Evaluation of Adhesive Bond Primers
2011 DoD Joint Committee on Tactical Shelters (JOCOTAS)for Repair Bonding of Aluminum
2 November 2011
Materials and Manufacturing DirectorateDan McCray and Jeff Smith (UDRI)
Jim Mazza and Kara Storage (AFRL/RXSAC)
JJM; AFRL/RXSAC 1
DISTRIBUTION STATEMENT A: Approved for Public Release; Distribution is Unlimited. (Case no. 88ABW-2010-5305, 1 Oct 2010).
Jim Mazza and Kara Storage (AFRL/RXSAC)
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1. REPORT DATE 02 NOV 2011 2. REPORT TYPE
3. DATES COVERED 00-00-2011 to 00-00-2011
4. TITLE AND SUBTITLE Evaluation of Adhesive Bond Primers for Repair Bonding of Aluminum
5a. CONTRACT NUMBER
5b. GRANT NUMBER
5c. PROGRAM ELEMENT NUMBER
6. AUTHOR(S) 5d. PROJECT NUMBER
5e. TASK NUMBER
5f. WORK UNIT NUMBER
7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) Air Force Research Laboratory,AFRL/RXSAC,Wright Patterson AFB,OH,45433
8. PERFORMING ORGANIZATIONREPORT NUMBER
9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR’S ACRONYM(S)
11. SPONSOR/MONITOR’S REPORT NUMBER(S)
12. DISTRIBUTION/AVAILABILITY STATEMENT Approved for public release; distribution unlimited
13. SUPPLEMENTARY NOTES 7th Bi-Annual DOD JOCOTAS Meeting with Rigid & Soft Wall Shelter Industry & Indoor & OutdoorExhibition, 1-3 Nov 2011, Panama City Beach, FL
14. ABSTRACT
15. SUBJECT TERMS
16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF ABSTRACT Same as
Report (SAR)
18. NUMBEROF PAGES
48
19a. NAME OFRESPONSIBLE PERSON
a. REPORT unclassified
b. ABSTRACT unclassified
c. THIS PAGE unclassified
Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18
Overview
• Backgroundg
• Materials and Processes
T t d T t M th d• Tests and Test Methods
• Lap Shear and Peel Data
• Wedge Test Data
• Conclusions
• Future Work
JJM; AFRL/RXSAC 2DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
Background
• Large Screening Effort to Evaluate Low-VOC Bond Primers• Primary Focus is to Eliminate Chromated Bond PrimersPrimary Focus is to Eliminate Chromated Bond Primers• Working with Industry-Government Non-Cr Adhesive Bond
Primer TeamEffort is part of the larger picture but also has USAF focus– Effort is part of the larger picture but also has USAF focus
• Desire Performance Equivalent to that Currently Obtained with Chromated Primers− Cytec’s BR 127 and BR 6747-1, primarily
• Bond Strength and Moisture Durability are Both Important• Looking for Primer that Works Well with Multiple Adhesives
on Adherends Prepared Using Grit-Blast/Sol-Gel (GBSG)– Currently, GBSG is used exclusively with Cytec’s BR 6747-1 primer
C t ' FM 73 dh i i t d d f ith GBSG
JJM; AFRL/RXSAC 33DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
– Cytec's FM 73 adhesive is not recommended for use with GBSG– 3M’s AF 163-2 adhesive tends to fail at its interface with BR 6747-1
Materials and Processes
• Five Waterborne Adhesive Bond Primers– Cytec’s BR 6747-1 (zero-VOC, chromated)– Cytec’s BR 6747-1NC (zero-VOC, nonchromated - no inhibitor)– Cytec’s BR 6700-1 (low-VOC, nonchromated corrosion inhibitor)y ( , )– 3M’s EW 5000 (low-VOC, chromated)– 3M’s EW 5000 AS (low-VOC, nonchromated corrosion inhibitor)
• Spray Applied Using Conventional Air Gun– Dry film thicknesses: 0.0025 mm - 0.0063 mm (0.0001 - 0.00025 in);
measured using Fischer Isoscope MP30E-S with ETA3 3H probemeasured using Fischer Isoscope MP30E-S with ETA3.3H probe(directly on PAA adherends and on travelers for GBSG adherends)
• Cured in an Air-circulating Oven at 121°C (250°F) for 60
JJM; AFRL/RXSAC 44DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
g ( )Mins after Air Dry at Ambient Conditions for 30 Mins
Materials and Processes (cont.)
• Seven Adhesives Evaluated with Each PrimerSeven Adhesives Evaluated with Each Primer– Henkel’s Hysol EA 9696 and Hysol EA 9628– Cytec’s FM 73M, FM 209M, and FM 300-2M– 3M’s AF 163-2M and AF 500M
• Mat Carrier• 290g/m2 (0.06 psf) Areal Weight• Cured per Manufacturers’ Recommendations UnderCured per Manufacturers Recommendations Under
Positive Pressure– 121°C (250°F) for 60-90 Minutes
JJM; AFRL/RXSAC 55DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
Materials and Processes (cont.)
• 2024-T3 (bare) Aluminum Adherends( )• Two Surface Preparations
– Phosphoric Acid Anodize (PAA) per ASTM D 3933• First choice for aluminum prebond surface preparation• Used in USAF for rework and preparation of repair doublers
– Grit Blast/Sol Gel (GBSG)– Grit-Blast/Sol-Gel (GBSG)• Al2O3 grit-blast followed by application of AC Tech AC-130
(Boegel-EPII) sol-gel solution; no rinse and ambient driedU d i USAF f ti f i ft dh d• Used in USAF for preparation of on-aircraft adherends
JJM; AFRL/RXSAC 66DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
Tests and Test Methods
• Tensile Lap Shear (ASTM D 1002)– Ambient temperature at 22°C (72°F)– Ambient temperature at 22 C (72 F)– Hot/Wet at 82°C (180°F) after conditioning for 90 days at 60°C
(140°F) and 95-100% relative humidity (RH)
• Metal-to-Metal Climbing Drum Peel (ASTM D 1781)– Ambient temperature at 22°C (72°F)
• Wedge Test (ASTM D 3762)– Conditioned at 60°C (140°F) and 95-100% RH for 28 days
C diti d t 49°C (120°F) d 95 100% RH f 28 d *– Conditioned at 49°C (120°F) and 95-100% RH for 28 days*
• Five Specimens per Test for Each Adhesive/Primer/Surface Preparation Combination
JJM; AFRL/RXSAC 77DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
Adhesive/Primer/Surface Preparation Combination
* These data are not reported in the paper and will not be presented; will be in a comprehensive report
The Wedge Test
• Used Extensively by AFRL for Screening to Assess Bonded Joint Moisture Durabilityy
• Considered by AFRL to be a Semiquantitative Test– Initial crack lengths provide important information (w.r.t. test severity)Initial crack lengths provide important information (w.r.t. test severity)– Crack extensions can be useful, but are not the bottom line– Most consideration is given to failure modes after conditioning
D i f il d 95% t h i ithi th dh i– Desire failure modes are 95% or greater cohesive within the adhesive
• CaveatsU f l f i f ti (i l di i )– Useful for comparing surface preparations (including primers)
– Many factors affect the test; must only vary the factor being evaluated– Several adhesive characteristics affect the test: modulus, bondline
JJM; AFRL/RXSAC 88DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
thickness, carrier, degree of cure, hot/wet properties– Test cannot be quantitatively correlated with in-service performance
EA 9696 Adhesive22°C (72°F) Lap Shear
6000
700045
50
i)Pa) EA 9696 Tech Data Sheet
4000
5000
6000
25
30
35
40
Strength (psi
tren
gth (M
P
1000
2000
3000
5
10
15
20
Lap Shear S
Lap Shear S
00
5
R 67
47‐1
747‐1N
C
R 67
00‐1
EW 500
0
5000
AS
PAA
GBSG
JJM; AFRL/RXSAC 9DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
BR
BR 67
BR E
EW GBSG
EA 9696 Adhesive82°C (180°F) Wet Lap Shear
3500
400025
30
si)
Pa)
2000
2500
3000
15
20
r Stren
gth (ps
Strength (M
P
e e e e e e
500
1000
1500
5
10
Lap Shear
Lap Shear
84% coh
esive
46% coh
esive
66% coh
esive
48% coh
esive
48% coh
esive
34% coh
esive
00
BR 674
7‐1
6747
‐1NC
BR 670
0‐1
EW 500
0
W 500
0 AS
PAA
GBSG
8 4 6 4 4 3
JJM; AFRL/RXSAC 10DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
B
BR 6 B
EW
EA 9696 Adhesive22°C (72°F) Climbing Drum Peel
120500
600
EA 9696 Tech Data Sheet
80
100
300
400
500
ue (in*
lbs/in)
ue (N
*m/m
)
20
40
60
100
200
CDP To
rqu
CDP To
rqu
% coh
esive
% coh
esive
% coh
esive
% coh
.
% coh
esive
0
20
0
6747
‐1
47‐1NC
6700
‐1
W 500
0
000 AS
PAA
GBSG
64%
72%
22%
18%
65%
JJM; AFRL/RXSAC 11DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
BR 6
BR 674
BR 6 EW
EW 50 GBSG
EA 9628 Adhesive22°C (72°F) Lap Shear
700045
50
)a) EA9628 Tech Data Sheet
4000
5000
6000
25
30
35
40
Strength (psi)
tren
gth (M
Pa EA 9628 Tech Data Sheet
1000
2000
3000
5
10
15
20
Lap Shear S
Lap Shear St
00
5
R 67
47‐1
747‐1N
C
R 67
00‐1
EW 500
0
5000
AS
PAA
GBSG
JJM; AFRL/RXSAC 12DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
BR
BR 67
BR E
EW GBSG
EA 9628 Adhesive82°C (180°F) Wet Lap Shear
400030
)
2500
3000
3500
15
20
25
tren
gth (psi)
rength (M
Pa)
500
1000
1500
2000
5
10
15
Lap Sh
ear S
Lap Shear St
0% coh
esive
5% coh
esive
2% coh
esive
0% coh
esive
2% coh
esive
8% coh
esive
0% coh
esive
0
500
0
R 67
47‐1
747‐1N
C
R 67
00‐1
EW 500
0
5000
AS
PAA
G SG
80 8542 40 5 58 30
JJM; AFRL/RXSAC 13DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
BR
BR 67
BR E
EW GBSG
EA 9628 Adhesive22°C (72°F) Climbing Drum Peel
70300
350EA 9628 Tech Data Sheet
40
50
60
200
250
ue (in*
lbs/in)
ue (N
*m/m
)
10
20
30
50
100
150
CDP To
rqu
CDP To
rq
00
R 67
47‐1
747‐1N
C
R 67
00‐1
EW 500
0
5000
AS
PAA
GBSG
JJM; AFRL/RXSAC 14DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
BR
BR 67
BR E
EW GBSG
FM 73M Adhesive22°C (72°F) Lap Shear
700045
50
)a)
FM 73M Tech Data Sheet
4000
5000
6000
25
30
35
40
Strength (psi)
tren
gth (M
Pa
1000
2000
3000
5
10
15
20
Lap Shear S
Lap Shear St
00
5
R 67
47‐1
747‐1N
C
R 67
00‐1
W 500
0
5000
AS
PAA
GBSG
JJM; AFRL/RXSAC 15DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
BR
BR 67
BR EW
EW 5 GBSG
FM 73M Adhesive82°C (180°F) Wet Lap Shear
400025
30
))
2000
2500
3000
3500
15
20
25
STreng
th (psi)
tren
gth (M
Pa
500
1000
1500
2000
5
10
Lap Sh
ear S
Lap Sh
ear St
84% coh
esive
7% coh
.
0% coh
.
70% coh
esive
60% coh
esive
38% coh
.
24% coh
.
4% coh
.
00
R 67
47‐1
747‐1N
C
R 67
00‐1
EW 500
0
5000
AS
PAA
GBSG
8 8 97 6 3 2 2
JJM; AFRL/RXSAC 16DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
BR
BR 67
BR E
EW GBSG
FM 73M Adhesive22°C (72°F) Climbing Drum Peel
10000
450
500
)FM 73M Tech Data Sheet
60
80
250
300
350
400
ue (in
*lbs/in)
que
(N*m
/m)
20
40
50
100
150
200
CDP To
rq
CDP To
rq
00
BR 674
7‐1
6747
‐1NC
BR 670
0‐1
EW 500
0
W 500
0 AS
PAA
GBSG
JJM; AFRL/RXSAC 17DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
B
BR 6 B
EW
FM 209M Adhesive22°C (72°F) Lap Shear
6000
700045
50
)a)
4000
5000
6000
25
30
35
40
Strength (psi
tren
gth (M
Pa
1000
2000
3000
5
10
15
20
Lap Shear S
Lap Shear St
00
5
R 67
47‐1
747‐1N
C
R 67
00‐1
W 500
0
5000
AS
PAA
GBSG
JJM; AFRL/RXSAC 18DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
BR
BR 67
BR EW
EW 5 GBSG
FM 209M Adhesive82°C (180°F) Wet Lap Shear
400025
30
)a)
2000
2500
3000
3500
15
20
25
Tren
gth (psi
tren
gth (M
Pa
500
1000
1500
2000
5
10
Lap She
ar S
Lap She
ar St
8% coh
esive
3% coh
esive
5% coh
esive
8% coh
esive
6% coh
esive
0
500
0
6747
‐1
47‐1NC
6700
‐1
W 500
0
000 AS
PAA
88 93 85 68 76
JJM; AFRL/RXSAC 19DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
BR 6
BR 674
BR 6 EW
EW 50
GBSG
FM 209M Adhesive22°C (72°F) Climbing Drum Peel
100
400
450
FM209M T h D t Sh t
60
80
250
300
350
e (in
*lbs/in)
ue (N
*m/m
) FM 209M Tech Data Sheet
20
40
50
100
150
200
CDP To
rqu
CDP To
rqu
84% coh
esive
86% coh
esive
00
R 67
47‐1
747‐1N
C
R 67
00‐1
EW 500
0
5000
AS
PAA
GBSG
8 8
JJM; AFRL/RXSAC 20DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
BR
BR 67
BR E
EW GBSG
FM 300-2M Adhesive22°C (72°F) Lap Shear
500035
40
)a)
FM 300‐2M Tech Data Sheet
3000
4000
5000
20
25
30
35
Strength (psi)
tren
gth (M
Pa
1000
2000
5
10
15
Lap Shear S
Lap Shear St
00
BR 674
7‐1
6747
‐1NC
BR 670
0‐1
EW 500
0
W 500
0 AS
PAA
GBSG
JJM; AFRL/RXSAC 21DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
B
BR 6 B
EW
FM 300-2M Adhesive82°C (180°F) Wet Lap Shear
400030
))
2000
2500
3000
3500
15
20
25
STreng
th (psi)
tren
gth (M
Pa
e e e
500
1000
1500
2000
5
10
Lap Sh
ear S
Lap Sh
ear St
82% coh
esive
91% coh
esive
84% coh
esive
40% coh
esive
71% coh
esive
00
BR 674
7‐1
6747
‐1NC
BR 670
0‐1
EW 500
0
W 500
0 AS
PAA
GBSG
8 9 8 4 7
JJM; AFRL/RXSAC 22DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
B
BR 6 B
EW
GBSG
FM 300-2M Adhesive22°C (72°F) Climbing Drum Peel
50
250
30
40
50
150
200
e (in
*lbs/in)
ue (N
*m/m
)
FM 300‐2M Tech Data Sheet
10
20
50
100
CDP To
rqu
CDP To
rqu
00
BR 674
7‐1
6747
‐1NC
BR 670
0‐1
EW 500
0
W 500
0 AS
PAA
GBSG
JJM; AFRL/RXSAC 23DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
B
BR 6 B
EW
AF 163-2M Adhesive22°C (72°F) Lap Shear
700045
50
)a) AF163 2M T h D t Sh t
4000
5000
6000
25
30
35
40
Strength (psi)
tren
gth (M
Pa AF 163‐2M Tech Data Sheet
1000
2000
3000
5
10
15
20
Lap Shear S
Lap Shear St
00
5
R 67
47‐1
747‐1N
C
R 67
00‐1
W 500
0
5000
AS
PAA
GBSG
JJM; AFRL/RXSAC 24DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
BR
BR 67
BR EW
EW 5 GBSG
AF 163-2M Adhesive82°C (180°F) Wet Lap Shear
3000
350025
i)a)
2000
2500
3000
15
20
STreng
th (psi
tren
gth (M
Pa
500
1000
1500
5
10
Lap Sh
ear S
Lap Sh
ear S
4% coh
esive
00
R 67
47‐1
747‐1N
C
R 67
00‐1
EW 500
0
5000
AS
PAA
GBSG
74
JJM; AFRL/RXSAC 25DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
BR
BR 67
BR E
EW 5 GBSG
AF 163-2M Adhesive22°C (72°F) Climbing Drum Peel
100450
500
60
80
100
250
300
350
400
e (in
*lbs/in)
e (N*m
/m) AF 163‐2M Tech Data Sheet
20
40
100
150
200
250
CDP To
rque
CDP To
rqu
00
50
6747
‐1
47‐1NC
6700
‐1
W 500
0
000 AS
PAA
JJM; AFRL/RXSAC 26DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
BR 6
BR 674
BR 6 EW
EW 50
GBSG
AF 500M Adhesive22°C (72°F) Lap Shear
700045
50
)a)
AF 500M Tech Data Sheet
4000
5000
6000
25
30
35
40
Strength (psi)
tren
gth (M
Pa
1000
2000
3000
5
10
15
20
Lap Shear S
Lap Shear St
00
BR 674
7‐1
6747
‐1NC
BR 670
0‐1
EW 500
0
W 500
0 AS
PAA
GBSG
JJM; AFRL/RXSAC 27DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
B
BR 6 B
EW
AF 500M Adhesive82°C (180°F) Wet Lap Shear
3000
350025
)a)
2000
2500
3000
15
20
STrength (psi
Strength (M
Pa
e e
500
1000
1500
5
10
Lap Sh
ear S
Lap Sh
ear S
70% coh
esive
88% coh
esive
00
BR 674
7‐1
6747
‐1NC
BR 670
0‐1
EW 500
0
W 500
0 AS
PAA
GBSG
7 8
JJM; AFRL/RXSAC 28DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
B
BR 6 B
EW
AF 500M Adhesive22°C (72°F) Climbing Drum Peel
80
90
350
400AF 500M Tech Data Sheet
40
50
60
70
200
250
300
ue (in*
lbs/in)
ue (N
*m/m
)
10
20
30
40
50
100
150
CDP To
rqu
CDP To
rqu
00
R 67
47‐1
747‐1N
C
R 67
00‐1
EW 500
0
5000
AS
PAA
GBSG
JJM; AFRL/RXSAC 29DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
BR
BR 67
BR E
EW GBSG
EA 9696 Adhesive with PAA60°C (140°F) Wedge Test
1 433.70
1.33
1.38
1.43
3 30
3.50
in)
cm)
BR 6747‐1
BR 6747 1NC
1.18
1.23
1.28
3.10
3.30
ack Length (i
ck Len
gth (c BR 6747‐1NC
BR 6700‐1
EW 5000
1.03
1.08
1.13
2.70
2.90
Cra
Crac EW 5000 AS
0.982.50
0 7 14 21 28
Conditioning Time (Days)
JJM; AFRL/RXSAC 30DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
Conditioning Time (Days)
EA 9696 Adhesive with GBSG60°C (140°F) Wedge Test
1 481.533.90
1.331.381.431.48
3.50
3.70
h (in
)
(cm)
BR 6747‐1
BR 6747‐1NC
1.181.231.28
3.10
3.30
rack Len
gth
ack Length
BR 6700‐1 (22% coh)
EW 5000 (88% coh)
EW 5000 AS (86% h)
1.031.081.13
2.70
2.90 Cr
Cr EW 5000 AS (86% coh)
0.982.50
0 7 14 21 28
Conditioning Time (Days)
JJM; AFRL/RXSAC 31DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
EA 9628 Adhesive with PAA60°C (140°F) Wedge Test
1 63
4.20
1.58
1.63
4.00
4.10
(in)
(cm)
BR 6747‐1
BR 6747‐1NC
1.48
1.53
3.80
3.90
ack Length
ack Length (
BR 6700‐1
EW 5000
1.433.60
3.70 Cra
Cra EW 5000 AS
1.383.50
0 7 14 21 28
Conditioning Time (Days)
JJM; AFRL/RXSAC 32DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
Conditioning Time (Days)
EA 9628 Adhesive with GBSG60°C (140°F) Wedge Test
1 684.30
1.63
1.68
4.10
4.20
n)m)
BR 6747‐1
BR 6747 1NC
1.53
1.58
3 80
3.90
4.00
ck Len
gth (in
k Length (cm BR 6747‐1NC
BR 6700‐1
EW 5000 (88% coh)
1.43
1.48
3.60
3.70
3.80
Crac
Crack
EW 5000 AS
1.383.50
0 7 14 21 28
JJM; AFRL/RXSAC 33DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
Conditioning Time (Days)
FM 73M Adhesive with PAA60°C (140°F) Wedge Test
3.70
1.40
1.42
1.44
3.55
3.60
3.65
(in)
cm)
BR 6747‐1
BR 6747‐1NC
1.34
1.36
1.38
3.40
3.45
3.50
ack Length (
ck Len
gth (c BR 6747 1NC
BR 6700‐1
EW 5000
1.28
1.30
1.32
3.25
3.30
3.35 Cra
Crac EW 5000 AS
1.263.20
0 7 14 21 28
Conditioning Time (Days)
JJM; AFRL/RXSAC 34DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
Conditioning Time (Days)
FM 73M Adhesive with GBSG60°C (140°F) Wedge Test
1 754.50
1.65
1.70
1.75
4 10
4.30
n)m)
BR 6747‐1
BR 6747 1NC
1.50
1.55
1.60
3.90
4.10
ck Len
gth (i
ck Len
gth (c BR 6747‐1NC
BR 6700‐1 (4% coh)
EW 5000 (84% coh)
1.35
1.40
1.45
3.50
3.70
Crac
Crac EW 5000 AS (64% coh)
1.303.30
0 7 14 21 28
Conditioning Time (Days)
JJM; AFRL/RXSAC 35DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
Conditioning Time (Days)
FM 209M Adhesive with PAA60°C (140°F) Wedge Test
1.564.00
1 46
1.51
1.56
3 70
3.80
3.90
(in)
cm)
BR 6747‐1
BR 6747‐1NC
1.41
1.46
3.50
3.60
3.70
ack Length (
ck Len
gth (c BR 6747 1NC
BR 6700‐1
EW 5000
1.31
1.36
3.30
3.40
Cra
Crac EW 5000 AS
1.263.20
0 7 14 21 28
Conditioning Time (Days)
JJM; AFRL/RXSAC 36DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
Conditioning Time (Days)
FM 209M Adhesive with GBSG60°C (140°F) Wedge Test
1.965.00
1.76
1.86
4.40
4.60
4.80
(in)
cm)
BR 6747‐1 (14% coh)
BR 6747‐1NC (50% coh)
1.56
1.66
3 80
4.00
4.20
ack Length (
ack Length ( ( % )
BR 6700‐1 (0% coh)
EW 5000 (0% coh)
1.36
1.46
3.40
3.60
3.80
Cra
Cra EW 5000 AS (0% coh)
1.263.20
0 7 14 21 28
Conditioning Time (Days)
JJM; AFRL/RXSAC 37DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
g ( y )
FM 300-2M Adhesive with PAA60°C (140°F) Wedge Test
1 76
4.60
1.66
1.76
4.50
4.55
(in)
(cm)
BR 6747‐1
BR 6747‐1NC
1.46
1.56
4 40
4.45
ack Length
ck Len
gth (
BR 6700‐1
EW 5000
1.36
1.46
4.35
4.40
Cra
Crac EW 5000 AS
1.264.30
0 7 14 21 28
C di i i Ti (D )
JJM; AFRL/RXSAC 38DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
Conditioning Time (Days)
FM 300-2M Adhesive with GBSG60°C (140°F) Wedge Test
5.00
1.89
1.94
4.80
4.90
in)
cm)
BR 6747‐1
BR 6747‐1NC
1 79
1.844.60
4.70
ack Length (
ck Len
gth ( c BR 6747‐1NC
BR 6700‐1 (74% coh)
EW 5000
1.74
1.79
4.40
4.50 Cra
Cra EW 5000 AS
1.694.30
0 7 14 21 28
Conditioning Time (Days)
JJM; AFRL/RXSAC 39DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
AF 163-2M Adhesive with PAA60°C (140°F) Wedge Test
1 403.60
1 30
1.35
1.40
3.40
3.50
in)
cm)
BR 6747‐1*
BR 6747‐1NC
1.25
1.30
3.10
3.20
3.30
ck Len
gth (
ck Len
gth (c BR 6747‐1NC
BR 6700‐1
EW 5000
1.15
1.20
2.90
3.00
3.10
Cra
Crac EW 5000 AS*
1.102.80
0 7 14 21 28
Conditioning Time (Days)
JJM; AFRL/RXSAC 40DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
Conditioning Time (Days)
* Visually appeared to fail at the primer-adhesive interface, but a thin layer of AF 163-2M remains on the primer
AF 163-2M Adhesive with GBSG60°C (140°F) Wedge Test
1 594.10
1.49
1.54
1.59
3 70
3.90
in)
cm)
BR 6747‐1 (94% coh)*
BR 6747 1NC
1.34
1.39
1.44
3.50
3.70
ck Len
gth (i
ck Len
gth (c BR 6747‐1NC
BR 6700‐1 (14% coh)
EW 5000 (42% coh)*
1.19
1.24
1.29
3.10
3.30
Cra
Cra c EW 5000 AS (32% coh)
1.142.90
0 7 14 21 28
Conditioning Time (Days)
JJM; AFRL/RXSAC 41DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
Conditioning Time (Days)
* Visually appeared to fail at the primer-adhesive interface, but a thin layer of AF 163-2M remains on the primer
AF 500M Adhesive with PAA60°C (140°F) Wedge Test
4.20
1.54
1.59
3 90
4.00
4.10
(in)
(cm)
BR 6747‐1
BR 6747‐1NC
1 44
1.49
3.70
3.80
3.90
ack Length
ack Length (
BR 6700‐1
EW 5000
1.39
1.44
3.50
3.60
Cra
Cra EW 5000 AS
1.343.40
0 7 14 21 28
Conditioning Time (Days)
JJM; AFRL/RXSAC 42DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
Conditioning Time (Days)
AF 500M Adhesive with GBSG60°C (140°F) Wedge Test
1 79
1.69
1.74
1.79
4.40
4.60
n)m)
BR 6747‐1 (94% coh)
BR 6747 1NC
1.54
1.59
1.64
4.00
4.20
ck Len
gth (i
ck Len
gth (cm BR 6747‐1NC
BR 6700‐1 (14% coh)
EW 5000 (42% coh)
1.39
1.44
1.49
3.60
3.80 Crac
Crac EW 5000 AS (32% coh)
1.343.40
0 7 14 21 28
Conditioning Time (Days)
JJM; AFRL/RXSAC 43DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
Conditioning Time (Days)
Typical Failure Modes Observed in 60°C (140°F) Wedge Tests
Typical Primer-Aluminum Interfacial Failure ith FM 209M Adh iwith FM 209M Adhesive
Typical AF 163-2M “100 Percent Cohesive Failure” Near Primer-Adhesive Interface
JJM; AFRL/RXSAC 44DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
Typical Good “100 Percent” Cohesive Failure
Summary of Failure Modes with GBSG in 60°C (140°F) Wedge Tests
100%
70%
80%
90%
hesi
ve)
BR 6700-1EW-5000ASEW-5000
40%
50%
60%
Mod
e (%
Coh BR 6747-1
BR 6747-1NC
BR 6747-1BR 6747-1NC
10%
20%
30%
Failu
re
BR 6700-1
EW-5000ASEW-50000%
JJM; AFRL/RXSAC 45DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
Conclusions
• Large Amount of Data Generated to Guide Future Efforts
• No Clear Path Forward for Non Cr Primer Qualification• No Clear Path Forward for Non-Cr Primer Qualification– Based on initial screening with only 5 specimens per test
• PAA Test Results were Overall Superior to GBSG• PAA Test Results were Overall Superior to GBSG – PAA is the premier aluminum surface preparation– PAA can be used with more combinations of surface preps & primers
• Hot/Wet Lap Shear Results when Using GBSG Exhibit Poor Failure Modes– Routinely seen even with good wedge tests data for same combination– A bit concerning
JJM; AFRL/RXSAC 46DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
• Wedge Test Results Must be Used with Caution– Screening w/ controlled variables; no quantitative correlation to service
Conclusions (cont.)
• BR 6747-1NC (No Corrosion Inhibitor) Yielded Amazingly Good Results
• BR 6700-1 Wedge Test Results with GBSG were Surprisingly Poor and Not Consistent with Previous AFRL (Good) Data
• FM 209M Wedge Test Data were Poor when with GBSG Prep
• FM 73M Generated Surprisingly Good Wedge Test Results p g y gwith GBSG/BR 6747-1; Contradicts Previous USAF Data
• FM 300-2M Adhesive Generated Larger Initial Cracks in the C GWedge Test and Tended to Produce Less Crack Growth
– Wedge test interrogates interface less stringently using FM 300-2M
AF 163 2M Adh i E hibit F il M d At N th
JJM; AFRL/RXSAC 47DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
• AF 163-2M Adhesive Exhibits Failure Modes At or Near the Primer-Adhesive Interface with BR 6747-1 & Others
Future Efforts
• USAF Will Work with Industry-Government Non-Cr Adhesive Bond Primer Team to Further Evaluate Some of the Products Screened, as well as Promising New Candidates
• Another Industry-Government Team was Awarded a SERDP Project Aimed at Understanding the Requirements for Bond Primers and their Corrosion Inhibitors– Investigate failed bonds and relationship to primerg p p– Evaluate various types/levels of corrosion inhibitor in bond primers– Develop a risk assessment tool for bonded joints
I ti t lt ti l t d i t l– Investigate alternative accelerated aging protocols
• Much Work is Required to Implement any New PrimerLaboratory testing beyond screening
JJM; AFRL/RXSAC 48DoD Distribution Statement A: Approved for Public Release; Distribution is Unlimited.
– Laboratory testing beyond screening– Generation of data based on field-level processing
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