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LCS Belgium Présenté lors de "l'Usinage et assemblage des matériaux composites" - 26 septembre 2013 - Chambre des Métiers - Luxembourg
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+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 !
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Repair of Glove Box Lock
VW Golf – Bondmaster E32 – 2K EP… Collage, Bricolage ! ???
®LCS - 2012-2013- V 1.6.1 Copyright LCS 4
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
+Composites - LCS Adhesive Bonding bvba (B) Luxembourg - 26-09-2013
© LCS 2
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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
+Composites - LCS Adhesive Bonding bvba (B) Luxembourg - 26-09-2013
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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
+Composites - LCS Adhesive Bonding bvba (B) Luxembourg - 26-09-2013
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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
+Composites - LCS Adhesive Bonding bvba (B) Luxembourg - 26-09-2013
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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
+Composites - LCS Adhesive Bonding bvba (B) Luxembourg - 26-09-2013
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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
+Composites - LCS Adhesive Bonding bvba (B) Luxembourg - 26-09-2013
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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.
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’
+Composites - LCS Adhesive Bonding bvba (B) Luxembourg - 26-09-2013
© LCS 10
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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
www.lcs-adhesivebonding.com