Adhesive Bonding

Walter Brockmann studied mechanical engineering in Hanover, gaining his doctorate in 1969. After many years at the Fraunhofer Institute for Applied Materials Research in Bremen, he has been heading a workgroup for materials and surface technology as professor for materials science at the TU Kaiserslautern since 1990. In 1997 and 1998 he was an honorary professor at Northeastern University Shenyang, China, where he also became Research Fellow Professor at the Heilongjiang Academy of Sciences, Harbin. In 1999 he received the order of merit from the DECHEMA. Professor Brockmann has six books and 266 scientific publications to his name, and is a founding member of the expert group for adhesive technology at DECHEMA and the EURADH conferences. Paul Ludwig Geiß studied mechanical engineering at the TU Kaiserslautern, where he earned his doctorate in 1998 under Professor Brockmann. After a spell in industry, in 2003 he accepted the post of junior professor in joining technology at the TU Kaiserslautern, taking over the workgroup for materials and surface technology from 2004 onwards. Dr. Geiß is head of the norm committee "Testing of construction adhesives, adhesive joining and sandwiching" at the DIN and a member of the scientific advisory board to the international meeting "Swiss Bonding". Jürgen Klingen studied chemistry at Duisburg University, majoring in instrumental chemical analysis. He gained his doctorate in polymer interlacing under Professor Robert Gillard at the University of Wales. He has been working at 3M Deutschland GmbH in Neuss for 20 years, since 1996 as head of the R&D department for adhesives, new materials and polymer processes. Dr. Klingen is the owner of several patents in the field of adhesives chemistry. Bernhard Schröder earned his doctorate following his chemistry degree in Münster in 1978. After many years working in industry, he switched to the Scientific and Medical Institute of Tübingen University in 1986, where he heads the department of surface technology responsible for R&D projects, in particular surface finishing processes for medical products with function layers and adhesive processes in medical technology. Dr. Schröder has several patents and publications in adhesive and medical technology to his name.

• Preface XVList of Contributors XVII1 Adhesive Bonding as a Joining Technique 12 The Historical Development of Adhesive Bonding 53 Adhesion 113.1 Introduction 113.2 Classical Adhesion Theories 143.2.1 Polarization Theory 173.2.2 Diffusion Theory 203.2.3 Chemical Reactions 213.3 Adhesion in Real Systems 243.3.1 Gold 253.3.2 Polyethylene and Polypropylene 253.3.3 Glass 263.4 New Concepts in the Field of Adhesion 263.5 Conclusions 284 Survey and Classification of Adhesives and Primers 294.1 Noncuring (Pressure-Sensitive) Adhesives 294.2 Physically Setting Adhesives 334.2.1 Contact Adhesives 334.2.2 Plastisol Adhesives 344.2.3 Hot-Melt Adhesives 344.3 Chemically Setting Adhesives 354.3.1 Two-Part Adhesives 354.3.2 Hot-Setting, One-Part Adhesives 364.3.3 Cold-Setting, One-Part Adhesives 364.3.4 Microencapsulated Adhesives 374.4 Primers 374.5 General Handling Instructions 385 Chemistry and Properties of Adhesives and Primers 395.1 Pressure-Sensitive Adhesives (PSAs) 405.1.1 Introduction 405.1.2 Chemistry of Pressure-Sensitive Adhesives 405.1.3 Physical Properties of Pressure-Sensitive Adhesives 435.1.4 Properties of Pressure-Sensitive Adhesives as a Function of Temperature 445.1.5 Tack 455.1.6 Peel Resistance 455.1.7 Creep 455.1.8 Formulations of PSAs 465.2 Contact Adhesives 475.2.1 Composition of Contact Adhesives 475.2.2 Properties and Fields of Application of Contact Adhesives 485.3 Hot Melts 495.3.1 Thermoplastic Hot Melts 505.3.2 Hot-Seal Adhesives 515.3.3 Plastisols 515.3.4 Self-Bonding Varnishes 525.3.5 Polyurethane-Based Reactive Hot Melts 525.3.6 Epoxy Resin-Based Reactive Hot Melts 525.3.7 Trends in Hot-Melt Technology 535.4 Phenolic Resin Adhesives 535.4.1 Chemistry of Phenolic Resins 535.4.2 Formulation of Phenolic Resin Adhesives 565.4.3 Behavior and Applications of Phenolic Resin Adhesives 575.5 Epoxy Resin Adhesives 585.5.1 Chemistry of Epoxy Resin Adhesives 585.5.2 Reactions of Epoxy Resins 595.5.3 Properties of Epoxy Resin Adhesives 605.5.4 Formulations of Epoxy Resin Adhesives 635.6 Polyurethane Adhesives 665.6.1 Chemistry of Polyurethanes 665.6.2 Raw Materials 675.6.3 Structure and Properties of Polyurethane Adhesives 695.6.4 Formulations of Polyurethane Adhesives 705.7 Acrylate Adhesives 715.7.1 Physically Setting Acrylates 715.7.2 Chemically Setting Acrylates 715.7.3 Formulations of Acrylate Adhesives 845.8 Silicones 855.8.1 One-Part Silicone Adhesives 855.8.2 Two-Part Silicone Adhesives 865.9 Natural Adhesives 885.9.1 Introduction 885.9.2 Natural Raw Materials 895.9.3 Modern Adhesives Based on Natural Raw Materials 915.9.4 Future Trends 945.10 Chemistry of Primers and Adhesion Promoters 945.10.1 Primers 955.10.2 Adhesion Promoters 965.11 Fillers 996 Design, Production and Quality Assurance of Adhesive Bonded Joints 1016.1 Design and Dimensioning 1016.1.1 Interaction of Polymer Behavior and State of Stress 1016.1.2 Design of Adhesive Bonded Joints 1036.1.3 Dimensioning of Adhesive Bonded Joints 1046.2 Surface Preparation 1086.2.1 Mechanical Surface Preparation Methods 1096.2.2 Chemical Surface Preparation Techniques 1116.2.3 Physical Surface Preparation Techniques 1116.2.4 The Preconditions of Adhesion 1126.2.5 Protection of Prepared Surfaces 1146.3 Application of the Adhesive 1156.3.1 Processing of Adhesives 1156.3.2 Quality Assurance 1237 Adhesives and Adhesive Joints: Test Methods and Properties 1257.1 Adhesive Bulk Properties 1267.1.1 Stress–Strain Analysis of Bulk Specimens 1267.1.2 Determination of Tg by Dynamic Mechanical Analysis or Differential Scanning Calorimetry 1277.1.3 Coefficient of Thermal Expansion (CTE) 1287.1.4 Temperature Resistance by Thermogravimetry 1287.2 Test Categories by Type of Mechanical Stress 1287.2.1 Tensile Stress (e.g. Butt Joints) 1287.2.2 Shear Stress (e.g. Single Lap Shear Specimen) 1307.2.3 Cleavage (e.g. Wedge Test) 1327.2.4 Fracture Resistance 1337.2.5 Wedge Test 1337.2.6 Peel Test 1347.3 Test Categories by Duration and Load Rate 1377.3.1 Long-Term Static Tests (e.g. Creep Experiments Under Dead Load) 1377.3.2 Impact Tests (e.g. Impact Wedge Test to Evaluate Crash Performance) 1387.3.3 Cyclic Loading (e.g. Fatigue Tests) 1397.4 Assessment of Durability and Service Life of Adhesive Joints 1397.5 Tests Related to Storage and Handling of Adhesives 1437.5.1 Determination of Words and Phrases Relating to the Product Life 1437.5.2 Open Time and Working Life 1437.5.3 Extrudability 1447.5.4 Sagging 1447.5.5 Volatile Organic Compound (VOC) Emissions 1447.6 Nondestructive Testing Methods 1457.6.1 Visual Techniques 1467.6.2 Radiographic Techniques 1467.6.3 Magnetic, Electrical and Chemical Techniques 1467.6.4 Mechanical Vibration 1477.6.5 Thermal Methods 1497.6.6 Assessment of Nondestructive Testing Methods 1557.7 Applications of Test Methods in Structural Adhesive Bonding 1567.7.1 Tensile Shear Strength Under Short-Term Loading 1577.7.2 Tensile Shear Strength Under Long-Term Static and Alternating Loading 1627.7.3 Peel Strength 1647.7.4 Impact Behavior 1657.7.5 Durability of Bonded Joints 1667.7.6 Adhesive Bonding of Aluminum 1687.7.7 Adhesive Bonding of Steel 1837.7.8 Adhesive Bonding of Glass 1887.7.9 Adhesive Bonding of Polymer Materials 1917.8 Experiences and Learning from Damage Cases 1917.8.1 Delamination of Bonded Rotor Blade Pockets 1937.8.2 Total Separation of a Rotor Blade Profile 1947.8.3 Bond-Line Corrosion in Wing Honeycombs 1967.8.4 Delamination of the Outer Cover Sheet of Tail Units of Aircraft 1977.8.5 Temperature-Induced Damage on a Tail Rotor Blade 1997.8.6 Temperature-Induced Delamination of a Bonded Glass Fiber Patch 2007.8.7 Incorrect Design of Bonded Filter Elements 2017.8.8 Deficiencies of the Peel Ply Treatment 2028 Adhesive Bonding Technology: Fields of Application 2058.1 Introduction 2058.2 Transportation 2068.2.1 Aircraft Manufacture 2078.2.2 The Automotive Industry 2208.2.3 Bonding in Rail Vehicle Manufacture 2348.2.4 Shipbuilding 2358.3 Building Industry 2378.3.1 Adhesives for the Bonding of Surfaces 2378.3.2 Adhesive Anchors in the Building and Construction Industry 2388.3.3 Building Reinforcement by Means of Bonded Surface Reinforcement 2418.3.4 Structural Bonding in Structural Steel and Facade Engineering 2418.4 Wooden Constructions 2438.4.1 Introduction 2438.4.2 The Structure of Wood 2458.4.3 Consequences 2468.4.4 Adhesive–Wood Interphase 2478.4.5 Adhesive Systems 2478.4.6 Adhesives Based on Renewable Resources 2488.4.7 Synthetic Wood Adhesives 2498.4.8 Wood Composites 2518.4.9 The Supreme Discipline: Laminated Wood Constructions (Civil Engineering Using Wood as Building Material) 2538.4.10 Prefabricated Elements 2558.4.11 Prospects of Wood Constructions 2578.5 Paper and Packaging Industry 2578.5.1 Introduction 2578.5.2 Manufacture of Packaging Materials 2588.5.3 The Setting-Up and Closing of Trays and Boxes 2648.5.4 Pallet Securing 2678.5.5 Labeling 2698.5.6 Cigarette Production 2748.5.7 Manufacture of Tissue Paper Products 2748.5.8 Graphic Products 2788.5.9 Envelopes and Advertising Mail 2868.5.10 Reuse and Recycling of Paper and Packages 2878.5.11 Regulations Stipulated by Law 2928.5.12 Perspectives 2928.6 Small-Scale Industries and Handicraft Trades 2938.6.1 Joining 2938.6.2 Protecting, Splicing and Masking 3018.6.3 Damping 3048.6.4 Labeling, Marking and Coding 3058.7 Electronics Industry 3078.7.1 Thermally Conductive Adhesives 3078.7.2 Electrically Conductive Adhesives 3088.7.3 Underfill Materials 3108.7.4 Functional PSA Tapes 3108.7.5 Spacers 3118.7.6 Labeling 3118.8 Optical Industry 3128.8.1 General Requirements for Adhesives in Optical Industry 3128.8.2 Optical Adhesives for the Temporary Fixture of Optical Elements 3138.8.3 Optical Cementing 3148.8.4 Bonding Optical Elements to Mounts 3158.9 Mechanical Engineering and Process Equipment Construction 3168.9.1 Mechanical Engineering 3168.9.2 Domestic Appliance Industry 3178.9.3 Manufacture of Internal Combustion Engines and Transmission Manufacturing 3178.9.4 Stainless Steel Structures 3198.10 Textile Industry 3208.10.1 The Early History of Fabric-Reinforced Rubber Materials 3208.10.2 How Textile Fibers Contribute to the Living Standards of the Industrial World 3218.10.3 General Properties of Elastomers (Rubber) 3238.10.4 Treatment of Textiles for Rubber Reinforcement 3248.10.5 Adhesion Mechanisms 3288.10.6 Aging of RFL-Dipped Textiles 3308.11 Footwear Industry 3328.12 Road and Highway Engineering 3338.12.1 Traffic Signs 3348.12.2 Pavement Markings 3358.12.3 License Plates 3378.13 Surface Design 3378.13.1 Surface Design and Surface Protection 3378.13.2 Fleet Graphics 3388.13.3 Public Transport Advertising 3388.13.4 Building and Floor Graphics 3408.14 Tamper-Indicating Labels 3418.15 Medical Sector 3438.15.1 Medical Devices with Short-Term, Superficial Body Contact 3438.15.2 Medical Devices with Several (up to 30) Days Body Contact 3438.15.3 Medical Devices with Long-Term (Over 30 Days) Body Contact 3448.16 Adhesion in Nature 3468.16.1 Design Principles of Biological Attachment Devices 3468.16.2 Gluing Under Water 3478.16.3 Adhesion in Terrestrial Insects 3548.16.4 Adhesion in Plants 3558.16.5 Surface-Replicating Mechanism Based on Growth 3568.17 Little-Known Applications 3568.17.1 Foils for the Rotors of Wind Turbines 3568.17.2 Adhesive Elastomer Composites 3588.17.3 Light Bulbs 3598.17.4 Bonding in Art, Jewelry Making and Archeology 3618.17.5 Removable Adhesive Joints 3659 Perspectives 3719.1 Economic Trends 3719.2 Technical Trends 371Appendix 375References 393Index 403

"Experts with many years of experience from the wide field of adhesive technology have cooperated to produce really excellent work, as each page of this book testifies. Currently available knowledge of adhesive technology and its possible applications is presented here in a very simple and readily comprehensible yet substantiated way in all its facets. (...) Much emphasis is placed on explanations by way of many diagrams, which are aimed at simplifying work and understanding some difficult topics - a task that this book fulfils. The systematic and well-ordered structure allows the reader easy orientation and fast access to the area in question. A really excellent and readily comprehensible expert book at the cutting-edge of technology that I can recommend without hesitation to any interested reader."Buchkritik.at From the evaluations of the project idea:"I am convinced that, due to his decades of experience, Professor Brockmann is one of the few people to have gained an excellent overview of the entire developments, and will produce a book that should be widely welcomed within the professional community." Dr. Gierenz, Solingen"There is hardly any literature on adhesive technology that is practice-oriented.""All relevant topics and aspects are considered.""The author's renown (...) very high!" Industrial Association of Adhesives"Adhesive technology is a cross-sectional technology and corresponds to the latest developments in materials science and is thus vital for innovations. It is considered a universal joining technology, meaning that it influences all technical fields." "Brockmann, the author, enjoys great renown, especially due to his comprehensive experience in this field." "In the new book, 'Adhesive Technology', published by Wiley-VCH, Brockmann et al. report on modern processes and technologies."Welt der Farben "The price is acceptable considering the scope and finish of this book. It can thus be recommended to all those interested in adhesive technology."Materials and Corrosion "... shows in a compact and easily comprehensible manner what adhesive technology is capable of today and in future in the various areas of application. ... It describes among other things practical questions ... Further, the reader gains insights into nature's sophisticated adhesive technologies and many everyday adhesive solutions. ...learns in this book that this technology often treated with skepticism is a very powerful joining technology when correctly developed and applied, while gaining help in successfully dealing with adhesive tasks."adhäsion - kleben & dichten (the expert journal for industrial adhesive and sealing technology) "The editors and co-authors have succeeded in interpreting the expert arguments in a comprehensible way, such that even newcomers can use them in their tasks. (...) This is why 'Adhesive Technology' is an important companion for engineers and chemists working in adhesive joining technology, so as to be able to professionally tackle everyday tasks in practice. Not only are the many bases of adhesives discussed, but also quality assurance, and testing methods for adhesive joints - something the practitioner will particularly appreciate..."Klebstoff-Dokumentum "...a highly gratifying and extremely successful work...Very rarely can a book be recommended so whole-heartedly."Chemie Ingenieur Technik