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Chapter 1: Introduction
Quelle: Wikipedia
Agenda
Bonding technology
2
Agenda
Bonding Technology
3
Short Overview of the Department for Cutting and Joining
Manufacturing Processes at the University of Kassel
4
Institute of Production Technology and Logistics (IPL)
Produktionsorganisation und
Fabrikplanung (pfp)
Univ.-Prof. Dr.-Ing. Sigrid Wenzel
Umformtechnik (metform)
Univ.-Prof. Dr.-Ing. habil. Kurt Steinhoff
Gießereitechnik (GTK)
Univ.-Prof. Dr.-Ing. Martin Fehlbier
5
Short overview of the Department for Cutting and Joining
Manufacturing Processes at the University of Kassel, Germany
6
The team of the Department for Cutting and Joining
Manufacturing Processes
7
Fields of Activity and Research
Adhesive
Technology
Research
Services
Teaching
8
Fields of Activity and Research
Adhesive Welding Cutting Teaching
Technology Technology Technology Student Projects,
Information and Sawing Seminar Papers,Diploma
Laser and electro beam
assistance as regards Theses, Bachelor and
welding
the selection of Drilling Master Theses
adhesives Arc Welding Turning Manufacturing
Design and Technology
Magnetic Pulse Welding Erosion
constructions suitable for
Production Technology
adhesive bonding Friction Stir Welding Milling
Adhesive Technology
Realisation of adhesive Threading
Resistance Spot
bonding Beam Technology
Welding
Thread Cutting
Destructive and non- Bonding Technology
destructive testing of Hybrid Processes Thread Mill Drilling
constructional elements Machining Tools for
Destructive and non- Flow Punch Forming Cutting Processes
Analysis,modification destructive testing of
and formulation of constructional elements EIPA
adhesives
9
Choice of Current Activities and Research Projects in the
Field of Adhesive Technologies
10
40th Anniversary of the University of Kassel
11
12
Use of ply wood parts in the body of white shop
Development, design
and manufacturing
of automotive oparts
Development of
Design of concepts joining technologies
for repairing and Use of ply wood parts for ply woods parts
recycling in the body of white
As alternative, innovative and
shop
Sustainable hybrid material for structural
automotive parts
Determination of
Creating of material
material and
models for
manufactured parts
simulation
properties
13
Adhesive bonding of cutting elements
Advantages of adhesive boning in comparison to brazing or welding:
Heat reduced joining method
Not destruction of the PCD elements
No heat affected distortion
no reworking necessary
Fast production of a sawing band
Resource efficient
Possibility of repairing
Aims of the projects:
Development of an adhesive bonding technology for the joining of PCD elements
Modification of adhesives for the temperature resistance
Design of the joints
14
Debond (separating) of adhesive bonded parts
Development of a pyrotechnic adhesive bond, which allows to debond adhesively
bonded with high efficiency and forceless
Safety handling with low pyrotechnic hazard classification
Design of suitable application technologies and description of possible productions
scenarios
Debond on command, fast and residue-free and without influencing the life time of the
bonded parts
16
ProStaR – Production technology for the production
of stator and rotor packets of electrical engines
17
Adhesive Integrated Damage Detection
Formulation of adhesives with encapsulated fragrance or coloring
Breaking open the capsules and release of the additives at the bonded joint injury
Detection of the color and fragrance
18
NDT of bonded joints and mechanical
joining processes
Prinzipskizze Prinzipskizze
IR-Kamera
IR-Kamera
(Blitz-) Lampe
Optische Welle
Defekt bzw. Impuls
Thermische Welle
Prinzipskizze
IR-Kamera
Induction coils
Heat fields
Laser beam
joint
Quelle: fluxtrol
21
Reduction of hot cracks by multilayer systems
Use of high-alloyed filler metals coated with sheets
→ simpler to use, because the additional material is already applied to the base material
→ Particularly suitable for remote welding possible
→ little understanding of the process required by the user
concentrator:
source: pstProducts 23
EMPT-tube welding
Aluminum
Steel
source: pstProducts
24
EMPT- sheet welding
properties
20μs process time
No heat affected zone
No thermal distortion
Smallest intermetallic phase
atomic bond
Contact Free
Inert gas free Multi layer welding
nearly "contactless"
25
Friction stir welding
26
Zircular FSW
27
Zircular FSW
28
Use of multi-pin tools for FSW
Experimental material: AlMgSi1 (EN AW 6082)
Material thickness: 1.5 mm
joint length: 100 mm
vf=400 mm/min,
n=800 min-1,
gap: 1 mm
(66,7%)
vf=400 mm/min,
n=800 min-1,
gap: 3 mm
(200%)
24 mm
29
orbital friction welding
Induction stimulation
31
NDT of laser welded joints
Lockin-Thermography
Probe 2
DP 600 ; 2 X 1.5 mm + gap
32
NDT of FSW joints
X-Ray
Macroscopic view
33
34
Stone cutting
Evaluation of cutting elements for the cutting of stones
Investigation of different cutting geometries
Determination of force development
Wear tests of cutting elements
35
Stone Cutting
Tool holder Specimen holder
tool
extraction
cooling
3-component Experimental
Dynamometer material
Linear engine;
vmax ca. 9 m/s
36
Metal cutting- single tooth test setup
• Set up: • Wear documentation:
37
Agenda
Bonding Technology
38
Contents of the Lectures
Introduction
● Bonding technologies in general
Classification of adhesives
● Polymer Chemistry
● Reaction mechanisms
● Wetting properties
● Ageing process
● Non-destructive testing 40
Contents of the Lectures
Hybrid joining
● Possible combinations with other joining techniques
● Rules of construction
Processing technology
● Application technology
41
Agenda
Bonding Technology
42
Joining Technology
Manufacturing methods are determined in DIN 8580:
Manufacturing
method according to
DIN 8580
6 Changing
1 Casting 2 Shaping 3 Separating 4 Joining 5 Coating of Material
Properties
43
Joining Technology
Manufacturing
processes
according to DIN
8580
6 Changing
1 Casting 2 Shaping 3 Separating 5 Coating of material
4 Joining properties
Definition of Joining:
Joining means to connect two or more workpieces that are geometrically
stable with a formless material. Hereby, the connection is formed locally and
then spreads out.
(DIN 1910-100)
44
Joining Technology
Introduction to the Joining technology: Adhesive bonding
Production
technologies
Due to DIN 8580
6 Changing of
3
1 Casting 2 Shaping
Separating
4 Joining 5 Coating
material
characteristic
s
DIN 8593
Material
closure
Cohesion
Adhesion
Forced closure Form closure
prevented Formation of
movement elemental pairs
Normal force
prevented
movement Static Friction
friction
46
Joining Technology: Overview
Type of fixation is caused by
Material
closure
material
Cohesion inherent
Joining
Adhesion external
Forced closure Form closure
after
prevented Formation of plastically
movement elemental pairs
Deforming
during
Joining
before
Normal force
elastically
during
prevented
plastically
movement Static Friction
friction
after
elasticallys
47
Joint detachable +
Limited detachment
possible o
Joining Technology: Overview No detachment possible
–
Type of joining
Type of fixation is caused by
technique
Welding –
Material
closure
material
Cohesion inherent
Joining
Melting –
Soldering o–
Adhesion external Adhesive bonding o–
Luting o–
Riveting o
Forced closure Form closure
Flanging o
Beading o
after Folding o
prevented Formation of plastically Curling o
movement elemental pairs Setting o–
Deforming
during Embedding –
Joining
before Widening +o
normal force
elastically
during Press-in
49
Bonding Technology
Definition of Adhesive:
50
Without joining and adhesive technology…
Agenda
Bonding Technology
52
History
For about 3 billion years unicellar organismens and primitive sea species
have already used self-produced adhesives
Source: Endlich 53
History
Some examples from flora and fauna
swallows´ nests
Honey combs
adhesive traps
used by
carnivorous plants
(„sundew“)
Source: Endlich 54
History
35000 B. C. First cave paintings
5000 B.C. Building of weapons
Cave paintings in
Spain ( the bonding
agent of the colour
is protein taken
from animal blood)
Paper is adhesively
bonded to the
inside
Source: Endlich 57
History
1890 Plywood industry uses adhesives
● used in aeroplane constructions and for furniture
Source: Endlich 59
History
1931 Carboxymethyl and methyl
cellulose (painter´s glue and wall paper
paste) introduced onto the market
1932 first adhesive for „everything“
1934 first adhesive (sticky) tape
1937 Polyurethane is patented by Bayer
1960 first instant gluee
1969 first glue stickt
Up until this day there have been many
new developments
Bonding Technology
61
Fields of Application for Adhesive Technologies
Car Body Constructions
windscreen is glued
to the car body
Source: Habenicht 63
Fields of Application for Adhesive Technologies
Aeroplane Constructions
Honey comb
structure for the
fuselage, wings,
tail unit, etc.
Source: Habenicht 64
Fields of Application for Adhesive Technologies
Construction of Railroad Vehicles
● Some examples were adhesion is
used:
– Locomotive of the ICE
– Discs
Source: Brockmann 65
Fields of Application for Adhesive Technologies
Leight-Weight Constructions of Car Bodies
Adhesive bonding of
different workpiece
materials such as
aluminium alloys and
synthetic material
Strutting of the
hood
Dampings and
seals (e.g. filler
cap)
Source: www.colour-europe.de/Anwenden-kleben 66
Fields of Application for Adhesive Technologies
Further uses in car constructions
● Structural foam absorbs the energy in case of crash
● Sandwich construction for isolation, covering layer made out of stainless steel
(optics), floor elements made out of waterproof plywood
● Adhesives that are suitable for crashes
semi-tough behaviour
A = modified
B
B = non-modified epoxy resin adhesive (BMW AG)
Quelle: Habenicht
A 67
Fields of Application for Adhesive Technologies
Car constructions
Production of
upholstery by spraying
Source: Endlich 68
Fields of Application for Adhesive Technologies
Mechanical engineering
Mounting of
bearing inner
ring
Adhesive bonding
of feather key on
shaft
Source: Endlich 69
Fields of Application for Adhesive Technologies
Mechanical Engineering
Quelle: Onusseit 70
Fields of Application for Adhesive Technologies
Electronics Adhesive bonding
of microelectronic
Casting of inductive
components onto a
proximity switches
circuit board to
with 2 c epoxy resins
conduct electricity
Fixation of coils
using UV-
acrylates
Source: www.ulbrich-group.com/klebstoffe.php 72
Fields of Application for Bonding Technologies
Labeling
Different labellings
for plastic bottles
Source: Onusseit 74
Fields of Application for Bonding Technologies
Packaging industry
● Corrugated board
● Bags, carrier bags etc.
● Cardboard packaging
● TetrapackTM
with pressure-
sensitive adhesive
Source: Onusseit 76
Fields of Application for Adhesive Bonding Technologies
Medical attendance
special cyanacrylate
adhesive (fast-setting
adhesive)
EPIGLU®
Source: www1.catgut.de/Catgut/phocadownload/Prospekte/hautkleber.pdf 77
Fields of Application for Adesive Technologies
Book binding and envelopes
Book cover is
joined by spraying
the adhesive on
Bonding Technology
79
Advantages of Adhesive Bonding
Glass plate is
bonded to a
stainless steel
frame
Source: www.weicon.com/pages/de/download/prospekte/WEICON%20Elastische%20Klebstoffe.pdf 80
Advantages of Adhesive Bonding
Riveting AND
adhesive bonding
allows an optimal
load distribution
Even distribution of stresses and loads over the entire joint surface
Adhesive
Screwing
Bonding
Source: www.henkel.de/innovation/news-38208_20110722-auswahl-entscheidet-optimale-klebung-fuer-
industrielle-38978.htm 82
Advantages of Adhesive Bonding
Source: www.henkel.de/innovation/news-38208_20110722-auswahl-entscheidet-optimale-klebung-fuer-industrielle-38978.htm 83
Advantages of Adhesive Bonding
Source: www.henkel.de/innovation/news-38208_20110722-auswahl-entscheidet-optimale-klebung-fuer-
industrielle-38978.htm 84
Advantages of Adhesive Bonding
Sealing of an
engine case
Source: www.weicon.com/pages/de/download/prospekte/WEICON%20Elastische%20Klebstoffe.pdf 85
Advantages of Adhesive Bonding
The materails that are to be joined are not changed and keep their specific
characteristics
Adhesive
Joining Element
86
Advantages of Adhesive Bonding
Work-piece elements are not stressed thermically (as in welding, for example)
Source: www.hurnaus.de/schweissen.htm 87
Advantages of Adhesive Bonding
Sealing of a
container wall
Quelle: saba.nl/5/business-unit-bc/aktivitaeten/umweltschutz/tanks-und-silos.html 88
Advantages of Bonding Technology
Source: Brockmann 89
Advantages of Adhesive Bonding
Vibration
damping of
different elements
(here: Volvo)
Source: www.monstersandcritics.de/artikel/200941/article_157170.php 90
Advantages of Adhesive Bonding
Optical characteristics
Glass plate
connected to table
leg (here: UV-
curable adhesive)
91
Advantages of Adhesive Bonding
Source: www.directindustry.de/prod/master-bond/epoxid-klebstoffe-fur-die-elektronik-17407-398327.html 92
Advantages of Adhesive Bonding
Hardly or no gases
or suspended solids
in the working
environment
Source: www.hurnaus.de/schweissen.htm 93
Advantages of Adhesive Bonding
Weight savings
Interior Seat
constructions s
Electronics
Fixing
Monitors
elements
Source: Delo 94
Disadvantages of Adhesive Bonding
To continue the
production
process, the
adhesive needs
to cure partly or
completly
Source: www.welt.de/wissenschaft/article5620311.html 95
Disadvantages of Adhesive Bonding
Limited thermal resistance of the adhesive bond within the building element
Limits of different
basic materials for
adhesives
Source: Habenicht 97
Disadvantages of Adhesive Bonding
– Type of usage
– UV-light
– etc.
98
Disadvantages of Adhesive Bonding
Peeling stress
on a joint should
always be
avoided!
Source: www.henkel.de/innovation/news-38208_20110722-auswahl-entscheidet-optimale-klebung-fuer-
industrielle-38978.htm 99
Disadvantages of Adhesive Bonding
Either no repare or
only a very limited Problem: the surfaces
repare possible are not suitable for
(here: cohesion and adhesion any more
adhesion fracture)
Estimation is roughly
and theoretically
possible
but tests offer
more results
(here: resistance in
dependence to the
thickness of the
adhesive layer)
102
Disadvantages of Adhesive Bonding
103
Disadvantages of Adhesive Bonding
● Shortly after applying the adhesive low strength further work on bonding
element only possible in a certain state of hardness (takes time)
105
Thank you for your attention!
!
106