LCS Belgium Présenté lors de "l'Usinage et assemblage des matériaux composites" - 26 septembre 2013 - Chambre des Métiers - Luxembourg

1. +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

2. +Composites - LCS Adhesive Bonding bvba (B) Luxembourg - 26-09-2013
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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 substrates
by 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

3. +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
compressionshearstrength[MPa]
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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

4. +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

5. +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

6. +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

7. +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

8. +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

9. +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
Perstijd
Opbrengtijd
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
• Nanotechnology 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 manufacturers with their
equipment
is working intensively and expertly
together, from the design phase on and
on all aspects of the application.
Success Guaranteed !
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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 84
B-3053 Haasrode – Leuven
+32-(0)16-38 90 45
+32-475-45 48 98
jan.lambrechts@consultant.com
www.lcs-adhesivebonding.com