Engineering Adhesive Solutions for Next

Generation Structural Bonding

 Topics

1. Materials and Processing

2. Next Generation Structural
Bonding
3. Engineering Solutions and
Artificial Intelligence
4. Conclusions and Q & A

2
Lightweighting Opportunities Target BIW Subsystems
BIW Material Distribution Vehicle Subsystems
180 Mpa 200 – 220 Mpa System Priority Low Medium High High
7% 9%
260 Mpa Rear doors Front doors Hood
Closures High
Decklid Fenders
Deep Drawn Steel 10%
19%
C-pillar Shock tower Engine cradle
Medium
BIW Floor Truck frame B-pillar
High
A-pillar

Tires Brakes Suspension

Others Unsprung Mass Medium
Wheels
300 – 340 Mpa
5%
AlSi Aluminum 21%
Acoustics Trim Seats
2% Interiors Medium
Restraints Instrument panel
1000 Mpa
12% Starter motor HVAC Power steering
Components Low
600 – 700 Mpa Electronics
380 – 450 Mpa
1% 14%
Medium Radiator Glazing Exhaust
Non-structural
Low
Low
Low High

▪ Broad distribution of materials used in BIW structures

▪ Closures and BIW show greatest opportunity for light-weighting
Baron et al. Assessing the Fleet-wide Material Technology and Costs to Lightweight Vehicles. CAR 2016
Engineering Adhesive Solutions for Next Generation Structural Bonding April 8, 2020 3
Lightweighting is Interdisciplinary
❶ Material ❷ Processing ❸ Engineering
Potential Weight Savings

50%
Composites

30%
Aluminum

20%
Steel-Alu-
Hybrid Mode I: Mode II: Mode III:
Innovative Opening In-plane shear Out-of-plane
Steels shear
10%
Year
2010 2015 2025+

▪ Substrate technology Adhesive attributes ▪ Modeling and design

▪ Surface chemistry/Interfaces ▪ Pumpability ▪ Numerical analysis
▪ Adhesive chemistry and function ▪ Wash-off resistance ▪ Simulation and experiment
▪ Adhesive material properties ▪ Weldability/Flammability
▪ Bulk Resistance
▪ Adhesion/failure mode ▪ Humidity resistance
▪ Cure kinetics
Crash modeling: Singh et al. NHTSA, 2018
Engineering Adhesive Solutions for Next Generation Structural Bonding April 8, 2020 4
 Topics

1. Materials and Processing

2. Next Generation Structural
Bonding
3. Engineering Solutions and
Artificial Intelligence
4. Conclusions and Q & A

Engineering Adhesive Solutions for Next Generation Structural Bonding 5

Next Generation Structural Bonding
Expanding Processing and Adhesive Properties
BIW Material Distribution Vehicle Subsystems
Wash-off and Humidity Resistance Fracture Toughness and Durability

▪ OEMs assemble and ship components globally ▪ Adhesive subject to various loads and strain rates
▪ Uncured adhesive must maintain fracture toughness after ▪ Toughening technology
humidity exposure ▪ APGE and durability

▪ Adhesive manufacturers need to consider both uncured and cured adhesive properties
▪ Help to expand OEM processing capabilities and enable light-weighing opportunities
▪ One formulation for steel and aluminum bonding
▪ -40°C impact wedge peel, good adhesion, stress durability, wash-off resistance, humidity resistance, flammability resistance

Engineering Adhesive Solutions for Next Generation Structural Bonding April 8, 2020 6
Next Generation Uncured Adhesive Requirements
Wash-off Resistance: Teroson EP 5095
EP 5089 EP 5089
50000
2000
EP 5095 EP 5095

Log Viscosity (Pa*s)

1500

Stress (Pa)
5000 1000
+115%

500

500 0
0.01 0.1 1 10 100 0 10 20 30 40
Log Shear Rate (1/s) Shear Rate (1/s)

Wash-Off Test Conditions:

𝑣ሶ = 8.3 L/min EP 5095 EP 5095
u = 5 m/s (deluge)
Impingement resistance via control of TH2O = 60 oC
Nozzle distance = 3”
adhesive yield stress, oil absorption & nozzle diam. = 0.25” 25 mm 15 mm
surface wetting Stream just under bead

▪ Increased thixotropy and yield stress improves adhesive wash-off resistance

▪ Reduces contamination in E-coat system and mitigates costly reworks
▪ Meets new GM 18077 specification with IR and WR designations

Engineering Adhesive Solutions for Next Generation Structural Bonding April 8, 2020 7
Next Generation Uncured Adhesive Requirements
Teroson EP 5150: Humidity Resistance and Adhesion to Aluminum
Open Bead T-peel Humidity Resistance Closed Bead T-peel Humidity Resistance Open Bead -40°C IWP
20 20 3 months uncured exposure 35 °C at 85% RH 45

-40 C impact Wedge Peel Strength (N/mm)

18 18 40
T-peel Strength (N/mm)

T-peel Strength (N/mm)

16 16 35
14 14 +50%
30
12 12
25
10 10
20
8 8
6 6 15
4 4 10
2 2 5
0 0 0
Initial 72 hr - 168 hr - Initial 1 Week 4 Week 8 Week 12 Week Initial 24 hr - 72 hr - 168 hr -
35°C/80% RH 35°C/80% RH Exposure Exposure Exposure Exposure 35°C/80% RH 35°C/80% RH 35°C/80% RH

(a) ▪ Toughening and cure chemistry designed and optimized for humidity resistance
▪ Overbake cure condition (205°C for 30 min. MT)
0.2 mm ▪ T-peel and IWP strength meets initial requirement after uncured open and closed
Initial Exposed bead exposure
(b) ▪ 3 months closed bead
▪ Reduced blistering and interfacial failure due to moisture absorption
0.2 mm ▪ Good impact wedge peel strength on CRS and AI at -40°C and above
Initial Exposed ▪ Young’s Modulus = 2.0 GPa

Engineering Adhesive Solutions for Next Generation Structural Bonding April 8, 2020 8
Next Generation Uncured Adhesive Requirements
Teroson EP 5150: Weld Flammability Resistance and Al Welding

Strip Requirement Result

1 <30 sec flame up/<5% welds flame up Pass: No flame up

2 <30 sec flame up/<5% welds flame up Pass: 1 x 8 second flame (no travel)
3 <30 sec flame up/<5% welds flame up Pass: 1x 8 second flame (no travel)
4 <30 sec flame up/<5% welds flame up Pass: 1 x 8 second flame (no travel)
5 <30 sec flame up/<5% welds flame up Pass: No flame up

▪ Temperatures reaching 230 °C+

▪ Also passes Al weld acceptance testing via FLTM BV 062-01
▪ IWP (-40 °C; 0.8 mm CRS; HB cure condition): 27.5 N/mm

Engineering Adhesive Solutions for Next Generation Structural Bonding April 8, 2020 9
Advanced Toughening Technology

▪ Traditional toughening chemistry utilizes reaction induced phase separation (RIPS)

▪ Core shell rubber toughening nanotechnology utilizes pre-dispersed nanoparticles to
more effectively toughen epoxy polymers
▪ Cavitation of rubbery particles ahead of crack tip
▪ Matrix shear yielding

Pre-dispersed core shell nanoparticles Scanning Electron Micrographs (SEM) of T-peel Fracture Surface

180° Peel

Engineering Adhesive Solutions for Next Generation Structural Bonding April 8, 2020 10
Next Generation Cured Adhesive Requirements
Teroson EP 5150: Toughness: T-peel and Impact Wedge Peel Strength
T-peel Strength (Initial) IWP Strength (-40°C) IWP Strength (+23°C)
20 50 50
T-peel Strength (N/mm)

18 45 45

+23 C Impact Wedge Peel

-40 C impact Wedge Peel
16 40 40

Strength (N/mm)

Strength (N/mm)
14 35 35
12 30 30
10 25 25
8 20 20
6 15 15
4 10 10
2 5 5
0 0 0
CRS CRS EZG HDG AI CRS CRS AI CRS CRS AI
(0.8mm) (1.6mm) (0.8mm) (0.8mm) (2.0mm) (0.8mm) (1.6mm) (2.0mm) (0.8mm) (1.6mm) (2.0mm)

Benefits of structural bonding ▪ Good T-peel and impact wedge peel strength -40 °C and above on various substrates
▪ Improved stiffness of car ▪ Overbake cure condition (205 °C for 30 min. MT)
body assemblies ▪ Good lap shear strength: 22.9 MPa on aluminum
▪ 100% cohesive mode of failure under static and dynamic peel loads
▪ Up to 25% increase of energy
absorption in the metal CRS EZG HDG Al LB HB
structures
▪ Increased fatigue durability
▪ Bonding of different
substrates possible
▪ Acoustic & vibration damping

Engineering Adhesive Solutions for Next Generation Structural Bonding April 8, 2020 11
Next Generation Cured Adhesive Requirements
Teroson EP 5150: Stress Durability on Al: Environmental Aging Under
Static Load
Stress Durability/APGE Cycling T-peel and IWP Mode of Failure
APGE Durability (# of Cycles) 60 CRS (0.8 mm) CRS (1.6 mm) HDG (0.8 mm) Al (2.0 mm)
50

40

30

20

10 22 cycle requirement

0 LB HB
Low Bake High Bake

▪ 2400N static load CRS (0.8 mm)

▪ No failure in LB tubes prior to 55 cycles -40 °C
▪ No failure in HB tubes prior to 32 cycles; 3 total failures prior
to 45 cycles

▪ Bulk adhesive properties and interfacial adhesion optimized for APGE durability with a 2400N static load
▪ Achieved stress durability with good adhesion to various substrates with good -40 °C IWP strength

Engineering Adhesive Solutions for Next Generation Structural Bonding April 8, 2020 12
Next Generation Adhesive Properties
Experimental Product Development Summary
T-peel Strength on CRS (0.8mm)
Stress Durability (HB, AL) 60 T-peel Strength on CRS (1.6mm)
50
Stress Durability (LB, AL) T-peel Strength on EZG (0.8mm)
40

IWP (RT, AI) 30 T-peel Strength on AI (2.0mm)

20

10
IWP (RT, CRS, 1.6mm) T-peel Strength (7 Day Open Bead) Requirements
0
Next Gen Product

IWP (RT, CRS) T-peel Strength (12 Week Closed)

IWP (-40°C, 7 Day Open Bead) LSS (CRS)

IWP (-40°C, AI) LSS (CRS)

IWP (-40°C, CRS, 1.6mm) IWP (-40°C, CRS)

▪ Developed Next Generation technology to exceed advanced body shop adhesive requirements
▪ One experimental product for aluminum and steel bonding

Engineering Adhesive Solutions for Next Generation Structural Bonding April 8, 2020 13
 Topics

1. Materials and Processing

2. Next Generation Structural
Bonding
3. Engineering Solutions and
Artificial Intelligence
4. Conclusions and Q & A

Engineering Adhesive Solutions for Next Generation Structural Bonding 14

Accelerating Development
Connecting Engineering and AI through Materials Science

Mobility
Surrogate Data Card Materials Science AI
Alliance

▪ Initiate product development and define requirements using a surrogate data card
▪ Utilize artificial intelligence and design of experiments (DOE) to accelerate product development
▪ Apply the scientific method to create new products to solve customer problems

Engineering Adhesive Solutions for Next Generation Structural Bonding April 8, 2020 15
 Conclusions
▪ Closures and BIW show greatest opportunity for lightweighting

▪ Established interdisciplinary connections between materials, processing and engineering for BIW structural
adhesive applications

▪ Developed an improved wash-off resistant structural adhesive

▪ Teroson EP 5095

▪ Developed a Next Generation Universal adhesive for aluminum and steel bonding
▪ Advanced uncured and cured properties to expand OEM
processing capabilities
▪ Excellent adhesion to various substrates (bare steel, coated steels and Al)
▪ Good dynamic impact strength over a broad temperature range
▪ Good durability to ensure long term, durable adhesion over vehicle lifetime

▪ Consolidation in body shop possible (BIW and closures)

▪ Accelerating product development through modelling and design, cutting edge materials science and artificial
intelligence (AI) April 8, 2020 16
 Thank you!

This material has been visually improved with the help of our team at the Graphic Design Center in SSC Manila.
To know more about this service, please visit http://graphics in the Henkel portal.com