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Suggested Citation:"Front Matter." National Research Council. 1984. Reliability of Adhesive Bonds Under Severe Environments. Washington, DC: The National Academies Press. doi: 10.17226/19387.
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Suggested Citation:"Front Matter." National Research Council. 1984. Reliability of Adhesive Bonds Under Severe Environments. Washington, DC: The National Academies Press. doi: 10.17226/19387.
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Suggested Citation:"Front Matter." National Research Council. 1984. Reliability of Adhesive Bonds Under Severe Environments. Washington, DC: The National Academies Press. doi: 10.17226/19387.
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Suggested Citation:"Front Matter." National Research Council. 1984. Reliability of Adhesive Bonds Under Severe Environments. Washington, DC: The National Academies Press. doi: 10.17226/19387.
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Suggested Citation:"Front Matter." National Research Council. 1984. Reliability of Adhesive Bonds Under Severe Environments. Washington, DC: The National Academies Press. doi: 10.17226/19387.
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Suggested Citation:"Front Matter." National Research Council. 1984. Reliability of Adhesive Bonds Under Severe Environments. Washington, DC: The National Academies Press. doi: 10.17226/19387.
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Suggested Citation:"Front Matter." National Research Council. 1984. Reliability of Adhesive Bonds Under Severe Environments. Washington, DC: The National Academies Press. doi: 10.17226/19387.
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Page viii Cite
Suggested Citation:"Front Matter." National Research Council. 1984. Reliability of Adhesive Bonds Under Severe Environments. Washington, DC: The National Academies Press. doi: 10.17226/19387.
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Suggested Citation:"Front Matter." National Research Council. 1984. Reliability of Adhesive Bonds Under Severe Environments. Washington, DC: The National Academies Press. doi: 10.17226/19387.
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Suggested Citation:"Front Matter." National Research Council. 1984. Reliability of Adhesive Bonds Under Severe Environments. Washington, DC: The National Academies Press. doi: 10.17226/19387.
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Suggested Citation:"Front Matter." National Research Council. 1984. Reliability of Adhesive Bonds Under Severe Environments. Washington, DC: The National Academies Press. doi: 10.17226/19387.
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Suggested Citation:"Front Matter." National Research Council. 1984. Reliability of Adhesive Bonds Under Severe Environments. Washington, DC: The National Academies Press. doi: 10.17226/19387.
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Page xiii Cite
Suggested Citation:"Front Matter." National Research Council. 1984. Reliability of Adhesive Bonds Under Severe Environments. Washington, DC: The National Academies Press. doi: 10.17226/19387.
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NATIONAL RESEARCH COUNCIL COMMISSION ON ENGINEERING AND TECHNICAL SYSTEMS NATIONAL MATERIALS ADVISORY BOARD The purpose of the National Materials Advisory Board is the advancement of materials science and engineering in the national interest. CHAIRMAN Dr. Arden L. Bemem. Jr. Vice President. Technical Resources Science and Technology Department TRW, Inc. 23555 Euclid Ave. Cleveland. OH 44117 PAST CHAIRMAN Dr. Donald J. McPherson (Retired) Kaiser Aluminum & Chemical Corporation 1 ISO Monticello Road Lafayette. CA 94549 MEMBERS Dr. James C. Burrows Vice President Charles River Associates 2(X) Clarendon Street John Hancock Tower. 43rd Floor Boston, MA 02116 Dr. Raymond F. Decker Vice President, Research Michigan Technological University Houghton, MI 49931 Mr. Edward J. Dulis President Crucible Research Center Colt Industries Inc. P.O. Box 88 Pittsburg, PA 15230 Dr. James Economy Manager. Organic Polymer Research IBM Corporation K42-282 Monterey & Cottle Road SanJose.CA95.lJ4 Dr. Merlon C. Flemings Professor and Chairman Department of Materials Science and Engineering Massachusetts Institute of Technology Cambridge. MA 02139 Dr. Brian R.T. Frost Senior Metallurgist. Materials Science and Technology Division Argonne National Laboratory 9700 South Cass Avenue Argonne.lL 60439 Dr. Serge Gratch Director. Material and Chemical Sciences Laboratory Research Staff Ford Motor Company 2(XX) Rotunda Drive Dearborn, MI 48121 Dr. Paul J. Jorgensen Vice President SRI International 333 Ravenswood Avenue Menlo Park. CA 94025 Dr. Bernard H. Kear Senior Consultant Scientist Exxon Research & Engineering Co. Clinton Township Route 22E Annadale.NJ 08801 Dr. Alan Lawley Professor Metallurgical Engineering Drexel University Department of Materials Engineering Philadelphia. PA 19104 Dr. David L. Morrison President IIT Research Institute 10 W. 35th Si. Chicago. 1L 60616 Dr. David Okrent Professor of Engineering & Applied Science University of California. Los Angeles 5532 Boelter Hall Los Angeles, CA 90024 Dr. R. Byron Pipes Director. Center for Composite Materials Department of Mechanical and Aerospace Engineering University of Defaware Newark. DE 19711 Dr. Dennis W. Readey Professor and Chairman. Department of Ceramic Engineering Ohio State University 2041 College Road Columbus, OH 43210 Dr. James R. Rice Gordon McKay Professor of Engeering Sciences and Geophysics Harvard University Pierce Hall Cambridge. MA 02138 Dr. William P. Slichter Executive Director. Research Materials Science and Engineering Division AT&T Bell Laboratories 600 Mountain Avenue Murray Hill, NJ 07974 Dr. William A. Vogely Professor and Head Department of Mineral Economics Pennsylvania State University University Park, PA 16802 Dr. Robert P. Wei Professor of Mechanics Department of Mechanical Engineering and Mechanics Lehigh University Bethlehem, PA 18015 Dr. Albert R.C. Westwood Corporate Director Martin Marietta Labs Martin Marietta Corporation 1450 South Rolling Road Baltimore, MD 21227 NMAB STAFF K.M. Zwilsky. Executive Director S.M. Barkin. Associate Executive Director 8/84

SECURITY CLASSIFICATION Of THIS PAGE It REPORT SECURITY CLASSIFICATION Unclassified REPORT DOCUMENTATION PAGE 1b RESTRICTIVE MARKINGS 2» SECURITY CLASSIFICATION AUTHORITY Department of Defense 3 . DISTRIBUTION /AVAILABILITY OF REPORT 2b. DE CLASSIFICATION /DOWNGRADING SCHEDULE Cleared for Open Publication NMAB-422 S MONITORING ORGANIZATION REPORT NUMBER(S) &• NAME OF National National PERFORMING ORGANIZATION 6b OFFICE SYMBOL Materials Advisory Bd. (tf app//ca6<e; 7« NAME OF MONITORING ORGANIZATION Department of Defense National Aeronautics and Space Admin. 6c ADDRESS (Dry, State, »nd ZIP Code) 2101 Constitution Ave., N.W. Washington, D.C. 20418 Research Council NMAB 7o ADDRESS Ifitf. itate, and M Code) Washington, D.C. &». NAME OF FUNDING /SPONSORING 6b OFFICE SYMBOL ORGANIZATION Department of De- 0f app/icjote; fense, Nat. Aeronautics & Space DOD/NASA A^iin "1 ii 9 PROCUREMENT INSTRUMENT IDENTIFICATION NUMBER MDA-903-82-C-0434 Be ADDRESS (City, State, and ZIP Code) 10 SOURCE OF FUNDING 'NUMBERS Washington, D.C. 20301 PROGRAM PROJECT ELEMENT NO. NO. TASK WORK UN'T NO ACCESSION NO. 1 1 TITLE (Include Jetunty a»aifitfiion) Reliability of Adhesive Bonds Under Severe Environments (Unclassified) 12 PERSONAL AUTHOR(S) Committee on Reliability of Adhesive Bonds in Severe Environments Ua TYPE OF Final REPORT |l3b TIME COVERED 1 FROM 2/1/84 TO 7/31/85 4 DATE Of REPORT (Tear. Month, Day} Fs PAGE COUNT December 1, 1984 1 62 16 SUPPLEMENTARY NOTATION 17 COSATi CODES 16 SUBJECT TERMS (Continue on reverie if neceoary and identify by block number) FIELD GROUP SUB-GROUP Adhesives Fini te element analysis NDE dity Polvmers rfaces Stress analysis anics Surfaces 1 Chemistry Hum! 19 ABSTRACT (Continue on rtverte if neceaary and identify by Wort number) Fatigue Mech A workshop organized by a National Research Council committee and entitled "Reliability of Adhesive Bonds in Severe Environments" was attended by about 100 invited experts. The detailed findings, reported herein, include the recommendation that the federal government spearhead a major effort to overcome the open issues that currently prevent the reliable structural use of adhesive bonding in severe environments. A pervasive comment was that the interdisciplinary nature of the subject requires close interaction of the experts on the chemistry, interphase science, and mechanics of adhesive bonds. 20 DISTRIBUTION /AVAILABILITY OF ABSTRACT D UNCLASSIFIED/UNLIMITED EPSAME AS RPT. D DTlC USERS 21. ABSTRACT SECURITY CLASSIFICATION Unclassified 22* NAME OF RESPONSIBLE INDIVIDUAL 22b TELEPHONE (Inc/iide Are* Code) (202) 695-0005 22c. OFFICE SYMBOL DOD Jerome Persh DD FORM 1473. M MAR " APR «5rtion may be u**d unt.l eihausted. JECURITY CLASSIFICATION OF THIS PAGE Unclassified

RELIABILITY OF ADHESIVE BONDS UNDER SEVERE ENVIRONMENTS Report of the Committee on Reliability of Adhesive Bonds in Severe Environments NATIONAL MATERIALS ADVISORY BOARD Commission on Engineering and Technical Systems National Research Council NAS-NAE Publication NMAB-422 -10 HQQ National Academy Press DEC 1 3 IjO 1984 LIBRARY

TP °C7o ,0V) \w*\ c-t NOTICE: The project that is the subject of this report was approved by the Governing Board of the National Research Council, whose members are drawn from the councils of the National Academy of Sciences, the National Academy of Engineering, and the Institute of Medicine. The members of the committee responsible for the report were chosen for their special competencies and with regard for appropriate balance. The report has been reviewed by a group other than the authors according to procedures approved by a Report Review Committee consisting of members of the National Academy of Sciences, the National Academy of Engineering, and the Institute of Medicine. The National Research Council was established by the National Academy of Sciences in 1916 to associate the broad community of science and technology with the Academy's purposes of furthering knowledge and of advising the federal government. The Council operates in accordance with general policies determined by the Academy under the authority of its congressional charter of 1863, which established the Academy as a private, nonprofit, self-governing membership corporation. The Council has become the principal operating agency of both the National Academy of Sciences and the National Academy of Engineering in the conduct of their services to the government, the public, and the scientific and engineering communities. It is administered jointly by both Academies and the Institute of Medicine. The National Academy of Engineering and the Institute of Medicine were established in 1964 and 1970, respectively, under the charter of the National Academy of Sciences. This study by the National Materials Advisory Board was conducted under Contract No. MDA 903-82-C-0434 with the Department of Defense and the National Aeronautics and Space Administration. This report is for sale by the Defense Technical Information Center, Cameron Station, Alexandria, Virginia 22312. Printed in the United States of America. ii

ABSTRACT A workshop organized by a National Research Council committee and entitled "Reliability of Adhesive Bonds in Severe Environments" was attended by about 100 invited experts. The detailed findings include the recommendation that the federal government spearhead a major effort to overcome the issues that currently prevent the reliable structural use of adhesive bonding in severe environments. A pervasive comment was that the interdisciplinary nature of the subject requires close interaction of the experts on the chemistry, interphase science, and mechanics of adhesive bonds. 111

COMMITTEE ON RELIABILITY OF ADHESIVE BONDS IN SEVERE ENVIRONMENTS Chairman SERGE GRATCH, Director, Material and Chemical Sciences Laboratory, Ford Motor Company, Dearborn, Michigan Members HALBERT F. BRINSON, Chairman, Center for Adhesion Science, Virginia Polytechnic Institute and State University, Blacksburg K. LAWRENCE DEVRIES, Professor and Chairman, College of Engineering, University of Utah, Salt Lake City ALAN N. GENT, Professor, Institute of Polymer Sciences, University of Akron, Ohio LIENG-HUANG LEE, Senior Scientist, Xerox Corporation, Webster, New York JAMES S. NOLAND, Manager, Engineered Materials Department, American Cyanamid Co., Stamford, Connecticut JOHN D. VENABLES, Associate Director, Martin Marietta Laboratories, Baltimore, Maryland Liaison Representatives ROBERT REEBER, Army Research Office, Research Triangle Park, North Carolina STANLEY E. WENTWORTH, Research Chemist, Army Materials and Mechanics Research Center, Watertown, Massachusetts LEIGHTON H. PEEBLES, JR., Senior Polymer Chemist, Office of Naval Research, Arlington, Virginia LAWRENCE T. DRZAL, Air Force Wright Aeronautical Laboratory, Wright-Patterson Air Force Base, Ohio BEN A. WILCOX, Defense Advanced Research Projects Agency, Arlington, Virginia ROBERT J. REYNIK, Section Head, Metallurgy, Polymers, and Ceramics Section, National Science Foundation, Washington, D.C. WILLIAM S. JOHNSON, NASA-Langley Research Center, Hampton, Virginia

JEROME PERSH, Staff Specialist, Materials and Structures, Office of Deputy Under Secretary for Defense for R&E (ET), The Pentagon, Washington, D.C. NMAB STAFF JOSEPH R. LANE, Staff Metallurgist vi

ACKNOWLEDGMENTS The contributions of the workshop participants are noted with thanks. Major functions were performed by the committee members and liaison representatives. In addition, the following had leadership roles: G. R. Hamed, P. M. Hergenrother, M. F. Kanninen, J. E. McGrath, and J. P. Wightman. These and many others not only contributed during the workshop but also provided important advance input.* The workshop benefited from a program review/workshop held by the Center for Adhesion Science at the Virginia Polytechnic Institute and State University immediately before the NMAB workshop.** *Two background papers used in the NMAB workshop may be obtained from Dr. K. L. DeVries of the University of Utah and from Dr. L. H. Lee of Xerox Corporation. **Additional information on this workshop may be obtained from Professor H. F. Brinson, Virginia Polytechnic Institute and State University. vii

CONTENTS Page 1 SUMMARY 1 2 INTRODUCTION 3 3 RECOMMENDATIONS 5 Chemistry 5 Interphases 6 Mechanics 7 4 INTERESTS AND ACTIVITIES OF THE DEPARTMENT OF 9 DEFENSE AND THE NATIONAL AERONAUTICS AND SPACE ADMINISTRATION 5 STATE OF THE ART: CHEMISTRY 13 Extreme High Temperatures 13 Extreme Low Temperatures 14 Extreme High Humidity 14 Seawater 14 Other Factors 14 6 STATE OF THE ART: INTERFACES (INTERPHASES) 17 Current Research 19 7 STATE OF THE ART: MECHANICS 21 8 SUMMARY OF DISCUSSION: CHEMISTRY 27 538 to 760°C (1000 to 1400°F) Adhesives 27 288 to 371°C (550 to 700°F) Adhesives 28 177 to 232°C (350 to 450°F) Adhesives 28 23 to 93°C (73 to 200°F) Adhesives 29 -240 to -54°C (-400 to -65°F) Adhesives 29 General Recommendations 29 9 SUMMARY OF DISCUSSION: INTERFACES 31 Surface Preparation 32 Nature of the Interphase 33 Bond Durability 34 10 SUMMARY OF DISCUSSION: MECHANICS 35 Nondestructive Evaluation 36 Test Methods 36 Stress Analysis 37 Finite Element Analysis 37 Failure Mechanisms 37 ix

APPENDIX I Workshop Purpose and Program 39 APPENDIX II Attendees 41 APPENDIX III Overview of Adhesion Science Program 47 Review/Workshop at Virginia Polytechnic Institute and State University APPENDIX IV Biographical Sketches of the Committee 51

PARTICIPANTS Serge Gratch Chairman at the WORKSHOP C. Lynn Mahoney Lawrence T. Drzal

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