Composite Film Adhesives: What They Are and What They Do
Among the many products we provide to the aerospace industry are composite film adhesives. Film adhesives may not seem like much on the surface, but they play a critical role in manufacturing both air and spacecraft. Without them, manufacturing modern airplanes and rockets simply would not be possible.
A Basic Explanation
If you are not familiar with composite film adhesives, think about an adhesive strip designed to bond two parts together. A film adhesive is a solid sheet of thermoplastic or B-stage thermosetting polymer that bonds different substrates and surfacing. They come in a variety of forms, including rolled films that are applied and then cured with heat and pressure.
Film adhesives are ideal for bonding substrates because of their key characteristics. Those characteristics include uniform bond line thickness, limited flow, and the ability to be used with other composites. Best of all, film adhesives create incredibly strong structural bonds more than capable of standing up to harsh environments and heavy loads.
4 Real-World Examples
Stating film adhesives is important to aerospace manufacturing is one thing. Actually seeing the products in action is another. Here are four real-world examples of how aerospace manufacturers utilize film adhesives:
1. Structural Component Bonding
Film adhesives successfully bond both interior and exterior aircraft components. The components can be identical or mixed materials. A film adhesive works equally well bonding composite-to-composite, composite-to-metal, and metal-to-metal. Manufacturers rely on them to bond interior aircraft parts, wing structures, and more.
2. Honeycomb Panel Assembly
Film adhesives are especially attractive when combining multiple honeycomb core structures. Bonding the structures to exterior skins allows engineers to create rigid yet lightweight panels with a variety of applications in an aircraft. Aircraft doors and floors, for example, are routinely made with honeycomb panels.
3. Mechanical Fastener Replacement
Mechanical fasteners do the job they are designed for, but they are subject to corrosion. Replacing the fasteners with film adhesives, where appropriate, reduces the need for mechanical fasteners and the maintenance they require. Weight savings is an added bonus. Best of all, replacing fasteners with film adhesives improves load distribution across the entire aircraft.
4. Reducing Maintenance and Repairs
Strategically deploying film adhesives can reduce aircraft maintenance and repair needs. More importantly, the adhesives help restore existing bond structure integrity to keep aircraft in the sky without jeopardizing safety. Aircraft last longer and perform as expected across a lifetime of flight.
Desirable Film Adhesive Properties
It is possible to bond composite substrates without the use of film adhesives. So why are film adhesives so attractive in the aerospace industry? Consider the following properties:
- Weight Reduction – When film adhesives replace mechanical fasteners and other bonding materials, significant weight reduction is possible. Lighter aircraft are more fuel efficient and aerodynamic.
- Manufacturing Efficiency – Film adhesives are usually sold as rows of film or pre-cut sheets. They are extremely easy to handle during manufacturing. They make for quick layups while minimizing waste and potential reworks. And through it all, they offer consistent adhesive thickness.
- Customizations – Film adhesives can be manufactured in a variety of weights, thicknesses, and curing profiles. This makes them highly customizable from manufacturers’ specific needs.
Despite their appearance off-the-shelf, film adhesives are exceptionally durable. Once cured, they resist fatigue, environmental factors, and vibrational stress. They are ideal for bonding the substrates that make modern aircraft and space vehicles both strong and lightweight.
Axiom Materials provides film adhesives to the aerospace industry. If you would like to know more about us and how we might be deployed in your designs, do not hesitate to contact us.