Influence of Dry-Film Lubricants on Bond Strength and Corrosion Behaviour of 6xxx Aluminium Alloy Adhesive Joints for the Automotive Industry

Abstract

In the automotive industry, the application of dry lubricants on aluminium is indispensable for achieving a high-quality forming behaviour. To provide a short production time, these forming aids are not removed during the joining step. The aim of this study is the characterisation of the influence of dry lubricants on the bond strength and the corrosion resistance of a 6xxx aluminium alloy for automotive applications. For this purpose, samples with a well-defined surface were coated with 1 g/m2 dry lubricant and joined with a commercial thermosetting 1K epoxy structural adhesive. The bond strength was measured with lap shear tests. To evaluate the corrosion resistance of the adhered aluminium samples, an immersion test in a 5 wt.% NaCl solution was used. Based on the fracture pattern analysis, the corrosion behaviour could be described, and the possible corrosion mechanisms are proposed. The influence of the load quantity of the dry lubricants is observed microscopically and mechanically. The environmentally induced degradation process of the adhesive is examined by an investigation of the volumetric change during the testing and with scanning electron microscopy. Using a simulation, the changes in the adhesive polymer matrix at the metal–adhesive interface caused by the dry lubricants are examined using polymer test procedures like dynamic mechanical analysis, differential scanning calorimetry and tensile tests. The results show a significant effect of the forming aid on the corrosion resistance of the adhered aluminium samples against the corrosive infiltration of the metal–adhesive interface.

Keywords

• dry-film lubricant
• aluminium metal sheet production
• automotive industry
• structural adhesive bonding
• accelerated corrosion testing
• corrosion mechanism