1、Designation: E1801 09Standard Practice forAdhesive Bonding of Aluminum Facings in Foam and BeamType Shelters1This standard is issued under the fixed designation E1801; the number immediately following the designation indicates the year oforiginal adoption or, in the case of revision, the year of las
2、t revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon () 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, proc
3、esses, 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 purpo
4、rt 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:2B209
5、 Specification for Aluminum and Aluminum-AlloySheet and PlateE1730 Specification for Rigid Foam for Use in StructuralSandwich Panel CoresE1749 Terminology Relating to Rigid Wall RelocatableSheltersE1793 Practice for Preparation of Aluminum Alloy forBonding in Foam and Beam Type Transportable Shelter
6、sE1794 Specification for Adhesive for Bonding Foam CoredSandwich Panels (200F Elevated Humidity Service), TypeII PanelsE1800 Specification for Adhesive for Bonding Foam CoredSandwich Panels (160F Elevated Humidity Service), TypeI Panels2.2 Federal Standard:3QQ-A-250/11 Alumium Alloy 6061T6 Plate and
7、 Sheet3. Significance and Use3.1 The formation of reproducible, durable 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 bo
8、nds. This practice is appli-cable to both the Type 1, 71C (160F), 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
9、shall be free of oils,grease, silicone, lint, or other contaminants 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 tempera
10、ture range shall be no more than 14C (25F).5. Apparatus5.1 Pressure 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 tw
11、o facings of the press platens during bonding will beequal and uniform within 63C (65F) of the indicatedtemperature. The platens shall be flat to within 0.08 mm/3051This practice is under the jurisdiction of ASTM Committee E06 on Perfor-mance of Buildings and is the direct responsibility of Subcommi
12、ttee E06.53 onMaterials and Processes for Durable Rigidwall Relocatable Structures.Current edition approved Nov. 1, 2009. Published December 2009. Originallyapproved in 1996. Last previous edition approved in 2003 as E1801 03. DOI:10.1520/E1801-09.2For referenced ASTM standards, visit the ASTM websi
13、te, www.astm.org, orcontact ASTM Customer Service at serviceastm.org. For Annual Book of ASTMStandards volume information, refer to the standards Document Summary page onthe ASTM website.3Available from Standardization Documents Order Desk, DODSSP, Bldg. 4,Section D, 700 Robbins Ave., Philadelphia,
14、PA 19111-5098, http:/dodssp.daps.dla.mil.1Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.mm (0.003 in./ft) and shall be smooth having a maximumsurface roughness of 125 rms. The pressure equipment shall beequipped with temperature and
15、 pressure recorders and controlsthat accurately control heat-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 purchase
16、r. All calibrations shall be traceableto the National Institute of Standards and Technology. Thelatest calibration certificate shall be attached to the equipmentnear each gage. Thermocouples placed at each corner and at thecenter of each facing shall be used to demonstrate the unifor-mity of the tem
17、perature. A permanent record of the pressure,time, and temperature during bonding shall be maintained.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
18、 by this practice shall be traceable to theNational Institute of Standards and Technology.6. Materials6.1 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
19、 degrading environments and me-chanical damage.6.2 Aluminum:6.2.1 FacingsThe facings shall be aluminum alloy con-forming to Specification B209 and shall be certified as com-plying with the alloy, temper, and thickness requirements of theshelter specification. Facings shall be free of corrosion, exce
20、s-sive oil canning (snap-buckling), dents, gouges, or otherdefects that may adversely affect the structural 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
21、Preparation of Aluminum-Alloy Parts for Bonding:6.2.2.1 Type 1, 71C (160F), Elevated Humidity ServiceSheltersThe aluminum-alloy parts used in the manufactureof Type 1 foam and beam panels shall be prepared for bondingin accordance with Practice E1793 and Specification E1800.The surface resistance of
22、 6061-T6 aluminum alloy (QQ-A-250/11) test coupons cleaned by the same process, shall be no morethan 100 microhms when measured under a nominal electrodeforce of 4.14 6 1.70 MPa (600 6 25 psi) and a current of 106 0.2 amperes. Five coupons shall be tested during each4hofcleaning operations.6.2.2.2 T
23、ype 2, 93C (200F), Elevated Humidity ServiceSheltersThe aluminum-alloy parts used in the manufactureof Type 2 foam and beam panels shall be prepared for bondingin accordance with Practice E1793 and Specification E1794.The surface resistance of the cleaned parts, or test coupons ofthe same alloy and
24、cleaned by the same process, shall be nomore than 100 microhms when measured under a nominalelectrode force of 4.14 6 1.7 MPa (600 6 25 psi) and a currentof 10 6 0.2 amperes. Five coupons shall be tested during each4 h of cleaning operations.6.3 Foam CoreThe foam core material shall be as speci-fied
25、 in the shelter specification and shall meet the requirementsof Specification E1730. Manufacturers certification or reportsof tests for conformance to this specification shall be availableor included with each shipment, or both.6.4 AdhesivesThe adhesive shall conform to SpecificationE1800 for Type 1
26、 shelters or Specification E1794 for Type 2shelters. The adhesive shall be stored and used in accordancewith the manufacturers recommendations. Manufacturerscertification or reports of tests for conformance to this speci-fication shall be available or included with each shipment, orboth.6.5 Preparat
27、ion of Nonmetallic Parts Prior to BondingIfnecessary, all plastic, wood, and foam parts used in theconstruction of these shelters shall be prepared for bondingprior to the application of the adhesive. Parts with gouges,broken edges, splits or cracks, or other defects shall not beused.7. Bonding and
28、Curing7.1 Preparation of Materials Bonding All cutting, trim-ming, and sizing of aluminum, plastic, and wood parts shall bemade prior to surface preparation or on the panel followingcompletion of the bonding operation. The faying surfaces ofaluminum parts to be bonded shall be prepared as designated
29、 in7.2.2. All prepared aluminum for bonded panels shall be storedto prevent contamination of the bonding surface. Preparedparts that are not bonded within 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 desi
30、gnatedin 7.5 and 7.6 respectively. All material prepared for bondingshall be handled with clean cotton gloves to prevent contami-nation of surfaces prior 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
31、such a manner and in sufficient quantity to fill allvoids between faying surfaces and to ensure a continuous bondbetween parts as evidenced by adhesive 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 (1
32、00F) 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 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 Cur
33、e 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) for 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 pres
34、sure 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 2 PanelsPanels shall be cured at a temperatureof not less than 93C (200F) for 90 min or at a temperature ofE1801 092107C (225F) for 60 min. Timing of
35、 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 temperature for either cure shall be fully attainedwithin 3 h after the application of adhesive.7.3.3 Post-CuringWhen required by the contra
36、ct 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 OperationThe bonding pressure shall berecorded for each bonding cycle. The pressure shall be main-tained within 10 % of indicated pressure during
37、the bondingcycle. Charts relating to the pressure and temperature shall bemaintained as a permanent record.7.5 Storage and Handling of Bonded PanelsPanels shallbe handled with care to avoid damage such as skin punctures,dents, and delaminations. Unreinforced edges are particularlysusceptible to dama
38、ge. Clamps shall be applied to panels onlyin areas reinforced with structural members.7.6 Panel CleanupAdhesive squeeze-out from the bondline shall be removed whenever part function or dimensionaltolerances are adversely affected. The adhesive shall be re-moved by mechanical means such that dimensio
39、nal tolerancesare maintained and to preclude delaminations and grindingdamage to the panel. Chemical strippers shall not be used.8. Process Control8.1 Aluminum FacingsUpon completion of the cleaningcycle in accordance with Practice E1793, the aluminum facingsshall be identified with a label or tape
40、indicating the date andtime of cleaning cycle. This label shall be used for determiningthe bonding time period in accordance with 7.2. The label ortape shall not transfer any residue to the facing when removed.8.2 AdhesiveAt the beginning of each bonding shift acalibration check of the mix ratio of
41、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 coupons 25.4 by 102 by 2.29mm (1 by 4 by 0.090 in.) 6061-T6 aluminum alloy (QQ-A-250/11) shall be cleaned in accordance with 8.1 a
42、nd bondedwith 12.7 mm (12 in.) overlap using production adhesive. Thetest coupons shall be cured at production time and temperatureand, when tested at room temperature, shall provide a mini-mum bond strength of 10.3 MPa (1500 psi) for Type 1 adhesiveand 13.7 MPa (2000 psi) for Type 2 adhesive.8.3 Wo
43、od 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 be redried prior to use.Testing shall be done using a wood moisture detector.48.4 Fabricated S
44、helter 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 processing. Theshelter panels shall be inspected and tested in accordance withSection 10.8.5 H
45、andlingThe 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 such a manner asto protect them against damage and deterioration.9. Certification9.1 At the r
46、equest 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 for Inspection Unless otherwisespecified by the purchaser, the manufacturer is responsible fo
47、rmeeting 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 forth in this practice, and shall beprovided every facility for careful inspection and sampl
48、ing.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. Failure to meet any test shall because for complete review of each process variable and forrequa
49、lification 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 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.10.4 V
