Development of adhesive bonds with reduced fracture strength as NDE benchmarks

A method for producing adhesively bonded aluminum joints with a predictable loss of fracture strength was developed and evaluated. The method uses an open-faced specimen geometry and a humid high-temperature environment to promote adhesive degradation. The rate of degradation was greatly increased over previous accelerated degradation schemes through the use of MgSO₄ as a contaminant. The contaminant was applied as an aerosol in a purpose-built duct having a controlled airflow. Specimens were prepared and subjected to accelerated aging under a variety of conditions and then fractured using a DCB loading jig. It was found that the contaminant surface concentration was a strong determinant of the fracture strength after hot-wet aging. Exposure to the hot-wet environment was shown to have little effect beyond an initial threshold. Standard ultrasonic imaging techniques were incapable of differentiating between fresh and hot-wet aged specimens, in spite of significant differences in the fracture strength. This is consistent with the hypothesis that the approach produced specimens that simulated the effects of environmental attack, since standard ultrasonic methods, such as those used in the present study, cannot detect such losses of fracture strength in the absence of any delamination between adhesive and adherend. FESEM and EDX analysis of the fracture surfaces showed residual aluminum, suggesting an intra-oxide locus of failure consistent with other accelerated degradation methods. The technique can be used to generate adhesive joint specimens to aid the development of ultrasonic methods capable of detecting the loss of fracture strength associated with environmental degradation.