Les Adhésifs comme Méthode Alternative pour l'Assemblage des Matériaux Composites

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

© LCS 1

®LCS - 2012-2013- V 1.6.1.1 Copyright LCS 1

« Les Adhésifs comme Méthode Alternative pour l’Assemblage des

Matériaux Composites ».

Luxembourg - 26 septembre 2013

®LCS - 2012-2013- V 1.6.1 Copyright LCS 2

Oh, yes !


Repair of Glove Box Lock

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


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


NASA – Spaceshuttle - Heatshield

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


Automotive Applications

Sun Roof

Tire Pressure Sensors

Turbo Charger Windscreen

Radiator Headlamps

Loudspeakers

Brake Linings

Mirrors

Seats

Chassis

Relais


© LCS 2


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


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


Sticking as a Gecko

www.wildeyereptiles.com


What’s “Bonding” ? Definition

Joining of

two substratesby means of a

third medium

= the adhesive

Adhesion vs Cohesion


But what’s really on the ‘Surface’ ?!


Why Surface Treatment ?

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


© LCS 3


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


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


Surface Treatment with Atmospheric Plasma

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


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

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Surface Testing

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

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

• Containing Formamid ! Toxic


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


© LCS 4


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


Adhesive Types


Windmill blades

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


Composites

2K Epoxy


Composites

Rivetless Nutplates


Adhesive Types - PHENOLICS

• Phenolics applications• Braking pads for automotive


© LCS 5


Adhesive Types - ACRYLATES

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


Turtle Surgery - Nanocomposites


Dental Surgery - Nanocomposites

Amalgam Restoration

Cavity Composite Restoration


Adhesive Types - Casein

Cork for (wine)bottles & knife handles


Adhesive Types - Tapes

• Tapes: single and double sided

8609 Wind Tapes Blade Protection


Podotactile Domes – Dual Bonding System


© LCS 6


Safety

Campuskrant KULeuven


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


That’s why there are Safety Measures …

Specific for Adhesive Bonding Operations


Stress Resistance

Tensile vs

Compression


Stress Resistance

Shear

Best for Bonding !


Stress Resistance

Cleavage


© LCS 7


Stress Resistance

Peel


Bewegende Belastingen

• Tensile - Trekbelasting

• Shear – Afschuiving L&R

• Cleavage - Splijtbelasting

• Peel - Afpelbelasting

• K07M03R21C.mov Cfr Video


Belasting van lijmnaden


Anti-Peel solutions


Bonding Composite Profiles

• Pultrusion profiles: – FibreForce = Exel Composites


Design with Tube Joints

• Suggestion: adhesive injection

H


© LCS 8


Lid of Washing Machine

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


Lid of Washing Machine


FEA – Finite Element Analysis

– Mathematical method to solve partial differential & intergral equations


FEA – Finite Element Analysis

– Example: Crash Simulation


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


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


© LCS 9


Curing of Adhesives

• Methods– RT cure

– Heat cure• Ovencure• Inductive• Microwave• Laser

– Light/UV curing

– Moisture cure– Dual systems


Curing of Adhesives

• Timing

Afbindtijd

PerstijdOpbrengtijd

Open tijd


Loudspeakers

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

Vibration, resonance, HT, plastics, …


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


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.

Success Guaranteed !®LCS - 2012-2013- V 1.6.1 Copyright LCS 54

Thanks for your attention,

and we welcome you in

’The Adhesive’s World’


© LCS 10


Any Questions ?

?Q&A


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

[email protected]

www.lcs-adhesivebonding.com

Les Adhésifs comme Méthode Alternative pour l'Assemblage des Matériaux Composites

Technology

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