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An unique bonding mechanism was studied after several instances, where the linings stuck to the brake drums on transit buses, were reported. Evidences suggested that the linings were “glued” to the brake drums surface after wear debris (dust) was turned into “adhesive paste” through complicated thermal and chemical changes. Factors such as the friction materials, environment and service conditions, which could activate and deactivate the lining bonding, were observed and discussed. The prevention measures are proposed.

NEW WELDING processes are dropping costs while providing improvements in weld quality. This paper describes some of the more promising new developments in pressure and fusion welding and brazing. Included in the discussion are ultrasonic, high frequency resistance, foil seam, magnetic force, percussion, friction, and thermopressure welding and diffusion bonding. The description of adhesive bonding includes the development of glass or ceramic materials as structural adhesives.*

To enable the tests required for development work to be performed with maximum efficiency, the Zwick Roell Group (ZwickRoell) – a global supplier of materials testing machines based out of Ulm, Germany – developed a materials testing machine that can be equipped with both a temperature chamber and a high-temperature furnace.

This report approaches the material selection process from the designer's viewpoint. Information is presented in a format designed to guide the user through a series of decision-making steps. "Applications criteria" along with engineering and manufacturing data are emphasized to enable the merits of aluminum for specific applications to be evaluated and the appropriate alloys and tempers to be chosen.

Two new developments in woodgrain finishing techniques for zinc die cast trim components are revealed which apply the permanent finishes to the casting surface. Product design details and comparative costs of chromium plated ABS and zinc are given for a typical instrument panel trim bezel. Recommended design features and basic pressure sensitive adhesive specifications are discussed which should eliminate adhesive bonding failures for woodgrain appliques used on trim components.

A series of carefully controlled simulated barrier crashes at speeds from 20 to 30 mph are used to compare the relative safety of rubber gasket, butyl tape and polysulfide adhesive methods of installing windshields. Only subtle differences were found in the severity index and the laceration index. There is an indication that the rubber gasket installation has a higher resistance to interlayer tears and the lacerations from impacts to polysulfide installations are slightly more severe. Head attitude at impact was found to have a significant effect on interlayer tears and resultant lacerations.

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Some adherends require extensive surface preparation prior to adhesive-bonding while other adherends will form strong adhesive bonds with little or no surface preparation. This paper will attempt to explain the reasons that the above statement is true. Several theories of adhesion will be discussed and the practical application of each will be described. Chemical and physical characteristics of adherend surfaces and several methods for surface analysis will be identified. Finally, an overview of surface preparation methods along with the advantages and disadvantages of each will be described.

Adhesive bonding has many applications in the automotive industry. The single-lapped bonded joint is the most typically used among various bonding types. This paper presents experimental research for determining the strain field of the single-lapped joint under tensile loading. The materials for the joint are epoxy-based structural adhesive and low-carbon electrolytic zinc steel plate. In the study, a DIC (digital image correlation) system was adopted to measure the strain distribution of the bonded joint during a tensile test. The bonded steel coupons in the tensile test were prepared according to the ASTM standard. During the measurement, images of the coupon joint were taken before and after the deformation process. Then the DIC system measured the strain of bonded joint by comparing two consecutive images. The measured data from the DIC was compared to data taken simultaneously from a traditional extensometer.

This paper describes the development of a process that will mold a urethane resin in the form of a laminate. The urethane resin is a most unusual material: it can be formulated to produce thermosetting foam of almost any density, and the formulation can also be made to produce either a flexible or rigid foam. It has excellent adhesive properties, which we have used to make the laminate. The process produces a laminate of two skins, which are combined with a film of urethane resin in its liquid form. This combination, when placed in a heated mold, causes the resin to expand until both skins reach the confine of the mold. This then cures to the shape of the mold and the texture of its surface, making it possible to mold sculptured and formed shapes or panels, which can be used for interior trim for automobiles.

This specification defines the requirements for joining metals and alloys using the gas-tungsten-arc welding (GTAW) methods.

This specification defines the requirements for joining metals and alloys using the gas-tungsten-arc welding (GTAW) methods.

This specification defines the requirements for joining metals and alloys using the gas-tungsten-arc welding (GTAW) methods.

This specification covers requirements for resistance spot and seam welding of the following metals and their alloys. Group 1 - Aluminum and magnesium Group 2 - Iron, nickel, and cobalt Group 3 - Titanium

This specification covers requirements for resistance spot and seam welding of the following metals and their alloys. Group 1 - Aluminum and magnesium Group 2 - Iron, nickel, and cobalt Group 3 - Titanium

This specification covers requirements for resistance spot and seam welding of the following metals and their alloys. Group 1 - Aluminum and magnesium Group 2 - Iron, nickel, and cobalt Group 3 - Titanium

This specification defines the procedures and requirements for joining metals and alloys using the electron-beam (EB) welding process.

This paper reviews the use of vibration welding for joining crash impact pad's and air duct systems to headliner. Increasing government regulation and the evolution of automotive safety are demanding a new innovative welding technology for crash impact pad's as well air duct systems to the headliner. Vibration welding is an approved welding technology to join both similar and dissimilar materials and is used in many automotive applications is an innovative solution for such headliner applications. Driven by customer needs, energy management is an important consideration in protecting the occupants of a vehicle from injury in a crash situation. Air ducts are becoming more and more important to distribute air to the rear passenger. In this case both are placed between the headliner and the roof of the vehicle.

Five structural adhesives were evaluated for vehicle stiffening. Commonly known as weld bonding, these epoxy adhesives were used in conjunction with spot welds to study the stiffening effect. The adhesives chosen required no surface cleaning prior to bonding and were formulated to allow spot welding through the adhesive layer. Experimental testing included structural components, coupon samples, and a vehicle build. The components were evaluated by static bending, torsional stiffness and fatigue testing. Coupon samples were evaluated by measuring lap shear and fatigue strength in various environments. The effects of adhesive type, bondline thickness, steel gauge and type, and environmental exposure on the adhesive's strength were studied. A vehicle build was conducted to determine the stiffening effect of an adhesively bonded structure. Lastly, a finite element model of the component was done.

This paper presents the results of an investigation into the material variables that influence the weldbonding of aluminum. The four major variables that were considered in this study were the aluminum alloy, type of adhesive, the presence of a forming lubricant, and the metal surface treatment. To maximize the amount of information gained from this study, a statistical design of experiments was used. The particular design used here is an example of a screening design, in which a relatively small number of variable combinations is investigated to identify those variables that have a strong impact on the measured responses. The responses in this experiment consist of both quantitative measurements and qualitative judgments that must be taken together to interpret the experimental results. The “quantifiable” responses included weld parameters (current and percent heat); nugget diameter; weld quality ratings (based on a subjective rating system); and tensile strength.