Handbook of Adhesives and Sealants

884 Pages·2006·4.3 MB·English

by  Edward Petrie

Handbook of
Adhesives and
Sealants
Edward M. Petrie
McGraw-Hill
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Petrie,EdwardM.
Handbookofadhesivesandsealants / EdwardM.Petrie.
p. cm.
Includesindex.
ISBN0-07-049888-1
1. Adhesives. 2. Sealingcompounds. I. Title.
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Acknowledgment
This book is dedicated to my wife, Carol—who is everything to me
including proofreader, motivator, and friend; and to my son, Eddie. I
alsodedicatethisbooktoallthoseexcellentengineersandtechnicians
that I have known in my years at Westinghouse Corporation. Thank
you for the experiences, many of which are in this book, that made
my early career worthwhile and never boring.
xxiii
Preface
Adhesivesandsealantsaretrulyremarkablematerials,andIfindthe
technologysupportingthesematerialstobeequallyextraordinaryand
at times a bit overpowering for infrequent users of these products. I
know of no other technology spread so expansively throughout our
lives. It is difficult to imagine a product—in the home, in industry,in
transportation, or anywhere else for that matter—that does not use
adhesives or sealants in some manner.
Yet, many of us who work with adhesives and sealants, probably
‘‘back into’’ being ‘‘experts’’ almost by default. We had no early inten-
tions of a close relationship with this technology. We went to school
andtrained,perhaps,tobematerialsspecialists,engineers,designers,
or manufacturers. One day our supervisor or the nature of our work
demands that we discover how to assemble a product. Howdowejoin
together parts to form a functional product that will endure all pos-
sibleserviceenvironments,isharmoniouswiththecompany’sproduc-
tion processes and schedules, and has some aesthetic and environ-
mental quality? How long will the joint survive in service? What is
the repeatability of the process? How do we control the process and
checkforinferiororimproperjoints?Ifthejointisofpoorquality,how
do we get the parts apart or must they be scrapped? Will thebonding
orsealingprocessaffecttheenvironmentorthesafetyoftheassembly
workers?
In answering these questions, we may have taken a broad, initial
approach and considered all forms of assembly including mechanical
fasteners,welding,andadhesives. Afterstudyingtheprosandconsof
each process, we possibly choose an adhesive or sealant. Either by
good guidance from suppliers, mentors, or just by chance, our first
assembled product looks competent. It provides a decent service life,
andmaybeevenresultsinaprofitableproduct.Wearenowfrequently
consulted because we have seemingly mastered a foreboding technol-
xix
xx Preface
ogythattoeveryoneelsehasasomewhatsinisterdemeanorandmag-
ical aura about it. Then, we are truly overwhelmed when it becomes
obvious that to fully understand and gain expert stature with adhe-
sives and sealants, we must master many fundamental principles.
These fundamentals are derived from diverse and alien sciences such
as polymeric materials, surface chemistry,andfracturemechanics.To
be successful, we know that one must master and integrate these sci-
ences.
Theabovesituationis,ofcourse,magnifiedabit,butIamsurethat
it reaches home to many who pick up this Handbook and desire an
efficient method of understanding adhesives and sealants and apply-
ing them reliably. As a periodicend-user,youpossiblydonothavethe
time or the resources to thoroughly study the various technologies
related to adhesives and sealants. You have little desire to wade
through volumes of text and product information looking for the spe-
cific methods, processes, and possible examples that will apply to the
joining application du jour. However, you do want such information
close-by if the need arises. Above all, you hope to learn from the ex-
periences of others. Ideally for your needs, a single reference source
can provide the guidance and fundamental knowledge required for
many adhesive bonding or sealing applications. I hope that I am cor-
rect in these assumptions, because this is why I have written this
Handbook.
There are a number of important handbooks, journals, and papers,
onadhesivesandsealantsalreadyintheliterature.Manyoftheseare
important works, and they serve as a foundation for this Handbook.
Totheauthorsoftheseremarkablevehicles,Iamexceedinglygrateful.
Muchoftheirworkisreferredtohere.ThisHandbookmaynotgointo
the technical depth that is evident in these previous works. However,
it will provide sufficient detail and a broad foundation to enable the
practitioner to reliably design, select, and use adhesives or sealants.
This Handbook will be a single, comprehensive source of recent in-
formation, historical experience, and guidance for any adhesive or
sealant application. The Handbook will define the universe of adhe-
sives and sealants from the perspective of the end-user, and in that
way will provide a practical and useful source of information.
My perspective is as an end-user as well. I have consulted on ad-
hesivesandsealantsforover33yearsindiversecommercialindustrial
applications, first in Westinghouse Electric Corporation and then in
Asea Brown Boveri (ABB) and other companies. Thus, I have seen
manysuccessfulapplicationsofadhesiveorsealantsystemsandmany
disasters and near disasters. As an industrial consultant, one gener-
ally becomes involved with a case because there is a problem that
cannot be solved with the resources at hand. Thus, horror stories as
Preface xxi
well as successful applications will litter my presentation.Ihopethat
the readers will find these experiences educational and illuminating.
The Handbook of Adhesives and Sealants is a guide to the entire
field of adhesives and sealants. Although primarily directed toward
the end-user and containing important application and design data,
the Handbook also provides significant information for those inter-
ested in developing, manufacturing, marketing, purchasing, or just
generally becoming familiar with these important materials.
The initial chapter covers the importance ofadhesivesandsealants
and the multi-disciplined nature of the technology. Also introducedin
the first chapter are markets and applications, the functions of ad-
hesives and sealants, and common materials and processes. Major
sourcesofinformationregardingadhesivesandsealantsareidentified
forreadersinterestedingainingadeeperunderstandingormaintain-
ing currency with this dynamic technology.
Subsequent chapters then cover important elements necessary to
determine where adhesives and sealants should and should not be
used and, when indicated, how to successfully use them. Chapters
cover adhesion theories, joint design rules, test methods, substrate
preparationmethods,adhesiveandsealantmaterials,applicationand
processing methods, and the effects of the service environment. The
final chapter describes how information technology is changing the
selection and knowledge gathering process.
Throughout the Handbook,specificapplicationsandexamplesillus-
trate the concepts being discussed. Due to the broad nature of this
technology, the reader will often be directed from one section to other
relevant sections within the book. Referencesattheendofeachchap-
ter direct the interested reader to more in-depth information and un-
derstanding regarding specific subjects.
I wish to express a sincere ‘‘thank you’’ to all those who made my
goal of putting this Handbook together a reality. Special thanks goes
toCharlieHarperforhismotivationandsupportandtoRonSampson
for his mentoring and wisdom in my early days as a young research
engineer.
Edward M. Petrie
Index
Abrasion,mechanical,223–226 multiplepartsystems,291–292
AcceleratedAging,713–717 pasteandliquids,310
Accelerator,321 pressuresensitive,301–305
Acetal,bondingof,629–631 reactivatable,305
Acrylic,modified,adhesive,391–392 resinoussolvent,306
Acrylic,thermoplastic,adhesive,410 singlepartsystems,292–300
Acrylic,thermoplastic,bondingof,631– solid,299–300
634 solventbased,312–313
Acrylonitrilebutadiene,399–400 solventless,310–312
Acrylonitrilebutadienestyrene,bonding thermoplastic,284–285,350–351
of,628–629 thermoset,281–284,348–349
Adherend,properties UV/lightcurable,296–297
importanttoadhesiveselection,425– waterbased,313–314
437 Adhesivebonding
importanttojointdesign,102–104 advantages,design,26
Adhesion advantages,mechanical,23
forces,41,49–51 advantages,other,28
practical,56 advantages,production,27
scienceof,8–10 competitivejoiningmethods,18–25,
workof,54 419–420
Adhesionpromoters,266–277 disadvantages,18,23
chromecomplex,267–273 disadvantages,design,29
silane,273–277 disadvantages,mechanical,28
titanate,273–277 disadvantages,other,30
zirconate,277 disadvantages,production,30
Adhesive,280–412 planning,420–424
chemicalcomposition,281–286,319– processes,417–419
326 stages,66–79
classifications,279–280,345–355 Adhesive,environmentalresistant
commercialformulation,341 chemicalsandsolvents,716–722
cost,316 combinedeffect,713–717
form,307–315 hightemperatures,693–702
formulation,326–338 humidityandwater,707–717
function,280–281 lowtemperatures,703–707
methodsofreaction,286–307 outdoorweathering,717–719
Adhesive,types,280–412 radiation,723–724
contact,301 vacuumandoutgassing,722–723
elastomeric,285,352–353 Adhesivejoints,93–125
hotmelt,306–307,315 adherendthickness,102–104
hybrid,285,330–333,354 angle,112–113
moisturecuring,295–296 bar,112
871
872 Index
Adhesivejoints(Cont.): phosphatecement,413
beveleddoublestrap,109 polyamide,408
beveledlap,107 polyaromaticresins,377–381,699,706
corner,113 polybenzimidazole,382,700
cylindrical,110–112 polyester,thermoplastic,408–409
depthoflap,101–104 polyesters,382–383
doublebuttlap,106 polyimide,378–381,699–700,706
doublelap,107 polyisobutylene,400
doublestrap,109 polyolefins,409
endlap,113 polysulfide,400–401,706
flatadherends,for,105–109 polysulfone,409,701
jogglelap,107 polyurethane,383–386,705
mitered,113 polyvinylacetal,404
mortise,113 polyvinylacetate,404–406
plasticandelastomeric,114 polyvinylalcohol,407
recesseddoublestrap,109 polyvinylmethylether,400
reinforcedplastic,115 reclaimedrubber,397
scarfbutt,106 resorcinolformaldehyde,373–374
scarf,115 silicone,401–403,698,705–706
stiffeningjoints,109 sodiumsilicate,412–413
strap,109 styrenebutadienerubber,398
tongueandgroove,106 sulfurcement,413
tube,112 thermoplasticelastomers,407
wood,115 toughenedepoxy,367–371
Adhesivethickness,100 ureaformaldehyde,374
Adhesive,family vinylphenolic,377
acrylic,modified,391–392,706 Aging
acrylic,thermoplastic,410 accelerated,713–717
acrylonitrilebutadiene,399–400 environmental,38,75–79,445–449,
anaerobicresins,386–390 685–724
bismaleimide,380–382,700–701 Airbladecoater,743–745
butylrubber,397–398,706 Airspray,742
cellulosicresin,408 Airlessspray,742
chloroprene(neoprene),398–399,706 Alkyd,bonding,621–622
cyanoacylate,390–391,701 Aluminum,bonding,595–602
epoxy,355–366,693–698,704–705 surfacepreparation,257,259,261
epoxyhybrid,366–373,706 Anaerobicresins,386–390
epoxynylon,372,705 Anglejoints,112
epoxyphenolic,371–372,705 Antifungalagent,325
epoxypolysulfide,372–375,705 Antihydrolysisagent,325
epoxyvinyl,373 Antioxidant,325
ethylenevinylacetate,407 Apparentcontactangle,68
gluesofagriculturalorigin,411 Application
gluesofanimalorigin,411–412 equipment,739–741
lithargecement,413 film,747–750
melamineformaldehyde,374 hotmelt,750–751
naturalrubber,396–397 liquid,741–745
neoprene,706 pastesandmastics,746
neoprenephenolic,377,698 powders,746–747
nitrilephenolic,375–377,698 Applications,17,24
phenolresorcinolformaldehyde,373– Augerelectronspectroscopy,194
374 Automation,736–741
phenolic,374–375,698,705 Backupmaterials,508
phenoxy,409–410 Baseresin,320
Index 873
Basicmaterials,42–46 Composites,thermosetting,bondingof,
Beadcoater,743–745 657–662
Beryllium,bondingof,602–606 Computerselectionprograms,759–764
Binderresin,320 ADHESIVES,763–764
Bismaleimide,381–382 AdhesivesSelector,761–762
Bitumen,sealant,483 AdhesivesMart,761
Bondfailure SealantSystem,762–763
energy,55–57 Concrete,sealingof,516
failuremode,40 substrate,205
mechanism,39–41 Contactangle,53
Bondinspection,183–190 Copper,bondingof,607–608
Bondingequipment,751–754 Cornerjoints,112
heating,752–754 Coronatreatment,237–239
pressure,752 Corrosionresistance,257
Boundaryfailureregion,58 Cost
Boundarylayer,5,64–66,199 adhesive,316
theory,88–89 assembly,27
Brazing,25 hidden,30–31
Brookfieldviscometer,139 Crackpropagation,99
Buttjoints Creep,77,160,167–168
adhesive,105 Criticalsurfacetension,54
sealant,122 commonsolids,56
Butylrubber,adhesive,397–398,706 measurement,54–55
C-Scan,188–189 Crosslinking,83
Cadmiumplate,bondingof,606–607 Cryogenicapplications,702–707
Carrier,323 CTBNadhesiveformulation,331–333
Catalyst,321 Curerate,141
Caulk,dryrope,485 Curingagent,320
Cellulosics,adhesive,408 Cyanoacrylate,adhesive,68,390–391
Cellulosics,bondingof,634 primers,261
Ceramics,bondingof,677–679 Cyanosilicone,sealant
substrate,205 Cylindricaljoints,110–112
Chemicalcleaning,221–222 Definitions,2–6
Chemicalresistance,36,719–722 adherend,5
Chemisorption,50 adhesion,4
Chlorinatedpolyether,bondingof,634– adhesive,3
635 boundarylayer,5
Chlorinatedpolyolefinprimer,258–364 cohesion,4
Chlorosulfonatedpolyethylene,sealant, interface,5
488 interphaseregion,5
Chromecomplexprimers,277 joint,5–6
Cleavage,156 non-structuraladhesive,3
Coatingequipment,743–745 primer,5
Cohesion sealant,3,4
forces,49–51 structuraladhesive,3
workof,54 Errorsindesign,179
Cohesivefailureregion,58 Desorption,77–79,710–713
Coindascope,189 Dialylphthalate,bondingof,622
Combinedadhesiveandmechanical Dielectricheating,564–565
fastening,31 Diffusionconstant,moisture,707–710
Combinedenvironments,713–717 Diluent,322
Composites,thermoplastic,bondingof, Diprollcoaters,743–745
662 DuNouyring,52
Composite,substrate,205,247–249 Dupreequation,54
874 Index
Elastomer,bondingof,666–669 waterbased,313–314
Surface,205,249–250 Frictionwelding,565–566
Elastomericadhesives,285 Gasketing,509–510
Electricalconductivity,336–338 formedinplace,510–512
Electrolyticcleaning,223 Glass,bondingof,677–679
Engravedrollcoaters,743–745 sealingof,517
Environment Glasstransitiontemperature,83–86
factors,754–757 naturalglues
resistanceto,685–689 agriculturalorigin,411
serviceconditions,446–449 animalorigin,411–412
servicestress,447 Grout,500
tests,161–163,163–169 Hardener,320
Epoxy,adhesive,355–366 Hardness,142
sealant,484 Heatsealing,552
Epoxy,bondingof,622–623 Heatedtoolwelding,543–553
Epoxyhybrid,adhesive,366–373 Highwayjoints,483
Epoxynylon,adhesive,331,372 Historicaldevelopment,10–11
Epoxyphenolic,adhesive,371–372 Honeycombbonding,679–680
Epoxypolysulfide,adhesive,372–373 Hotgaswelding,553–557
Epoxyvinyl,adhesive,373 Hotspray,742
Equilibriumspreadingpressure,53–54 Humidityresistance,707–717
ESCA,195 Hybridadhesive,285
Ethylenevinylacetate,adhesive,407 Hydrocarbonrubberbased,sealant,485–
LaPlace-Kelvinequation,67 487
lasertreatment,242 Hydrogenbonding,50,84
Extenders,322 Hydrolyticstability,707–710
Failure Impact,158–160
adhesive,4,39–40 Inductionwelding,561–564
cohesive,4,40 Informationtechnology,759–764
sealant,79–81 Infraredwelding,560
Fatigue,26 Inhibitors,321
test,157–158 Interface,5,83–87
Fillers,322 Internetwebsites,759–760
Filmformer,325 Interphase,5,89–90
Flametreatment,239–240 Ionscatteringspectroscopy,194
Flowcontrol,327 Jointdesign
Floworcurtaincoater,743–745 adhesiveselection,438–439
Fluoroalkyarylenesiloxanylene,sealant, bondthickness,439–441
702,706 effectofbondarea,101–102
Fluorocarbon,bondingof,635–637 efficiency,98–104
Fluoropolymer,sealant,489–490 generalrules,104–105
Foam,bondingof,662–666 planning,422–423
Fokkerbondtester,187 Kisscoater,743–745
Forces Knifespreader,743–745
adhesion,49–51 Lapjoints
cohesion,49–51 adhesive,105
Form,physical,307–315 sealant,122
film,314 test,149–150
hotmelt,315 Laplace-Kelvinequation,67
liquid,310 Laserwelding,558–560
paste,310 Lead,bondingof,608–609
powder,314 Lithargecement,413
solventbased,312–313 Magnesium,bondingof,609–611
tape,314 Manufacturingprocesses,44–47