Letter 41058

Bonding Aluminum  

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My name is Mike Guarino. I am currently working on an Electro-Mechanical assembly that needs to pass the immersion test specified in Mil-Std-810-F in section 512. The unit will be dunked in a cold state (Not at running temperature). The target ambient operating temperature range is -20 (Goal) to 60 degrees C. Atmospheric pressure consistent with ground based environment. I am currently specifying to weld the "Outer Shell" together. Picture a tongue and groove with weld on one side of the groove. The vendor has been complaining that the welding is distorting the assembly. He also said that because it is welded does not mean it will not leak as some welds are porous. He recommended bonding it together. Both pieces are 6061 T6 aluminum alloy. I found a couple of adhesives I'm considering and was wondering if any one out there had any experience with them. They are 3M Automix 8115 1 part adhesive, 3M 5042 1 part Adhesive and Click Bond CB200 2 part Acrylic adhesive. I was also considering using some of these Aluminum radiator sealants found at your local Auto parts store. After the bonding process there is a machining operation so whatever it is it needs to be able to be machined.

Michael Guarino
Enerdyne Technologies Inc. - El Cajon, CA

Sure will bend or warp IF you put too much heat in the weld. A proper weld is not porous to water or air and only minimally porous to helium gas.
I do not think that he wants to work on hard parts.
That said, there are some good adhesives on the market. Talk to tech services of major companies like 3-M and Master Bond and ??? The UV cured ones are nice because there is no cure until you hit it with a particular frequency light beam, and then it is much faster. No pot life to worry about, no mixing and can be readily automated.

James Watts
- Navarre, Florida

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