Adhesive Bonding: ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Adhesive Bonding
Joining process in which a filler material is used

to hold two (or more) closely‑spaced parts
together by surface attachment
 Used in a wide range of bonding and sealing
applications for joining similar and dissimilar
materials such as metals, plastics, ceramics,
wood, paper, and cardboard
 Considered a growth area because of
opportunities for increased applications
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Terminology in Adhesive Bonding
 Adhesive = filler material, nonmetallic, usually
a polymer
 Adherends = parts being joined
 Structural adhesives – of greatest interest in
engineering, capable of forming strong,
permanent joints between strong, rigid
adherends
Curing in Adhesive Bonding
Process by which physical properties of the
adhesive are changed from liquid to solid,
usually by chemical reaction, to accomplish
surface attachment of parts
 Curing often aided by heat and/or a catalyst
 If heat used, temperatures are relatively low
 Curing takes time ‑ a disadvantage in
production
 Pressure sometimes applied between parts to
activate bonding process
Joint Strength
 Depends on strength of:
 Adhesive
 Attachment between adhesive and
adherends
 Attachment mechanisms:
 Chemical bonding – adhesive and
adherend form primary bond on curing
 Physical interactions - secondary bonding
forces between surface atoms
 Mechanical interlocking - roughness of
adherend causes adhesive to become
entangled in surface asperities
Joint Design
 Adhesive joints are not as strong as welded,
brazed, or soldered joints
 Joint contact area should be maximized
 Adhesive joints are strongest in shear and
tension
 Joints should be designed so applied
stresses are of these types
 Adhesive bonded joints are weakest in
cleavage or peeling
 Joints should be designed to avoid these
types of stresses
Types of Stresses in Adhesive Bonding
Figure 32.10 Types of stresses that must be

considered in adhesive bonded joints: (a) tension,
(b) shear, (c) cleavage, and (d) peeling.
Joint Designs in Adhesive Bonding
Figure 32.11 Some joint designs for adhesive bonding: (a) through
(d) butt joints; (e) through (f) T‑joints; (b) and (g) through (j) corner
joints.
Adhesive Types
 Natural adhesives - derived from natural
sources, including gums, starch, dextrin, soya
flour, collagen
 Low‑stress applications: cardboard cartons,
furniture, bookbinding, plywood
 Inorganic - based principally on sodium silicate
and magnesium oxychloride
 Low cost, low strength
 Synthetic adhesives - various thermoplastic
and thermosetting polymers
Synthetic Adhesives
 Most important category in manufacturing
 Synthetic adhesives cured by various
mechanisms:
 Mixing catalyst or reactive ingredient with
polymer prior to applying
 Heating to initiate chemical reaction
 Radiation curing, such as UV light
 Curing by evaporation of water
 Application as films or pressure‑sensitive
coatings on surface of adherend
Applications of Adhesives
 Automotive, aircraft, building products,
shipbuilding
 Packaging industries
 Footwear
 Furniture
 Bookbinding
 Electrical and electronics
Surface Preparation
 For adhesive bonding to succeed, part
surfaces must be extremely clean
 Bond strength depends on degree of
adhesion between adhesive and adherend,
and this depends on cleanliness of surface
 For metals, solvent wiping often used for
cleaning, and abrading surface by
sandblasting improves adhesion
 For nonmetallic parts, surfaces are
sometimes mechanically abraded or
chemically etched to increase roughness
Application Methods
 Manual brushing and rolling
 Silk screening
 Flowing, using manually operated dispensers
 Spraying
 Automatic applicators
 Roll coating
Advantages of Adhesive Bonding
 Applicable to a wide variety of materials
 Bonding occurs over entire surface area of joint
 Low temperature curing avoids damage to
parts being joined
 Sealing as well as bonding
 Joint design is often simplified, e.g., two flat
surfaces can be joined without providing
special part features such as screw holes
Limitations of Adhesive Bonding
 Joints generally not as strong as other joining
methods
 Adhesive must be compatible with materials
being joined
 Service temperatures are limited
 Cleanliness and surface preparation prior to
application of adhesive are important
 Curing times can limit production rates
 Inspection of bonded joint is difficult

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Adhesive Bonding

Joining process in which a filler material is used

Figure 32.10 Types of stresses that must be

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