles: – FibreForce = Exel Composites

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Design with Tube Joints

• Suggestion: adhesive injection

H

+Composites - LCS Adhesive Bonding bvba (B) Luxembourg - 26-09-2013

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Lid of Washing Machine

• Plastic-frame + Composite decorative worktop + Fixations• Fast 2K PU - Flex

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Lid of Washing Machine

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FEA – Finite Element Analysis

– Mathematical method to solve partial differential & intergral equations

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FEA – Finite Element Analysis

– Example: Crash Simulation

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Formulation of Adhesives

• Resin : epoxy, polyol, …• Hardener : amine, anhydride, DDA, isocyanates• Fillers : Quarts, Al2O3, TiO2, talc, mica …

• hardness and shape determine abrasiviness• quantity & type determine material properties

• Colorants & pigments :• titaniumdioxide white• ironoxide red• soot / carbon black black

• Additives : = ‘pepper & salt’ for an adhesive

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Formulation of Adhesives - Additives

• Thixotropic agents: Aerosil• Adhesion promotors: Silanen• Flow modifiers: eg heat exchanger story• Antifoam agents: deairing• Diluents: reactive vs. non-reactive• Fungicides• Drying agents: molecular sieve• Spacers: bondline thickness• Cure accelerators – retarders• Flame retarders: e.g. UL94 V0• Indicators: UV for QC & Radio-opaque markers

• Stabilisators: eg UV resistance

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Curing of Adhesives

• Methods– RT cure

– Heat cure• Ovencure• Inductive• Microwave• Laser

– Light/UV curing

– Moisture cure– Dual systems

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Curing of Adhesives

• Timing

Afbindtijd

PerstijdOpbrengtijd

Open tijd

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Loudspeakers

To 12 bonding area’s – Ep, Acrylate, CA, UV

Vibration, resonance, HT, plastics, …

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A few Trends

• More machine- & environment friendly (Green) products: REACH & RoHS en Recyclability - Cradle-to-cradle

• Multiple functionalities: Vibration dampening - S&R

• More user friendly products– Fluo & RI-ACT –– Low T°hotmelts: safe, easy cleaning, cost reduction

• More composites and ‘all-in’ adhesives• Increasing Price pressure ↑ : Lopez effect - raw materials &

energy price increases

• Nano technology in adhesives• It all happens on the surface , less in the adhesive• Selfhealing Adhesives• More automation with adhesives• More ‘Bonding’ for your new Application

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Conclusion

The only chance realising bonding projects successfully, is that the “Triumvirate” of– the customer with his project– the glue manufacturer with the adhesive– the machine manufacturer s with their

equipment

is working intensively and expertly together, from the design phase on and

on all aspects of the application.

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Thanks for your attention,

and we welcome you in

’The Adhesive’s World’

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Any Questions ?

?Q&A

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LCS – Your partner in Adhesive Bonding

LCS Belgium bvba

Consultancy in

Adhesive Bonding Technology

Bergenstraat 84B-3053 Haasrode – Leuven

+32-(0)16-38 90 45+32-475-45 48 98

jan.lambrechts@consultant.com

www.lcs-adhesivebonding.com