SIST-TP CEN/TR 17603-32-21:2022

SLOVENSKI STANDARD
01-september-2022
Vesoljska tehnika - Priročnik za lepljenje
Space engineering - Adhesive bonding handbook
Raumfahrttechnik - Handbuch zu geklebten Verbindungen
Ingénierie spatiale - Manuel de collage
Ta slovenski standard je istoveten z: CEN/TR 17603-32-21:2022
ICS:
49.025.50 Lepila Adhesives
49.140 Vesoljski sistemi in operacije Space systems and
operations
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

TECHNICAL REPORT CEN/TR 17603-32-21

RAPPORT TECHNIQUE
TECHNISCHER BERICHT
June 2022
ICS 49.025.50; 49.030.99; 49.140

English version
Space engineering - Adhesive bonding handbook
Ingénierie spatiale - Manuel de collage Raumfahrttechnik - Handbuch zu geklebten
Verbindungen
This Technical Report was approved by CEN on 13 April 2022. It has been drawn up by the Technical Committee CEN/CLC/JTC 5.

CEN and CENELEC members are the national standards bodies and national electrotechnical committees of Austria, Belgium,
Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy,
Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Republic of North Macedonia, Romania, Serbia,
Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom.

CEN-CENELEC Management Centre:
Rue de la Science 23, B-1040 Brussels
© 2022 CEN/CENELEC All rights of exploitation in any form and by any means
Ref. No. CEN/TR 17603-32-21:2022 E
reserved worldwide for CEN national Members and for
CENELEC Members.
Table of contents
European Foreword . 27
1 Scope . 28
2 References . 29
3 Terms, definitions and abbreviated terms . 30
3.1 Terms from other documents . 30
3.2 Terms specific to the present document’ . 30
3.3 References . 48
4 Joining . 49
4.1 Joining methods for space structures. 49
4.1.1 General . 49
4.1.2 Adhesive bonding . 49
4.1.3 Mechanical fastening disadvantages . 50
4.2 References . 51
4.2.1 General . 51
4.2.2 ECSS documents . 52
5 Adherends . 53
5.1 Introduction . 53
5.1.1 General . 53
5.1.2 Polymer composites . 54
5.1.3 Metals . 54
5.1.4 Ceramics . 55
5.2 Advanced composites . 56
5.2.1 Polymer-based composites . 56
5.2.2 FML - Fibre metal laminates . 60
5.2.3 MMC - Metal matrix composites . 60
5.3 Metals . 61
5.3.1 Structural materials . 61
5.3.2 New materials . 61
5.4 Higher-temperature applications . 62
5.4.1 Adherends . 62
5.4.2 Adhesives . 62
5.4.3 General guidelines . 64
5.5 Low-temperature and cryogenic applications . 64
5.5.1 Adherends . 64
5.5.2 Adhesives . 64
5.5.3 General guidelines . 65
5.6 Bonds between adherends . 65
5.6.1 General . 65
5.6.2 Composite-to-composite . 65
5.6.3 Composite-to-metal . 66
5.6.4 Metal-to-metal . 66
5.6.5 Dissimilar materials . 66
5.7 References . 67
5.7.1 General . 67
5.7.2 ECSS documents . 68
6 Adhesive characteristics and properties . 69
6.1 Introduction . 69
6.1.1 General . 69
6.1.2 Guidelines . 69
6.2 Types of adhesives . 70
6.2.1 Formulation . 70
6.2.2 Characteristics . 70
6.2.3 Mechanical properties . 73
6.2.4 Environmental durability . 73
6.2.5 Aerospace structural adhesives . 74
6.3 Epoxy-based adhesives . 74
6.3.1 General . 74
6.3.2 Properties . 75
6.3.3 Environmental durability . 80
6.4 Polyimide-based adhesives . 84
6.4.1 General . 84
6.4.2 Properties . 85
6.5 Bismaleimide-based adhesives. 87
6.5.1 General . 87
6.5.2 Properties . 87
6.6 Silicone-based adhesives . 89
6.6.1 General . 89
6.6.2 Properties . 89
6.6.3 Environmental durability . 91
6.7 Elastomeric adhesives . 92
6.7.1 General . 92
6.8 Adhesives used in space . 92
6.8.1 Adhesive systems . 92
6.9 References . 96
6.9.1 General . 96
6.9.2 Data sheets . 97
6.9.3 Sources . 98
6.9.4 ECSS documents . 98
6.9.5 Other standards . 98
7 Adhesive selection . 99
7.1 Introduction . 99
7.2 Adhesive selection factors . 99
7.2.1 Guidelines . 99
7.2.2 Evaluation exercise . 99
7.2.3 Trade-off . 100
7.3 Post application selection factors . 101
7.3.1 Earth environment . 101
7.3.2 Space environment . 103
7.4 Pre-application selection factors . 106
7.4.1 Joint design . 106
7.4.2 Adhesive systems . 106
7.4.3 Environmental factors . 108
7.4.4 Cost factors . 108
7.5 Application . 109
7.5.1 Method . 109
7.5.2 Cure factors . 110
7.5.3 Health and safety . 111
7.6 Adhesive screening criteria for space . 112
7.7 References . 113
7.7.1 General . 113
7.7.2 ECSS documents . 114
7.7.3 Other standards . 115
8 Basic joint types . 116
8.1 Introduction . 116
8.2 Bond or mechanically fasten . 116
8.2.1 General . 116
8.2.2 Adhesive bonding in the space industry . 118
8.3 Loading modes . 118
8.4 Tensile shear loading . 119
8.4.1 General . 119
8.4.2 Joint geometry . 120
8.4.3 Composite adherends . 122
8.5 References . 124
8.5.1 General . 124
8.5.2 Sources . 124
8.5.3 ECSS documents . 125
9 Joint selection . 126
9.1 Introduction . 126
9.2 Joint strength . 126
9.2.1 Failure modes . 126
9.2.2 Guidelines . 130
9.2.3 Joint design . 131
9.3 Fatigue resistance . 132
9.3.1 General . 132
9.3.2 Joint evaluation . 132
9.3.3 Factors influencing fatigue resistance . 133
9.4 Acoustic fatigue resistance . 135
9.4.1 Bonded carbon/epoxy composite joints . 135
9.5 References . 137
9.5.1 General . 137
10 Theory and design practices . 138
10.1 Introduction . 138
10.1.1 Analysis . 138
10.1.2 Factors of safety . 138
10.2 Basic theories of bonded joints . 138
10.2.1 Shear lag analysis . 138
10.2.2 Linear-elastic stress-strain response . 139
10.2.3 Non-linear stress-strain response . 139
10.3 Environmental factors for bonded joints . 144
10.3.1 Effect of temperature and moisture . 144
10.4 Effect of bonding defects . 148
10.4.1 General . 148
10.4.2 Description of bonding defects . 148
10.4.3 NDT non-destructive techniques . 156
10.5 Double lap and double strap joints . 158
10.5.1 Stress distribution . 158
10.6 Single lap joints . 162
10.6.1 General . 162
10.6.2 Load path eccentricity . 162
10.6.3 Joint efficiencies . 162
10.6.4 Adhesive characteristics. 165
10.7 Double-sided stepped lap joints . 165
10.7.1 Joint strength . 165
10.7.2 Adherend stiffness balance . 165
10.8 Single-sided stepped lap joints . 168
10.8.1 Joint strength . 168
10.9 Scarf joints . 168
10.9.1 Joint strength . 168
10.10 Calculation of bonded joint strength . 169
10.11 Analysis of joint configurations . 169
10.11.1 Analytical notation . 169
10.11.2 Single lap shear joint . 170
10.11.3 Double lap shear joint . 173
10.11.4 Double-lap shear joint under mechanical and temperature loads . 175
10.11.5 Single taper scarf joint . 183
10.11.6 Double taper scarf joint . 184
10.11.7 Stepped lap joint . 185
10.11.8 Analysis of environmental factors . 186
10.12 Analytical design tools . 187
10.12.1 General . 187
10.12.2 Commercial software . 187
10.12.3 In-house software . 187 ®
10.13 ESAComp . 187
10.13.1 Background . 187
10.13.2 Usage and scope . 188
10.13.3 Analysis and data . 188
10.14 Astrium: Example spreadsheet . 191
10.14.1 General . 191
10.14.2 Usage and scope . 191
10.14.3 Analysis and data . 191
10.15 ESDU data and software . 194
10.15.1 General . 194
10.15.2 ESDU 78042: Bonded joints - 1. 194
10.15.3 ESDU 79016: Bonded joints – 2 . 195
10.15.4 ESDU 80011: Bonded joints – 3 . 196
10.15.5 ESDU 80039: Bonded joints – 4 . 196
10.15.6 ESDU 81022: Bonded joints – 5 . 197
10.16 Design chart . 198
10.16.1 Aide memoire . 198
10.16.2 Joint category . 198
10.17 References . 201
10.17.1 General . 201
10.17.2 ECSS documents . 203
10.17.3 Other standards . 203
11 Design allowables . 204
11.1 Introduction . 204
11.2 Single lap joint . 205
11.2.1 Static loading . 205
11.2.2 Dynamic loading . 209
11.3 Double lap joint . 211
11.3.1 Static loading . 211
11.4 Symmetrical double scarf joint . 212
11.4.1 Static loading . 212
11.4.2 Dynamic loading . 214
11.5 References . 216
11.5.1 General . 216
11.5.2 ECSS documents . 216
12 Surface preparation . 217
12.1 Introduction . 217
12.1.1 General . 217
12.1.2 Standard processes . 218
12.1.3 Development processes . 219
12.1.4 Process steps . 219
12.1.5 Legislation . 219
12.2 Composites: Thermosetting matrix . 219
12.2.1 General . 219
12.2.2 Techniques . 220
12.2.3 Abrasion . 220
12.2.4 Peel ply . 222
12.3 Composites: Thermoplastic matrix . 222
12.3.1 General . 222
12.3.2 Proposed methods . 223
12.4 Aluminium alloys . 224
12.4.1 Aerospace aluminium alloys . 224
12.4.2 MMC and Al-Lithium alloys . 224
12.4.3 Optimised Forest Products Laboratory (FPL) etch. 225
12.4.4 Phosphoric acid anodising (PAA) . 227
12.4.5 Chromic acid anodising (CAA) . 227
12.4.6 Boric sulphuric acid anodising (BSAA) . 228
12.4.7 Thin film sulphuric acid anodising (TFSAA) . 231
12.4.8 Solvent vapour cleaning . 231
12.4.9 Development processes . 232
12.5 Titanium alloys . 233
12.5.1 General . 233
12.5.2 Acid or alkali etch . 234
12.5.3 Non-chromium proprietary process . 235
12.6 References . 235
12.6.1 General . 235
12.6.2 ECSS documents . 237
13 Bonding methods . 238
13.1 Introduction . 238
13.1.1 Basic methods . 238
13.1.2 Adhesives . 238
13.1.3 Composite structures . 239
13.2 Co-curing . 240
13.2.1 Applications. 240
13.2.2 Loading . 242
13.2.3 Adhesives . 242
13.2.4 Tooling . 243
13.3 Secondary bonding . 243
13.3.1 General . 243
13.3.2 Adhesives . 243
13.3.3 Tooling . 244
13.4 Applying adhesives . 244
13.4.1 Film adhesives . 244
13.4.2 Paste adhesives . 245
13.4.3 Manufacturing processes . 248
13.5 Manufacturing factors for adhesives . 249
13.5.1 General . 249
13.5.2 Product-specific factors . 249
13.6 Bondline integrity . 251
13.6.1 General . 251
13.6.2 Manufacturing-related factors . 251
13.7 Thermal bonding thermoplastic composites . 251
13.7.1 General . 251
13.7.2 Direct bonding . 252
13.7.3 Thermabond process . 252
13.7.4 Welding techniques . 253
13.8 Rapid adhesive bonding (RAB) . 253
13.8.1 General . 253
13.8.2 Applications. 253
13.8.3 Materials . 253
13.8.4 Process . 255
13.8.5 Equipment . 255
13.8.6 Carbon fibre reinforced composites . 256
13.8.7 Joint strength . 257
13.9 References . 257
13.9.1 General . 257
13.9.2 ECSS documents . 257
14 Quality assurance . 258
14.1 Introduction . 258
14.1.1 Documentation . 258
14.1.2 Standards . 258
14.1.3 Aerospace applications . 258
14.2 Quality system . 259
14.2.1 General . 259
14.3 Specifications . 259
14.3.1 Procurement . 259
14.3.2 Incoming inspection . 260
14.3.3 Design . 260
14.3.4 Processes . 260
14.3.5 Materials . 261
14.3.6 Training personnel . 262
14.4 Check lists . 262
14.4.1 Material procurement . 262
14.4.2 Bonded joints . 266
14.5 References . 268
14.5.1 General . 268
14.5.2 ECSS documents . 268
15 Test methods . 269
15.1 Introduction . 269
15.1.1 Use of test methods . 269
15.1.2 Adhesives for space use . 269
15.1.3 Characterisation of adhesives . 271
15.1.4 Assessment of adhesive bonding process . 272
15.1.5 Test methods and standards . 273
15.2 Tensile tests for adhesives . 274
15.2.1 General . 274
15.2.2 Adhesive evaluation . 274
15.2.3 Sandwich panels: Flatwise tensile strength . 275
15.3 Shear tests for adhesives . 275
15.3.1 General . 275
15.3.2 Napkin ring . 275
15.3.3 Thick adherend single lap . 276
15.3.4 Single lap . 276
15.3.5 Double lap . 278
15.3.6 Cracked lap shear (CLS) . 280
15.4 Cleavage of adhesives . 281
15.4.1 General . 281
15.4.2 Specimen geometry . 281
15.4.3 Typical test results . 284
15.4.4 Calculation of fracture strength. 285
15.4.5 Loading . 287
15.5 Bond durability by wedge test . 287
15.5.1 General . 287
15.5.2 Test specimen and configuration . 287
15.5.3 Results and analysis . 289
15.6 Peel tests . 289
15.6.1 General . 289
15.6.2 Climbing drum peel test for adhesives. 290
15.6.3 T-peel test . 291
15.6.4 Floating roller peel. 291
15.7 Fatigue resistance . 292
15.7.1 Fatigue properties of adhesives . 292
15.7.2 Fatigue resistance of bonded joints . 293
15.7.3 Acoustic fatigue . 295
15.8 Creep resistance . 295
15.8.1 Adhesive properties . 295
15.8.2 Test methods . 296
15.9 Environmental resistance . 296
15.9.1 Earth . 296
15.9.2 Space. 296
15.10 References . 297
15.10.1 General . 297
15.10.2 ECSS documents . 299
15.10.3 Other standards . 299
16 Inspection . 300
16.1 Introduction . 300
16.2 Role of inspection . 300
16.2.1 General . 300
16.2.2 Quality control and inspection . 300
16.2.3 Non-destructive testing . 301
16.3 Defects . 301
16.3.1 Bonded joints . 301
16.3.2 Adhesion . 301
16.3.3 Cohesive properties of adhesives . 302
16.3.4 Significance of defects .
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