Summary for bonding aluminum to polypropylene foam Discussion
Bonding aluminum to polypropylene foam is the core issue in this thread, with the question asking for a structural adhesive for anodized aluminum sheet bonded to expanded polypropylene foam in an outdoor enclosure that must operate from -20 to +70 °C. Ted van Kessel asks for a solution suitable for tropical exterior service. In reply, one answer notes that 2-part epoxy adhesives are commonly used with polypropylene and that many products can cover the temperature range, but warns that finding one that also meets the other requirements may be harder. The reply emphasizes practical factors such as enclosure size, how pressure will be applied during cure, production volume, required strength and toughness, and whether the assembly will see heavy loads or impact. Ciaron Murphy advises selecting one or two manufacturers and working with them directly for detailed guidance, since there is usually a tradeoff between rigidity and toughness.
Q. 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
January 6, 2011
“Handbook of Aluminum Bonding Technology and Data”
by J. D. Minford
on Amazon
or
or
(affil link)
A. 2 part epoxy adhesive epoxy_adhesive+.html
⇦ on
or
Amazon [affil link] 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