FASTENER ENGINEERING_DESIGN WORLD_JULY 2022

Engineering July 2022

A supplement of Design World

Inside: 78_ How ultrasonic welding can change your carbon footprint 82_ Adhesives Choices: Epoxies versus hybrids or acrylics

| Courtesy of 3M

86_ From mining to adhesives: The growth of a global conglomerate

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Reducing Risks A practical understanding of

hydrogen embrittlement Page 74 7/5/22 12:55 PM

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A reason to reconnect In May, I attended my first trade show in nearly three years. After months behind a screen, connecting with others via conference calls and Zoom meetings, it took leaving my home office before I realized how much I missed meeting new people and interacting with others — in person. Kudos to Fastener Fair USA for hosting such a well-run event in Detroit this year. It was wonderful meeting and learning from so many high-quality exhibitors.

People, like myself, are starting to get out again and it’s nice to reconnect. Here are just a few highlights that I took away from the Fair…

• There’s a reason to celebrate! Case in point: Advance Components is celebrating 50 years of supplying fasteners. This womenowned business has been a top U.S. industrial fasteners master distributor since 1972. Check out the company’s online FastenerLab for “everything you’ve always wanted to know about fasteners but were afraid to ask.” (And be sure to visit their booth at the International Fastener Expo in Vegas this October for some retro ’70s fun!). advancecomponents.com • Fasteners are the future. I interviewed Earl Price in 2020 when he developed the ForeverLok anti-vibration design (learn more at tinyurl.com/ForeverLok). Price, who once owned an ice-skate shop in Michigan, figured he could design a fastener that more reliably

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secured skate blades to the boot… and he was right. Little did he expect to become a part of the fasteners market — or exhibit at a trade show. Yet his company, Multi Piece Fasteners, had a booth at the Fastener Fair, with a new ForeverLok design on display. It seems no matter how dependable fasteners are, there’s always room for improvement. foreverlok.com • Possibilities abound. “There are many different tools available to the fastener industry,” shared Mason Fischer Paul, an engineer with the Würth Additive Group. “And that means you’re not tied to just one.” Würth showcased its 3D-printing capabilities at the Fair — serving as another valuable tool for designers and manufacturers. For example, manufacturing a fastener prototype is typically time-consuming and costly. 3D printing saves on both. It can also be ideal for manufacturing components with complex geometries. Today, you have plenty of options. wurthindustry.com There was so much more, including new security fasteners, coatings, threadlockers, automated inspection technologies, packaging options, and then some. It was a pleasure seeing everyone at the Fastener Fair and I’m looking forward to the next in-person event.

| AdobeStock.com

For those who questioned the likelihood of such events making a comeback after the pandemic, it’s understandable. In 2019, statistics showed that the B2B trade show market in the U.S. was worth $15.58 billion.

That clearly dipped in 2020 and 2021, but things are looking up. The market is expected to recover by 2024, nearing about $14.5 billion by then. And according to the Fastener Fair, pre-registration was up by 30% in Detroit compared to its event in Cleveland last November.

Until then, feel free to share your news, insights, and new products with us at fasteners@wtwhmedia.com FE

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A practical understanding

of hydrogen embrittlement fastener failure Randy Lammers • Technical Instructor | Co-host YouTube series Würth Knowing Würth Industry North America The head of a 5/8-inch-diameter, zinc-plated socket cap screw bursts off

a piece of recently produced equipment and shoots, much like a bullet, across a manufacturing plant, through a metal toolbox — just missing a nearby worker. A 5/16inch wave washer fractures, causing a product recall of about $400,000. A hardened wood screw breaks, causing a chair to collapse and resulting in the loss of life.

Unfortunately, there are many other high-cost examples of product failures, leading to equipment malfunction, personal injury, or worse because of fastener fractures.

These can result from hydrogen-assisted cracking, more commonly known as hydrogen embrittlement or HE. This is a complex scientific subject with much research and several papers written to explain the phenomenon, along with ongoing testing and investigation. Despite years of accumulated insight, there are still risky choices made concerning HE in the fastener industry.

Hydrogen-assisted cracking in fastener applications Atomic hydrogen is one of the smallest-known elements and is all around us. The potential damage, at a micro-level, in hardened steel fasteners that have been electroplated is of particular concern. Hydrogen atoms are introduced to the steel

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An engineer at work at the WINA Quality Lab. in high concentrations during the pre-cleaning and electrolytic process of applying metallic materials (most commonly, zinc).

After electroplating, a layer of chromate/passivate is added to provide additional corrosion protection and good aesthetic values. This high concentration of introduced hydrogen provides an opportunity for these atoms to accumulate and become trapped within the steel’s molecular structure.

Depending on the metallic plating’s permeability, the plated surface finish acts like a barrier to hydrogen effusion.

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Externally applied load and/or internal residual tensile stress leads to a widening of the steel’s grain boundaries. And hydrogen atoms are highly mobile. Now consider such widened grain boundaries, where free hydrogen atoms accumulate to such a degree that pressure is created within the boundary. This accumulation of pressure can cause the grain boundary to crack open in susceptible hardened steel.

Eventually, the molecular structure of the steel is compromised and can no longer withstand the applied www.fastenerengineering.com

stress. The structure fails from internally cracked grain boundaries and a sudden burst of the total structure occurs. Granted, this fracturing process takes time. Typically, a delayed failure occurs one to 48 hours after fastener installation, once sufficient stress has been applied.

What is susceptible hardened steel?

Consider which is stronger, a candy cane or a piece of soft chewy taffy? Certainly, a candy cane is hard and has high tensile strength, but it’s also brittle. Taffy is soft, easily stretches in tensile pull, and is ductile. Now, think about creating pressure within the structure of a July 2022

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This is what hydrogen embrittlement looks like on a bolt.

candy cane. What would happen? It would likely explode or burst, which is how a hydrogen embrittlement fracture is described — as a burst.

What’s more: the surface of a hydrogen embrittlement rupture looks similar to rock candy. So, the hardness of a candy cane is highly susceptible to failure because of HE cracking.

What would happen if you applied the same pressure within the structure of a piece of taffy? It would likely stretch and relax, thanks to its soft ductile capabilities. The hardness of taffy would be considered non-susceptible.

This provides a simplified analogy of the correlation between steel hardness and susceptibility to an HE fracture.

For susceptible material hardness, reference ASTM F1941 and ISO 4042 specifications for electroplating fasteners. ASTM F1941 places the threshold above 39 HRC and ISO 4042 above 390 HV. When electroplating fasteners with material hardness in the susceptible category, specifications mandate the parts are baked after electroplating and before the addition of chromate/ passivate and/or any topcoat materials.

Baking facilitates the outgassing of the permeated hydrogen atoms.

Temperatures of 375-425° F (190-220° C) are applied for eight to 24 hours, depending on the fastener type, size, and strength, in combination with the

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plating system and process.

In recent studies, the practice of baking susceptible materials for four hours has proven inadequate for most fasteners.

To further avoid HE, some industry and company standards have placed the susceptible material hardness threshold at 32-34 HRC (~320 HV) as a precaution against manufacturing errors in raw material, fastener production, and electroplating process. SAE J429 Grade 8 and ISO 898 Property Class 10.9 have material hardness above this threshold and would fall into this susceptible category.

Unfortunately, these errors are common when buying from a supply chain with unknown sources and controls within the supply chain. It’s advisable to consider materials in this lower hardness range as susceptible, which should be baked when electroplated.

High-risk items: • Inch series socket cap screws, including button head and flat head • Metric property class 12.9 fasteners • Any spring action washer including wave, conical, Belleville, and helicallock washers

A close-up of hydrogen embrittlement at work.

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Now, what is the risk of electroplating fasteners with a material hardness above 39 HRC (390 HV)? The introduction of ASTM F1941 states in part: “With normal methods of depositing metallic coatings from aqueous solutions, there is a risk of delayed failure due to hydrogen embrittlement for case hardened fasteners and fasteners having a hardness above 39 HRC. Although this risk can be managed by selecting raw materials suitable for the application of electrodeposited coatings and by using modern methods of surface treatment and post heat-treatment (baking), the risk of hydrogen embrittlement cannot be completely eliminated. Therefore, the application of a metallic coating by electrodeposition is not recommended for such fasteners.”

Consequently, it’s advisable to avoid using any fastener with a hardness above 39 HRC (390 HV) that has been electroplated.

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A hydrogen embrittlement fracture in steel is commonly described to occur as a “burst.”

• Any spring steel clips • Retaining rings • Spring pins • Any part above 39 HRC (390 HV) that will or might experience tensile stress

What can you do?

Use low to non-hydrogen generating finishes, such as mechanically applied zinc, thermal diffusion zinc, or zinc-flake coatings. If the high strength of an inch series socket cap screw is not required for the application, use readily available metric property class 8.8 or stainless steel. There are less risky solutions to every potential HE part. Do research to ensure the ideal choice.

In conclusion, HE is a delayed failure not seen during assembly. It’s advisable to bake parts between 34 to 39 HRC (320 – 390 HV) when purchasing through an unknown or uncontrolled supply chain. Avoid electroplating fasteners with a hardness above 39 HRC (390 HV).

Hydrogen embrittlement is a complex scientific subject. Further investigation and studies are ongoing.

Stay informed as more information on this phenomenon is released. This is a serious topic and failure is typically paired with a high cost. The risk is not worth the reward. FE

WHAT DO YOU THINK? Connect and discuss this and other engineering design issues with thousands of professionals online

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Branson Ultrasonic solutions from Emerson are used to produce medical test strips, collection swabs, and complete, sealed test packages. Ultrasonic technology can also create a clean weld site and consistent join quality for various package shapes and sizes, including plastic containers, cartons, and more.

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How can

ultrasonic welding reduce your carbon footprint?

Patrick O’Sullivan • Product Specialist Branson Welding and Assembly at Emerson When it comes to fastening, joining, and assembling plastic materials, heat

sealing has been a commonly accepted joining technique since the 1950s. It’s a fast, efficient process that’s still used extensively today.

However, as companies are under increasing pressure to become more sustainable and reduce their overall carbon footprint, it’s worth questioning if heat sealing is the best environmental option.

Ultrasonic sealing or welding has been in existence for nearly as long (since the ’60s) and has proven just as fast and reliable. What’s more: it offers several notable advantages.

For example, it: • Consumes less electricity • Reduces the amount of plastic material required for a reliable seal • Seals bio-derived and recycled materials more effectively • Yields less waste • Uses zero adhesives, solvents, or other consumables.

Together, these features mean that ultrasonic welding can cut the carbon footprint of an assembly line by up to 75%.

• All images courtesy of Emerson

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Weld Surface In a conduction heat seal, a heated bar (red) is applied to either side of the mating surfaces (blue) to melt the plastic, and then pressure is applied to weld them into a bond.

Weld Surface In an ultrasonic weld, mechanical vibrations applied between two sealing surfaces create frictional heat that melts the surfaces, which are then compressed into a welded seal.

Heat versus ultrasonics Heat seals are a relatively simple process. Component surfaces are held together and heated sealing bars are applied on one or both sides. Heat flows (conduction) from the bars through the material to the seal interface, where the mating surfaces melt to form a bond. The conduction sealing controls — including the temperature, pressure, and dwell time — are based on the melt characteristics of the plastics to be joined.

Ultrasonic welding generates and applies heat and pressure differently. It generates heat by applying a vibration with a precise frequency and amplitude between the surfaces of the thermoplastic layers. It does so while controlling parameters such as force, pressure, and speed to optimize the weld results. The frictional heat melts the interior of these surfaces and, under pressure, creates a permanent bond.

Comparing energy use Since the heat required for heat sealing is generated by a resistance-heated bar, the sealing elements are held at operating temperatures for 100% of the time. This generates a lot of heat that’s transferred into the weld zone and the surrounding environment — meaning, energy is wasted.

Ultrasonic seals generate heat by high-frequency friction, with seals completed in as little as 100 milliseconds. The tooling is cool except during that brief time. Much more

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energy is required for resistance heating than for generating the ultrasonic sealing vibrations. The Energy Comparison table below shows the potential to reduce electricity use by 25%.

Energy Comparison

Seals per minute Equipment Energy use (W/hr) Daily energy use (W/16-hr day) Energy savings

ULTRASONIC SEALING

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2 units x 50 seals/min.

1 unit x 100 welds/min

4 x 500W cartridge heaters = 2,000W/hr 32,000

1,500W power supply + 1,500W max.

24,000 assuming continuous operation At least 25%

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Comparing material To provide a high-quality closure, heat sealing generally produces a 0.5-inch seal. Let’s assume a package gets a 0.5-inch seal at the top and bottom. That means a full inch of material goes into the sealing area alone.

On the other hand, two comparable ultrasonic welds require only 0.25 of an inch of total package length (0.125 inches each on the top and bottom), resulting in a savings of 0.75 of an inch per package. The Material Comparison table shows the potential material savings using a six-inch bag as an example.

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HEAT SEALING

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Selecting the right adhesive can be a challenge

Material Comparison PACKAGE:

HEAT SEALS

ULTRASONIC SEALS

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5.25

0.5 (1.)

0.125 (0.25)

Internal package height (in.)

5

5

Production rate (million)

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Material savings/package

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0.75 in.

Net material savings

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24 million x 0.75 in/36 or about 500,000 yards/year

Overall package height (in) Width per seal (x2) (in.)

Hard to bond surfaces can be difficult Application properties exceed standard adhesive offerings Two sides of adhesive are sometimes better than one

For heat-sensitive materials, which include non-fossil-fuel-derived biopolymers and some recycled materials, the high temperatures and longer cycle times involved with heat sealing can also lead to material damage.

This problem is eliminated with ultrasonics since heating is minimal and momentary. It can also be precisely set by the welder control.

One more consideration: unlike heat sealers, ultrasonic welders are unaffected by contamination in the weld area. Any product or residual oils in the sealing area during the filling process are squeezed out when the package is compressed and ultrasonic energy is applied. With heat sealing, the seal integrity can be compromised and, if so, the entire package and its contents must be discarded.

Ultrasonic welding offers important environmental and sustainability advantages compared to heat sealing and other technologies, including chemical sealants. However, the choice of which technology represents the ideal solution for a given manufacturing application is not always clear. Source an expert in the field that offers quality technology and support for your specific application. FE

CS Hyde Company specializes in adhesive lamination of hard to bond substrates like high performance polymer films.

With our in house lamination services we are able to produce single or double sided adhesive products utilizing 3M™ transfer adhesives.

Common adhesives we apply include 3M™ VHB®, Acrylic, High-Bond, Optically clear, and High Temperature silicone.

A food safety testing device performs safely while providing 100% contamination protection.

Ultrasonic welding is is used to create a strong bond that keeps contamination out.

Your worldwide source for high performance Tapes, Films, Fabrics, and Silicone

800-461-4161 sales@cshyde.com www.cshyde.com DESIGN WORLD

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Adhesive Choices: Epoxies versus hybrids or acrylics Jake Klaus • Marketing Director • Infrastructure Division – Adhesives Technology Corp.

Industrial adhesives come in as many colors, consistencies, and formulations as there

are specification requirements for these products. This means for every IBC, IRC, FBC, LABC, LARC, AC308, NSF 61 requirement, there’s a fast cure, high strength, medium strength, long pot life, non-sag, ultra-tensile-strength-super-non-sag-seismic-tested-for-cracked-anduncracked-or-medium-cracked-concrete adhesive solution that’s best for the job.

With all the options on the market, which one is ideal for your application? Given all the adhesive choices and variables for a project (such as the curing environment and potential budget constraints), it’s a conversation that could last for days. So, for now, we’re focusing on two major classes of products: epoxies and hybrids or acrylics.

The formulas An epoxy is formed by blending epoxy resin with some type of amine. After this combination cures for a moderate amount of time (>6 hours at 75° F), it forms long cross-linked polymer chains, known for strength, durability, and water resistance.

Epoxies are sensitive to the mix ratio (typically, 1:1 or 3:1) between the resin and hardener, so must be blended well to achieve full performance. It’s worth noting that low temperatures increase viscosity and reduce molecular mobility, which hampers the cross-linking (curing) of most epoxies.

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There are plenty of adhesive solutions available, so it’s important to narrow down the options based on your application. Consider factors such as temperature, bond strength, project time (to allow for curing), and the overall budget.

Vinyl ester — a type of hybrid adhesive — is formed by freeradical polymerization, made by the esterification of an epoxy resin with acrylic or methacrylic acids. This process happens rapidly (<1 hour at 75° F) due to curing via a chain reaction that can occur at both low and elevated temperatures.

Vinyl esters and hybrid urethanemethacrylates are less sensitive to the mix ratio (typically, 10:1) between the resin and catalyst. But they’re usually affected by the presence of moisture during cure, and much more so than DESIGN WORLD

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their epoxy counterparts.

In many cases, an epoxy or a hybrid will meet your specification requirement, so it’s important to know the key differentiating factors between these two primary classes of adhesives.

Temperature and bond strength The temperature at an installation site is often an important and relevant factor when deciding what type of adhesive to select.

Epoxies become harder to dispense at lower temperatures and cure very www.fastenerengineering.com

slowly as temperatures approach the 40° F mark.

At extremely high temperatures, epoxies are easy enough to dispense, but they begin to lose some of their performance properties, which may be far from ideal for certain applications.

When temperatures are either very high or low, a vinyl ester, acrylic, or hybrid can offer an alternative.

Applications that carry critical safety considerations tend to specify products based on their bond strength, and not every solution will meet these stringent requirements. Typically, epoxies outperform their acrylic and vinyl ester counterparts in this arena.

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A contractor dispenses Adhesives Technology Corp.’s ULTRABOND HS-1CC. Made in the USA, HS-1CC is currently the world’s strongest 1:1 anchoring epoxy and the first anchoring epoxy formulated to be IBC/IRC compliant in bulk and cartridge delivery systems.

Some hybrid adhesives also carry high bond strength numbers but are unlikely to compete with epoxies at the highest end of the bond strength chart. Therefore, when bond strength requirements are paramount, an epoxy is typically going to win the specification. This said, acrylic adhesives and hybrid formulations carry other beneficial characteristics that could make them ideal for your project, particularly when factors other than bond strength are important.

Additional considerations Although temperature and bond strength often dictate adhesive

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selection, there is a myriad of other factors to consider. For example, epoxies are moisture insensitive and some can be applied underwater.

But if time is a factor and you need a product that will install and cure quickly, think vinyl esters, hybrids, and acrylics. They cure fast for shorter return to service or load times. Now, what if you need to anchor in a large or deep hole? Epoxies are typically your best choice, thanks to lower viscosity options and longer working times. If you have a large job to cover, epoxies can also be used with bulkdispensing systems and are available in several size offerings.

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For every engineer and contractor on the job, there’s an accountant somewhere watching the budget, so cost is also a factor in deciding which adhesive is going to work. Generally speaking, epoxies will carry a lower cost per ounce. Epoxies also offer a longer shelf life, with some exceeding 24 months.

Acrylics and hybrids carry a larger price tag and usually come with a shelf life of 12 to 18 months.

However, they can make up the cost per ounce difference by providing less downtime on the project and higher constructability rates.

Clearly, you have options. There are often several formulations that will meet the specification for a given project so when in doubt, reach out to an adhesives manufacturer and leverage their knowledge.

Choosing the ideal adhesive for the job conditions can ensure a successful project that’s completed on time and on budget. FE

Comparing adhesives

Precision Laser or Ultrasonic Welds for Critical Plastic Components

Epoxies:

• Higher bond strengths • Moisture insensitive – some can be applied underwater • Longer working times • Longer shelf life • Better in large holes or deep embedment applications • Bulk-dispensing systems available • More diverse packaging options

Two market-leading weld platforms from Emerson meet growing demand for the assembly of complex plastic parts. Using patented Simultaneous Through-Transmission Infrared (STTIr®) technology, Branson™ GLX Laser welders deliver ultra-clean, aesthetically superior welds on parts with complex 3-D contours and delicate embedded electronics or sensors.

Branson™ GSX Ultrasonic welders feature an advanced electro-mechanical actuation system that welds even smaller, thinner parts with exceptional consistency and industry-low trigger force. Both welders offer real-time production monitoring and data collection to ensure superior quality.

Vinyl esters / acrylics / hybrids:

• Extremely fast cure for faster bolt-up times • Dispenses easily, even in freezing temperatures • Historically performs better in long-term creep • Perform better in elevated temperatures

Learn more at: Emerson.com/Branson

The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2020 Emerson Electric Co.

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From mining in Minnesota to a global corporation

How 3M continues to innovate Michelle Froese • Editor

When a handful of colleagues set up shop in Minnesota more than a century ago,

no one would have predicted their efforts would lead to a multinational conglomerate corporation, with global corporate operations in 70 countries and sales offices in another 200 locations. The founders of 3M Company — an acronym for Minnesota Mining and Manufacturing — were simply mining for corundum, a mineral ideal for making sandpaper and grinding wheels.

However, their mining efforts fell short, and corundum was never found. After a couple of years of persistence, they finally decided to purchase the necessary abrasive minerals from another source and constructed their first manufacturing building in 1905 — a two-story sandpaper plant in Duluth.

Bad luck seemed to follow. Not long afterward, the floor collapsed in the new facility as a result of the weight of the equipment and raw materials. Still, the 3M team persisted. In 1910, they hit a break. The company moved to a more central location in St. Paul, which helped visibility, and a few years later launched its first exclusive product: 3M Three-M-ite Abrasive Cloth. It could be used for commercial and industrial wood or metal sanding jobs.

“It’s a unique story,” shares Scott Buss, director, Global Key Accounts, Industrial Adhesives and Tapes Division at 3M. “While 3M started as a mining company struggling with sales, particularly in relation to mineral anorthosite, it eventually managed to successfully sell abrasives to the automotive industry — and to Ford, in particular.”

The Three-M-ite cloth was just the start. Afterward, the company introduced the world’s

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3M Bonding Process Centers support manufacturers with automated assembly solutions, with options to engage in interactive, remote, or in-person experiences. There’s a U.S. location in St. Paul, MN. first water-resistant and coated abrasive, 3M Wetordry Waterproof Sandpaper. It quickly became of interest to the auto industry because it let manufacturers use the product with water to reduce dust and decrease the friction that typically marred into a vehicle’s finish.

“Around then, one of our lab employees had overheard that two-tone cars were becoming a thing. To achieve the dual-tone look, an area of a vehicle was typically masked off using animal or natural-based glue and newspaper,” explains Buss. “So, they’d brush and mask off a car and then paint it. Long story short, this led to the invention of DESIGN WORLD

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masking tape.”

If you ever wondered how or when the Scotch brand tape products were developed, it started with masking tape for the auto industry and advanced from there.

“A few years later, 3M developed transparent tape using cellophane, which is no longer made with cellophane, so I’ll refer to it as ‘magic tape’ or what most now call Scotch Tape,” he says. 3M keeps the exact recipe for its Scotch Tape (yes, the one used on wrapping paper) a trade secret. Not long after that, the company invented the iconic, snail-like designed www.fastenerengineering.com

handheld tape dispenser.

This is the origin of how 3M became associated with tapes and bonding — and, eventually, adhesives.

“So much of what we’ve accomplished, and continue to accomplish, relates to assembling things and holding them together. We’ve noticed gaps in technology where we could invent a better or a previously non-existent solution,” he says. “But our work with adhesives really began early on and with learning how to best get minerals to bond to paper. To make sandpaper, the abrasive side needed to stick and hold up.”

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Fastening + Joining

Bonding tape has advanced to offer reliable use in several different applications. Here, 3M X-Series Hi-Tack Transfer Tape is applied for recreational vehicle panel bonding.

Buss says demand for more industrial adhesives accelerated in the ’40s. “For example, 3M launched a neoprene rubber adhesive when natural rubber became short, primarily because of World War II.” It was initially used to bond hoses and gaskets. “This ability to assemble parts without a conventional fastener slowly began to gain more recognition and interest.”

In the ’50s and ’60s, structural adhesive films started being used in the aerospace sector to bond wings, fuselage components, and helicopter blades. “As an accepted practice, I’d say the aerospace industry was really one of the pioneering areas for adhesive use,” he shares.

Today, 3M’s tapes and adhesives are found in aerospace, automotive, electronics, medical devices, office supplies, and other consumer products.

The company currently has four large business groups — transportation and electronics, safety and industrial, health care, and consumer goods — with another 22 different divisions beneath them.

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global business management team and primarily focused on product assembly using liquid adhesives or pressuresensitive tapes.” He’s seen the changes in industry demands and the evolution of adhesives over time.

“Today, you have multi-material designs with one purpose: to decrease costs. To meet this goal, there are application-dependent considerations,” he says. “One is to reduce weight, say for fuel efficiency in an airplane.

Another is to distribute stress, which could mean energy absorption in the case of a vehicle crash. Then, there’s miniaturization, particularly in the Continued growth electronics sector like for smartphones.

Buss has certainly witnessed the Trends, such as light-weighting and growth. He began his career with 3M miniaturization, mean new materials as a process engineer in the industrial sector, primarily manufacturing pressure- have to be introduced.”

Tapes and adhesives provide a sensitive tapes. Then, he moved into solution that typically reduces the an application engineering role where weight of an application, at least he became more of a technical liaison, helping solve questions and applications compared to mechanical fasteners, and offers micro-dispensing options for on behalf of customers. those miniature assemblies. They also “I stayed in that sector for about 28 years, working in business development, meet multi-material designs.

“Take vehicles, for example, marketing, and sales. Now, I’m part of the “What’s nice is that the material science 3M offers crosses from division to division and industry to industry. So, because all of the technology is owned by the company, it’s accessible to each division” he says.

Essentially, this allows for a large toolbox of R&D and product innovation to draw from. Considering more than 60,000 3M products are used in homes, businesses, schools, hospitals, and other industries, it’s clearly made sense to share this insight throughout the company.

www.fastenerengineering.com

DESIGN WORLD

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Advanced Fastening and Sealing Technologies

PRE-APPLIED

THERMOSEAL

™

Thermoseal is an ND Industries pre-applied process in which a proprietary hybrid medium strength sealant is applied to fasteners, giving them excellent sealing and threadlocking capabilities.

Thermoseal is designed for high temperature, high pressure applications where other thread locking materials fail. In addition, it may also provide a lower coefficient of friction than alternative preapplied thread lockers to help with ease of installation.

PRE-APPLIED PROCESS FEATURES How It Works Thermoseal is a dual-encapsulated dry film adhesive which is inert on-part until engagement with the mating fastener.

During installation, shearing forces cause the microsphere capsules to rupture, mixing the two components, initializing the reaction and curing to form a strong chemical bond and effective seal.

High Pressure Seal Thermoseal processed fasteners exhibit exceptional sealing properties and the ability to withstand pressures in excess of 5800 psi (40MPa) under challenging conditions. Thermoseal can replace the need for PTFE tape due to its better reproducibility and installation speed.

CONTACT US

ND Industries 7-22.indd 89

Surface Insensitive

Chemical Resistant Upon fastener installation Thermoseal cures to a cross-linked molecular structure; making it one of the most resistant types of adhesives. Oil, gasoline, salt spray, acids, solvents, and water have virtually no effect on parts when introduced after final cure.

Long Shelf Life

Thermoseal processing is compatible with most fastener sizes, configurations, materials and finishes. The use of an acrylic based microsphere adhesive ensures that a strong reliable lock and seal is formed.

Thermoseal processed fasteners have an on-part life of 1 year and will remain inert until a cure is activated by engagement with a mating thread.

Email: info@ndindustries.com www.ndindustries.com

CERTIFICATIONS & ACCREDITATIONS

Surpasses DIN & IFI Thermoseal processed fasteners meet or exceed all torque requirements of DIN 267-27, IFI 125, IFI 525, as well as automotive adhesive coated fastener performance specifications.

Product Specifications Break Away Torque: >20 Nm Prevailing Torque: <2.5 Nm Lubricity: 0.19 Temp Range: -40°C to 220°C

AS9100:2009, Rev. C • QPL-18240F • QSLM • ITAR • ISO-9001:2015 • ISO/IEC 17025:2005 CE Directive 2006/42/EC • ISO-14121 • ISO-12110-1/12110-2 • IEC-EN 60204-1

6/28/22 3:41 PM

Fastening + Joining

they were originally made of steel.

Conventional fasteners or welding made sense because these options do better with thicker or similar materials. But now, cars are made of plastic, aluminum, and a mix of alloys and composites.

Adhesives and tapes can join this range of materials…so, you can bond two different metals and not worry about galvanic corrosion, right? They also offer some energy absorption or vibration dampening,” he says. “It just makes sense.”

Despite early adoption by the aerospace industry, however, educating product designers and engineers about advances in adhesives has always been a large part of Buss’ job. It’s typically not taught in school.

“I was trained as a mechanical engineer and at the time, there were not too many young engineers and students learning about chemical bonding or attachment in my program or within the industry.” Buss went to the University of Minnesota. “While we were taught how to bend metal and how to

select fasteners correctly, there was unfamiliarity with chemical bonding and some disbelief about its advantages.”

So that’s been the main focus of his career at 3M, especially during the last 15 years. “It’s important to us that we offer technical support and properly educate customers, ensuring they understand and fully realize the potential of an adhesive or a tape.

By sharing insight from aerospace, transportation, and electronic markets, we can show how certain types of assemblies are well-suited to adhesives and can also derive benefits aside from just bonding.”

Additional benefits could include better overall aesthetics, process flow or production efficiency, or a performance benefit (such as lightweighting for fuel efficiency in a vehicle) that would not be available through other fastening methods.

“However, I’m in no way suggesting it’s a competition between assembly methods. Mechanical fasteners, welding, and adhesives or tapes should

all be complementary to one another and be used when and where ideal depending on the application,” Buss says. “Chemical bonding has advanced and offers several advantages that many design engineers are unaware of but could benefit from.”

And 3M is showing no signs of slowing down as it continues to innovate new options. This includes formulas with lower odor (common in chemicals) for improved worker comfort, reduced or non-flammability (so the adhesives are safer to store and transport), and greater sustainability features (such as fewer volatile organic compounds).

“There’s always new applications, new materials to bond or temperature ranges to comply with, or greater strength and durability measures to ensure,” adds Buss. “So, we’re always working to ensure success and extend what’s possible.” FE

Finding the ideal adhesive or tape for bonding typically involves testing them in an application. As substrates

have different characteristics, it’s important to fully understand the adhesion process and a product’s features before choosing one for your assembly.

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DESIGN WORLD

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Selecting the Optimal Washer Flat: Generally used for load disbursement Tab/Lock: Designed to effectively lock an assembly into place Finishing: Often found on consumer products Wave: For obtaining loads when the load is static or the working range is small Belleville: Delivers the highest load capacity of all the spring washers Fender: Distributes a load evenly across a large surface area Shim Stacks: Ideal for simple AND complex applications

Boker’s Inc. 3104 Snelling Avenue Minneapolis, MN 55406-1937 Phone: 612-729-9365 TOLL-FREE: 800-927-4377 (in the US & Canada)

bokers.com

Why custom converting is beneficial for adhesive applications CS Hyde Company specializes in converting adhesive tapes, polymer films, fabrics, and silicone.

We utilize high tech converting technology to provide custom solutions for adhesive applications like low surface energy substrates, thin bond lines, or adhesive waste reduction. We specialize in single or doublesided adhesive systems as well as liner application or zone adhesive application. Adhesive can be laminated in house utilizing 3M™ transfer adhesives. Commonly laminated materials include PTFE, Mylar, PEEK, Nylon, and more. We offer rotary tool die cutting services ideal for kiss cut parts in peel and stick applications.

For specialized parts like VHB™ mounting gaskets, we utilize digital knife cutting machinery to produce rapid prototype parts, while reducing waste through an automatic nesting program.

CS Hyde Company www.cshyde.com Lake Villa, IL 60046

DESIGN WORLD

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Emerson electric actuators provide application flexibility Emerson high performance electric actuators offer superior application flexibility Emerson has launched a versatile range of precise and highly repeatable rod-style cylinders. Typically only one screw type is available, but the AVENTICS SPRA Electric Actuators offer a precision ball screw, which provides exceptional durability and accuracy, a cost-effective lead screw and roller screws for precision, speed and heavy loads. Compliance with the ISO-15552 standard, four sizes, a wide range of accessories and mounting options and an online calculation tool and configurator allows configuration to exacting application requirements that help improve sustainability and efficiency.

Read More: Emerson.com/AVENTICS TM

Contact Info : 160 Park Ave., Florham Park, NJ 07932 www.emerson.com/en-us

NBK Suggests and Supplies Solutions with Specialty Screws NBK’s history and craftsmanship date back to 1560 when the company first began. Our predecessors were proud to offer their advanced knowledge, state-of-the-art technology and using this today, we have developed various products.

One of NBK’s strengths in the high-tech sector is our Specialty Screws such as vacuum application screws, anti-galling screws, specialty metal screws such as Inconel and Hastelloy, and more.

Furthermore, NBK deals with unique functional screws like low-profile screws, small head diameter screws, captive screws, miniature screws (less than M2), ball transfer screws, ball plungers, clamping screws, and more. We are proud to support our customer’s projects with NBK’s Specialty Screws and their unlimited matching applications. We also offer customized screws!

NBK America LLC 307 East Church Road, Suite 7 King of Prussia, PA 19406 Phone: 484-685-7500 https://www.nbk1560.com/en-US/ 92

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DESIGN WORLD

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A family-owned business since 1955, ND Industries specializes in the development of innovative materials and processes which increase the safety and reliability of fastener assemblies.

Headquartered outside Detroit, Michigan, ND serves a global market with divisions across the continental US, facilities in Taiwan, and licensees around the world. ND’s core business revolves around the application of a wide variety of custom formulated materials onto fasteners and assemblies to aid in functions such as locking, sealing, masking, lubricating, and noise and vibration damping. ND also manufactures a line of bottled adhesive and sealant products under the Vibra-Tite brand name for MRO and retail use.

ND Industries, Inc. www.ndindustries.com info@ndindustries.com

Fastener Engineering This area has long been one of the most read and sought after by our engineering audience! From screws to bolts and adhesives to springs, these critical but often overlooked components are the key to every successful design.

FastenerEngineering.com will serve readers in the mechanical design engineering space, providing news, product developments, application stories, technical how-to articles, and analysis of engineering trends. This site will focus on key issues facing the engineering markets around fastener technology, along with technical background on selected components.

Engineering September 2019

A supplement of Design World

covering nuts, bolts, rivets, screws, u-clips, eye bolts, washers and more.

ADDITIONAL RESOURCES: • Special print section in select issues of Design World • Fastener Engineering monthly newsletter

LEARN MORE AT: FASTENERENGINEERING.COM DESIGN WORLD

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