Durability metal-adhesive joints

In essence, the durability of metal/adhesive joints is governed primarily by the combination of substrate, surface preparation, environmental exposure and choice of adhesive. As stated earlier, the choice of the two-part nitrile rubber modified epoxy system (Hughes Chem - PPG) was a fixed variable, meeting the requirement of initial joint strength and cure cycle and was not, at this time, examined as a reason for joint failure. Durability, as influenced by substrate, surface preparation, and environmental exposure were examined in this study using results obtained from accelerated exposure of single lap shear adhesive joints. 

The primary challenge facing adhesive bonding of metals is to obtain sufficient durability of a bonded structure. Initial bond strength in metal-polymer adhesive joints is almost invariably excellent. Challenging the application of adhesives in polymer-polymer joining, however, is the problem of obtaining a joint that is... 

While a non-phosphated topcoat/adhesive interface provided an excellent, moisture resistant, occlusive seal even under the most severe cycle testing, phosphated ZM adherends did not prove to be as durable in comparison (Figure 11). The reason for this lies in the fact that phosphate coverage on Zincrometal is incomplete. Partially crystalline phosphates are non-uniformly interspersed on randomly exposed zinc dust spheres at the surface. Consequently, the moisture resistance normally provided at the adhesive/topcoat interface was reduced due to the incomplete sealing between the topcoat/ adhesive surfaces. This became apparent as most of the failures examined after aging in these environments were concentrated at the adhesive/phosphate/paint interface. Results obtained on these samples were similar to those obtained for phosphated CRS joints, indicating that the locus of failure occurred at phosphate crystal sites. Note, however, that the durability of these joints was still considered to be very good in comparison to other metallic oxide/ adhesive interfaces. 

The predominant applications of present day metal/polymer adhesion technology are for the development of strong metal-to-metal structural adhesive joints and durable protective coatings. 

Some primers will improve the durability of the joint by protecting the substrate surface area from hydration and corrosion. These primers suppress the formation of weak boundary layers that could develop during exposure to wet environments. Primers that contain film-forming resins are sometimes considered interfacial water barriers. They keep water out of the joint interface area and prevent corrosion of the metal surfaces. By establishing a strong, moisture-resistant bond, the primer protects the adhesive-adherend interface and lengthens the service life of the bonded joint. 

Chemical Surface Modification. In considering the interface, one must contemplate not only the possibility of moisture disrupting the bond but also the possibility of corrosion of the substrate. Corrosion can quickly deteriorate the bond by providing a weak boundary layer before the adhesive or sealant is applied. Corrosion can also occur after the joint is made and, thereby, affect its durability. Mechanical abrasion or solvent cleaning can provide adhesive joints that are strong in the dry condition. However, this is not always the case when joints are exposed to water or water vapor. Resistance to water is much improved if metal surfaces can be treated with a protective coating before being bonded. 

Olson, W. Z., et al., Resistance of Adhesive Bonded Metal Lap Joints to Environmental Exposure, Report No. NADC TR59-564, October 1962. Also in DeLollis, N. J., Durability of Structural Adhesive Bonds A Review, Adhesives Age, September 1977. 

This paper wiU build on previous reviews which have sought to explore the marmer in which surface analysis methods can be purposefully employed to understand adhesion phenomena [4—6], with an emphasis on the elucidation of interphase chemistry. The rationale behind such an approach is that it is this critical region of a polymer/metal or polymer/polymer couple that will influence the performance of the overall system, be it the durability of an adhesive joint or the corrosion protection performance of an organic coating. 

From the above discussion, it follows that it should be possible to improve the durability of bonded joints by the introduction of suitable coupling agents at the interface. If the coupling agent is capable of chemically interacting with the metal or its oxide, displacement of the adhesive at the interface will be prevented. 

Forms durable adhesive joints to metallic substrates high peel strength... 

Also, in common with most metals, the majority of conventional mechanical pre-treatments, such as grit blasting, give relatively poor durability results (see Durability fundamentals, Weathering of adhesive joints and Weathering tests). For example. Wedge test... 

Durability is one of the most important aspects of the performance of a structural adhesive. The durability of an adhesive joint is the sum total of its responses to environmental effects such as heat, moisture, other chemicals, radiation, and mechanical stresses. Cyanoacrylate-based adhesives have a reputation for poor durability, especially when bonding metals... 

The principles involved in producing bonds of optimum strength and durability are the same, irrespective of the nature of the adherends. The surface must be free of contamination, must be receptive to the adhesive (or primer, if used), and the adhesive/adherend interface formed must be stable to environmental exposure. It is the last mentioned factor that is of most concern in a discussion of the durability of adhesive bonds, particularly for metallic adherends. The prebond treatment of the metal surface is of paramount importance in determining joint performance. With wood and plastic adherends, long-term performance is usually determined by other factors, provided that good initial joints are formed. 

Finally, it is noteworthy that if water (or indeed other highly polar liquids) is the environment of interest, then metallic and ceramic substrates are those which result in joints most likely to exhibit poor durability. This is a consequence, of course, of the relatively polar nature of their surfaces and their high surface free energies. Thus, ingressing water molecules are preferentially attracted to the surfaces of these substrates and will displace the physisorbed molecules of the adhesive. These comments are also reflected [5,6] in the values of Wa and Wai for joints based upon carbon-fibre-reinforced plastic (CFRP) substrates typically being of the order of 90 mJ/m and 30 mJ/m, respectively. The positive values of both of these terms indicate that the durability of adhesively bonded CFRP joints should not represent a major problem. This is indeed found to be the case, from the aspect of the stability of the interface. (Although problems may arise if (a) the... 

The durability of epoxy-aluminium joints that used a homopolymerised epoxy resin was studied by researchers based in Spain [15], and the effects of relative humidity, temperature, and salt concentration analysed. The homopolymerised epoxy resin absorbed little water (1.5 wt%) because of its non-polar network structure. Increasing relative humidity and temperature enhanced water uptake, but the joint strength remained constant because of epoxy plasticisation. A saline environment was damaging to the adhesive joints because of metal corrosion, but was not significantly harmful to the epoxy resin because of the lower diffusion coefficient of salt water. The decrease in glass transition temperature of the epoxy adhesive due to water absorption was dependent upon only the amount of absorbed water and was independent of hydrothermal ageing conditions. The durability of epoxy adhesive joints made underwater has been studied [16]. 

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