Adhesive Sealer

INDEX

A. Scope
B. Requirements
C. Manufacturing Process Application
D. Defects
SCOPE

1 This standard applies to extrudable and tape adhesive joints that are produced
using manual and/or robotic dispense equipment on Jaguar and Land Rover
production vehicles.
2 Materials covered by this standard are: steel and aluminum sheet, aluminum
and magnesium castings and aluminum extrusions.
3 Although the title is for sealed adhesive joints it also applies to all methods that
join through the sealing product i.e. spot welding, bolts and cold joining
techniques.
REQUIREMENTS

The application of sealed adhesives within joint flanges is required for a

number of reasons, these include:
• Corrosion resistance
• Adhesive bond strength performance
• Water ingress (assist in reducing environmental ingress into cabin)
MANUFACTURING PROCESS APPLICATION

When a vehicle joint is tested to destruction and opened during an audit, the
adhesive must exhibit cohesive failure, not adhesive failure, as described in the
below Table:

Acceptable - Cohesive Failure Mode

Adhesive remains on both sides of the
bonded joint.
Acceptable - Near Surface Cohesive
Failure Mode
Adhesive on both sides of the bonded
joint –
failure representative of near surface
cohesive failure.

Unacceptable - Adhesive Failure Mode

50% adhesive failure mode within the
bonded region (adhesive did not bond to
substrate – only bare metal remains on
one surface)
Defects

The sum of the defects per evaluated length must not exceed 20% of the total
matching surface area of the joint. Defects consist of:

1. Length deviations.
Each time there is an intended stop and start in the adhesive bead path, the
sections (bond lengths) are evaluated separately for joint failure. The
tolerances on length are given in the below table:
2. Width deviations
Width deviations are critical when the joint is required for strength or sealing, as
specified in the sealing manual. The minimum tolerances on width are given in
the below Table. Bead widths below these minimum tolerances should be
treated as gaps as described in the next section. Squeeze out can be allowed as
this is a good indicator of a filled joint, but wipe and wash off should be taken
into consideration.
3. Gaps in bond length
When the joint is required for strength AND sealing, gaps in bond length are not
permitted.
When the joint is required for strength ONLY, the following tolerances can be
applied:
• The maximum permitted total gap length (all gaps added together) is 5% of the
overall bond length.
• The maximum permitted single gap length is 20mm.
• Acceptable and unacceptable gap conditions are given in the below Table