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1 Henkel 09 Trouble Shooting

The document discusses common failures that can occur when bonding rubber to metal. It identifies the main types of failures as those between the metal and primer (M), primer and cover (PC), and cover and rubber (RC). M failures, which account for almost 90% of issues, are often due to incorrect substrate pretreatment, poor primer preparation, or improper primer application. RC failures can result from covercoat preparation/application problems or issues during molding. The document provides details on potential causes for each failure type and emphasizes the importance of proper surface cleaning, priming, coating thickness, drying, and molding conditions.

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Ankur Panwar
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116 views17 pages

1 Henkel 09 Trouble Shooting

The document discusses common failures that can occur when bonding rubber to metal. It identifies the main types of failures as those between the metal and primer (M), primer and cover (PC), and cover and rubber (RC). M failures, which account for almost 90% of issues, are often due to incorrect substrate pretreatment, poor primer preparation, or improper primer application. RC failures can result from covercoat preparation/application problems or issues during molding. The document provides details on potential causes for each failure type and emphasizes the importance of proper surface cleaning, priming, coating thickness, drying, and molding conditions.

Uploaded by

Ankur Panwar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 17

Trouble shooting-

or
why failures sometimes happen

Wolfgang Weimar
Which are the different kinds
of failures ?

% M = Metal / Primer
% PC = Primer / Cover
% RC = Rubber / Cover

Rubber % R = Rubber

3
Which are the most kinds of failures?

% M = Metal / Primer
• M failures
between metal and primer
% RC = Rubber / Cover

Rubber
• RC Failures
between cover and rubber

4
Why does a failure happen between
the metal and the primer ?

% M ??? % M = Metal / Primer

Almost 90 % of all metal failures are caused by incorrect


substrate pretreatment !

1.) Poor primer preparation

2.) Poor primer application

3.) Incorrect metal preparation


5
What is poor primer preparation ?

% M ???

• Inadequate Stirring
Bonding agents must be carefully stirred before application !
Most common failure in using adhesives !!!

• Incorrect Dilution
Correct viscosity is important to achieve an even film thickness !

• Product out of shelf life


check product expiry date, before use material !
6
What is poor primer application ?

• Dry spraying
The primer should be able, to form a proper film on the substrate surface.

• Inadequate film thickness


primer approx. 5-10µm
% M ???
• Inadequate drying

• No primer or incorrect product


In automatic spraying machines it is important to ensure
that the primer is actually applied. For calibration use flexible primer.

• Contamination of the air lines


7
Temperature changes can cause water in air lines
What is incorrect metal preparation?

• Contaminated blast grit


Non metallic grit should be used for non ferrous metals
this will lead to a galvanic disbondment
Oil or grease in shot blasting grit should be avoided % M ???
grit size, grit type and grit condition is most important

• Contaminated degreaser
Special attention when degreasing process is done with solvents
or in alcaline bath

• Inadequate chemical conversion treatment


Use only recommended or suitable chemical treatments

• Outside of recommended time window


Excessive delay in primer application will lead to re-oxidation of metal
8 Specially non ferrous or stainless steel requirres imediate primer
application after treatment
Why does a failure happen between
the primer and the cover ?

% PC = Primer / Cover

• the most rare failures


• wrong application (wet in wet- wrong drying conditions)
• contamination between application primer and cover
• wrong cover application - sweap off effect
9
Why does a failure happen
between cover and rubber ?

% RC ???

% RC = Rubber / Cover

1.) Poor covercoat preparation


2.) Poor covercoat application
3.) Moulding operation problems

10
What is poor Covercoat
preparation?

• Inadequate Stirring
Bonding agents must be adequately stirred before application !
covercoats especially have to be stirred at least for 30 minutes
Most common failure in using adhesives !!!
% RC ???
• Incorrect Dilution
Correct viscosity is important to achieve an even film thickness !

• Product out of shelf life


11

Check shelf life before using the material !


What is poor covercoat application ?

• Inadequate film thickness


Cover 15-20µm, softer compound higher filmthickness

• Inadequate Drying
to high temperatur during drying process

• Wrong adhesive % RC ???


different reactivity between different polymers

• Contaminated spray air lines


Temperature changes can cause water in air lines

• Dry spraying
substrate too hot, bad filmformation
12
What are moulding
operation problems ?
• Preheating stability of bonding agent
loading time of metal parts is too long
temperature of mold is too high % RC ???
• Contamination of adhesive film
• Leaking molds, construction of mould
pressure in mold is insufficient, because rubber keeps flowing out
• Mold temperature to low
big and high moulds have too big temperature loss
• Demoulding
Hot tear strengths of freshly molded parts is sometimes low
• Rubber compound
Use the correct elastomer or compound
• Release agent
is not applied in the correct way
13
Production of Rubber-to-Metal parts
Possible reasons for failures
Degreasing
Grit size
Grit type
Pretreatment
Contamination
Storage Overstorage
Type of primer
Mixing
Viscosity
Solvent Primer
Application
Coating thickness Temperature
Drying time
Drying Contamination
Type of cover
Mixing
Viscosity Covercement
Solvent
Application
Temperature
Coating thickness
Drying time
Drying Contamination

Contamination
Overstorage Storage
Construction of
mould
Temperature
Vulcanisation Pressure
Demoulding Time
Deflashing Loading time
Painting Release agent
Galvanising Posttreatment
14
Different geometries of test parts

are able to show different results

ASTM 429 B Peel test part

P 24 test-bumper

P 25 test-bumper Test part for shear strenght


15
Influence of surface treatment and geometry

Geometry of part 65 Shore A 50 Shore A


shot blastet phosphated shot blastet phosphated

19-23 19-23 17-22 17-22 N/mm²

100%R 100%R 100%R 100%R % rubber

11-13 11-13 10-12 10-12 MPa

97%R 95%R 98%R 97%R % rubber

8-11 5-8 8-10 6-9 MPa

90%R 45%R 100%R 100%R % rubber

16
Do not hesitate
17
to call Henkel !

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