Advances in Structural Adhesive Bonding

Advances in Structural Adhesive Bonding, Second Edition reviews developments in adhesive bonding for a range of advanced structural engineering applications. This new edition has been fully revised to include the latest advances in materials, testing and modeling methods, lifecycle considerations, and industrial implementation. Sections review advances in commonly used groups of structural adhesives, covering epoxy, acrylic, anaerobic and cyanoacrylate, polyurethane, and silicone adhesives, along with toughening. Other chapters cover various types of adherends and pre-treatment methods for structural materials, including metals, plastics, composites, wood and joint design and testing, including topics such as fracture mechanics, life prediction techniques, and advanced testing methods.

This is a valuable guide for all those working with structural adhesives, including those in an industrial setting, adhesive specialists, structural engineers, design engineers, R&D professionals, and scientists, as well as academic researchers and advanced students in adhesives, joining technology, materials science and mechanical engineering.

Cover image
Title page
Table of Contents
Copyright
Contributors
Preface
References
Part One: Adhesive chemistries and formulations
1: Advances in epoxy adhesives
Abstract
Acknowledgments
1.1: Introduction and history of epoxy adhesives
1.2: Major uses and important minor uses
1.3: Epoxy resins and epoxy functional raw materials, processes, and suppliers
1.4: Curatives for epoxy resins and epoxy functional raw materials, processes, and suppliers
1.5: Accelerators and catalysts
1.6: Tougheners and flexibilizers
1.7: General property specifications and certificate of analysis
1.8: Environmental, health, and safety considerations
1.9: Typical form factors and packaging of epoxy adhesives
1.10: Formulation and design
1.11: Adhesive production
1.12: Use and properties of epoxy adhesives
1.13: Recent advances in epoxy adhesives
1.14: Additional resources
References
2: Advances in acrylic structural adhesives
Abstract
Acknowledgments
2.1: Introduction
2.2: Basics of acrylic structural adhesives
2.3: Interfacial adhesion
2.4: Trends in acrylic structural adhesives
2.5: Applications
2.6: Futures trends
References
3: Advances in polyurethane structural adhesives
Abstract
3.1: Introduction
3.2: Characterization of PUR adhesives
3.3: Chemical overview and PUR structure to property relationships
3.4: Formulation and raw materials of PUR adhesives
3.5: Selected applications of structural polyurethane adhesives
3.6: Recent advances in PUR adhesives
References
4: Advances in cyanoacrylate structural adhesives
Abstract
Acknowledgments
4.1: Introduction
4.2: Chemistry of α-cyanoacrylates
4.3: Industrial synthesis/manufacture of α-cyanoacrylate esters
4.4: Typical performance characteristics of α-cyanoacrylates—Strengths, weaknesses, and recent developments
4.5: Two-component (2K) cyanoacrylate adhesives
4.6: Photocuring cyanoacrylates
4.7: Biomedical cyanoacrylate adhesives
4.8: Cyanoacrylates and sustainability
4.9: Summary
References
5: Advances in anaerobic adhesives
Abstract
Acknowledgments
5.1: Anaerobic adhesives
5.2: Recent advances in anaerobic technology
5.3: Summary
References
6: Advances in structural silicone adhesives
Abstract
6.1: Introduction
6.2: Properties of silicone structural adhesives
6.3: Product forms and cure chemistry
6.4: Silicone adhesive formulations
6.5: Applications of structural silicone adhesives
6.6: Design techniques
6.7: Conclusions
6.8: Future trends
6.9: Sources of further information and advice
References
7: Emerging structural adhesive chemistries and innovations
Abstract
Acknowledgments
7.1: Introduction
7.2: Structural adhesives innovations
7.3: Functionality beyond structural reinforcement
7.4: Using digital tools to advance the adhesives industry
7.5: Conclusions
References
8: Advances in toughening strategies for structural adhesives
Abstract
Acknowledgment
8.1: Introduction: What is toughness and why is it important?
8.2: Toughening of bulk epoxy polymers
8.3: Prediction of effectiveness of toughening
8.4: Toughness of an adhesive joint
8.5: Future trends
8.6: Conclusions
References
Part Two: Adherends and surfaces: Addressing and troubleshooting bonding challenges
9: What went wrong? Solving bonding challenges through surface science
Abstract
9.1: Prologue: Example of a bonding process suffering from “unexplainable” failures
9.2: Introduction
9.3: Adhesion: Resistance of an interface to failure
9.4: Adhesion failure in bonded and coated structures
9.5: Failure analysis
9.6: Critical concepts for surface preparation
9.7: Surface cleaning and treatment technologies
9.8: Processes out of control
9.9: Summary
References
10: Advances in bonding plastics
Abstract
10.1: Introduction
10.2: Principles governing plastics bonding
10.3: Challenge and surface characteristic in bonding plastics
10.4: Advanced surface treatment to improve plastic bonding
10.5: Chemical treatment to improve plastic bonding
10.6: Aging effect of plastic treatment
10.7: Advances in polyolefin adhesion
10.8: Summary and future trends in plastic bonding
References
11: Structural bonds without an adhesive: Understanding adhesion of semicrystalline thermoplastic interfaces
Abstract
Acknowledgments
11.1: Challenges in obtaining high adhesion at semicrystalline polymer interfaces
11.2: Overview of overmolding experiments and thermal modeling
11.3: Adhesion of overmolded polyamide 6 interfaces
11.4: Requirements for strong polymer interfaces
11.5: Summary of overmolding experiments and insights from quantifying crystallization and diffusion timescales
11.6: Exploiting geometry to achieve adhesion
11.7: Outlook and conclusions
References
12: Adhesive joining of thermoplastic composites
Abstract
12.1: Introduction
12.2: Brief summary of surface treatment techniques for TPCs
12.3: UV irradiation of the TPCs
12.4: Joining TPCs to TPCs
12.5: Joining TPCs to metals
12.6: Joining TPCs to TSCs
12.7: Conclusions and future work
References
13: Advances in structural wood products adhesive bonding
Abstract
13.1: Overview
13.2: Substrate considerations
13.3: Structural wood composite products
13.4: New developments of wood adhesives
13.5: Adhesive/wood interactions
13.6: Wood-adhesive bondline characterization
13.7: Strength characterization—Quality control methods
13.8: Fracture testing
13.9: Adhesive bond durability
13.10: Characterizing bondline stiffness
References
Part Three: Joint design, testing and modeling for performance & durability
14: Standard test methods and their need to evolve
Abstract
14.1: Expanding roles in structural bonding
14.2: Infrastructure of standard test methods and measurements
14.3: Strength and fracture: An evolution in adhesive joint measurements
14.4: The evolution of strength and fracture energy in adhesive design
14.5: Future opportunities: The interface between standards and advances in structural adhesives
14.6: Conclusions
References
15: Predicting adhesive bond performance
Abstract
15.1: Introduction
15.2: Stress and strain concepts
15.3: Stress types in bonded joints
15.4: Sources of adhesive joint stresses
15.5: Analytical approaches
15.6: Numerical methods
15.7: Hybrid analytical/numerical methods
15.8: Effects of joint geometry
15.9: Effects of strain rate
15.10: Effects of aging
15.11: Effects of temperature
15.12: Conclusions
References
16: Innovations in fracture testing of structural adhesive bonds
Abstract
16.1: Introduction
16.2: Data reduction techniques
16.3: Advances in quasistatic single-mode testing
16.4: Novel developments in mixed-mode testing
16.5: Extending experimental methods to fatigue, aging, and creep
16.6: Experimental challenges in impact and high-rate testing
16.7: Conclusions and future trends
References
17: Understanding fracture mode-mixity and its effects on bond performance
Abstract
17.1: Introduction
17.2: Brief summary of test methods to introduce mixed-mode loading
17.3: Mixed-mode partitioning schemes
17.4: Application of global partitioning to mixed-mode bi-material interface joints
17.5: Mixed-mode fracture behavior
17.6: Conclusions and outlook
References
18: Bondline thickness: Fracture mechanics perspective
Abstract
18.1: Introduction
18.2: From thin to thick adhesive layers
18.3: Adhesive thickness analysis using double cantilever beam (DCB) configuration
18.4: Effect of adhesive thickness on failure modes and fracture properties
18.5: Summary and future directions
References
19: Evaluating and predicting fatigue behavior in adhesively bonded joints
Abstract
19.1: Introduction
19.2: General considerations for fatigue of adhesives
19.3: Experimental techniques
19.4: Stress/strain-life approaches
19.5: Strength/stiffness wearout
19.6: Fracture mechanics
19.7: Effect of joint features
19.8: Environmental and loading effects
19.9: Damage mechanics
19.10: Summary
References
20: Durability and accelerated characterization of adhesive bonds
Abstract
20.1: Introduction
20.2: Correlating environmental exposure to mechanistic changes in polymer structure
20.3: Test methods for characterizing durability
20.4: TTSP and accelerated characterization
20.5: Examples and a case study
20.6: Summary: Status and future needs
References
21: High-rate testing of structural adhesives
Abstract
21.1: Introduction
21.2: The physics of high-rate testing
21.3: Rate-dependent properties in structural adhesives
21.4: DMA methods
21.5: Servohydraulic methods
21.6: Drop weight, falling striker, and pendulum impact tests
21.7: Kolsky bar/split-Hopkinson bar
21.8: Advancements and gaps in high-speed testing
References
22: Application of high-throughput methodologies and artificial intelligence for adhesion testing
Abstract
Acknowledgments
22.1: Introduction
22.2: Background
22.3: Considerations in HT workflow and screen development
22.4: Previous instances of HT in adhesion science
22.5: Workflow concept overview
22.6: Shear test: From workflow concept to integration
22.7: Durability: From workflow concept to integration
22.8: Supporting the adhesion HT workflow
22.9: Role of machine learning/artificial intelligence in adhesion science
22.10: Summary
References
Part Four: Adhesive specification, quality control, & risk mitigation
23: Aerospace structural bonding: Qualification, quality control, substantiation, and risk mitigation
Abstract
Acknowledgments
23.1: Introduction
23.2: Certification regulations and guidance
23.3: Bonding systems for both metal and composite bonds
23.4: Bonded joint certification
23.5: Bonded joint applications
23.6: Conclusion
References
24: Automotive adhesives: Specification, qualification, and quality control
Abstract
24.1: Introduction
24.2: Specifications
24.3: Qualification
24.4: Quality control
24.5: Future trends
References
25: Construction adhesives: Qualification, specification, quality control, and risk mitigation
Abstract
25.1: Scope and structure of this chapter
25.2: Adhesive bonding for typical civil engineering materials
25.3: Structural verification
25.4: Manufacturing, quality control and risk mitigation
25.5: Conclusions
References
26: General industrial adhesive applications: Qualification, specification, quality control, and risk mitigation
Abstract
Acknowledgments
26.1: Usage of adhesives in general industry
26.2: Capital goods end-user sector
26.3: Durable goods end-user sector
26.4: Consumable goods end-user sector
References
27: Biomedical adhesives: Qualification, specification, quality control, and risk mitigation
Abstract
27.1: Introduction
27.2: Biomedical adhesives
27.3: Clinical application of adhesives: Tissue adhesives
27.4: Adhesives in medical device industry
27.5: Certification, safety, quality, and specifications
References
28: Structural monitoring of adhesive joints using machine learning
Abstract
28.1: Introduction
28.2: Nondestructive testing and evaluation
28.3: Structural health monitoring
28.4: Weak adhesion detection using Lamb wave signals
28.5: Void detection using EMIS signals
28.6: Conclusion
References
Part Five: Emerging technologies for structural bonding
29: Sustainable adhesives: Bioadhesives, chemistries, recyclability, and reversibility
Abstract
29.1: Introduction
29.2: Controlled adhesion in biological systems; multifunctional materials in nature
29.3: Sustainable materials for adhesives
29.4: Smart adhesives for recyclability: Reversible adhesion and adhesion on demand
29.5: Self-healing adhesives
29.6: Conclusions and outlook
References
30: Accelerated curing of bonded joints
Abstract
30.1: Introduction
30.2: Influence of accelerated curing on the adhesive
30.3: Accelerated curing of large-scale joints
30.4: Modeling accelerated curing processes
30.5: Conclusions
References
31: Residual stress development in curing processes: Material characterization and modeling
Abstract
31.1: Introduction
31.2: Adhesive curing processes and material property evolution
31.3: Experimental methods
31.4: Modeling methods
31.5: Additional notes
References
32: Digital image correlation: Advancing mechanical property characterization of adhesive joints
Abstract
Acknowledgments
32.1: Introduction
32.2: Digital image correlation background
32.3: DIC applications in adhesive and bonded joint testing
32.4: Augmenting traditional fracture analysis with DIC
32.5: DIC utilization for traction-separation laws and finite element modeling
32.6: Case study: Using DIC with FEA to develop a mixed-mode fracture envelope
32.7: Conclusions
References
33: Improving joint performance through graded materials and geometries
Abstract
33.1: Introduction
33.2: Mixed adhesive joints
33.3: Functionally graded adhesives
33.4: Functionally graded adherends
33.5: Conclusions
References
34: Architected adhesive joints with improved fracture toughness
Abstract
34.1: Introduction
34.2: Overview of working principles for extrinsic joint toughening
34.3: Embodiments of toughening principles through architecture
34.4: Summary and possible future trends
References
35: Sensing stresses and damage in adhesive bonds using mechanophores
Abstract
35.1: Introduction
35.2: Introduction to mechanoresponsive materials
35.3: Mechanochemistry for sensing stress in bulk adhesives
35.4: Mechanochemistry for sensing interfacial damage
35.5: Challenges to implementation
35.6: Conclusions and future trends
References
Index

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Advances in Structural Adhesive Bonding

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David A. Dillard

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