RESEARCH / DESIGN / TESTING / CERTIFICATION

Adhesive Behavior in Aircraft Applications

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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

Wichita State University

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

[FAA Report: DOT/FAA/AR-02/97]

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]
[FAA Report: DOT/FAA/AR-03/21]

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

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

Research Effort
Funded by

FAA

Industry Partners

Partnered with

Purdue
University

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State 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

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

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

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

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

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

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

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

Failure Modes

ASTM D5656

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

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

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

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

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

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

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

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

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

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

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

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

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

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)

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Wichita State University

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

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

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

NATIONAL INSTITUTE FOR AVIATION RESEARCH

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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

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

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

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

Modified ALCOA Stressing Fixture

P

Calibration for each environmental

condition
t)

tt

t)

Load Cell

Test Results
Format

Time

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

Stress Level Determination

Shear
Stress

Test Temperatures
150F
180F
Yield Stress

210F

25% YS
15% YS
10% YS

Shear Strain

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

Creep Deformation

Loctite
25% YS
180 F
167 hours

~18
[50X magnification]

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

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

NATIONAL INSTITUTE FOR AVIATION RESEARCH

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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

NATIONAL INSTITUTE FOR AVIATION RESEARCH

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Adhesive Lap Joint Specimen

Gage width ~ 0.5
Gage section ~
17.25

Flat Joint
PTM&W
EA9360
Loctite

Joggle Joint
PTM&W
EA9360

NATIONAL INSTITUTE FOR AVIATION RESEARCH

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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]

NATIONAL INSTITUTE FOR AVIATION RESEARCH

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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

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

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

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

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

NATIONAL INSTITUTE FOR AVIATION RESEARCH

Wichita State University

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