AIR FORCE MIL-HDBK-83377-1997 ADHESIVE BONDING (STRUCTURAL) FOR AEROSPACE AND OTHER SYSTEMS REQUIREMENTS FOR [Superseded AIR FORCE MIL-A-83377 B CANC NOTICE 2 AIR FORCE MIL-A-83377.pdf

1、NOTE: MIL-A-83377B has been redesignated as a handbook, and is to be used forguidance purposes only. For administrative expediency, the only physical change fromMIL-A-83377B is this cover page. However, this document is no longer to be cited as arequirement. If cited as a requirement, contractors ma

2、y disregard the requirements of thisdocument and interpret its contents only as guidance.MIL-HDBK-8337731 December 1997SUPERSEDINGMIL-A-83377B6 October 1978DEPARTMENT OF DEFENSEHANDBOOKADHESIVE BONDING (STRUCTURAL) FOR AEROSPACE ANDOTHER SYSTEMS, REQUIREMENTS FORTHIS HANDBOOK IS FOR GUIDANCE ONLYDO

3、NOT CITE THIS DOCUMENT AS A REQUIREMENTAMSC N/A FSC 8040DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.NOT MEASURMENT SENSITIVEProvided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-1MIL-A-83377B6 October 1978SUPERSEDINGMIL

4、-A-83377A(USAF)24 June 1975MILITARY SPECIFICATIONADHESIVE BONDING (STRUCTURAL) FOR AEROSPACE ANDOTHER SYSTEMS, REQUIREMENTS FORThis specification is approved for use by all Departments and Agencies of theDepartment of Defense.1. SCOPE1.1 Scope.This document covers requirements applicable to structur

5、al adhesive bonding ofmetal, composites, and core material in any combination.1.2 Classification.The classification of adhesive bonded structures specified herein shall be asfollows:Type I - Primary structure (see 6.3.4)Type II - Secondary structure (see 6.3.4)2. APPLICABLE DOCUMENTS2.1 Issues of do

6、cuments.The following documents of the issue in effect on date of invitation for bids orrequest for proposal, form a part of this specification to the extent specified herein.SPECIFICATIONSFEDERALUU-P-268 Paper, Kraft, WrappingBeneficial comments (recommendations, additions, deletions) and any perti

7、nentdata which may be of use in improving this document should be addressed to theAir Force Materials Laboratory, MXA, WPAFB, Ohio 45433 by using the self-addressed Standardization Document Improvement Proposal (DD Form 1426)appearing at the end of this document or by letter.FSC 8040Provided by IHSN

8、ot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-A-83377B2MILITARYMIL-C-5541 Chemical Conversion Coatings on Aluminum andAluminum AlloysMIL-I-6870 Inspection Program Requirements,Nondestructive: For Aircraft and Missile Materialsand PartsMIL-A-8625 Anodic Coating

9、s, for Aluminum and AluminumAlloysMIL-A-83376 Adhesive Bonded Metal Faced SandwichStructures, Acceptance Criteria(Copies of specifications, standards, drawings, and publications required bycontractors in connection with specific procurement functions should be obtainedfrom the procuring activity or

10、as directed by the contracting officer.)2.2 Other publications.The following documents form a part of this specification to the extent specifiedherein. Unless otherwise indicated, the issue in effect on date of invitation for bidsor request for proposal shall apply.AMERICAN SOCIETY FOR TESTING AND M

11、ATERIALS (ASTM)ASTM D2674 Analysis of Sulfochromate Etch Solution Used in SurfacePreparation of AluminumASTM D2919 Determining Durability of Adhesive Joints Stressed inShear by Tension LoadingASTM D3433 Fracture Strength in Cleavage of Adhesives in BondedJoints(Application for copies should be addre

12、ssed to the American Society for Testingand Materials, 1916 Race Street, Philadelphia, PA 19103.)SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)ARP 1524 Surface Preparation and Priming of Aluminum Alloy Partsfor High Durability Structural Adhesive Bonding,Phosphoric Acid Anodizing(Application for copies shoul

13、d be addressed to the Society of AutomotiveEngineers, Incorporated, 400 Commonwealth Drive, Warrendale, PA 15096.)Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-A-83377B33. REQUIREMENTS3.1 Policy.This document specifies two basic documentary req

14、uirements for contractors (andtheir subcontractors) manufacturing adhesively bonded parts and assemblies foraerospace use. These requirements are to provide a process specification and anengineering report. The process specification is required to insure that the controlof quality and uniformity dur

15、ing fabrication of bonded assemblies is recorded. Theengineering report is to provide the Government procuring activity a recordshowing which of the important technical areas necessary for the production ofdependable quality bonded aerospace components have been considered by thecontractor. (See 6.3

16、). The process specification and engineering report shall beprepared and submitted to the contracting agency at the commencement of theproduction of material to which it applies and, thereafter, during the course ofproduction for use by authorized Government and industry inspectors in the facilityof

17、 the contractor, his subcontractors, or his vendors.3.1.1 Process specification.A detailed description of the manufacturing and fabricating process and methodsof control of manufacturing variables in the form of a titled, numbered, and datedprocess specification shall be prepared by the prime contra

18、ctor. The specificrequirements, processes, inspection methods, and precautions specified shall beincluded and completely described.3.1.2 Engineering report.Unless the information is already included in the structural report, an engineeringreport shall be prepared describing all tests used as a basis

19、 for preparation of theprocess specification and the detail drawing requirements of adhesive bondedcomponents. The engineering report shall contain a discussion of the effects onthe strength of the adhesively bonded assemblies of various environment factorsthat may be encountered by the bonded parts

20、 during their operational life. Withexisting contracts where materials and processes have been well established, alimited engineering report may suffice. Following is a partial checklist of factorswhose effects shall be considered, as applicable:(a) humidity(b) salt spray or other deleterious atmosp

21、here(c) vibration(d) cyclic temperature and temperature extremes,(e) outgassing due to space vacuum(f) x-ray, gamma-ray, UV, IR, electrical, and other energies(g) toxicity of adhesive materials originally, and after exposure toenvironmental extremesProvided by IHSNot for ResaleNo reproduction or net

22、working permitted without license from IHS-,-,-MIL-A-83377B4(h) thermal and chemical sterilization(i) stress durability, and(j) fatigue and fracture.3.1.3 Approval of documents.Prior to commencement of production, the process specification and engineeringreport shall be submitted to the procuring ac

23、tivity for approval. Subsequentchanges, such as to shop processes, which affect the validity of the approveddocument shall be made when considered necessary. However, the procuringactivity shall be contacted immediately concerning the changes. Further, formaldocumentation of the changes shall be sub

24、mitted to the procuring activity within 30days of the initiation of the changes.3.2 General requirements.3.2.1 3.2.1 The prime contractor shall assure adherence by his subcontractors to theprovisions of this document. In the event of bonded assembly failures, the primecontractor shall be responsible

25、 for assisting in the resolution of any subcontractorproblems.3.2.2 3.2.2 The adhesives and primers used and their application procedures shallprovide for the specified durability, integrity and minimum strength for the bondedparts during the proposed life of the bonded assembly and throughout expos

26、ure toall environmental factors that could reasonably be encountered during theanticipated life of the assembly.3.2.3 3.2.3 All materials used in the adhesive bonding process shall conform toapplicable Government or other specifications as stipulated by the procuringactivity. Justification shall be

27、presented in the contractors engineering report whenGovernment or Government approved material specifications cannot be used.Where Government or Government approved specifications are not completelyadequate, contractors material specifications shall specify, whenever possible,that the materials conf

28、orm to the Government or Government approved documentplus any additional requirements necessary.3.2.4 For aluminum (other than core), bonding to a chemical film coating such asMIL-C-5541 or to any surface cladding which is anodic to the base metal is notrecommended. The contractors engineering repor

29、t shall completely substantiatethe need to employ this type of bonding and shall document the reliability of thebond.3.2.5 Techniques or precautions required for proper storage and use of adhesivesand associated materials, such as bondline thickness control, control of adhesiveapplication, special t

30、emperature or humidity controls necessary during handling ofadhesive and method of adhesive and primer application, which may be applicableto the particular adhesive or to the conditions of fabrication being employed shallbe included in the process specification.Provided by IHSNot for ResaleNo repro

31、duction or networking permitted without license from IHS-,-,-MIL-A-83377B53.2.4 Stress durability for materials and process selection.The selection of adhesive, primer and other bonding process procedures shall bebased on the materials and processes which exhibit good stress durability inenvironment

32、s as determined by methods such as ASTM D2919, similar stressedlap shear tests, or ASTM D3433. The primary mode of failure in the environmentaltests documented in the engineering report shall be cohesive within the adhesiverather than adhesive failure between the substrate and the primer or between

33、theprimer and adhesive. Cyclic stressed durability is preferred whenever possible.Environments should include the highest temperatures and humidities to be seenby the bonded assembly.3.2.5 Corrosion proofing of bond joint.All aluminum bond joint areas that can at any time be exposed to humidity,mois

34、ture, salt spray, or other corrosive environments shall be protected againstdelamination and corrosion by either phosphoric acid anodize per ARP 1524 orchromic acid anodize per MIL-A-8625 plus corrosion inhibiting primer (CIP) or atreatment determined to be equal to these in stress durability studie

35、s. Sealing orovercoating of the bond joint by sealants or coatings shall not be deemed sufficientprotection to eliminate this requirement. All processes shall include corrosioninhibiting primer (CIAP), unless non-use is adequately substantiated by thecontractors engineering report.NOTE: Phosphoric a

36、cid anodizing is the preferred method for all bonding of 250Fand lower temperature curing adhesives, and also for higher curing adhesiveswherever compatibility has been established.3.2.6 Protection of bonded joints.Complete details of the materials and procedures to be used in the protection ofbonde

37、d joints shall be included in the process specification. Bonded joints, such asat the exposed edges of sandwich components, access doors, and windows shallbe protected against exposure to or entrance of liquids (water, fuel, oil, etc.) intothe core of the sandwich. Bonded sandwich assemblies shall b

38、e tested foradequacy of sealing by leak tests specified in 4.2.3.4. All permanent fastenerspenetrating bond joints shall be wet installed with sealant. Instructions for thisoperation shall be included in the contractors process specification.NOTE: Instructions for the drilling of holes for attachmen

39、ts through bonded joints ina manner that prevents bond line delamination and the installation of fastenerswith sealant shall be included in the contractors process specification.Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-A-83377B63.2.7 Bondi

40、ng personnel.Structural bonding operations shall only be performed by qualified personnel.Qualified personnel are those who have demonstrated the knowledge and practicalproficiency to indicate they possess the skills and job knowledge necessary toensure acceptable workmanship. A list of qualified pr

41、ime or subcontractor bondingpersonnel shall be issued indicating qualification and level of proficiency, andrequalification date. This list shall be available for review by Governmentpersonnel.3.3 Processing.3.3.1 Bonding.3.3.1.1 Process and assembly area.All application of adhesive and primers shal

42、l be conducted in a controlled area asspecified in the contractors process specification. If priming and cleaning areasare not immediately adjacent to each other, parts shall be moved into a controlledarea within one hour maximum. Areas through which unprotected treated detailsare transported shall

43、not contain dust, oily vapors, aerosols, or contaminantsdeleterious to bonding.3.3.1.2 Controlled area.The controlled area shall be maintained under positive pressure differential at alltimes by a continuously operating air handling system. The following conditionsapply unless otherwise documented b

44、y engineering report:(a) air filtration - regular maintenance of filters(b) no eating or smoking in the area(c) maintain records of controlled area conditions(d) vehicles permitted in the controlled area must be nonpolluting inoperation, such as electrically or hand propelled(e) no process or operat

45、ion which produces uncontrolled spray, dust, fumes,or particulate matter is permitted in the controlled area.3.3.1.3 Temperature/relative humidity in controlled areas.ranging from 65 to 85F (18.3 to 29.4C) and a maximum relative humidity of 60percent shall be the controlled conditions.3.3.2 Equipmen

46、t.3.3.2.1 Presses, bond forms, autoclaves, ovens and pressure equipment.The temperature and pressure requirements for bonding operations (includingprimer curing), and details of procedures to be followed shall be included in theprocess specification. All pressure and temperature equipment and gauges

47、 shallbe tested and calibrated on a scheduled basis. Thermal qualification shall becertified only by qualified measurement personnel, not production personnel.Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-A-83377B73.3.2.2 Tool qualification.Eac

48、h bonding tool shall be qualified prior to production by the verification filmtechnique specified in 3.3.3.1, or by the destructive evaluation of the first bondedassembly, or by proof loading or other suitable means approved by the contractingagency. Succeeding parts will be selected for requalifica

49、tion based on the resultsof the Quality Control tests in 4.2.1, 4.2.2, and 4.2.3.1. Each bonding tool shall besubject to contractor engineering review to determine if requalification is necessaryif any dimensional or thermal control changes are made to the tool. This includeschanging the thickness or method of placement of bleeder cloth, shims, caulplates, etc., that could be reasonably expected to affect the thermal or dimensionalcharacte