Adhesive Presentation - Tomblin

RESEARCH / DESIGN / TESTING / CERTIFICATION
Adhesive Behavior in Aircraft Applications

Ny
Nx
Nxy
Nxy
Nxy
Nxy
Ny
Nx
John Tomblin
Waruna Seneviratne
Paulo Escobar
Yoon-Khian Yap
Pierre Harter
National Institute for
Aviation Research
Wichita State University

FAA Workshop on
Key Characteristics for Advanced Material Control
September 16 18, 2003
NATIONAL INSTITUTE FOR AVIATION RESEARCH
Program Overview
Coupon Level Testing
Investigation of Thick Bondline Adhesive Joints
Adhesive test methods
Bondline thickness effects
Environmental effects
[FAA Report: DOT/FAA/AR-01/33]
Characteristic Shear Responses of Structural Adhesives

Fatigue & Stress Relaxation of Adhesive Joints

[FAA Report: Submitted to FAA]
Subcomponent Testing & Analysis

Box Beam Torsion Lap Shear Test
Shear Loaded Bonded Joint (SLBJ) Theory [Purdue University]
Available electronically at http://actlibrary.tc.faa.gov
Research Effort
Funded by
FAA
Industry Partners
Partnered with
Purdue
University
Motivation
Number of certification programs
involve a large range of adhesive
bonding applications
Migration from secondary to
primary structure
Limited guidance material existed
Limited experimental analytical
models that can be effectively
used in design
Motivation (contd..)
Traditional bondline thicknesses
used : less than 0.010
Current bondline thicknesses : up
to 0.140
Generate data regarding the
effects of thick bondlines
Long term durability of adhesive
joint (fatigue/creep) needs to be
addressed with respect to thick
bondline joints
Closeout
Bonded to
Spar Caps
Section A-A
Bending and
Torsion Loads
Pinned Joints
Through Spar
Web
Wing Skin Bonded

Directly to Spar Caps
Adhesive Test Methods

7000.0
Apparent Shear Strength (psi)
6000.0
Adhesive/Cohesive
5000.0
4000.0
Adhesive/Cohesive
3000.0
Adhesive
Adhesive
2000.0
ASTM D1002
ASTM D3165
1000.0
ASTM D5656
0.0
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
Average bondline thickness (in)
ASTM D1002 & D3165 for joint characterization

ASTM D5656 for adhesive characterization
ASTM D5656 Test Method

Thick adherend
Adhesive characterization
rather than Joint
characterization
Elastic Limit & Plastic Strain
Design & Analysis
Reduced peel stresses
Correction for metal

deformation
Four-Pin Configuration
Reduces errors due to rotation
and slippage
Reduced scatter in data
Failure Modes
ASTM D5656
Bondline Thickness Effects

4500
4000
3500
Shear Stress
3000
PTM&W ES6292
2500
Bondline Thickness
2000
t = 0.013 in
t = 0.043 in
t = 0.083 in
1500
1000
t = 0.123 in
500
0
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
Shear Strain
Increasing bondline thickness resulted in reduced

plastic strain and lower yield stress
Environmental Effects
7000
CTD
Bondline Thickness = 0.013" nom.

Tg (dry) = 175F
Tg (wet) = 135F
6000
RTD
MGS
A100/B100
Shear Stress (psi)
5000
ETD 160
4000
ETW 160
ETD 200
3000
ETW 200
2000
1000
0
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
Shear Strain
Yield stress and stiffness decreased with increasing

temperature and humidity
Environmental condition affects failure mode
Characteristic Shear Responses of Structural

Adhesives
18 Adhesive Types
6 Film Adhesives
12 Paste Adhesives
ASTM D5656 [4 pin holes]

Three Environmental Conditions
Room Temp. ambient [RTD]
Elevated Temp. (180F) dry [ETD]
Elevated Temp. (180F) wet [ETW]
145 F and 85% relative humidity for 1000 hrs
Bondline Thickness
Film Adhesives: 0.01 0.03
Paste Adhesives: 0.03 0.05
Adhesive Types Investigated

Film Adhesives (6)
Paste Adhesives (12)
AF 126
EA 9628
EA 9695
EA 9696
FM 300
FM 73
Adhesives & Aluminum subpanels (Phosphoric Anodized)

were provided by Cessna Aircraft,
Wichita, KS
EA 9309.3 NA
EA 9346.5
EA 9359.3
EA 9360
EA 9392
EA 9394
EA 9396
MGS L418
PTM&W ES 6292
3M DP-460 EG
3M DP-460 NS
3M DP-820
Apparent Shear Strength Comparison

7
RTD
ETD
ETW
Film Adhesive
S h e a r S t r e n g t h (k s i )
2
7
RTD
ETD
ETW
1
6
0
Film Adhesive
S h e a r S t r e n g t h ( k si )
Paste Adhesive
Paste Adhesive
Shear Modulus Comparison

0.20
RTD
ETD
ETW
0.18
0.15
Film Adhesive
S h e a r M o d u l u s (M s i )
0.13
0.10
0.08
0.05
0.03
0.00
0.20
Film Adhesive
RTD
ETD
ETW
0.18
S h e a r M o d u lu s ( M s i)
0.15
0.13
0.10
0.08
0.05
Paste Adhesive
0.03
0.00
Paste Adhesive
FAA Final Report: DOT/FAA/AR-02/97
Fatigue of Thick Bondline Adhesive Joints

Modified ASTM D3166-99
[Aluminum Adherend of 0.375]
Three Adhesives
PTM&W [0.060 & 0.160]
Loctite [0.032]
EA9696 [0.02]
Three Stress Levels

103, 104 and 105 cycles
Three Frequencies
F=2 Hz, 5 Hz and 10 Hz
Three Environmental
Conditions
RTD, RTW
CTD (-40F)
Stress Level Determination

100
90
Based on the initial SN Curve
80
y=-3.227*ln(x)+100.96
70
100000Cy SL165% UL 183% LL

10000Cy SL272% UL 202% LL
1000Cy SL378% UL 220% LL
Note: For RTW and CTD, %UL are
different
% of Ultimate
60
50
40
Loctite
(RTD)
30
20
10
0
0
200000
400000
600000
800000
Number of Cycles
1000000
1200000
Loctite Stress Levels

Loctite CTD
Loctite RTD
6000
3000
5000
2 3 0 6 psi
4000
2 117 p s i
19 18 p s i
3379 p s i
3 10 2 p s i
2 8 10 p s i
2000
3000
Lin e a r Limit Lo a d
3 9 3 lb s (1 04 8 p si)
Lin e a r Lim it Lo a d
5 7 6 lb s ( 15 3 6 p s i)
2000
10 0 0
10 0 0
0
0
0 .1
0 .2
0 .3
0 .4
0 .5
0 .6
S h e a r S t ra i n (in / in )
0
0
0 .1
0 .2
0 .3
0 .4
0 .5
S h e a r S t ra i n (i n / i n )
Loctite RTW
3000
2500
2000
15 0 0
Fatigue life in a range below

knee point and above linear
limit point.
13 2 4 p s i
12 15 p s i
110 1 p s i
10 0 0
Lin e a r Lim it Lo a d
2 2 5 lb s ( 6 0 0 p s i)
500
0
0
0 .1
0 .2
0 .3
S h e a r S t ra in (in /in )
0 .4
0 .5
0 .6
0 .6
Fatigue Behavior of Adhesives

1
3
S
9
C
m
i
i m
l t
l t
l t
S
%
1
S
2
S
5
4
S
0
5
4
S
5
S
0
4
2 Hz
0
0
5 Hz
10 Hz
Stress Relaxation of Adhesive Joints
G1
G1
Ge
G2
Applied stress gradually decreases to a stable value over time

Elastic strain that appears during initial rapid loading is slowly replaced by
creep strain, with the total of the two being constant
Steady-state creep and linear viscoelastic material behavior
Modified ALCOA Stressing Fixture

P
Calibration for each environmental

condition
t)
tt
t)
Load Cell
Test Results
Format
Time
Stress Level Determination
Shear
Stress
Test Temperatures
150F
180F
Yield Stress
210F
25% YS
15% YS
10% YS
Shear Strain
Creep Deformation
Loctite
25% YS
180 F
167 hours
~18
[50X magnification]
Loctite Stress Relaxation Results

450
400
350
150 F
25% YS
250
200
15% YS
150
10% YS
250
100
50
200
0
10000
20000
30000
Time (sec)
40000
25% YS
50000
150
15% YS
100
10% YS
180 F
120
50
100
0
0
10000
20000
30000
Time (sec)
210 F
40000
Stress (psi)
Stress (psi)
Stress (psi)
300
50000
80
25% YS
60
15% YS
40
10% YS
20
0
0
10000
20000
30000
Time (sec)
40000
50000
Box Beam Lap Shear Torsion Test

Fixed-end
Base
Fixed-end
block
Load
Side Plate
(Inboard)
Loading
Plate
Side Plate
(Outboard)
non-linear
constitute behavior
of adhesive
Shear Loaded
Bonded Joint
(SLBJ) Theory
2 Cylindrical
Shaft
Box Beam Lap

Shear Torsion
Testing
Joint Failure
Prediction
Pivot-end
Base
Validation
Design Guidelines &
Certification
Adhesive Lap Joint Specimen

Gage width ~ 0.5
Gage section ~
17.25
Flat Joint
PTM&W
EA9360
Loctite
Joggle Joint
PTM&W
EA9360
Materials
Adhesives
PTM&W ES6292 [t = 0.05 ~ 0.20]
EA 9360 [t = 0.10]
Loctite (CESSNA Proprietary) [t = 0.05]
Adherend
NEWPORT E-Glass Fabric 7781 / NB321
NEWPORT NB321/3K70P Carbon Cloth
Fiberglass/Carbon Layup Schedule [04/45/-45/04]
Aluminum 2024-T3 Clad
Phosphorus Anodized & Bond Primed
[CESSNA Aircraft, Wichita, Kansas]
Maximum Shear Flow (Comparison)

2500
Max. Shear Flow (lbf/in)
ES6292 - Newport
7781FG
2000
1500
1000
q-Experimental
500
0
0.00
q-SLBJ
0.05
0.10
0.15
0.20
0.25
Bondline Thickness (in)
Constitutive behavior for

0.20 was not available
Conclusions
Environmental Effects
Adhesives become weak and ductile at high temperatures and
brittle at low temperatures.
Yield stress and modulus of all adhesives decrease with
increasing temperature and humidity
The plastic behavior of adhesives at elevated temperatures
caused significant shear deformation
Mechanical properties of adhesives can be substantially
degraded by the absorption of moisture
Environmental condition affects the failure mode as well as the
mechanical properties
Conclusions (Contd..)
Fatigue
High stress fatigue life of adhesive exists in a range below Knee
point and above linear limit point
Failure modes indicate that moisture affects adhesive bulk
instead of the adhesive-adherend interface (RTW cohesive
failures)
Observation lower void in bondline = longer fatigue life
Film adhesive indicates better resistance to moisture (less voids?)
Stress Relaxation
Stress relaxation was increased as the stress level and
temperature was increased
Conclusions (Contd)
Box Beam Lap Shear Torsion
Load carrying capabilities of adhesive joints decreases as bondline
thickness increases
Purdue Analysis predictions (SLBJ Theory) comparable with box
beam test results
Increasing bondline thickness affects the failure mode of bonded
joints
Accumulation of large plastic strains in thin bondlines resulted in
high adherend interlaminar strains and caused substrate (first-ply)
failure
Unstable damage development of thick bondlines (lower plastic
strain development) resulted in adhesive cracking in multiple
locations with a cohesive type failure and lower failure strengths

Adhesive Presentation - Tomblin

Încărcat de

Informații document

Descriere originală:

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Adhesive Presentation - Tomblin

Încărcat de

Drepturi de autor:

Formate disponibile

RESEARCH / DESIGN / TESTING / CERTIFICATION

Adhesive Behavior in Aircraft Applications

Wichita State University

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

Characteristic Shear Responses of Structural Adhesives

Fatigue & Stress Relaxation of Adhesive Joints

Subcomponent Testing & Analysis

Available electronically at http://actlibrary.tc.faa.gov

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

Wing Skin Bonded

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

Adhesive Test Methods

Apparent Shear Strength (psi)

Average bondline thickness (in)

ASTM D1002 & D3165 for joint characterization

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

ASTM D5656 Test Method

Correction for metal

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

Bondline Thickness Effects

Increasing bondline thickness resulted in reduced

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

Bondline Thickness = 0.013" nom.

Shear Stress (psi)

Yield stress and stiffness decreased with increasing

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

Characteristic Shear Responses of Structural

ASTM D5656 [4 pin holes]

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

Adhesive Types Investigated

Paste Adhesives (12)

Adhesives & Aluminum subpanels (Phosphoric Anodized)

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

Apparent Shear Strength Comparison

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

Shear Modulus Comparison

FAA Final Report: DOT/FAA/AR-02/97

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

Fatigue of Thick Bondline Adhesive Joints

Three Stress Levels

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

Stress Level Determination

Based on the initial SN Curve

100000Cy SL165% UL 183% LL

NATIONAL INSTITUTE FOR AVIATION RESEARCH