Evaluation Of Mechanical Properties Of Inorganic Based Composities Adhesive By Experimental Method.

SUPERVISOR DECLARATION

“I hereby declared that I have read this thesis and in my opinion this report is sufficient in Terms of scope and quality for the award of the degree of

Bachelor of Mechanical Engineering (Structures-Material)”

Signature : ……….

Supervisor’s Name : Nor Liana Binti Salleh

Date : ……….

Signature : ………. Supervisor’s Name : Mohd Zaid Bin Akop

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EVALUATION OF MECHANICAL PROPERTIES OF INORGANIC BASED COMPOSITIES ADHESIVE BY EXPERIMENTAL METHOD

HAMZAITUL AKMARIZAL BIN HAMDAN

This report submitted in accordance with requirement for the Bachelor Degree of Mechanical Engineering (Structure and Material)

Faculty of Mechanical Engineering Universiti Teknikal Malaysia Melaka

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“I hereby declare that the work in this report is my own except for summaries and quotations which have been duly acknowledged.”

Signature : ...

Author : Hamzaitul Akmarizal Bin Hamdan Date : ...

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Special for

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ACKNOWLEDGEMENTS

Bismillah al rahman al rahim. In the name of Allah, I was very thankful because were able to faced any challenge while working on this Projek Sarjana Muda report. I very glad were given strength and patience for finish this report.

My deepest appreciation to Cik Nurliana Salleh because willing to take me as her PSM student, supports and cooperates with me to successfully complete my reports. As a lecturer and my supervisor, thank for taking some time of her busy schedule to guide me. I also like to extend my gratitude to Puan Zakiah and Mr Azrin Ahmad as my presentation panel for their intellectual comments and bright ideas to make my report better.

I’m also obliged to everyone who had directly and indirectly involve through contributions of ideas especially for my beloved family as well as materials supports and professional opinions. I would also like to thank all the friends for their co-operation during my studies session and their moral support and valuable help. Thank you.

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ABSTRAK

Perekat komposit berunsurkan bukan organik telah menjadi jenis perekat yang penting sekarang. Sambungan perekat amat sensitive terhadap rawatan permukaan, suhu servis , kelembapan dan keadaan persekitatan yang lain. Ia begitu susah untuk menentukan lingkungan tebal yang sesuai yang memenuhi keperluan mekanikal. Dalam pengajian ini, sifat – sifat mekanikal pengikatan perekat akan di nilai dengan menggunakan kaedah eksperimen. Bahan ujikaji di dalam suhu bilik akan di uji dengan kaedah ujian ketegangan. Keluli tahan karat SU 303 dengan 3 ketebalan berbeza akan di bina dan diuji. Kesan sifat-sifat mekanikal, ketebalan perekat dan suhu bahan ujikaji diuji berdasarkan standard ASTM. Mesin Ujikaji Universal (INSTRON Model 5585) akan digunakan sebagai mesin ujikaji utama. Terdapat 12 bahan ujikaji digunakan untuk 4 ketebalan perikat yang berbeza. Untuk bahan ujikaji di mana ketebalan perikat adalah 0.1 mm, 0.3 mm, 0.5 mm dan 0.7 mm, keputusan ujikaji ketegasan adalah 4.2 MPa, 11.2 MPa, 14.4 MPa dan 16.2 MPa. Ini jelas menunjukkan bahawa apabila ketebalan perikat meningkat, kekuatan sambungan juga meningkat. Ini bermaksud perikat yang tebal menghasilkan sambungan yang lebih kuat.

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ABSTRACT

Inorganic based composites adhesive become one of the most important adhesive types now. Adhesive joints are very sensitive to surface treatments, service temperature, humidity and other environmental condition. It also hard to determine the suitable range of thickness range that fulfill the mechanical requirement. In this study, the mechanical properties of adhesive bonding will be evaluated by experimental method. Same specimen temperature with different thickness will be tested using tensile testing method. 3 different thickness of adhesive by using stainless steel SU 303 as specimen were manufacture and tested. Effect of material properties, adhesive thickness, and specimen temperature is tested using ASTM standard. Universal Testing Machine (INSTRON Model 5585) will be used as main testing machine. There were 12 specimen used for 4 different adhesive thickness. For specimen which adhesive thickness were 0.1 mm, 0.3 mm, 0.5 mm and 0.7 mm, the tensile stress results were 4.2 MPa, 11.2 MPa, 14.4 MPa and 16.2 MPa. That clearly shows that, when the adhesive thickness increases, strength of the joint will be increase. That means, the thicker adhesive layer, the stronger joining will produce

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TABLE OF CONTENT

CONTENT PAGES

TITLE i

DECLARATION ii

DEDICATION iii

ACKNOWLEDGEMENT iv

ABSTRACT v

ABSTRAK vi

LIST OF TABLE x

LIST OF FIGURE xi

LIST OF APPENDIX xv

CHAPTER 1 INTRODUCTION 1

1.1 Background of Study 1

1.2 Problem Statement 2

1.3 Objective of Study 3

1.4 Scope of Study 3

CHAPTER 2 LITERATURE REVIEW 4

2.1 Introduction of Adhesive Bonding Strength 4

2.2 Adhesive Strength with Different Thickness

and Length 5

2.3 Testing of Adhesive 10

2.4 Shear Test 11

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2.5 Stress Distribution: Bond Thickness 13

2.6 Stress Distribution: Mode of Failure 14

2.7 Industrial Applications of Adhesives 16

CHAPTER 3 METHODOLOGY 18

3.1 Material Selection 18

3.2 Single Lap Joint Specimen 19

3.2.1 Significance and Use 19

3.2.2 Mechanical Properties of Specimen

Joints 20

3.2.3 Specimen Dimension 21

3.3 Specimen Surface Preparation 21

3.3.1 Preparation Handling 22

3.3.2 Preparation Procedures 22

3.4 Test Method for Tensile Properties of

Adhesive Bonds 23

3.4.1 Test Specimen and Adhesive 24

3.4.2 Procedures 24

3.4.3 Reports 25

3.5 Tensile Test 25

3.5.1 Tensile Test Machine 26

3.5.2 Universal Testing Machine

(INSTRON 5585) 27

3.6 Specimen Preparations 28

3.6.1 Specimen Milling Process 29

3.6.2 Vertical Milling Machine 30

3.6.3 Milling Methodology 35

3.6.4 Specimen after Milling Process 36

3.6.5 Safety Measures 38

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3.8 Experimental Procedure 42

CHAPTER 4 RESULTS 44

4.1 Tensile Test 44

4.2 Experimental Results 45

4.2.1 Test Results for Adhesive

Thickness 0.1 mm 45

4.2.2 Test Results for Adhesive

Thickness 0.3 mm 48

4.2.3 Test Results for Adhesive

Thickness 0.5 mm 51

4.2.4 Test Result for Adhesive

Thickness 0.7 mm 54

4.3 Comparison between Each Results 57

CHAPTER 5 DISCUSSION 58

5.1 Results Analysis 58

5.1.1 Tensile Test Results Analysis 58

5.1.2 Adhesive Main Ingredient 59

5.1.3 Adhesive Behaviors 59

5.1.4 Voids in Adhesive Layer 61

5.2 Criteria of Adhesive Failure 62

5.2.1 Cohesive Fracture in Adhesive Layer 63

CHAPTER 6 CONCLUSION 66

6.1 Conclusion 66

6.2 Recommendation 67

REFERENCES 68

BIBLIOGRAPHY 70

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LIST OF TABLE

NUM TITLE PAGES

Table 2.1: ASTM and BS classification 13

(Source: ASTM and BS Standard)

Table 3.1: Mechanical Properties of Specimen Joints 20

(Source: Shirley, 2005)

Table 3.2: Adhesive Thickness vs Milling Area Thickness 30

Table 4.1: Tensile Test Result for 0.1mm Adhesive Thickness 46

Table 4.2: Tensile Test Result for 0.3mm Adhesive Thickness 49

Table 4.3: Tensile Test Result for 0.5mm Adhesive Thickness 52

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LIST OF FIGURE

NUM TITLE PAGES

Figure 2.1: Tensile test specimen and stress strain curve 6

(Source: Jae, H.P et al, 2009)

Figure 2.2: Manufactured an adhesive joint specimen 7

(Source: Jae, H.P et al, 2009)

Figure 2.3: Experimental failure load of adhesive joints of

different adhesive thickness 8

(Source: Jae, H.P et al, 2009)

Figure 2.4: Experiment failure load of adhesive joints of

different adhesive lenghts 9

(Source: Jae, H.P et al, 2009)

Figure 2.5: Variation of shear modulus and loss tangent with the temperature for an epoxy resin cured for different

times at 160 °C 11

(Source: Kim and Kedward, 2001)

Figure 2.6 (a) shear deformation (b) lap joint (c) torsional joint 11

(Source: Adam and Peppiatt, 1974)

Figure 2.7 Altering the loading mode can result in (clockwise

from top left) cohesive, interfacial, alternating and oscillating 15 (Source: Erdogan and Aydinogluy, 1982).

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Figure 2.8 Crack tends to grow perpendicular to the largest tensile stress, a shear stress state has a tendency to drive cracks in different directions. (Line arrows show stresses, open arrows

show crack propagation tendency) 16

(Source: Erdogan and Aydinogluy, 1982).

Figure 2.9: Typical applications of adhesive in car body 17

(Source Jethwa and Kinloch, 1996).

Figure 3.1: Single Lap Joint 20

Figure 3.2: Single Lap Joint 21

Figure 3.3: Universal Testing Machine (INSTRON Model 5585) 27

Figure 3.4: Specimen SS 304 25mm x 100mm x 7mm 29

Figure 3.5: Specimen before and after Milling Process 29

Figure 3.6: Edge Finder 31

Figure 3.7: Face Mills 31

Figure 3.8: Centre Drills 32

Figure 3.9: Drill 32

Figure 3.10: Roughing 33

Figure 3.11 End Mill 33

Figure 3.12: Counter Bore 34

Figure 3.13: Counter Sink 34

Figure 3.14 Vertical Milling Machine 35

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Figure 3.16: Specimen for 0.3mm adhesive thickness 36

Figure 3.17: Specimen for 0.5mm adhesive thickness 37

Figure 3.18: Specimen for 0.7mm adhesive thickness 37

Figure 3.19: Aron Ceramic C Adhesive 39

Figure 3.20: Adhesive were placed at the clean surface 40

Figure 3.21: The specimen were left in room temperature 40

Figure 3.22: Heating Oven 41

Figure 3.23: Heating Temperature 90 °C 41

Figure 3.24: Specimen were taken out from the oven for atural cooling 42

Figure 3.25: Adhesive condition after experiment 43

Figure 4.1: Tensile Test Graph for 0.1mm Adhesive Thickness 45

Figure 4.2: Tensile Test Graph for 0.3mm Adhesive Thickness 48

Figure 4.3: Tensile Test Graph for 0.5mm Adhesive Thickness 51

Figure 4.4: Tensile Test Graph for 0.7mm Adhesive Thickness 54

Figure 4.5: Load at Break for each adhesive thickness 57

Figure 4.6: Tensile Stress for each adhesive thickness 57

Figure 5.1: Stress-Strain Curve for Ductile and Brittle Materials 60

Figure 5.2: Adhesive Layer after Tensile Test 61

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Figure 5.4: Adhesive Layer after experiment 64

Figure 5.5: Cohesive in the middle 65

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LIST OF APPENDIX

NUM TITLE PAGES

1 Appendix A: Flow Chart 71

2 Appendix B: PSM Gantt Chart 72

3 Appendix C: Aron Ceramic C Specification 73

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CHAPTER 1

INTRODUCTION

1.1 Background of Study

Heading to the end of the 2010, the development of composites as adhesive materials become more and more important. An inorganic based composite enters new level and play a bigger role in structure joints. Commonly, the available joining methods can be classified into two types, mechanical and adhesive. Adhesive joints do not require holes and they distribute load over a large area than mechanical joints.

Compare to mechanical joints like fastened, adhesive joints are stronger. Mechanical fastening can only achieve a maximum tensile strength of 50% of the weakest adherend in the joint due to the stress concentrations caused by the fastener holes. In comparison, adhesively bonded joints can achieve in excess of 80% of the tensile strength of the weakest adherend even with a simple single-shear configuration However; adhesive joints are very sensitive to surface treatments, service temperature, humidity and other environmental conditions.

There a long list that can become the factor that can cause the failure of the adhesive bonding. One of the factors is cohesive fracture. Cohesive fracture is obtained if a crack propagates in the bulk polymer which constitutes the adhesive. In this case the

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surfaces of both adherents after debonding will be covered by fractured adhesive. The crack may propagate in the centre of the layer or near an interface. Others factor is interfacial fracture. Cohesive fracture is obtained if a crack propagates in the bulk polymer which constitutes the adhesive. In this case the surfaces of both adherents after debonding will be covered by fractured adhesive. The crack may propagate in the centre of the layer or near an interface.

1.2 Problem Statement

Adhesive joints are often the weakest link at the structure joints. Adhesive joints are very sensitive to surface treatments, service temperature, humidity and other environmental condition. To overcame and get the full performance from adhesive joints, it requires a specific adhesive joint design, enhancing its performance and reducing its limitations.

There have many factors that influence the mechanical properties of the adhesive bonding. The two main factors are the thickness of the adhesive and the specimen/object temperature. The main problem is to find the suitable thickness range that fulfill the mechanical requirements and guarantee for a suitable reliability. The results of this study will has a clear economic impact on the manufacturing processes because if the result of the study show that the less thickness of the adhesive produce the higher bonding strength, it will save adhesive materials cost.

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1.3 Objective of Study

The main objective are this study is to make a research about mechanical properties of inorganic based composites adhesive. In this study, the strength of the inorganic based composites will be tested based on the thickness of the adhesive bonding and the specimen temperature. The objective of this study is:

i. To evaluate the mechanical properties of Inorganic Based Composites adhesive

at room temperature.

ii. To study the influences of the adhesive thickness to the mechanical properties of the bonding joints.

iii. To used the appropriate experimental method to evaluate the result of the adhesive thickness to the bonding joints

1.4 Scopes of Study

To make this study more specific and details, there were some scopes must be considered as well:

i. Focusing on single lap joint will be tested in experimental method

ii. Using SUS 304 as specimen material

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CHAPTER 2

LITERATURE REVIEW

2.1 Introduction of Adhesive Bonding Strength

The true strength of an adhesive is a material property independent of the geometry, adherend properties and load and is a good starting point for determining an allowable design stress. Allowable stresses in shear and tension are needed to design safe, efficient, adhesively bonded joints and structures. The composite adhesives become very important research now.

Many researchers have studies and investigate this adhesive joint. Jae-Hyun Park, Park Jin-Ho Choi and Jin-Hwe Kweon (Jae, H.P et al. 2009) studies the evaluating the strengths of thick aluminum to aluminum joints with different adhesive lengths and thickness. Do Won Seo and Jae Kyoo Lim (Do, W.S et al, 2005) investigates tensile, bending and shear strength distributions of adhesive of adhesive-bonded butt joint specimen. They carried an experiment in order to provide the statistical data with strength evaluation methods: tensile, shear and four-point bending

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tests for thermosetting epoxy resin based adhesive-bonded butt joints. The certification of the probability in the adhesive is evaluated.

Jose M. Arenas, Julian J. Narbon and Cristina Alia (Arenas, J.M et al, 2009) investigate optimum adhesive thickness in structural adhesives joints using statistical techniques based on Weilbull distribution. The experiment study consisted of a shear tensile strength test of 20 specimen representative of each thickness of adhesive considered (7 thickness of between 0.2 mm and 0.8 mm) following standard UNE-EN 1465 on the determination of the shear strength of single lap joints adhesively bonded with rigid substrates.

Kim KS, Yoo JS, Yi YM (Kim. K.S et al, 2006) studies failure mode and strength of indirectional composite single lap bonded joints with different bonding methods They investigated how best to predict the strength of a single adhesive lap

joints. Owens James and Sullivian(James and Sullivian, 2000) analyzed and tested the

modulus of an single lap joint composed of composite material and aluminum.

Karl E Hokanson and Avram Bar-Coben (Hokanson and Coben, 1995) studies a

shear-based optimization of adhesive thickness for die bonding. Choi JH and Lee (Choi and Lee, 1994) investigate the torque transmission capabilities of the adhesive bonded tubular single lap joint and the double lap joint. Hart-Smith LJ (Smith, 1985) designing to minimize peel stresses in adhesive bonded joints. He proposed a maximum strain failure criterion to predict failure loads for a given adhesive joint.

2.2 Adhesive Strength with Different Thickness and Length

Jae-Hyun Park, Park Jin-Ho Choi and Jin-Hwe Kweon in their studies in 2009 used 8 different lengths and 4 adhesive thicknesses to test and analyze the strengths of single lap joints made of thick aluminum adherends. Aluminum alloy 660-T6 and FM73 M epoxy adhesive film were used. Elastic modulus of adhesive is 4.2 GPa, Poisson‟s

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ratio is 0.45 and tensile strength is 58.7 MPa. Figure 2.1 show the tensile test specimen and the stress-strain curve of the adhesive.

The surface treatment of the aluminum adherend follows ASTM D 2851 and includes several steps. First, the surface of the aluminum was polished with the 40 mesh sandpaper and corroded using 27% sulfuric acid and 135g/L ferric sulfate for 12 minutes. After the corrosion step, the surfaces were cleaned and dried using water. The assembled adhesive joints were cured by autoclaving at 120°C for 120 minutes. The fillets of the adhesive joints were removed using razor.

Figure 2.1 Tensile test specimen and stress strain curve. (Source: Jae, H.P et al. 2009)

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Figure 2.2: Manufactured adhesive joint specimen (Source: Jae, H.P et al. 2009)

Universal Testing Machine Instron 5582 with crosshead speed fixed at 1 mm/min. Five specimens were tested for each case to obtain an average failure load. A drop in load was used to detect a failure. From experiment result, they note that the adhesive would adhere to both aluminum surfaces and that a cohesive failure would subsequently occur. Figure 2.4 show the experimental failure loads of the adhesive joints with the adhesive length of (a) l = 25mm and (b) l = 30mm.

As shown in Figure 2.3 , the failure loads of the adhesive joints increased with the increasing adhesive length but the adhesive strengths decreased if the adhesive length was over 15 mm The failure loads and strength of these joint were found to be constant with the adhesive length of 25mm. In addition, the failure loads of the adhesive loads of the adhesive joints for which the adhesive thickness was greater than 0.3 mm increased when the adhesive length reached 30mm.

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Figure 2.3: Experimental failure load of adhesive joints of different adhesive thickness (Source: Jae, H.P et al. 2009)

1.3 Objective of Study

The main objective are this study is to make a research about mechanical properties of inorganic based composites adhesive. In this study, the strength of the inorganic based composites will be tested based on the thickness of the adhesive bonding and the specimen temperature. The objective of this study is:

i. To evaluate the mechanical properties of Inorganic Based Composites adhesive at room temperature.

ii. To study the influences of the adhesive thickness to the mechanical properties of the bonding joints.

iii. To used the appropriate experimental method to evaluate the result of the adhesive thickness to the bonding joints

1.4 Scopes of Study

To make this study more specific and details, there were some scopes must be considered as well:

i. Focusing on single lap joint will be tested in experimental method ii. Using SUS 304 as specimen material

CHAPTER 2

LITERATURE REVIEW

2.1 Introduction of Adhesive Bonding Strength

The true strength of an adhesive is a material property independent of the geometry, adherend properties and load and is a good starting point for determining an allowable design stress. Allowable stresses in shear and tension are needed to design safe, efficient, adhesively bonded joints and structures. The composite adhesives become very important research now.

Many researchers have studies and investigate this adhesive joint. Jae-Hyun Park, Park Jin-Ho Choi and Jin-Hwe Kweon (Jae, H.P et al. 2009) studies the evaluating the strengths of thick aluminum to aluminum joints with different adhesive lengths and thickness. Do Won Seo and Jae Kyoo Lim (Do, W.S et al, 2005) investigates tensile, bending and shear strength distributions of adhesive of adhesive-bonded butt joint specimen. They carried an experiment in order to provide the statistical data with strength evaluation methods: tensile, shear and four-point bending

tests for thermosetting epoxy resin based adhesive-bonded butt joints. The certification of the probability in the adhesive is evaluated.

Jose M. Arenas, Julian J. Narbon and Cristina Alia (Arenas, J.M et al, 2009) investigate optimum adhesive thickness in structural adhesives joints using statistical techniques based on Weilbull distribution. The experiment study consisted of a shear tensile strength test of 20 specimen representative of each thickness of adhesive considered (7 thickness of between 0.2 mm and 0.8 mm) following standard UNE-EN 1465 on the determination of the shear strength of single lap joints adhesively bonded with rigid substrates.

Kim KS, Yoo JS, Yi YM (Kim. K.S et al, 2006) studies failure mode and strength of indirectional composite single lap bonded joints with different bonding methods They investigated how best to predict the strength of a single adhesive lap joints. Owens James and Sullivian(James and Sullivian, 2000) analyzed and tested the modulus of an single lap joint composed of composite material and aluminum.

Karl E Hokanson and Avram Bar-Coben (Hokanson and Coben, 1995) studies a shear-based optimization of adhesive thickness for die bonding. Choi JH and Lee (Choi and Lee, 1994) investigate the torque transmission capabilities of the adhesive bonded tubular single lap joint and the double lap joint. Hart-Smith LJ (Smith, 1985) designing to minimize peel stresses in adhesive bonded joints. He proposed a maximum strain failure criterion to predict failure loads for a given adhesive joint.

2.2 Adhesive Strength with Different Thickness and Length

Jae-Hyun Park, Park Jin-Ho Choi and Jin-Hwe Kweon in their studies in 2009 used 8 different lengths and 4 adhesive thicknesses to test and analyze the strengths of single lap joints made of thick aluminum adherends. Aluminum alloy 660-T6 and FM73 M epoxy adhesive film were used. Elastic modulus of adhesive is 4.2 GPa, Poisson‟s

ratio is 0.45 and tensile strength is 58.7 MPa. Figure 2.1 show the tensile test specimen and the stress-strain curve of the adhesive.

The surface treatment of the aluminum adherend follows ASTM D 2851 and includes several steps. First, the surface of the aluminum was polished with the 40 mesh sandpaper and corroded using 27% sulfuric acid and 135g/L ferric sulfate for 12 minutes. After the corrosion step, the surfaces were cleaned and dried using water. The assembled adhesive joints were cured by autoclaving at 120°C for 120 minutes. The fillets of the adhesive joints were removed using razor.

Figure 2.1 Tensile test specimen and stress strain curve. (Source: Jae, H.P et al. 2009)

Figure 2.2: Manufactured adhesive joint specimen (Source: Jae, H.P et al. 2009)

Universal Testing Machine Instron 5582 with crosshead speed fixed at 1 mm/min. Five specimens were tested for each case to obtain an average failure load. A drop in load was used to detect a failure. From experiment result, they note that the adhesive would adhere to both aluminum surfaces and that a cohesive failure would subsequently occur. Figure 2.4 show the experimental failure loads of the adhesive joints with the adhesive length of (a) l = 25mm and (b) l = 30mm.

As shown in Figure 2.3 , the failure loads of the adhesive joints increased with the increasing adhesive length but the adhesive strengths decreased if the adhesive length was over 15 mm The failure loads and strength of these joint were found to be constant with the adhesive length of 25mm. In addition, the failure loads of the adhesive loads of the adhesive joints for which the adhesive thickness was greater than 0.3 mm increased when the adhesive length reached 30mm.

Figure 2.3: Experimental failure load of adhesive joints of different adhesive thickness (Source: Jae, H.P et al. 2009)