Raising performance in aerospace industry - Highlight

Advanced Materials
Raising performance in aerospace production, maintenance and repair
Quarter 1, 2015

Advanced Materials 2
Table of contents
Bonding solutions for production,
maintenance and repair
Applications in aerospace
Panel forming and bonding
Edge fill and close-out: NEW Epocast 1645 FR A/B
Insert potting and panel reinforcement
Laminating and repair
Composites bonding Choosing adhesives for composites assembly
Araldite® 2015 for dynamic loading
Araldite® 2031 for toughness
Araldite® AW4858 / HW4858 for toughness and resilience
Araldite® AW4859 / HW4859 for high temperature resistance
Araldite® 2048 for high flexiblility
Epibond® 100 A/B for high shear and peel strength
Araldite® 420 A/B for toughness and resilience
Adhesives overall comparison
FST adhesives Epibond® 8000 FR A/B
Araldite® 1570 FST A/B
FST syntactic Epocast® 1622 FST A/B

Advanced Materials
Bonding solutions for aerospace
production, maintenance and repair
3
Insert bonding
with Epocast®
syntactics
Edge close-out
with Epocast®
syntactics
Panel bonding
with Araldite®
epoxy adhesives
Insert potting
with Epocast® and
Uralane® adhesives
Skin repair
with Araldite®
and Epocast®
epoxy adhesives
Panel forming
with Epocast®
syntactics
Component bonding
with Araldite®, Epibond®
and Uralane® adhesives
< Table of content Bonding solutions > Composites bonding > FST adhesives > FST syntactic >
Panel and core
reinforcement
with Epocast®
syntactics

Advanced Materials
Main applications in aerospace
4
Panel forming and bonding > Edge fill and close-out >
Laminating and repair >Insert potting and panel reinforcement >

Advanced Materials
Component bonding
5
Panel bonding
with
CG 1305 A/B
Epibond® 100 A/B
Epibond® 8000 FR A/B
Panel forming
with
Epocast® 1618 D/B
Epocast® 1622 FST A/B
CG 1305 A/B
Component bonding
with
Araldite® EP 1000 A/B
Araldite® 420 A/B
Uralane® 5774 A/C

Advanced Materials
Component bonding
6
Syntactics Features and benefits
PF Epocast® 1618 D/B Flame-retardant, pumpable, low-density epoxy syntactic
PF
PB
CG 1305 A/B Flame-retardant, pourable, medium-density epoxy syntactic
PF Epocast® 1622 FST A/B Medium-density, FST, pumpable epoxy syntactic
Adhesives Features and benefits
CB Araldite® 420 A/B Multi-purpose, toughened, high-strength epoxy adhesive
CB Uralane® 5774 A/C High peel strength, bonds dissimilar substrates (metals and
plastics), self extinguishing, polyurethane adhesive
CB Araldite® EP 1000 A/B Nano-toughened, chemical resistant, high-strength and high-
temperature epoxy adhesive
PB Araldite® 1570 FST A/B Halogen-free, flame retardant, room temperature curing epoxy
adhesive
PB
CB
Epibond® 8000 FR A/B Nano-toughened, pumpable, high-peel, FR epoxy adhesive
PB Epibond® 100 A/B High dry-wet Tg, toughened, structural epoxy adhesive
PF: panel forming
PB: panel bonding
CB: component bonding

Advanced Materials
Edge fill and close-out
7
Edge fill / close-out
with
Epocast® 1645 FR A/B
Epocast® 1618 D/B
Epocast® 1628 A/B
Epocast® 1633 A/B
Araldite® 1641 A/B

Advanced Materials
Products Features and benefits
NEW Epocast® 1645 FR A/B Ultra-low density, FR, easy to process epoxy syntactic
Epocast® 1618 D/B Flame-retardant, pumpable, low-density epoxy syntactic
Epocast® 1633 A/B Extrudable, low-density, FR, fast cure epoxy syntactic
Epocast® 1628 A/B Extrudable, ultra-low density, FR, room-temperature cure epoxy
syntactic
Araldite® 1641 A/B Ultra-low density, vibration damping, non-sagging epoxy syntactic
Epocast® 1622 FST A/B Medium-density, FST, pumpable epoxy syntactic
Edge fill and close-out
8

Advanced Materials
NEW Epocast® 1645 FR A/B
9
Two-parts, ultra-low density, 1 year shelf life, epoxy syntactic
Application
Aerospace and transport interior, reinforcement and edge close-out applications in honeycomb panel structures.
Features and benefits Technical data
!! Ultra-low density of 0,48
!! 90% compressive strength in 1 day at RT
!! Room temperature or heat (3 hours at 50°C) cure
!! Excellent tolerance with off ratio
!! Flame Retardant (meets FAR 25.853a)
!! Easy 1:1 pbw / pbv mix ratio with color mix indicator
!! 12 months shelf life at RT
Gel time, 100g at 23°C 65 min
Tg 50°C
Compressive strength at 23°C 20 MPa
Compressive strength at 150°C 3,5 MPa
LSS, Al / Al at 23°C 7,5 MPa
Compressive modulus at 23°C 1300 MPa
Shore D hardness 55 - 60
CTE 42 !m / (m.°C)

Advanced Materials
10
Insert potting
with
Epocast® 1617 A/B
Epocast® 1618 D/B
Epocast® 1633 A/B
Panel and core
reinforcement
with
Epocast® one-part mixed
frozen syntactics
Epocast® 1645 FR A/B

Advanced Materials
11
Products Features and benefits
PCR Eposert® Pre-formed, cured, customizable epoxy syntactic insert
PCR Epocast® one-part mixed
frozen syntactics
High-compressive strength, medium- to high-density, frozen
epoxy syntactics, FR versions available
PCR NEW Epocast® 1645 FR A/B Ultra-low density, FR, easy to process epoxy syntactic
IP Epocast® 1618 D/B Flame-retardant, pumpable, low-density syntactic
IP Epocast® 1617 A/B Flame-retardant, low-density, room temperature-cure epoxy
syntactic
IP Epocast® 1633 A/B Extrudable, low density, FR, fast-cure epoxy syntactic
IP Epocast® 1622 FST A/B Medium-density, FST, pumpable epoxy syntactic
PCR: panel and core reinforcement
IP: insert potting

Advanced Materials
12
Skin repair / laminating
with
Epocast® 50 A1 / 946
or 9816
Epocast® 52 A/B
Epocast® 54 A/B
Araldite® LY 5052 /
Aradur® 5052
Repair mis-drilled hole
with
Epocast® 1635 A/B
General repair
with
Araldite® AV 8574 /
HV 8574

Advanced Materials
13
Laminating and repair systems Features and benefits
Epocast® 50 A1 / 946 or 9816 Flame-retardant, low-viscosity, epoxy laminating system
Epocast® 52 A/B CACRC qualified, high-strength, high-temperature, good hot / wet
strength, chemical-resistant, epoxy laminating system
Epocast® 54 A/B FR, high compressive strength and modulus, fast-setting epoxy
laminating system
Araldite® LY 5052 / Aradur® 5052 Low-viscosity, high-strength multi-purpose epoxy laminating
system
Repair systems Features and benefits
Epocast® 1635 A/B High-density, high-strength, high-temperature epoxy syntactic
repair material
Araldite® AV 8574 / HV 8574 High-temperature, chemical-resistant, RT curing epoxy adhesive

Advanced Materials
Epocast® 52 A/B
14
First wet lay-up system qualified according to the Commercial Aircraft Composite Repair Committee (CACRC)
standard AMS 2980 for the structural repair of carbon epoxy airframe components
Application
Manufacturing and repair of composites parts.
!! Good wetting
!! Low viscosity, 5.500 mPa.s at RT
!! Good adhesion property
!! Good hot / wet strength, service temperature 150°C
!! Excellent resistance to aircraft fluids and moisture
LSS at RT on Alu/Alu 17 MPa
LSS at 150°C on Alu/Alu 13.5 MPa
Tg
(cure: 3h at 55°C)
133°C
Tg
(cure: 3h at 55°C + 1h at 175°C)
155°C
Specification
AIMS 08-01-002, IPS 08-01-002-01, BMS 8-301

Choosing adhesives
for composites assembly
Adhesives are the 1st class choice
!! Assembly of similar and dissimilar substrates
!! Weight reduction compared to other mechanical
assembly
!! Reduce the stress concentration
!! Superior fatigue resistance
!! Easily processable (manually / automatically)
!! No damage to the substrates (no holes)
!! Sealed joints
!! Compensation of dimensional tolerances
!! Aesthetic aspect
Requirements for composites bonding
!! Good adhesion to the substrates
!! High mechanical resistance
!! High peel resistance
!! High temperature resistance
!! High toughness
!! Good chemical / environmental resistance
!! Low temperature cure

Araldite® adhesives
Epoxy adhesives
Main benefits
!! Excellent adhesion to metals
and thermoset composites
!! High strength and high stiffness
!! High creep resistance
!! High fatigue resistance
!! High temperature resistance
(up to 190°C)
!! Excellent chemical resistance
and long-term durability
!! Low shrinkage over curing
Methacrylate adhesives
Main benefits
!! Excellent adhesion to metals,
thermoset composites and
most thermoplastics
!! Good adhesion with minimum
surface preparation
!! Tolerant to mix ratio variations
!! Mechanical properties from
rigid to flexible
!! Wide spectrum of available
reactivity
!! Optimum ratio open time /
cure time
!! Good chemical resistance
and long term durability
!! Possibility for hardener
lacquer and no mix methods
Polyurethane adhesives
Main benefits
!! Excellent adhesion to most
composite materials and plastics
!! Good adhesion to metals
!! Mechanical properties from
rigid to flexible
!! High fatigue resistance
!! Good long-term durability
Wide spectrum of available
lacquer and no mix methods

Araldite® 2015
2K epoxy adhesive (1:1 v/v)
Main properties
!! High mechanical performance
!! Gap filling
!! Toughened
!! Bonds well dissimilar substrates
Benefits
!! Ideal for dynamic loading
!! Good thermal resistance (Tg " 65°C)
!! Good impact resistance

Araldite® 2031
Main properties
!! High mechanical performances
!! Mat black
!! Toughened
!! Multipurpose
Benefits
!! Ideal for big parts
!! Good thermal resistance (Tg " 65°C)
!! Good adhesion to polyamide

Araldite® AW 4858 / HW 4858
Main properties
!! High LSS on metal and FRP
!! High peel resistance, toughened
!! Shiny black, gap filling
!! Multipurpose
Benefits
!! Ideal for big CFRP parts assembly (open time > 60 min)
!! Outstanding resilient bondlines
!! Ideal for dissimilar substrates bonding, impact resistant

Araldite® AW 4859 / HW 4859
Main properties
!! High LSS on metals and FRP
!! Toughened
!! Black, gap filling
!! Multipurpose
Benefits
!! Resistant up to 145°C (Tg " 125°C)
!! Outstanding combination of high toughness and high mechanical performance
!! Outstanding chemical resistance

Araldite® 2048
2K MMA adhesive (10:1 v/v)
Main properties
!! High LSS on metal and most of thermoplastics
!! Gap filling
!! Flexible (>90% elongation)
!! Multipurpose
Benefits
!! Quick setting
!! Ideal for composite / thermoplastic assemblies
!! Good balance of flexibility and temperature resistance (Tg " 65°C)

Epibond® 100 A/B
Main properties
!! High shear and peel strength
!! High dry/wet Tg
!! Gap filling
Benefits
!! Good chemical and environmental resistance
!! High impact resistance
!! Service temperature up to 150°C

Advanced Materials
Epibond® 100 A/B
23
Two-part, heat-curing epoxy adhesive for structural bonding of composites
Application
Primary and secondary bonding of composites and dissimilar substrates where high service temperatures and elevated
hot/wet Tg performance is needed. Suitable for carbon fiber, glass reinforced composite, PEEK and aluminum.
!! Service temperatures up to 165°C
!! Moderate cure cycle / variable handling
!! Long working time of 100-120 min allows for large
composite part assembly
!! Variety of handling strengths vs. time allow flexibility
of process
!! Extrudable, gap filling
!! No bagging or autoclave steps (out of autoclave
process compatible)
!! Easy process by hand or cartridge (2:1 Mix ratio)
!! Retention of properties under demanding high hot /
wet conditions
Cure schedule 1h at 65°C + 5h at 93°C
LSS at RT on Alu/Alu
(phosphoric acid anodized)
34 MPa
LSS at 93°C on Alu/Alu
23 MPa
7 MPa
LSS at RT on GRP/GRP 24 MPa
LSS at RT on PEEK/PEEK
(abraded + nitrogen)
11 MPa
LSS at 150°C on PEEK/PEEK
(abraded + nitrogen)
6.5 MPa

Advanced Materials
Araldite® 420 A/B
24
Two-part, toughened epoxy adhesive for structural bonding
Application
Bonding of composite aeroplane parts (wing sections). Aircraft interior furnishings, such as wardrobes, stowage bins,
toilet modules, produced from honeycomb. Bonding of metallic inserts.
!! Dark green liquid
!! Very high shear and peel strength adhesive
!! Extremely tough and resilient
!! Good moisture resistance
!! Easy to use
!! RT cure
!! Service temperature 70°C
Cure schedule 16h at 40°C
LSS at RT
Aluminum (sandblasted) 23 MPa
Steel (sandblasted) 27 MPa
CFRP (abraded) 35 MPa
GRP (abraded) 31 MPa
Tg (DMA) 56°C
Specification
ASNA 4125, Issue B (Airbus)

Performance on composites
Lap shear strength at 23°C (MPa) - ISO 4587

Performance* versus temperature
Lap shear strength (MPa) - ISO 4587
* Lap shear strength on aluminum
Lap shear strength (MPa) - ISO 4587

Performance on metals

Strength on aluminum : comparison to epoxy adhesive references
Peel strength (N/mm) / Lap shear strength (MPa) / Service temperature (LSS > 5 MPa)
(1) 2K rigid epoxy - RT cure (2) 1K epoxy - 180°C cure
Peel strength (N/mm) / Lap shear strength ( ) / Service temperature (LSS > 5 )

Assembly of composites : main properties overview
Product designation LSS performance Peel performance Thermal
resistance
Chemical
resistance
Elongation at
break
Handling time RT curing
Araldite® 2015
Araldite® 2031
Araldite® AW 4858 /
Hardener HW 4858
Araldite® AW 4859 /
Hardener HW 4859
Epibond® 100 A/B
Araldite® 2048
Araldite® 420 A/B
Ideal Recommended

Selection for specific requirements
High service temperature
!! Araldite® AW 4510 / Hardener HW 4511
1/3 of initial LSS retained at 180°C
Fast curing epoxy
!! Araldite® AW 2101 / Hardener HW 2951
5 min gel time - 60 min handling time
High performance structural PU
!! Araldite® 2029-1
combination of high LSS on composites
and flexibility - 40% elongation

Advanced Materials
31
Two-parts, FR / FST interior epoxy adhesive
Application
Bonding interior honeycomb panels, metals and composite materials as well as insert bonding. Use anywhere FST / FR
properties* are desired such as aerospace and transport interiors.
!! One system for both FR and FST: meets requirements
of FAR 25.853
!! Rigid adhesive with high lap shear strength
!! Accelerated cure at RT, allows high shop productivity
!! Extrudable, gap filling, suitable for overhead
application
!! RT or heat cure
!! Easy process by hand or cartridge, 2:1 mix ratio
Cure schedule 1.5h at 55°C
Cure time to 10 MPa at RT < 4h
27 MPa
6 MPa
Flammability CFR 25.853
appendix F, part 1
FST properties FAR 25.853
appendix F
* Except for OSU heat release

Advanced Materials
32
Two-parts, flame retardant epoxy adhesive
Application
Bonding of Aircraft interior - flooring parts. PE foam to phenolic GRP bonding in cargo areas.
!! Outstanding FST properties (complying with FAR
25.853)
!! Semi-rigid adhesive with high elongation at break
!! Long pot life at RT
!! Suitable for structural application on metal or plastic
substrates
!! Non halogenated
!! Dark grey paste
Cure time to 10 MPa at RT: 10h
Pot life ca 2,5h
(chromic acid etched)
18 MPa
LSS at RT on CFRP/CFRP 17 MPa
LSS at RT on PPS/PPS
(polyphenylene sulphide)
9.5 MPa
LSS at RT on PC/PC 4 MPa
LSS at RT on PEEK/PEEK
(plasma)
5.5 MPa
Specification
AIMS 10-04-006 (Airbus), FAR 25.853

Advanced Materials
33
Two-parts, low density, fast, epoxy syntactic with high compressive strength
Application
Aerospace and transport interior potting of fasteners, panel joining, reinforcement and edge closeout applications in
honeycomb panel structures. Emphasis on applications requiring low density, high compressive strength and FR / FST
properties.
!! Low density of 0,77
!! High compressive strength of 59 MPa
!! Extrudable, gap filling
!! Room temperature (3 to 5 days) or heat (3 to 5 hours
at 55°C) cure
!! Fast gel time of 15 min, allows for higher shop
productivity
!! FR / FST properties (meets FAR 25.853)
!! Easy process by Semco® cartridge, 100:11.5 parts by
weight mix ratio
Tg 80°C
Insert pull-out strength at 23°C 1300 N
Compressive modulus at 23°C 2.5 GPa
LSS, Al / Al at 23°C 12 MPa
Shrinkage 0.4 %
CTE below / above Tg 40 / 80 !m / (m.°C)

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For more information
www.huntsman.com/advanced_materials
advanced_materials@huntsman.com
Europe
Huntsman Advanced Materials (Switzerland) GmbH
Klybeckstrasse 200
P.O. Box - 4002 Basel
Switzerland
Tel. +41 61 299 1111
Fax +41 61 299 1112

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