Miscellaneous Joining Processes

Adhesive Bonding
• Adhesive Bonding is the process of joining two surfaces together, usually with the
creation of a smooth bond. This may involve the use of glue, epoxy, or one of a
wide range of plastic agents which bond either through the evaporation of a
solvent or through curing via heat, time, or pressure.
• The use of adhesives offers certain advantages over other binding techniques
such as sewing, mechanical fastenings, or welding. These include
✓ The ability to bind different materials together,
✓The more efficient distribution of stress across a joint,
✓The cost-effectiveness of an easily mechanized process, and
✓Greater flexibility in design.
Disadvantages of Adhesive Bonding
• They are prone to failure when exposed to high heat or weathering.
• Adhesives can also take time to fully fix and acquire full strength.
• They also often require surface preparation treatments including
cleaning the surface of the materials to be joined.
• Greater difficulty in separating objects during testing.
Types of Adhesives
• By reactiveness
Non-reactive
➢Drying
• There are two types of adhesives that harden by drying: solvent-based
adhesives and polymer dispersion adhesives, also known as emulsion adhesives.
Solvent-based adhesives are a mixture of ingredients (typically polymers) dissolved in
a solvent. As the solvent evaporates, the adhesive hardens. Polymer dispersion
adhesives are milky-white dispersions often based on polyvinyl acetate (PVAc). They
are used extensively in the wood working and packaging industries.
➢Hot adhesives, also known as hot melt adhesives, are thermoplastics applied in
molten form (in the 65–180 °C range) which solidify on cooling to form strong bonds
between a wide range of materials.
➢Pressure-sensitive adhesives (PSA) form a bond by the application of light
pressure to marry the adhesive with the adherend. The bond forms because the
adhesive is soft enough to flow (i.e., "wet") to the adherend.
➢Contact adhesives are used in strong bonds with high shear-resistance
like laminates, such as bonding Formica to a wooden counter, and in footwear, as
in attaching outsoles to uppers. Natural rubber and polychloroprene (Neoprene)
are commonly used contact adhesives.

Reactive adhesive
➢means an adhesive system composed, in part, of volatile monomers that react
during the adhesive curing reaction, and, as a result, do not evolve from the film
during use.
➢Chemically-reactive adhesives are available in several forms, including single-part
and multi-part solutions, as well as liquids, pastes, tapes, films, and powders.
Some examples of this type of adhesive include acrylic, anaerobic,
cyanoacrylates, and epoxy adhesives.
• By origin
Natural
➢Natural adhesives are made from organic sources such as vegetable starch (dextrin),
natural resins, or animals (e.g. the milk protein casein). These are often referred to
as bioadhesives.
Synthetic
➢Synthetic adhesives are made out of organic compounds. Many are based
on elastomers, thermoplastics, emulsions, and thermosets. Examples of thermosetting
adhesives are: epoxy, polyurethane, cyanoacrylate and acrylic polymers.
Rivet joining
• Riveting is a permanent and non-thermal joining method that involves using a
mechanical fastener/rivet to join sheet metal parts. It consists a shot cylindrical bar
with head on one end. The cylindrical portion is known as the shank and the end
opposite to the head is known as tail. The material of rivet is soft enough to get it
bucked by normal impulse force. Riveting involves drilling a hole in the two sheet
metal parts you want to join together and installing a rivet.
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• Rivets are more capable and preferred for supporting shear loads rather than
tension loads. For tension applications, bolts and screws more suitable than the
rivet.

Applications of riveting
•
Aerospace and automotive industries: The riveting adopted in aerospace
assembling due to light weight and high shear strength.
• Building and construction
• Wood-works and decorative working
• Jewelry
• Riveting is used in almost all kitchenware.
• Some metal cannot weld due to the change in property at high temperature. In
that cases, riveting is adopted.
• For fastening of sheets of dissimilar materials.
• Types of Riveted Joints
Primarily there are two major types of riveted joints depending upon
the way the structures may be joined: lap joints and butt joints.
• Lap Joint: In this type the ends carrying the drillings of the two
members are positioned such that their surfaces slightly overlap. The
riveting is then done through the coincident holes
Butt Joint: Here, the two members or the
elements are linked edge to edge in one
straight line. The clamping is produced using
an external cover plate which is then riveted as
above through the parallel drilled holes.

Riveted joints may be further classified into the

following, depending upon the way they are
inserted:
Single Riveted Joint: In this type more than one
rivet are fixed along a single row.

Double Riveted Joint: When two rows of rivets

are included.
• Chain Riveted Joint: In this type the
accommodated rows of rivets may lie exactly
opposite to each other over straight lines.

• Zig Zag Riveted Joint: Unlike the above type,

here the rows may appear staggered and not
complementing each other.

• Diamond Riveted Joint: Typically in butt joints.

 Ceramic Joining Processes
• Different welding and allied processes used for joining ceramics
include the following:
✓Fusion Welding
✓Diffusion Bonding
✓Diffusion Bonding via Interlayer
✓Isostatic Bonding
✓Glaze Bonding
✓Metallising and Brazing
✓Adhesive Bonding.
Fusion Welding:
Successful use of electron beam welding to form Al2O3-Ta, ZrO2-Mo, ZrO2-Nb
couples with substantial bond strength has been reported since 1960’s.
However, the applicability of fusion welding methods to ceramic-metal
systems is very limited. It is imperative to match the melting temperature
and thermal contraction characteristics of pieces being bonded.

Diffusion Bonding:
• In this method the components to be joined are pressed together and
subjected to a high temperature for a certain period of time. The pressure
used must be high enough to cause diffusion to take place at the mating
surfaces but must not cause bulk deformation in the components being
joined.
• The temperature employed is in the range of 0.65—0.98 Tm where Tm is
the melting point of the metal in degrees absolute. Complex physical and
chemical reactions take place at the interface to effect a joint. Wide range
of metals to ceramics and glasses to glass-ceramics can be successfully
bonded by this process, provided the thermal contraction characteristics
of the parts being joined are matching.
Diffusion Bonding via Interlayer:
• In this method of joining ceramics to metals a ductile metal interlayer
is introduced between the faces to be joined thus the application of
high pressure is not necessary. This interlayer helps to distribute the
stresses at the interface avoiding stress concentration as well as
accommodates some of the differential expansion and contraction of
the two components during heating.
Glaze Bonding:
• This method is most often used in assembling large complex pieces
and the joining of dissimilar ceramic components. The surfaces to be
joined are ground flat and then coated with a suitable glaze slip. The
surfaces are then placed in contact and fixed to fuse the glaze and
bond the pieces together.
• Most oxide ceramics can be bonded by silicate glasses or glazes and
the joints can also be made with borate and phosphate based
glasses. Non-oxide ceramics are more difficult to join by this process
as they tend to react with the glazes releasing gas bubbles which
weaken the bond.
Metallising and Brazing:
• Usually this method is employed for joining ceramics to metals.
Brazing requires that the brazing alloy used must wet the surfaces
to be joined. Most of the metal surfaces can be wetted by brazing
alloys but ceramics are not. Therefore the ceramic component is
first given a layer of compatible alloy by the process of metallising.
• It is then followed by brazing using the conventional alloys.
Adhesive Bonding:
• Stress-free joints can be produced by gluing and cementing when
high temperatures and vacuum tightness are not involved. Cold- cure
resins and glues adhere well to ceramics. Joint performance is
dependent on the service temperature as well as the duration and
the rate of stressing.
• Epoxide, phenolic, acrylic and polyurethane adhesives can be used for
applications involving temperatures upto 200°C. For high temperature
applications above 200°C polyamides or other thermally stable
polymers are used.