Designation: D 3163 – 01

Standard Test Method for

Determining Strength of Adhesively Bonded Rigid Plastic
Lap-Shear Joints in Shear by Tension Loading1
This standard is issued under the fixed designation D 3163; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (e) indicates an editorial change since the last revision or reapproval.

1. Scope can be compared. This test method is intended to meet such a

1.1 This test method is intended to complement Test Method need.
D 1002 and extend its application to single-lap shear adhesive 4.2 This test method is limited to test temperatures below
joints of rigid plastic adherends. The test method is useful for the softening point of the subject adherends, and is not
generating comparative shear strength data for joints made intended for use on anisotropic adherends such as reinforced
from a number of plastics. It can also provide a means by plastic laminates.
which several plastic surface treatments can be compared. 4.3 The misuse of strength values obtained from this test
1.2 The values stated in SI units are to be regarded as the method as allowable design-stress values for structural joints
standard. The values in parentheses are for information only. could lead to product failure, property damage, and human
1.3 This standard does not purport to address all of the injury. The apparent shear strength of an adhesive obtained
safety concerns, if any, associated with its use. It is the from a given small single-lap specimen may differ from that
responsibility of the user of this standard to establish appro- obtained from a joint made with different adherends or by a
priate safety and health practices and determine the applica- different bonding process. The normal variation of temperature
bility of regulatory limitations prior to use. and moisture in the service environment causes the adherends
and the adhesive to swell and shrink. The adherends and
2. Referenced Documents adhesive are likely to have different thermal and moisture
2.1 ASTM Standards: coefficients of expansion. Even in small specimens, short-term
D 907 Terminology of Adhesives2 environmental changes can induce internal stresses or chemical
D 1002 Test Method for Apparent Shear Strength of Single- changes in the adhesive that permanently affect the apparent
Lap-Joint Adhesively Bonded Metal Specimens by Ten- strength and other mechanical properties of the adhesive. The
sion Loading (Metal-to-Metal)2 problem of predicting joint behavior in a changing environ-
D 2093 Practice for Preparation of Surfaces of Plastics Prior ment is even more difficult if a different type of adherend is
to Adhesive Bonding2 used in a larger structural joint than was used in the small
D 4896 Guide for Use of Adhesive-Bonded Single Lap- specimen.
Joint Specimen Test Results2 4.3.1 The apparent shear strength measured with a single-
lap specimen is not suitable for determining allowable design
3. Terminology stresses for designing structural joints that differ in any manner
3.1 Definitions—Many of the terms used in this test method from the joints tested without thorough analysis and under-
are defined in Terminology D 907. standing of the joint and adhesive behaviors.
4.3.2 Single-lap tests may be used for comparing and
4. Significance and Use selecting adhesives or bonding processes for susceptibility to
4.1 Due to the increased use of adhesive-bonded plastics as fatigue and environmental changes, but such comparisons must
a result of the inherent advantages afforded by bonded rather be made with great caution since different adhesives may
than mechanically fastened joints, particularly the alleviation respond differently in different joints. See Guide D 4896 for
of stress raisers and stress cracking, there is a need for standard further discussion of the concepts relative to interpretation of
tests by which joints of various plastic substrates and adhesives adhesive bonded single-lap joints.
5. Apparatus
5.1 Testing Machine, conforming to the requirements of and
1
This test method is under the jurisdiction of ASTM Committee D14 on having the capabilities of the machine prescribed in Test
Adhesives and is the direct responsibility of Subcommittee D14.40 on Adhesives for Method D 1002. The grips are self-aligning and capable of
Plastics.
Current edition approved March 10, 2001. Published May 2001. Originally
securely grasping the specimen throughout the test, without
published as D 3163 – 73. Last previous edition D 3163 – 96. allowing the specimen to slip.
2
Annual Book of ASTM Standards, Vol 15.06.

Copyright © ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959, United States.

1
 D 3163
5.2 Temperature-Controlling Equipment, capable of main- temperature does not adversely affect the mechanical proper-
taining the test temperature to 63°C (65°F). If ambient ties of the adherends.
laboratory conditions are employed the same degree of control 6.4 Cut test specimens from the bonded panels pictured in
is required. Fig. 1. Cut the specimens without overheating or otherwise
physically damaging the adherend or bonded interface. Indi-
6. Test Specimen vidual specimens may also be prepared if desired.
6.1 Make specimens that conform to the form and dimen-
sions set forth in Test Method D 1002 where possible. How- 7. Procedure
ever, due to the low yield points in plastics compared with 7.1 Place the specimens in the grips of the testing machine
those of metals, it may not always be feasible to limit test so that the applied load coincides with the long axis of the test
specimen geometry to that called for in Test Method D 1002. specimen. Load the specimen to failure at a rate of 8.3 to 9.7
Therefore adherend thicknesses and joint overlaps must be MPa (1200 to 1400 psi) of shear area per minute (approxi-
chosen so that failure occurs preferentially in the joint and not mately 0.05 in./min cross head speed).
in the substrate. Thicker adherends allow the stress on the
7.2 Condition specimens for definite periods of time under
bonded area to be increased, before either tensile failure or
specified conditions before testing if desired. After condition-
yield occurs in the adherend. Recognize, however, that depend-
ing, it is recommended that all specimens be stabilized in the
ing on the surface treatment and adhesive used, the bond
test environment for 1 h before testing.
strength may often be greater than the tensile yield strength of
the adherend. Use data collected by this test method only for 8. Calculation
comparative purposes when the investigator is certain that the
specimen configurations and joint geometries of the specimens 8.1 Calculate the bond area to the nearest 0.06/cm2 (0.01
being compared are identical. in.2). Record both load at failure and type of failure (percent
6.2 The surface preparation used on the adherend depends cohesive and apparent adhesive). Calculate failing stress as
on the subject plastic adherend. Procedures such as those megapascals (pounds force per square inch) of shear area.
recommended in Practice D 2093 serve as a useful guide.
6.3 Apply the adhesives in accordance with the manufac- 9. Report
turer’s recommendations. Choose adhesives such that the cure 9.1 Report the following information:

FIG. 1 Standard Test Panel and Specimen Configuration

2
 D 3163
9.1.1 Complete identification of the adhesive tested, includ- method of obtaining the thickness of the adhesive layer
ing type, source, date manufactured, manufacturer’s code including procedure, location of measurements, and range of
number, form, etc. measurements.
9.1.2 Complete identification of the plastic used, its thick-
ness, and the method of cleaning and preparing its surface prior NOTE 1—The length of overlap, L, may be varied where necessary. The
length of the test specimen in the jaws, however, must not be varied. The
to bonding.
distance from the end of the overlap to the end of the jaws should be 63
9.1.3 Method of adhesive application (brush, spray, roller mm (21⁄2 in.) in all tests.
coat, tape, etc.).
NOTE 2—The thickness of the adherend, t, may be varied to strengthen
9.1.4 Conditions present at time of bonding (temperature, the adherend relative to the strength of the bonded area. A maximum
etc.). thickness of 4.76 mm (3⁄16in.) is recommended, however, to minimize the
9.1.5 Length of overlap used. effects of offset.
9.1.6 Conditioning of joint prior to testing.
9.1.7 Maximum, minimum, and average values of the fail- 10. Precision and Bias
ing load.
10.1 The precision and bias statement for this test method
9.1.8 Number of test specimens tested.
has not yet been determined. Archival and round-robin infor-
9.1.9 Type of failure. Include estimated percent cohesion
mation is being reviewed, and the results are expected by
failure, unbonded area, apparent failure in adhesion, and failure
September 2004.
in the adherend.
9.1.10 Test temperature employed.
11. Keywords
9.1.11 Average thickness of adhesive layer after formation
of the joint, within 0.0127 mm (0.0005 in.). Describe the 11.1 adhesive bonds; plastic; shear strength; tension

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