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Bonding aluminum to polypropylene foam

January 6, 2011

We are constructing an enclosure that will be operated in exterior environments at tropical latitudes.

We seek to bond anodized aluminum sheet (sealed but without dye) to expanded polypropylene foam.

Can you suggest a structural adhesive that will tolerate -20 to +70 °C operation.

Ted van Kessel
Engineer - Yorktown Heights, New York, USA

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2 part epoxy adhesive [on eBay or Amazon]s are commonly used with polypropylene however there are dozens of manufacturers with hundreds of options. You will find it hard to find a structural adhesive that won't cover that temperature range.
What you will find is there are many that don't meet your requirements for a number of other reasons.

Size and options on processing method will be an important factor. What size is your enclosure?
What facilities do you have to apply pressure during cure? What is your likely output how many a day/week do you need to make?

How strong/mechanically tough do you need it. There is normally a trade off in rigidity and toughness. Is this going to be heavily loaded? Will there be likely impact damage?

My advice would be to pick 1 or 2 of the manufacturers and go to them to get in depth advice.

Ciaron Murphy
Aerospace - South Wales, United Kingdom
January 11, 2011