1、Designation: E 1801 03Standard Practice forAdhesive Bonding of Aluminum Facings in Foam and BeamType Shelters1This standard is issued under the fixed designation E 1801; the number immediately following the designation indicates the year oforiginal adoption or, in the case of revision, the year of l
2、ast revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon (e) indicates an editorial change since the last revision or reapproval.This standard has been approved for use by agencies of the Department of Defense.1. Scope1.1 This practice covers the materials, p
3、rocesses, and qual-ity controls to be used in the manufacture of adhesive-bonded,aluminum-faced, foam core sandwich panels for tactical shel-ters.1.2 The values stated in SI units are to be regarded as thestandard. The values given in parentheses are for informationonly.1.3 This standard does not pu
4、rport to address all of thesafety concerns, if any, associated with its use. It is theresponsibility of the user of this standard to establish appro-priate safety and health practices and determine the applica-bility of regulatory limitations prior to use.2. Referenced Documents2.1 ASTM Standards:B
5、209 Specification for Aluminum and Aluminum-AlloySheet and Plate2E 1730 Specification for Rigid Foam for Use in ShelterSandwich Panel Cores3E 1749 Terminology of Rigid Wall Relocatable Shelters3E 1793 Practice for the Preparation of Aluminum Alloy forBonding in Foam and Beam Type Transportable Shelt
6、ers3E 1794 Specification forAdhesive for Bonding Foam CoredSandwich Panels (200F Elevated Humidity Service), TypeII Panels3E 1800 Specification forAdhesive for Bonding Foam CoredSandwich Panels (160F Elevated Humidity Service), TypeI Panels33. Significance and Use3.1 The formation of reproducible, d
7、urable adhesive bondsin structural units requires great care in the performance of thesteps in the bonding process. Experience has shown thatadhesive bonding carried out in accordance with this practiceproduces reproducible adhesive bonds. This practice is appli-cable to both the Type 1, 71C (160F),
8、 and Type 2, 93C(200F), elevated humidity service type of foam and beamshelter.4. Facilities4.1 Panel Assembly Layup AreaThe panel assembly layuparea shall be a ventilated area maintained at a minimumtemperature of 20C (68F). The area shall be free of oils,grease, silicone, lint, or other contaminan
9、ts detrimental to theproduction of adhesive bonds.4.2 Post-Curing RoomsThe post-curing rooms shall pro-vide a uniform temperature distribution over all panels andover all portions of the panels exposed for post-curing. Thetotal temperature range shall be no more than 14C (25F).5. Apparatus5.1 Pressu
10、re EquipmentPressure equipment for bondingof shelter panels shall be large enough to permit the bonding ofa complete panel in one step. The manufacturer shall providecalibration and test data demonstrating that the temperature onthe two facings of the press platens during bonding will beequal and un
11、iform within 63C (65F) of the indicatedtemperature. The platens shall be flat to within 0.08 mm/305mm (0.003 in./ft) and shall be smooth having a maximumsurface roughness of 125 rms. The pressure equipment shall beequipped with temperature and pressure recorders and controlsthat accurately control h
12、eat-up, pressure applied, and dwelltime.5.2 Calibrations, Temperature and Pressure Requirements,and ControlsGages shall be calibrated every 6 months by anaccredited independent laboratory or by the panel manufacturerif approved by the purchaser. All calibrations shall be traceableto the National Ins
13、titute of Standards and Technology. Thelatest calibration certificate shall be attached to the equipmentnear each gage. Thermocouples placed at each corner and at the1This practice is under the jurisdiction of ASTM Committee E06 on Perfor-mance of Buildings and is the direct responsibility of Subcom
14、mittee E06.53 onMaterials and Processes for Durable Rigidwall Relocatable Structures.Current edition approved April 10, 2003. Published May 2003. Originallyapprove in 1996. Last previous edition approved in 2000 as E 180100.2Annual Book of ASTM Standards, Vol 02.02.3Annual Book of ASTM Standards, Vo
15、l 04.11.1Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.center of each facing shall be used to demonstrate the unifor-mity of the temperature. A permanent record of the pressure,time, and temperature during bonding shall be maintaine
16、d.5.3 Calibration of Testing Equipment Calibration of therequired testing equipment shall be done in accordance withthe equipment manufacturers instructions. All calibrations oftest equipment required by this practice shall be traceable to theNational Institute of Standards and Technology.6. Materia
17、ls6.1 The materials used in bonded panels shall meet therequirements of the contract or specified drawings. All mate-rials shall be stored and handled in such manner so as toprovide protection against degrading environments and me-chanical damage.6.2 Aluminum:6.2.1 FacingsThe facings shall be alumin
18、um alloy con-forming to Specification B 209 and shall be certified ascomplying with the alloy, temper, and thickness requirementsof the shelter specification. Facings shall be free of corrosion,excessive oil canning (snap-buckling), dents, gouges, or otherdefects that may adversely affect the struct
19、ural integrity of thebonded panel. Manufacturers certification of reports of testsfor mechanical properties and chemical composition shall beavailable or included with each shipment, or both.6.2.2 Preparation of Aluminum-Alloy Parts for Bonding:6.2.2.1 Type 1, 71C (160F), Elevated Humidity ServiceSh
20、eltersThe aluminum-alloy parts used in the manufactureof Type 1 foam and beam panels shall be prepared for bondingin accordance with Specification E 1793. The surface resis-tance of 6061-T6 aluminum alloy test coupons cleaned by thesame process, shall be no more than 100 microhms whenmeasured under
21、a nominal electrode force of 4.14 6 1.70 MPa(600 6 25 psi) and a current of 10 6 0.2 amperes. Fivecoupons shall be tested during each4hofcleaning operations.6.2.2.2 Type 2, 93C (200F), Elevated Humidity ServiceSheltersThe aluminum-alloy parts used in the manufactureof Type 2 foam and beam panels sha
22、ll be prepared for bondingin accordance with Specification E 1793. The surface resis-tance of the cleaned parts, or test coupons of the same alloy andcleaned by the same process, shall be no more than 100microhms when measured under a nominal electrode force of4.14 6 1.7 MPa (600 6 25 psi) and a cur
23、rent of 10 6 0.2amperes. Five coupons shall be tested during each4hofcleaning operations.6.3 Foam CoreThe foam core material shall be as speci-fied in the shelter specification and shall meet the requirementsof Specification E 1730. Manufacturers certification or reportsof tests for conformance to t
24、his specification shall be availableor included with each shipment, or both.6.4 AdhesivesThe adhesive shall conform to SpecificationE 1800 for Type 1 shelters or Specification E 1794 for Type 2shelters. The adhesive shall be stored and used in accordancewith the manufacturers recommendations. Manufa
25、cturerscertification or reports of tests for conformance to this speci-fication shall be available or included with each shipment, orboth.6.5 Preparation of Nonmetallic Parts Prior to BondingIfnecessary, all plastic, wood, and foam parts used in theconstruction of these shelters shall be prepared fo
26、r bondingprior to the application of the adhesive. Parts with gouges,broken edges, splits or cracks, or other defects shall not beused.7. Bonding and Curing7.1 Preparation of Materials Bonding All cutting, trim-ming, and sizing of aluminum, plastic, and wood parts shall bemade prior to surface prepa
27、ration or on the panel followingcompletion of the bonding operation. The faying surfaces ofaluminum parts to be bonded shall be prepared as designated in7.2.2. All prepared aluminum for bonded panels shall be storedto prevent contamination of the bonding surface. Preparedparts that are not bonded wi
28、thin 72 h after cleaning shall bereprocessed as designated in 7.2. The faying surfaces of plasticand foam and wood parts to be bonded shall be as designatedin 7.5 and 7.6 respectively. All material prepared for bondingshall be handled with clean cotton gloves to prevent contami-nation of surfaces pr
29、ior to bonding.7.1.1 Adhesive ApplicationAdhesive shall be applied uni-formly on all faying surfaces of the parts being bonded. It shallbe applied in such a manner and in sufficient quantity to fill allvoids between faying surfaces and to ensure a continuous bondbetween parts as evidenced by adhesiv
30、e flash (squeeze-out) atthe edges when the parts are cured.7.2 Assembly of Panels:7.2.1 Type 1 PanelsNo more than 75 min at 25C (77F)(45 min at 38C (100F) shall elapse between the firstapplication of adhesive to the panel and the application ofpressure to that panel.7.2.2 Type 2 PanelsNo more than 2
31、 h at 25C (77F) (45min at 38C (100F) shall elapse between the application ofadhesive to the panel and the application of pressure to thatpanel.7.3 Cure of Bonded Panels:7.3.1 Type 1 PanelsPanels shall be cured at a temperatureof not less than 52C (125F) for 4 h or at a temperature of63C (145 6 5F) f
32、or not less than 1 h. Timing of the cure shallnot start until the panel skins have reached the specifiedtemperature. Either cure shall be under a pressure of 0.05 60.007 MPa (8.0 6 0.5 psi). The temperature for either cureshall be fully attained within 2 h after the application ofadhesive.7.3.2 Type
33、 2 PanelsPanels shall be cured at a temperatureof not less than 93C (200F) for 90 min or at a temperature of107C (225F) for 60 min. Timing of cure shall not start untilthe panel skins have reached the specified temperature. Eithercure shall be under a pressure of 0.05 6 0.007 MPa (8.0 6 0.5psi). The
34、 temperature for either cure shall be fully attainedwithin 3 h after the application of adhesive.7.3.3 Post-CuringWhen required by the contract or adhe-sive manufacturers recommendation, bonded panels shall bestored at 27 6 5C (80 6 10F) for a minimum of 24 h beforefurther handling.7.4 Bonding Opera
35、tionThe bonding pressure shall berecorded for each bonding cycle. The pressure shall be main-tained within 10 % of indicated pressure during the bondingcycle. Charts relating to the pressure and temperature shall bemaintained as a permanent record.E18010327.5 Storage and Handling of Bonded PanelsPan
36、els shallbe handled with care to avoid damage such as skin punctures,dents, and delaminations. Unreinforced edges are particularlysusceptible to damage. Clamps shall be applied to panels onlyin areas reinforced with structural members.7.6 Panel CleanupAdhesive squeeze-out from the bondline shall be
37、removed whenever part function or dimensionaltolerances are adversely affected. The adhesive shall be re-moved by mechanical means such that dimensional tolerancesare maintained and to preclude delaminations and grindingdamage to the panel. Chemical strippers shall not be used.8. Process Control8.1
38、Aluminum FacingsUpon completion of the cleaningcycle per Specification E 1793, the aluminum facings shall beidentified with a label or tape indicating the date and time ofcleaning cycle. This label shall be used for determining thebonding time period per 7.2. The label or tape shall not transferany
39、residue to the facing when removed.8.2 AdhesiveAt the beginning of each bonding shift acalibration check of the mix ratio of the adhesive shall beperformed. The ratio shall be within 10 % of the manufactur-ers recommended mix ratio. For each8hofbonding opera-tions, five adhesive lap shear test coupo
40、ns 25.4 by 102 by 2.29mm 6061-T6 aluminum alloy (1 by 4 by 0.090 in.) shall becleaned per 8.1 and bonded with 12.7 mm (12 in.) overlap usingproduction adhesive. The test coupons shall be cured atproduction time and temperature and, when tested at roomtemperature, shall provide a minimum bond strengt
41、h of 10.3MPa (1500 psi) for Type 1 adhesive and 13.7 MPa (2000 psi)for Type 2 adhesive.8.3 Wood PartsDuring bonding operations, five woodproduction parts shall be tested at the beginning of the shift andat 4-h intervals for moisture content. Parts which have inexcess of 12 % moisture content shall b
42、e redried prior to use.Testing shall be done using a wood moisture detector.48.4 Fabricated Shelter PanelsCompletely fabricated shel-ter panels processed in accordance with the requirements ofthis practice shall be inspected and tested as specified. Eachpanel shall be inspected prior to subsequent p
43、rocessing. Theshelter panels shall be inspected and tested in accordance withSection 10.8.5 HandlingThe laminated panels shall be handled withdue care to avoid damage that would cause their rejection.8.6 StorageBonded panels prepared in accordance withthis practice shall be stored until required in
44、such a manner asto protect them against damage and deterioration.9. Certification9.1 At the request of the purchaser in the contract or order,a manufacturers certification shall be provided indicating thatthe panel-bonding process complied with this practice.10. Quality Assurance10.1 Responsibility
45、for Inspection Unless otherwisespecified by the purchaser, the manufacturer is responsible formeeting all inspection requirements. The manufacturer mayuse his/her own or any other suitable facilities approved by thepurchaser. The purchaser has the right to perform any of thetests and inspections set
46、 forth in this practice, and shall beprovided every facility for careful inspection and sampling.10.2 Acceptability CriteriaThe bonding process shallconform to all requirements specified herein, and the testspecimens shall pass all applicable examinations and tests inSection 10 of this practice. Fai
47、lure to meet any test shall because for complete review of each process variable and forrequalification of each constituent material to the extentnecessary to determine the cause of the failure and takenecessary corrective action. Items not in compliance with thispractice and referenced documents in
48、 regard to materials,dimensions, tolerances, and workmanship shall be rejected.10.3 Component and Material Inspection The manufac-turer is responsible for assuring that components and materialsused are manufactured, examined, and tested in accordancewith the requirements of the referenced standard.1
49、0.4 Visual Inspection of PanelsAfter the bonded panelshave cooled to the ambient temperature, and before furtherprocessing, visually inspect each bonded panel. Reject anypanel that has a bulge, depression, or dent greater than twicethe facing thickness. Reject any panel that has a bulge,depression, or dent greater than the facing thickness and anarea greater than 5000 mm2(8 in.2). Reject any panel with afacing gouge deeper than one fourth the facing thickness.Measure deviation from flatness witha1m(39.4 in.) long
