- Program Areas
- Energy and Water
- Environmental Restoration
- Munitions Response
- Resource Conservation and Climate Change
- Weapons Systems and Platforms
- Surface Engineering and Structural Materials
- Energetic Materials and Munitions
- Noise and Emissions
- Fuels and Greenhouse Gases
- Waste Reduction and Treatment in DoD Operations
- Lead-Free Electronics
Shelf Stable Epoxy Repair Adhesive
The U.S. Air Force and U.S. Navy, along with their suppliers, Northrop Grumman and Henkel, have a significant need to reduce the amount of waste generated during composite aircraft manufacture and repair. Large aircraft repair facilities spend millions of dollars each year to replace and discard expired epoxy film adhesives.
The objective of this project is to develop a nonhazardous, one-part epoxy film adhesive that is stable at ambient temperatures for up to one year and can be thermally activated immediately prior to use. The new adhesive would significantly reduce waste without releasing volatile organic compounds (VOC) or hazardous air pollutants (HAP).
The reactivity of the adhesive will be preserved at higher temperatures and for longer periods of time by microencapsulating the curing accelerant and allowing it to be released under controlled conditions. Key components of the one-part epoxy film adhesive are (1) the use of accelerants with low toxicity and environmental impact and (2) their encapsulation with materials that have very low permeability and will not interfere with the epoxy curing process. The adhesive is compatible with existing film formulations and processes. One-part adhesive systems are now recognized by the aerospace industry as a superior choice because of their ability to provide control over bond line thickness, improved mechanical properties, reduced risk of entrapped air in the bond line, and improved quality control by eliminating component mixing.
One-part epoxy adhesives that can be stored at ambient temperature for up to one year would enable critical improvements in the environmental impact, performance, and total costs of composite repair processes. Advantages relative to existing products include longer shelf life, ability to store at room temperature, no emissions of VOCs or HAPs, significant waste reduction, significant reduction in material costs, reduced storage complexity and cost, and equivalent mechanical properties. (Anticipated Project Completion - 2013)
Points of Contact
Mr. Michael Cushman
Phone: 781-890-1338 x225
Weapons Systems and Platforms
SERDP and ESTCP
- Fact Sheet - Brief project summary with links to related documents and points of contact.
- Final Report - Comprehensive report for every completed SERDP and ESTCP project that contains all technical results.
- Cost & Performance Report - Overview of ESTCP demonstration activities, results, and conclusions, standardized to facilitate implementation decisions.
- Technical Report - Additional interim reports, laboratory reports, demonstration reports, and technology survey reports.
- Guidance - Instructional information on technical topics such as protocols and user’s guides.
- Workshop Report - Summary of workshop discussion and findings.
- Multimedia - On demand videos, animations, and webcasts highlighting featured initiatives or technologies.
- Model/Software - Computer programs and applications available for download.
- Database - Digitally organized collection of data available to search and access.