1、Designation: E1801 09E1801 15Standard 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 yea
2、r of last 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 U.S. Department of Defense.1. Scope1.1 This practice covers the ma
3、terials, processes, and quality controls to be used in the manufacture of adhesive-bonded,aluminum-faced, foam core sandwich panels for tactical shelters.1.2 The values stated in SIinch-pound units are to be regarded as the standard. The values given in parentheses are forinformation only. mathemati
4、cal conversions to SI units that are provided for information only and are not considered standard.1.3 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibilityof the user of this standard to establish appropriate safety and healt
5、h practices and determine the applicability of regulatorylimitations prior to use.2. Referenced Documents2.1 ASTM Standards:2B209 Specification for Aluminum and Aluminum-Alloy Sheet and PlateE631 Terminology of Building ConstructionsE1730 Specification for Rigid Foam for Use in Structural Sandwich P
6、anel CoresE1749 Terminology Relating to Rigid Wall Relocatable SheltersE1793 Practice for Preparation of Aluminum Alloy for Bonding in Foam and Beam Type Transportable SheltersE1794 Specification forAdhesive for Bonding Foam Cored Sandwich Panels (200F Elevated Humidity Service), Type II PanelsE1800
7、 Specification forAdhesive for Bonding Foam Cored Sandwich Panels (160F Elevated Humidity Service), Type I Panels2.2 Federal Standard:3QQ-A-250/11 Alumium Alloy 6061T6 Plate and Sheet3. Terminology3.1 DefinitionsSee Terminologies E631 and E1749 for definitions of general terms used in this practice.
8、4. Significance and Use4.1 The formation of reproducible, durable adhesive bonds in structural units requires great care in the performance of the stepsin the bonding process. Experience has shown that adhesive bonding carried out in accordance with this practice producesreproducible adhesive bonds.
9、 This practice is applicable to both the Type 1, 71C (160F),160F (71C), and Type 2, 93C(200F),200F (93C), elevated humidity service type of foam and beam shelter.5. Facilities5.1 Panel Assembly Layup AreaThe panel assembly layup area shall be a ventilated area maintained at a minimumtemperature of 2
10、0C (68F).68F (20C). The area shall be free of oils, grease, silicone, lint, or other contaminants detrimental tothe production of adhesive bonds.1 This practice is under the jurisdiction of ASTM Committee E06 on Performance of Buildings and is the direct responsibility of Subcommittee E06.53 on Mate
11、rials andProcesses for Durable Rigidwall Relocatable Structures.Current edition approved Nov. 1, 2009May 1, 2015. Published December 2009August 2015. Originally approved in 1996. Last previous edition approved in 20032009as E1801 03.E1801 09. DOI: 10.1520/E1801-09.10.1520/E1801-15.2 For referencedAS
12、TM standards, visit theASTM website, www.astm.org, or contactASTM Customer Service at serviceastm.org. For Annual Book of ASTM Standardsvolume information, refer to the standards Document Summary page on the ASTM website.3 Available from Standardization Documents Order Desk, DODSSP, Bldg. 4, Section
13、 D, DLA Document Services, Building 4/D, 700 Robbins Ave., Philadelphia, PA19111-5098, http:/dodssp.daps.dla.mil.19111-5094, http:/quicksearch.dla.mil.This document is not an ASTM standard and is intended only to provide the user of an ASTM standard an indication of what changes have been made to th
14、e previous version. Becauseit may not be technically possible to adequately depict all changes accurately, ASTM recommends that users consult prior editions as appropriate. In all cases only the current versionof the standard as published by ASTM is to be considered the official document.Copyright A
15、STM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States15.2 Post-Curing RoomsThe post-curing rooms shall provide a uniform temperature distribution over all panels and over allportions of the panels exposed for post-curing. The total temperature range s
16、hall be no more than 14C (25F).25F (14C).6. Apparatus6.1 Pressure EquipmentPressure equipment for bonding of shelter panels shall be large enough to permit the bonding of acomplete panel in one step. The manufacturer shall provide calibration and test data demonstrating that the temperature on the t
17、wofacings of the press platens during bonding will be equal and uniform within 63C (65F)65F (63C) of the indicatedtemperature. The platens shall be flat to within 0.08 mm/305 mm (0.003 in./ft)0.003 in./ft (0.08 mm/305 mm) and shall be smoothhaving a maximum surface roughness of 125 rms. The pressure
18、 equipment shall be equipped with temperature and pressurerecorders and controls that accurately control heat-up, pressure applied, and dwell time.6.2 Calibrations, Temperature and Pressure Requirements, and ControlsGages shall be calibrated every 6six months by anaccredited independent laboratory o
19、r by the panel manufacturer if approved by the purchaser. All calibrations shall be traceableto the National Institute of Standards and Technology. The latest calibration certificate shall be attached to the equipment near eachgage. Thermocouples placed at each corner and at the center of each facin
20、g shall be used to demonstrate the uniformity of thetemperature. A permanent record of the pressure, time, and temperature during bonding shall be maintained.6.3 Calibration of Testing EquipmentCalibration of the required testing equipment shall be done in accordance with theequipment manufacturers
21、instructions.All calibrations of test equipment required by this practice shall be traceable to the NationalInstitute of Standards and Technology.7. Materials7.1 The materials used in bonded panels shall meet the requirements of the contract or specified drawings. All materials shallbe stored and ha
22、ndled in such manner so as to provide protection against degrading environments and mechanical damage.7.2 Aluminum:7.2.1 FacingsThe facings shall be aluminum alloy conforming to Specification B209 and shall be certified as complying withthe alloy, temper, and thickness requirements of the shelter sp
23、ecification. Facings shall be free of corrosion, excessive oil canning(snap-buckling), dents, gouges, or other defects that may adversely affect the structural integrity of the bonded panel.Manufacturers certification of reports of tests for mechanical properties and chemical composition shall be av
24、ailable or includedwith each shipment, or both.7.2.2 Preparation of Aluminum-Alloy Parts for Bonding:7.2.2.1 Type 1, 71C (160F),160F (71C), Elevated Humidity Service SheltersThe aluminum-alloy parts used in themanufacture of Type 1 foam and beam panels shall be prepared for bonding in accordance wit
25、h Practice E1793 and SpecificationE1800. The surface resistance of 6061-T6 aluminum alloy (QQ-A-250/11) test coupons cleaned by the same process, shall be nomore than 100 microhms when measured under a nominal electrode force of 4.14 6 1.70 MPa (600 6 25 psi)600 6 25 psi (4.146 1.70 MPa) and a curre
26、nt of 10 6 10 6 0.2 amperes. Five coupons shall be tested during each 4 h of cleaning operations.7.2.2.2 Type 2, 93C (200F),200F (93C), Elevated Humidity Service SheltersThe aluminum-alloy parts used in themanufacture of Type 2 foam and beam panels shall be prepared for bonding in accordance with Pr
27、actice E1793 and SpecificationE1794. The surface resistance of the cleaned parts, or test coupons of the same alloy and cleaned by the same process, shall beno more than 100 microhms when measured under a nominal electrode force of 4.14 6 1.7 MPa (600 6 25 psi)600 6 25 psi (4.146 1.7 MPa) and a curr
28、ent of 10 6 0.2 10 6 0.2 amperes. Five coupons shall be tested during each 4 h of cleaning operations.7.3 Foam CoreThe foam core material shall be as specified in the shelter specification and shall meet the requirements ofSpecification E1730. Manufacturers certification or reports of tests for conf
29、ormance to this specification shall be available orincluded with each shipment, or both.7.4 AdhesivesThe adhesive shall conform to Specification E1800 for Type 1 shelters or Specification E1794 for Type 2shelters. The adhesive shall be stored and used in accordance with the manufacturers recommendat
30、ions. Manufacturerscertification or reports of tests for conformance to this specification shall be available or included with each shipment, or both.7.5 Preparation of Nonmetallic Parts Prior to BondingIf necessary, all plastic, wood, and foam parts used in the constructionof these shelters shall b
31、e prepared for bonding prior to the application of the adhesive. Parts with gouges, broken edges, splits orcracks, or other defects shall not be used.8. Bonding and Curing8.1 Preparation of Materials BondingAll cutting, trimming, and sizing of aluminum, plastic, and wood parts shall be madeprior to
32、surface preparation or on the panel following completion of the bonding operation. The faying surfaces of aluminum partsto be bonded shall be prepared as designated in 7.2.28.2.2. All prepared aluminum for bonded panels shall be stored to preventcontamination of the bonding surface. Prepared parts t
33、hat are not bonded within 72 h after cleaning shall be reprocessed asdesignated in 7.28.2. The faying surfaces of plastic and foam and wood parts to be bonded shall be as designated in 7.58.5 and7.68.6 respectively. All material prepared for bonding shall be handled with clean cotton gloves to preve
34、nt contamination ofsurfaces prior to bonding.E1801 1528.1.1 Adhesive ApplicationAdhesive shall be applied uniformly on all faying surfaces of the parts being bonded. It shall beapplied in such a manner and in sufficient quantity to fill all voids between faying surfaces and to ensure a continuous bo
35、nd betweenparts as evidenced by adhesive flash (squeeze-out) at the edges when the parts are cured.8.2 Assembly of Panels:8.2.1 Type 1 PanelsNo more than 75 min at 25C (77F)77F (25C) (45 min at 38C (100F)100F (38C) shall elapsebetween the first application of adhesive to the panel and the applicatio
36、n of pressure to that panel.8.2.2 Type 2 PanelsNo more than 2 h at 25C (77F) (45 min at 38C (100F)77F (25C) (45 min at 100F (38C) shallelapse between the application of adhesive to the panel and the application of pressure to that panel.8.3 Cure of Bonded Panels:8.3.1 Type 1 PanelsPanels shall be cu
37、red at a temperature of not less than 52C (125F)125F (52C) for 4 h or at atemperature of 63C (145 6 5F) 145 6 5F (63C) for not less than 1 h. Timing of the cure shall not start until the panel skinshave reached the specified temperature. Either cure shall be under a pressure of 0.05 6 0.007 MPa (8.0
38、 6 0.5 psi). 8.0 6 0.5 psi(0.05 6 0.007 MPa). The temperature for either cure shall be fully attained within 2 h after the application of adhesive.8.3.2 Type 2 PanelsPanels shall be cured at a temperature of not less than 93C (200F)200F (93C) for 90 min or at atemperature of 107C (225F)225F (107C) f
39、or 60 min. Timing of cure shall not start until the panel skins have reached thespecified temperature. Either cure shall be under a pressure of 0.0560.007 MPa (8.060.5 psi).8.060.5 psi (0.0560.007 MPa).The temperature for either cure shall be fully attained within 3 h after the application of adhesi
40、ve.8.3.3 Post-CuringWhen required by the contract or adhesive manufacturers recommendation, bonded panels shall be storedat 2780 6 5C (8010F (27 6 10F)5C) for a minimum of 24 h before further handling.8.4 Bonding OperationThe bonding pressure shall be recorded for each bonding cycle. The pressure sh
41、all be maintainedwithin 10 % of indicated pressure during the bonding cycle. Charts relating to the pressure and temperature shall be maintainedas a permanent record.8.5 Storage and Handling of Bonded PanelsPanels shall be handled with care to avoid damage such as skin punctures, dents,and delaminat
42、ions. Unreinforced edges are particularly susceptible to damage. Clamps shall be applied to panels only in areasreinforced with structural members.8.6 Panel CleanupAdhesive squeeze-out from the bond line shall be removed whenever part function or dimensionaltolerances are adversely affected. The adh
43、esive shall be removed by mechanical means such that dimensional tolerances aremaintained and to preclude delaminations and grinding damage to the panel. Chemical strippers shall not be used.9. Process Control9.1 Aluminum FacingsUpon completion of the cleaning cycle in accordance with Practice E1793
44、, the aluminum facings shallbe identified with a label or tape indicating the date and time of cleaning cycle. This label shall be used for determining the bondingtime period in accordance with 7.28.2. The label or tape shall not transfer any residue to the facing when removed.9.2 AdhesiveAt the beg
45、inning of each bonding shift a calibration check of the mix ratio of the adhesive shall be performed.The ratio shall be within 10 % of the manufacturers recommended mix ratio. For each 8 h of bonding operations, five adhesivelap shear test coupons 25.41 by 102 by 2.29 mm (1 by 4 by 0.090 in.) 4 by 0
46、.090 in. (25.4 by 102 by 2.29 mm) 6061-T6 aluminumalloy (QQ-A-250/11) shall be cleaned in accordance with 8.19.1 and bonded with 12.7 mm (12 in.)in. (12.7 mm) overlap usingproduction adhesive. The test coupons shall be cured at production time and temperature and, when tested at room temperature,sha
47、ll provide a minimum bond strength of 10.3 MPa (1500 psi)1500 psi (10.3 MPa) for Type 1 adhesive and 13.7 MPa (2000psi)2000 psi (13.7 MPa) for Type 2 adhesive.9.3 Wood PartsDuring bonding operations, five wood production parts shall be tested at the beginning of the shift and at 4-hintervals for moi
48、sture content. Parts which have in excess of 12 % moisture content shall be redried prior to use. Testing shall bedone using a wood moisture detector.49.4 Fabricated Shelter PanelsCompletely fabricated shelter panels processed in accordance with the requirements of thispractice shall be inspected an
49、d tested as specified. Each panel shall be inspected prior to subsequent processing. The shelter panelsshall be inspected and tested in accordance with Section 1011.9.5 HandlingThe laminated panels shall be handled with due care to avoid damage that would cause their rejection.9.6 StorageBonded panels prepared in accordance with this practice shall be stored until required in such a manner as toprotect them against damage and deterioration.4 Delmhurst, Model G-30, or equi
