ARL-ADHES-QA-001.01 REV. 2.2 ● APR 2016

ARL-SR-0356 ● APR 2016

US Army Research Laboratory

Adhesives: Test Method, Group Assignment, 

and Categorization Guide for High-LoadingRate Applications – Preparation and Testing of 

Single Lap Joints (Ver. 2.2, Unlimited)

by Robert Jensen, Daniel DeSchepper, David Flanagan, 

Gerard Chaney, and Charles Pergantis

Approved for public release; distribution is unlimited.
NOTICES

Disclaimers

The findings in this report are not to be construed as an official Department of the 

Army position unless so designated by other authorized documents.

Citation of manufacturer’s or trade names does not constitute an official 

endorsement or approval of the use thereof.

Destroy this report when it is no longer needed. Do not return it to the originator.
ARL-ADHES-QA-001-01 REV. 2.2 ● APR 2016

ARL-SR-0356 ● APR 2016

US Army Research Laboratory

Adhesives: Test Method, Group Assignment, 

and Categorization Guide for High-LoadingRate Applications – Preparation and Testing of 

Single Lap Joints (Ver. 2.2, Unlimited)

by Robert Jensen, Daniel DeSchepper, David Flanagan, 

Gerard Chaney, and Charles Pergantis

Weapons and Materials Research Directorate, ARL

Coatings, Corrosion, and Engineered Polymers Branch (CCEPB)*

*CCEPB is ISO 9001:2008 Certified by SRI Quality System Registrar

Approved for public release; distribution is unlimited.
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1. REPORT DATE (DD-MM-YYYY)

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4. TITLE AND SUBTITLE

Adhesives: Test Method, Group Assignment, and Categorization Guide for 

High-Loading-Rate Applications – Preparation and Testing of Single Lap Joints

(Ver. 2.2, Unlimited)

5a. CONTRACT NUMBER

5b. GRANT NUMBER

5c. PROGRAM ELEMENT NUMBER

6. AUTHOR(S)

Robert Jensen, Daniel DeSchepper, David Flanagan, Gerard Chaney, and 

Charles Pergantis

5d. PROJECT NUMBER

R.00104455.2.92

5e. TASK NUMBER

5f. WORK UNIT NUMBER

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)

US Army Research Laboratory

ATTN: RDRL-WMM-C

Aberdeen Proving Ground, MD 21005-5069

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ARL-SR-0356

ARL-ADHES-QA-001.01 Rev. 2.2

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13. SUPPLEMENTARY NOTES

Send comments or inquiries to: usarmy.APG.arl.mbx.adhesive-research@mail.mil 

14. ABSTRACT

This standard process description (SPD) provides the instructions needed in qualifying candidate adhesives for the screening 

tests specified in ARL-ADHES-QA-001.00, Sections 8.2 and 8.3. The single-lap-joint testing configuration relies upon a 

relatively small bond area between adherends, which can lead to high standard deviations in measured strengths. Geometrical 

misalignment and variations in bondline thickness are potential sources of inaccurate property measurements. Poor surface 

treatment of the adherends prior to bonding will increase the likelihood failure of testing following hot/wet conditioning as 

specified in ARL-ADHES-QA-001.00, Section 8.3. This SPD illustrates the techniques for the preparation and testing of 

adhesively bonded single lap joints. Supplemental drawings are illustrated for coupon and tooling fixture machining. 

Checklists are also provided to assist in documenting experimental metadata during fabrication, testing, and adhesive bondline 

thickness measurement.

15. SUBJECT TERMS

single lap joint, adhesive, sample preparation, testing, database, metadata, material pedigree, ISO

16. SECURITY CLASSIFICATION OF:

17. LIMITATION

OF ABSTRACT

UU

18. NUMBER

OF PAGES

66

19a. NAME OF RESPONSIBLE PERSON

Robert E Jensen

a. REPORT

Unclassified

b. ABSTRACT

Unclassified

c. THIS PAGE

Unclassified

19b. TELEPHONE NUMBER (Include area code)

410-306-1910

Standard Form 298 (Rev. 8/98)

Prescribed by ANSI Std. Z39.18
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Contents

List of Figures v

List of Tables vii

1.0 Purpose 3

2.0 Scope 3

3.0 Policy 3

4.0 Responsibilities 3

5.0 Requirements 3

6.0 Terms and Definitions 3

7.0 Records 5

8.0 Preparation of Lap-Joint Coupon Panels and Testing of Single-LapJoint Test Specimens 5

8.1 Safety Precheck .................................................................. 6

8.2 Lap-Joint Coupon Panel Dimensions and Thickness 

Measurements.................................................................... 6

8.3 Surface Preparation ............................................................ 7

8.4 Adhesive Mixing ................................................................13

8.5 Single-Lap-Joint Coupon Panel Assembly and Fabrication...14

8.6 Bondline Thickness Measurements....................................28

8.7 Environmental Conditioning of Specimens.........................30
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8.8 Mechanical Testing ............................................................32

8.9 Data Collection ..................................................................34

9.0 References and Notes .................................................................37

10.0 Appendix A. Test Panel Dimensions ............................................41

11.0 Appendix B. Tooling Fixture Dimensions .....................................43

12.0 Appendix C. Single-Lap-Joint Fabrication Checklist ......................49

13.0 Appendix D. Single-Lap-Joint Mechanical Testing 

Checklist ....................................................................................51

14.0 Appendix E. Bondline Thickness Measurements..........................53

Distribution List 56
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v

List of Figures

Fig. 1 Test panel design configuration used for single-lap-joint preparation 

and testing in accordance to ASTM D1002-10......................................6

Fig. 2 Surface treating the lap-joint coupon panel using the acetone solvent 

wipe surface preparation method...........................................................8

Fig. 3 Image showing the grit-blasting surface preparation method applied to 

the bonding tab surfaces of a lap-joint coupon panel inside the gritblasting cabinet and note the typical nozzle stand-off distance (a) and 

an image of the finished grit blasted coupon panel (discolored tab 

sections due to abrasion) (b) ..................................................................9

Fig. 4 Heavy surface oxidation may be removed prior to grit blasting using 

an abrasion pad (Scotch-Brite 048011-65530 A VFN, or equivalent) 10

Fig. 5 View showing the typical gas spray cleaning process used to remove 

residual surface grit medium after the grit-blasting process from tab 

bonding surfaces ..................................................................................11

Fig. 6 Immersion of grit-blasted primed aluminum single-lap-joint coupon 

panel tabs submerged in the GPS silane coupling agent solution bath 

for 90 s by the clock.............................................................................12

Fig. 7 The removal of excess GPS silane coupling agent solution from the 

treated lap-joint tabs using the directed nitrogen gas method..............13

Fig. 8 The tooling stacking assembly for the fabrication of a single-lap-joint 

coupon panel ........................................................................................15

Fig. 9 Single-lap-joint tooling fixture components, including release sheets to 

prevent bonding of the tooling fixture and shim plates to control 

bondline thickness................................................................................16

Fig. 10 Single-lap-joint tooling fixture stacking sequence: bottom tooling 

fixture plate with alignment posts........................................................16

Fig. 11 Shim plates placed on top of the bottom tooling fixture plate. Note the 

thicker shim plate (top) compensates for the single-lap-joint panel 

thickness, and the thinner, secondary shim plate (bottom) sets the 

bondline thickness................................................................................17

Fig. 12 Placement of the bottom release sheet layer........................................18

Fig. 13 Placement of bottom prepared single-lap-joint panel ..........................19

Fig. 14 Application of adhesive to prepared tabs onto bottom lap-joint coupon 

panel.....................................................................................................20

Fig. 15 Placement of top lap-joint panel ..........................................................21

Fig. 16 Placement of top release sheet .............................................................22
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vi

Fig. 17 Placement of the top shim plate over the top release sheet, aligned with 

the lap-joint coupon panel. (The shim plates match the coupon and 

bondline thickness to evenly offset the top single-lap-joint panel.) ....23

Fig. 18 Completed lap-joint panel tooling package .........................................24

Fig. 19 Single-lap-joint tooling fixture weighted plate stacking method with 

additional weighted plates for increased bonding pressure .................25

Fig. 20 Representative example of the plate-loaded single-lap-joint tooling 

fixture undergoing oven cure at elevated temperature.........................26

Fig. 21 Representative example of fully bonded single-lap-joint coupon panel 

upon completion of cure in the tooling fixture ....................................27

Fig. 22 “Intact” bonded single-lap-joint panel showing adhesive fillets, side 

overflow, and the cardboard shim (left) and each individual single-lapjoint coupon specimen being separated from the panel using a band 

saw (right)............................................................................................27

Fig. 23 Finishing preparation of a single-lap-joint coupon test specimen using 

a belt sander (left) and a side view of the test specimen after removing 

the excess adhesive (right)...................................................................28

Fig. 24 Perform the single-lap-joint bondline thickness measurements using a 

calibrated micrometer ..........................................................................28

Fig. 25 Illustration of the single-lap-joint bondline thickness measurement 

points....................................................................................................29

Fig. 26 Alternate elevated temperature/water immersion conditioning test for 

lap-joint test specimens using the test tubes and convection oven 

method..................................................................................................31

Fig. 27 Samples undergoing elevated temperature testing at 71 °C, +/−3 °C 

(160 °F, +/−5 °F), with the chamber door opened (left) and closed 

(right) ...................................................................................................32

Fig. 28 An instrumented mechanical testing frame with a load cell and work 

station is used to measure the load vs. displacement response of the 

single lap joint until breaking failure ...................................................33

Fig. 29 Images showing the jaws of the grips engaging a single-lap-joint 

specimen at each end, secured in the center of the grips and parallel to 

the direction of tensile force to be applied as per ASTM D1002-10, 

Paragraph 5.1 .......................................................................................33

Fig. 30 Representative example of raw load vs. displacement plot .................34

Fig. 31 Representative example of raw load vs. time plot ...............................35

Fig. 32 Representative scanned failure surfaces showing sample ID 

information embedded within the image (ruler is included for 

quantitative dimensional scaling) ........................................................35
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List of Tables

Table. Representative single-lap-joint bondline thickness measurements and 

calculations ..........................................................................................29
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INTENTIONALLY LEFT BLANK.
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Coatings, Corrosion, and Engineered Polymers Branch

Standard Process Description (SPD)

Adhesives: Test Method, Group Assignment, and Categorization Guide for 

High-Loading-Rate Applications – Preparation and Testing of Single Lap 

Joints (Ver. 2.2, Unlimited)

ARL-ADHES-QA-001.01 rev 2.2

Origin Date: 07/06/2011 Rev. No. 2.2 Date: 4/6/2016

Prepared by:

Robert Jensen

Daniel DeSchepper

David Flanagan

Adhesives and Interfaces Research Team

Coatings, Corrosion, and Engineered Polymers Branch

Materials and Manufacturing Science Division

US Army Research Laboratory

RDRL-WMM-C

APG, MD 21005

Send comments or inquiries to: usarmy.APG.arl.mbx.adhesive-research@mail.mil

Reviewed by:

CCEPB ISO 9001:2008 Working Group

Charles Pergantis

Gerard Chaney

Coatings, Corrosion, and Engineered Polymers Branch

Materials and Manufacturing Science Division

US Army Research Laboratory

RDRL-WMM-C

APG, MD 21005

Approved by:

James F Snyder (Chief)

Coatings, Corrosion, and Engineered Polymers Branch

Materials and Manufacturing Science Division

US Army Research Laboratory

RDRL-WMM-C

APG, MD 21005

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1.0 Purpose

This document provides guidance from within the Adhesives and Interfaces Research Team of the 

Coatings, Corrosion, and Engineered Polymers Branch (CCEPB) and the US Army Research 

Laboratory (ARL) operating procedures for the preparation, testing, and evaluation of adhesively 

bonded single lap joints.

2.0 Scope

This standard process description (SPD) provides the instructions needed in qualifying candidate 

adhesives for the screening tests specified in ARL-ADHES-QA-001.00 rev 1.0, Subsections 8.2 

and 8.3. The single-lap-joint testing configuration relies upon a relatively small bond area between 

adherends, which can lead to high standard deviation in measured strength. Geometrical 

misalignment and variation in bondline thickness are potential sources of inaccurate property 

measurements. Poor surface treatment of the adherends prior to bonding will increase the 

likelihood of failure in testing following hot/wet conditioning as specified in ARL-ADHES-QA001.00, Subsection 8.3. This SPD illustrates the techniques for the preparation and testing of 

adhesively bonded single lap joints. Supplemental drawings are illustrated for the machining of 

coupons and fixture tooling. Checklists are also provided to assist in documenting experimental 

metadata during fabrication, testing, and adhesive bondline thickness measurement.

3.0 Policy

This SPD applies to all personnel developing, fabricating, testing, characterizing, and evaluating

adhesives for bonding applications within the CCEPB.

4.0 Responsibilities

The Branch Chief, CCEPB, Adhesives Team Leader, and Principal Investigator(s) will ensure that 

all personnel working on adhesives development, fabrication, testing, characterization, and 

evaluation have and maintain full knowledge and/or proper training of this process, including 

equipment usage/operation, test procedures, and safety issues/factors before commencing relevant 

work within the CCEPB.

5.0 Requirements

All researchers performing adhesives development and evaluation work in the CCEPB must follow 

the procedures described within this SPD.

6.0 Terms and Definitions

For the purposes of this document, the following terms and definitions apply:

Adherend: As stated within ASTM D907-12a, an adherend is “a body held to another 

body by an adhesive.”1 Specifically for this SPD, the bodies are 2 rectangular sheets of 

2024 T3 aluminum alloy.

Adhesion Promoter: As stated within ASTM D907-12a, an adhesion promoter is “a 

substance used to improve bonding of the adhesive to the substrate.”1
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APS – 3-aminopropyltrimethoxylsilane (Chemical Abstracts Service [CAS] registry 

number 13822-56-5): An amine functionalized silane coupling agent.

Bondline: As stated within ASTM D907-12a, bondline shall be “the layer of adhesive 

which attaches the two adherends.”1

Coupling Agent: As stated within ASTM D907-12a, “A substance having functional 

groups that are capable of reacting with the surfaces of two different substances, thereby 

chemically bridging them.”1

Database: As stated within ISO/IEC 2382-17:1999, a database shall be “a collection of 

data organized according to a conceptual structure describing the characteristics of these 

data and relationships among their corresponding entities, supporting one or more 

application areas.”2

Digital Archive: The term “digital archive” shall be referred to as an electronic repository 

of digital data and metadata “to preserve the authenticity, reliability, integrity, and usability 

of such records” as stated in ISO 13008:2012(E).3

GPS – 3-glycidyloxypropyltrimethoxylsilane (CAS registry number 2530-83-8): An 

epoxy functionalized silane coupling agent.

Lap Joint: As stated within ASTM D907-12a, a lap joint shall be “a joint made by placing 

one adherend partly over another and bonding together the overlapped portions.” 1

Material Pedigree: The term “material pedigree” shall refer to the documentation used to 

ensure the traceability of an adhesive and its constitutive formulation ingredients to the 

original manufacturer.4

Metadata: As stated within ISO/IEC 2382-17:1999, the term “metadata” pertains to “data 

elements, possibly including their data descriptions, and data about data ownership, access 

paths, access rights and data volatility.”2

MPS – 3-methacryloxypropyltrimethoxysilane [CAS registry number 2530-85-0]: A 

methacrylate functionalized silane coupling agent.

Surface Preparation: As stated within ASTM D907-12a, surface preparation shall pertain 

to “physical or chemical treatments, or both, applied to adherends to render suitable for 

bonding.”1

Trustworthiness: In the context of this SPD, trustworthiness relates to “judgments of 

reliability, dependability and competence”5,6 of the experimental sample preparation and 

testing.
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7.0 Records

Per Army Regulation (AR) 25-400-2, all records (including data and associated metadata) shall be 

considered to “have value beyond the business process, such as for historical, lessons learned, or 

research purposes; these are generally long-term records.”7 Records will be kept in physical 

laboratory notebooks and digitally archived for permanent retention, consistent with AR 25-400-

2 code “TP” (i.e., Transfer Permanent).7

8.0 Preparation of Lap-Joint Coupon Panels and Testing of Single-Lap-Joint Test 

Specimens

The flow chart below illustrates the procedure to prepare and fabricate lap-joint coupon test 

specimens, as well as to test, record, and analyze data used by ARL to determine if the adhesive is 

acceptable for further consideration for higher-tier testing. Under this process, specimens must be 

tested in 3 environmental conditions—dry-room temperature, hot/wet, and dry-elevated 

temperature—with the data obtained, analyzed, and categorized by grouping prior to ARL’s review.

 

 

 

 

 

 

Specimens designated into 3 sets for conditioning and testing (Sections 8.7-8.9): 

1. Dry Condition (Control Specimens): Stored at room temperature

2. Elevated Temperature/Wet Condition: Immersed in water at 63 °C for 14-day 

soaking period

3. Hot Dry Condition: Tested while in a heated chamber for 45 min at 71 °C

Researcher fabricates single-lap-joint test specimens for SECOND TIER testing (single batch), if 

not already done so, preparing specimens using one of the 5 surface preparation methods (or 

suitably documented alternative) stated in Section 8.3 and fabricated in conformance to 

Sections 8.4-8.5, measured and documented as in Sections 8.6-8.9.

NO

Did the

adhesive meet/exceed

SECOND TIER 

requirements? 

Researcher assigns Grouping l-lV. ARL reviews all documentation 

and results from testing, archives all provided information, and 

verifies grouping assignments to adhesives. ARL may fund and 

conduct optional THIRD and FORTH TIER testing.

YES (continue to next TIER)

Dry Condition

Specimens

Elevated Temp. and Wet 

Immersed Conditioned

Specimens

Hot-Dry 

Condition

Specimens

Researcher may reformulate, 

optimize, enhance, refine, 

improve adhesive, and resubmit 

for FIRST TIER acceptance.
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8.1 Safety Precheck

Prior to the preparation or testing of single-lap-joint coupons or test specimens, a safety precheck 

shall be performed. The safety precheck shall focus on the following actions, and compliance shall 

be documented. If any safety issues arise, they must be resolved and corrected before proceeding. 

• Address all protective clothing, protective equipment, and ventilation requirements.8–13

• Inspect all equipment to be used to identify and correct any damage or malfunction that 

could hinder operation or create a potential hazard.14

• Address all chemical hazards and ensure all material safety data sheets (MSDSs) for the 

chemicals to be used in the aluminum surface preparation and adhesives are readily 

available.

15

• Address start-up for all equipment needed for the fabrication and testing processes. Refer 

to applicable internal operating procedures when needed to operate laboratory equipment.16

8.2 Lap-Joint Coupon Panel Dimensions and Thickness Measurements

The complete drawing with dimensions and tolerances of the aluminum lap-joint coupon panel 

shall conform to ASTM D1002-10, “Fig. 3 Optional Panel for Acceptance Tests Only”17 (refer to 

Section 10.0, Appendix A, Test Panel Dimensions). A drawing of the panel geometry is shown in 

Fig. 1, having a recommended aluminum plate thickness of 1.62 ± 0.125 mm (0.064 ± 0.005 inch) 

with an overlap length of 12.7 ± 0.25 mm (0.5 ± 0.01 inch). Aluminum alloy 2024, T3 temper, is 

the recommended grade for testing this panel. (The panel has been modified with the inclusion of 

alignment holes for use in the tooling fixture.)

Fig. 1 Test panel design configuration used for single-lap-joint preparation and testing in accordance to 

ASTM D1002-1017
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8.3 Surface Preparation

The first step in the fabrication of single-lap-joint test specimens is the preparation of the surfaces 

to be bonded. The surface preparation methods stated are appropriate for a wide range of adhesives, 

which are most commonly used by ARL. ARL also acknowledges that the outlined protocols may 

not be suitable for optimal bond performance for all adhesives. The surface preparation technique 

used, either recommended or alternative, shall be fully documented in a laboratory notebook with 

sufficient detail to serve as trustworthy database metadata. There are 4 distinct laboratory-scale 

surface preparation methods ARL performs for an aluminum substrate: Basic Untreated, Acetone 

Solvent Wipe, Grit Blasting, and Silane Coupling Agent. A general description of the procedures 

used in each method is listed here, followed by a more detailed description.

Basic Untreated Surface Preparation

• Basic cleaning of the surface with a clean, dry lint-free cloth

Acetone Solvent Wipe Surface Preparation

• Includes Basic Untreated method

• Uses acetone as a solvent to wipe clean the surface

Grit-Blasting Surface Preparation

• Includes Basic Untreated method

• Includes Acetone Solvent Wipe method

• Uses grit blasting to pretreat the surface before cleaning

Silane Coupling Agent Surface Preparation

• Includes Basic Untreated method

• Includes Acetone Solvent Wipe method

• Includes Grit-Blasting method

• Employs either GPS, MPS, or APS as a coupling agent following the other preparation

8.3.1 Basic Untreated Surface Preparation

This method is the most basic surface preparation technique and is used within all other procedures 

as a first step. Remove loose debris from the fabricated aluminum lap joint test panel using a clean 

and dry cloth or paper towel. Single-lap-joint testing results obtained from untreated aluminum 

panels are useful for troubleshooting suspect chemical and etch surface treatments by providing 

an estimate of the lowest bond strength for the adhesive. The chemical or etch surface treatment 

process needs to be examined if it provides similar or lower bond strength values as those obtained 

from untreated surfaces.
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8.3.2 Acetone Solvent Wipe Surface Preparation

This method includes Subsection 8.3.1 preparation and also involves wiping the bonding surfaces 

of the lap-joint coupon panel tabs to be adhered with acetone (CAS #67-64-1) with a soft, lint-free 

cloth and allowing it to air dry, as shown in Fig. 2. This method of surface preparation is 

recommended for very rapid screening tests, such as studying/investigating process optimization 

(i.e., mixing, application, and cure) of an adhesive with unfamiliar handling characteristics.

Fig. 2 Surface treating the lap-joint coupon panel using the acetone solvent wipe surface preparation 

method

8.3.3 Grit Blast Surface Preparation

This method includes Subsections 8.3.1 and 8.3.2 preparation. After the lap-joint coupon panel is 

cleaned of dirt and debris and is solvent wiped, the bonding surface is then ready and submitted 

for the grit-blasting process. Virgin 54- to 60-grit aluminum oxide abrasive blasting media shall 

be used for the grit-blasting process.18 It is critical that unused aluminum oxide is used at all times 

during this procedure. Grit-blasting cabinets are typical commodity laboratory equipment that can 

have multiple users, which can result in significant cross-contamination of the grit-blasting 

medium. The media also has a finite life in the blasting process. This critical application requires 

fresh, sharp-edged particles of a specific size. Grit-blasting cabinets using compressed air shall be 

fitted with a moisture separator. The grit-blasting cabinet shall be equipped with a foot-operated 

blast gun capable of at least 12 cubic feet per minute (CFM) and a 100-CFM dust collector. Grit 

blasting is to be repeated until the bonding surfaces of each short tab of the lap-joint coupon panel 

are visually uniform in color and appearance. For aluminum lap-joint panels the surface appears 

gray and dull as shown in Fig. 3. Further guidance can be found in TT-C-490F and SSPC-SP 

10/NACE No. 2.19,20 Heavy surface oxidation may be removed prior to grit blasting using an 

abrasion pad (Scotch-Brite 048011-65530 A VFN, or equivalent), as shown in Fig. 4.
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Fig. 3 Image showing the grit-blasting surface preparation method applied to the bonding tab surfaces of a 

lap-joint coupon panel inside the grit-blasting cabinet and note the typical nozzle stand-off distance (a) and an 

image of the finished grit blasted coupon panel (discolored tab sections due to abrasion) (b)

(a)

(b)
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Fig. 4 Heavy surface oxidation may be removed prior to grit blasting using an abrasion pad (Scotch-Brite 

048011-65530 A VFN, or equivalent)

Upon removal from the grit-blasting cabinet, make sure the abraded portions of the lap-joint 

panel’s tabs are only in direct contact with either other grit-blasted panel tabs or the air. The lapjoint coupon panel is further cleaned using a high-volume gas spray, such as a pressurized stream 

of nitrogen gas, to remove loose dust and grit blast debris particles on the surface, as shown in 

Fig. 5. ARL typically uses bottled or in-house nitrogen gas to avoid surface contamination at 

approximately 690 kPa (100 psi) outlet pressure, directed from a 6.35-mm (0.25-inch) inner 

diameter plastic tubing to concentrate the flow (orange tubing shown in Fig. 5). Never use housecompressed air, since it can contain too many contaminants, such as dirt, water, and oil. It is very 

important when using this method that panels be bonded within 4 h after gas spray cleaning to 

minimize exposure to ubiquitous airborne contaminants and moisture degradation.
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Fig. 5 View showing the typical gas spray cleaning process used to remove residual surface grit medium after 

the grit-blasting process from tab bonding surfaces

8.3.4 Silane Coupling Agent Pretreatment Preparation

The preparation for all silane coupling agent pretreatment methods (e.g., GPS, MPS, and APS) 

includes first performing the steps outlined in Subsections 8.3.1, 8.3.2, and 8.3.3: basic surface 

cleaning, solvent swiping, and grit blasting the lap-joint coupon panel tabs, respectively.

8.3.4.1 GPS Silane Coupling Agent (3-glycidyloxypropyltrimethoxylsilane) Solution 

Preparation

The following steps outline the preparation process for GPS silane coupling agent solution:

8.3.4.1.1 Mix 4 L by volume of 90:10 ethyl alcohol and water (e.g., 3.6 L of ethyl alcohol [64-

17-5] and 0.4 L of deionized [DI] water). Use a large graduated cylinder and a glass 

funnel to measure and pour the components, making sure to clean the glassware 

thoroughly before and after use by scrubbing and/or brushing with soap and water, then 

rinsing with DI water. Gently shake the solution after the components are all added.

8.3.4.1.2 Next, to the 90:10 alcohol mixture, add with a clean glass pipette enough acetic acid 

[64-19-7] to adjust the pH to 4.5 and label the container “90:10, EtOH:H2O, with Acetic 

Acid, pH = 4.5, For GPS.”

8.3.4.1.3 Transfer 200–300 mL of the acidic EtOH:H2O mixture to a clean glass flask and add 

1% by weight GPS silane coupling agent material to form the solution. Stir moderately 

on a magnetic stir plate using a clean stir bar for 30–60 min. Use of a clock or stopwatch 

is recommended.
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8.3.4.1.4 Transfer the mixed solution into a glass container large enough to coat the tabs of the 

coupon panel. Waste generation of about 250 mL of excess solution is common for each 

use. Waste can be labeled as “____ mL 90:10 EtOH:H2O with 1 weight % GPS silane.”

8.3.4.1.5 The silane coupling agent solution must be applied to the single-lap-joint coupons within 

4 h of initial mixing. Mixed silane coupling agent solutions are to be considered expired 

after 4 h.

8.3.4.2 GPS Silane Coupling Agent Application

After the grit-blasting process (Subsection 8.3.3), the abraded lap-joint coupon panel tabs shall be 

treated with the GPS silane coupling agent solution bath, prepared in Subsection 8.3.4.1. A thin 

chemical dip coating shall be applied to the tabs by immersing them for 90 s within the bath, as 

shown in Fig. 6. Once removed from the bath, immediately remove any excess GPS silane coupling 

agent solution using a high-volume nitrogen gas spray, using approximately 690 kPa (100 psi) 

outlet pressure directed from a 6.35-mm (0.25-inch) inner diameter plastic tubing, as shown in Fig. 

7. Caution must be taken to avoid rewetting the tabs once dry. Using a low angle approach, start 

the nitrogen gas spray at one end of the panel tabs, remove the excess from beneath the aluminum 

substrate (the back side opposite of the bonding surface); this method will reduce splatters and the 

inadvertent redeposition of GPS silane solution back onto the bonding surface. It is crucial to not 

touch the treated tabs (specifically, the bonding area), even with gloves, after treatment is 

completed. Bake the treated lap-joint coupon panel for 1 h at 100 °C, +/–3 °C (212 °F, +/–5 °F) in 

a closed static (nonconvection) oven. (The GPS coupling agent shall be applied within 4 h after 

the grit-blasting process.) Store the treated lap-joint coupon panel in an inert atmosphere until it is 

ready for bonding. The bonding process shall begin no later than 4 h after treatment.

Fig. 6 Immersion of grit-blasted primed aluminum single-lap-joint coupon panel tabs submerged in the GPS 

silane coupling agent solution bath for 90 s by the clock
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Fig. 7 The removal of excess GPS silane coupling agent solution from the treated lap-joint tabs using the 

directed nitrogen gas method

8.3.5 MPS Silane Coupling Agent (3-methacryloxypropyltrimethoxysilane) Pretreatment 

Preparation

Follow the surface treatment procedures outlined in Subsections 8.3.4 and 8.3.4.1 and substitute 

the GPS with MPS.

8.3.6 APS Silane Coupling Agent (3-aminopropyltrimethoxylsilane) Pretreatment 

Preparation 

Follow the surface treatment procedures outlined in Subsections 8.3.4 and 8.3.4.1 and substitute 

the GPS with APS but eliminate the acetic acid pH adjustment step. APS will self-hydrolyze its 

methoxysilane groups into hydroxyl groups and does not require pH adjustment.

8.4 Adhesive Mixing

It is beyond the scope of this SPD to provide universal instructions for the mixing and handling of 

the adhesive component. As a starting point, the operator should refer to the manufacturer’s 

technical data sheet (TDS) and MSDS for preliminary guidance. Operator safety is the first and 

most important consideration in preparing single lap joints due to the potential for chemical 

exposure. Once any safety concerns are addressed, the key factors in fabricating a reliable single

lap joint are ensuring a complete cure, ensuring consistent bond thickness, and minimizing voids. 

Therefore, the operator should first prepare (if possible) a bulk sample of the adhesive in the safety 

of a ventilated fume hood to gauge an experimental understanding of the handling characteristics. 

The operator should note the adhesive’s viscosity, pot life, and if normal atmospheric conditions 
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(oxygen or moisture) inhibit the cure. If the adhesive does not gel at room temperature, or 

additional postcuring is required, the operator should observe for out-gassing and large exothermic 

reactions at elevated temperature. The operator will note any possible handling and cure behavior 

of the adhesive that will lead to incomplete cure, inconsistent bond thickness, or voiding (i.e.,

formation of voids and/or porosity) within the single lap joints.

The operator will document in a laboratory notebook with sufficient detail to serve as trustworthy 

database metadata the adhesive preparation procedure, the method of application of the adhesive 

to the single-lap-joint samples, cure cycle, mixing to applied pressure time, pressure during cure, 

temperature at sample preparation, and the ambient temperature and humidity during sample 

preparation.

8.5 Single-Lap-Joint Coupon Panel Assembly and Fabrication

The single-lap-joint coupon panel tooling fixture provides joint overlap and alignment control 

when used with the test panels described in Subsection 8.2. An illustration indicating the tooling’s 

stacking assembly to fabricate single-lap-joint coupon panels is depicted in Fig. 8. The actual 

tooling fixture is shown in Fig. 9, with the stacking sequence to fabricate a single-lap-joint coupon 

panel illustrated in Figs. 10–19. Complete engineering drawings, with dimensions for tooling, are

provided in Appendix B.
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Fig. 8 The tooling stacking assembly for the fabrication of a single-lap-joint coupon panel

Bottom Single-Lap-Joint Tooling 

Plate with Alignment Posts

Top Single-Lap-Joint Tooling Plate 

with Mating Alignment Holes

Bottom 

Shim

Top 

Shim

Bottom 

Release 

Sheet

Top 

Release 

Sheet

Bottom 

Single-Lap-Joint 

Coupon Panel with 

Adhesive Applied 

at Tabs

Top 

Single-LapJoint Coupon 

Panel
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Fig. 9 Single-lap-joint tooling fixture components, including release sheets to prevent bonding of the tooling 

fixture and shim plates to control bondline thickness

8.5.1 Single-Lap-Joint Coupon Panel Assembly and Fabrication Procedure

8.5.1.1 Step 1

Make sure the work area to assemble the lap-joint tooling fixture, as well as the surfaces of each 

tooling fixture component, is clean, dry, and free of any dirt and debris. Start by placing the bottom 

tooling plate with alignment posts on a sturdy flat, level surface. Inspect the alignment posts to 

ensure they are not bent, loose, or damaged. Figure 10 shows the bottom lap-joint tooling plate for 

the base of the assembly.

Fig. 10 Single-lap-joint tooling fixture stacking sequence: bottom tooling fixture plate with alignment posts
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8.5.1.2 Step 2

Place the bottom shim plate(s) for the required controlled bondline thickness as needed onto the 

bottom tooling fixture plate, along one side, as the next level in the stacking sequence. Shims 

should slide freely over posts and lay flat as shown in Fig. 11.

Fig. 11 Shim plates placed on top of the bottom tooling fixture plate. Note the thicker shim plate (top) 

compensates for the single-lap-joint panel thickness, and the thinner, secondary shim plate (bottom) sets the 

bondline thickness
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8.5.1.3 Step 3

Place the bottom release sheet as shown in Fig. 12. It is highly recommended to use release sheets 

to ease in dismantling the tooling fixture and removing the lap-joint panel specimen from the 

tooling due to adhesive overflow.

Fig. 12 Placement of the bottom release sheet layer
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8.5.1.4 Step 4

Place the bottom lap-joint coupon panel opposite to the bottom shim on top of the release sheet, 

tabs facing inward, with the prepared tab surfaces facing upward as shown in Fig. 13. The lapjoint panel should slide freely over alignment posts with little lateral movement.

Fig. 13 Placement of bottom prepared single-lap-joint panel
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8.5.1.5 Step 5

Apply the adhesive to a sufficient length on the prepared tab surfaces of the bottom single-lapjoint coupon so that the adhesive will cover a space approximately 6 mm (0.25 inch) longer than 

the full prepared 12.7-mm (0.50-inch) bond overlap area, as shown in Fig. 14.

Fig. 14 Application of adhesive to prepared tabs onto bottom lap-joint coupon panel
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8.5.1.6 Step 6

Place the top lap-joint coupon panel onto the adhesive opposite the bottom coupon panel with its 

prepared tabs facing downward as shown in Fig. 15. The bonded panels will be held rigidly in 

place by the alignment posts during curing. In addition, the length of the overlap will be controlled,

and shims will provide a fixed bondline thickness.

Fig. 15 Placement of top lap-joint panel
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8.5.1.7 Step 7

Place the top release sheet over the lap-joint coupon panels as shown in Fig. 16. Release sheets 

provide a layer of protection for the other tooling components from the adhesive while being 

processed.

Fig. 16 Placement of top release sheet
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8.5.1.8 Step 8

Place the top shim(s) over the right side of the alignment posts as shown in Fig. 17. The singlelap-joint tooling fixture configuration provides thickness and overlap controls through the use of 

the shims and alignment posts, respectively. In the example shown, the shims will produce an 

approximately 0.762-mm (0.030-inch) bondline thickness. A bondline thickness of 0.762 mm 

(0.030 inch) is a recommended starting point, but this may not be optimal for all adhesives.21–23

Bondline shims are also available in 0.127 mm (0.005 inch), 0.381 mm (0.015 inch), and 1.14 mm 

(0.045 inch), with additional thicknesses available by acquiring the needed shim stock.

Fig. 17 Placement of the top shim plate over the top release sheet, aligned with the lap-joint coupon panel. 

(The shim plates match the coupon and bondline thickness to evenly offset the top single-lap-joint panel.)
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8.5.1.9 Step 9

Place the top tooling fixture plate with the alignment holes to complete the tooling package as 

shown in Fig. 18.

Fig. 18 Completed lap-joint panel tooling package
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8.5.1.10 Step 10

For simplicity ARL incorporates the stacking weighted plate method of applying pressure (~7.8 

KPa) to the single lap joints during bonding as shown in Fig. 19. Three steel plates (5.4 kg each) 

are stacked on top of the single-lap-joint tooling fixture during cure. (The first stacking plate 

contains alignment holes that also mate with the alignment posts of the bottom tooling plate.) To 

obtain the needed pressure, 3 stacking plates are used. Using this method, the pressure can also be 

adjusted as necessary to optimize for specific adhesives.

a. Single-stack weighted plate setup

 

b. Double-stack weighted plate setup

c. Triple-stack weighted plate setup

Fig. 19 Single-lap-joint tooling fixture weighted plate stacking method with additional weighted plates for 

increased bonding pressure
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8.5.1.11 Step 11

If the adhesive is a room temperature cure material, no further processing assistance is required. 

Conversely, if heat is required for the curing, the tooling can be placed in an oven. The tooling 

fixture can also be vacuum-bagged and heated in an oven, vacuum-bagged for autoclave 

processing, or simply processed in a hydraulic press where higher bonding pressure is required 

(the last 2 methods would not require any plate stacking). Furthermore, the tooling fixture can also 

be vacuum-bagged and backfilled with a nitrogen gas purge for adhesives that are moisture or 

oxygen sensitive. Figure 20 shows the tooling fixture placed within a typical convection oven, 

with unobstructed circulated airflow around the tooling package. Thermal lag can be compensated 

for by referencing the cure schedule to a thermocouple measurement taken from between the 

tooling fixture plates. Alternative methods can also be used during the curing process as dictated 

by the adhesive.

Fig. 20 Representative example of the plate-loaded single-lap-joint tooling fixture undergoing oven cure at 

elevated temperature

8.5.1.12 Step 12

Remove the cured and bonded single-lap-joint coupon panel from the tooling fixture as shown in 

Fig. 21. Precautions should be taken to avoid unnecessary stresses in bending the panel in cases 

where the alignment holes are binding to the locating pins of the tooling fixture. Excessive force 

may degrade the bond strength of the joint.

Separate each individual single-lap-joint coupon specimen from the bonded panel as shown in 

Fig. 22. It is normal to observe adhesive side overflow of the bonded single-lap-joint panel and the 

formation of adhesive fillets. For added stability during the cutting process, cardboard shim stock 

can be placed under the single-lap-joint coupon panel to keep it flat, steady, and firm, and will 

reduce chatter and vibration when passing through the blade. Separate each coupon specimen using

a band saw to rough-cut between each specimen and remove the excess overflow adhesive from 

the sides of the joints. The saw blade used for this demonstration contained 19 mm (0.75 inch) ×

0.90 mm (0.035 inch) × 0.3–0.5/teeth per mm (8–12/teeth per inch), which is sufficient to produce 

a clean cut.
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Fig. 21 Representative example of fully bonded single-lap-joint coupon panel upon completion of cure in the 

tooling fixture

Fig. 22 “Intact” bonded single-lap-joint panel showing adhesive fillets, side overflow, and the cardboard shim 

(left) and each individual single-lap-joint coupon specimen being separated from the panel using a band saw

(right)
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Finally, each lap-joint coupon specimen is finished into a test specimen in accordance with ASTM 

D100217 as shown in Fig. 23. Any sharp edges remaining on the aluminum adherends after cutting 

with the band saw are removed using a belt sander, which produces smooth edges and reduces any

cutting injury risk to laboratory personnel during further handling and testing. Remove all excess 

adhesive from the sides of the joint. This facilitates an easier visual inspection for detecting 

possible excessive voids within the bondline and ensures an accurate bondline thickness 

measurement.

Fig. 23 Finishing preparation of a single-lap-joint coupon test specimen using a belt sander (left) and a side 

view of the test specimen after removing the excess adhesive (right)

8.6 Bondline Thickness Measurements

Once individual single-lap-joint test specimens have been fabricated, the adhesive bondline 

thicknesses need to be recorded for each specimen. It is important when taking thickness 

measurements of the single-lap-joint test specimen that a calibrated micrometer, such as the one 

shown in Fig. 24, is used.

Fig. 24 Perform the single-lap-joint bondline thickness measurements using a calibrated micrometer
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Three measurements shall be taken along the width of the lap-joint test specimen at specified 

locations, and then averaged, as indicated in Fig. 25. Measurements of the overall thickness include 

the thickness of adherend A and B over their prepared substrate surfaces of the lap joint itself at 

location C. Bondline thickness can be simply calculated by subtracting the adherend A and B 

measurements from the overall thickness measurement. Averages shall be determined and 

recorded. Furthermore, the operator will document in a laboratory notebook with sufficient detail 

to serve as trustworthy database metadata the method of obtaining the average thickness of the 

adhesive layer. The following Table is an example of an appropriate table that one can use to 

record, calculate, and submit as metadata.

Fig. 25 Illustration of the single-lap-joint bondline thickness measurement points

Table. Representative single-lap-joint bondline thickness measurements and calculations
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8.7 Environmental Conditioning of Specimens

It is essential that test specimens be environmentally conditioned and then mechanically tested to 

assess the adhesive’s performance and that ARL determine the acceptance of the adhesive for 

higher-tier testing outlined in ARL-ADHES-QA-001.00. It is necessary to condition specimens in 

accordance to this standard.

Test specimens shall be designated into the following 3 sets:

• Room Temperature–Dry Conditioning

• Hot/Wet Conditioning

• Elevated Temperature–Dry Conditioning

Prior to mechanical testing, samples shall be kept under dry conditions at ambient temperatures 

until tested and then stored in sealed plastic bags, dry desiccant containers, nitrogen purged 

containers, or similar. Even samples to be tested following hot/wet conditioning (i.e., high 

temperature/water immersion) will still be stored in dry conditions prior to initiating the immersion 

cycle. The operator will document the sample conditioning and all relevant test information in a 

laboratory notebook with sufficient detail to serve as trustworthy database metadata.

A sufficient number of lap-joint test specimens (a minimum of 5) within a set shall be mechanically 

tested, as per Subsection 8.8, to determine the average tensile breaking strength of that set, under 

each condition. Specimens producing extremely low values from the test set average may be 

omitted and an additional sample tested. Anomalies could be due to flaws within the bondline, 

inadequate surface preparation, or possibly an issue with the testing apparatus.

8.7.1 Room Temperature–Dry Conditioning

Room temperature–dry conditioning samples will be considered baseline values for the adhesive. 

Samples shall be taken from the sealed dry container and tested within 30 min.

8.7.2 Elevated Temperature/Water Immersion (Hot/Wet) Conditioning

Samples conditioned at elevated temperature and 100% submersed in water (hot/wet conditioning) 

shall be placed within a water immersion tank (circulating or noncirculating), preferably using DI 

or distilled water, maintaining a constant water temperature of 63 °C, +/–3 °C (145 °F, +/–5 °F),

for a duration of 14 days.24 Duration and temperature of the conditioning are based upon 

considerations referenced in MIL-STD-810G, Laboratory Test Method 507.5, Humidity.25

As an alternate method, if an immersion tank is not available, individual lap-joint test specimens 

may be placed within a large test tube, with a screw top, to fully accept the length of the specimen, 

filled with water and cap securely tightened. Test tubes may then be placed in a rack, sitting upward 

and placed into a static or convection oven set at 63 °C, +/–3 °C (145 °F, +/–5 °F), as shown in 

Fig. 26. In both test methods it is highly recommended that a calibrated digital thermometer will 

be continually used to monitor the water temperature of the immersion tank or the air temperature 

within the oven as a verification.
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After the 14-day duration, samples shall be removed from the bath, patted dry, and allowed to cool 

at room temperature to be handled. Samples must be mechanically tested no later than 30 min after 

removal from the water immersion tank.

Fig. 26 Alternate elevated temperature/water immersion conditioning test for lap-joint test specimens using 

the test tubes and convection oven method

8.7.3 Elevated Temperature–Dry Conditioning

The temperature of the test is based upon considerations referenced in MIL-STD-810G, 

Laboratory Test Method 501.5, High Temperature.26 A representative example of hightemperature testing is shown in Fig. 27. Dry-elevated temperature conditioning consists of a 

specialized heated test chamber that surrounds the test specimen and the grips of mechanical test 

apparatuses yet still allows mechanical testing to be performed. The left-hand image of Fig. 27 

shows the specialized test chamber with its door open and a single lap joint installed, ready to be 

conditioned for mechanical testing. The right-hand image shows the door in the closed position,

allowing the test chamber air to equilibrate to the proper elevated temperature for testing.

Prior to placing a test specimen in the chamber, the test chamber air shall be set to an elevated and 

stabilized temperature of 71 °C, +/−3 °C (160 °F, +/−5 °F), and held for at least 45 min as measured 

by an adjacent thermocouple (TC) within the chamber. A single-lap-joint test specimen shall then 

be placed inside and the chamber door closed. The test chamber shall then be allowed to reach a 

stable 71 °C, +/−3 °C (160 °F, +/−5 °F), for dwell time of no less than 10 min prior to testing. This 

will allow the test chamber and test specimen to reach steady-state equilibrium.
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Fig. 27 Samples undergoing elevated temperature testing at 71 °C, +/−3 °C (160 °F, +/−5 °F), with the chamber 

door opened (left) and closed (right)

8.8 Mechanical Testing

The test procedure for the tensile breaking strength of the single lap joint is performed according 

to Paragraphs 9.1 and 9.2 of ASTM D1002-10.

17 An instrumented mechanical testing frame shall 

be used, with an adequate load cell selected to ensure that the breaking load of the single lap joint 

shall fall between 15% and 85% of its full-scale capacity. A typical mechanical test frame and load 

cell is shown in Fig. 28. The crosshead speed shall be 0.0212 mm/s (1.27 mm/min, 0.05 inch/min) 

and will be equipped with a suitable pair of self-aligning grips to hold both ends of the single lap

joint. The jaws of the grips shall engage the outer 25.4 mm (1 inch) of each end of the single lap

joint. The mechanical testing frame shall conform to Paragraph 5.1 of ASTM D1002-10. An 

example of an acceptable test setup is shown in Fig. 29.

The operator will document the test information, test conditions, and test frame in a laboratory 

notebook with sufficient detail to serve as trustworthy database metadata.
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Fig. 28 An instrumented mechanical testing frame with a load cell and work station is used to measure the 

load vs. displacement response of the single lap joint until breaking failure

Fig. 29 Images showing the jaws of the grips engaging a single-lap-joint specimen at each end, secured in the 

center of the grips and parallel to the direction of tensile force to be applied as per ASTM D1002-10, Paragraph 

5.1

25.4 mm

25.4 mm
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8.9 Data Collection

All the raw experimental mechanical test data for each lap-joint specimen shall be saved in a 

comma-separated values (CSV) file format. Both the load versus displacement and load versus 

time data are required for subsequent analysis and are graphically shown in Figs. 30 and 31,

respectively. Any unit of measure is acceptable provided it is indicated in the data files.

Fig. 30 Representative example of raw load vs. displacement plot
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Fig. 31 Representative example of raw load vs. time plot

The failed test coupons will be manually labeled with appropriate sample identification (ID) 

information to embed this information within the image, which preserves data integrity by 

eliminating file-naming errors. Images will be scanned at 300 dots per inch (dpi) resolution and 

saved in tagged image file format (TIFF), which is a common minimum recommendation for photo 

archiving.27 Test coupons will minimally be visually assigned either an adhesive, cohesive, or 

mixed-mode of failure. More complex mode-of-failure descriptions can be found in ASTM 

D1002-10 and ASTM D5573-99.28 A representative scanned failure surfaces showing sample ID 

information embedded within the image is shown in Fig. 32.

Fig. 32 Representative scanned failure surfaces showing sample ID information embedded within the image

(ruler is included for quantitative dimensional scaling)
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8.9.1 Data Assembly and Retention

The following information will be collected and retained:

• Adhesive TDS and safety data sheet

• Individual load versus displacement results exported in CSV format

• Electronically scanned Single-Lap-Joint Fabrication Checklist (Appendix C)

• Electronically scanned Single-Lap-Joint Mechanical Testing Checklist (Appendix D)

• Electronically scanned Bondline Thickness Measurements sheets (Appendix E)

• Scanned TIFF formatted failure surfaces
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9.0 References and Notes

1. ASTM D907-12a. Standard terminology of adhesives. West Conshohocken (PA): ASTM 

International; 2012. DOI: 10.1520/D0907-12A.

2. ISO/IEC 2382-17:1999. Information technology – vocabulary - part 17: databases. Geneva

(Switzerland): International Organization for Standardization/International Electrotechnical 

Commission; 1999.

3. ISO 13008:2012(E). Information and documentation - digital records conversion migration 

process. Geneva (Switzerland): International Organization for Standardization; 2012.

4. Wikipedia. Materials data management [accessed 2014 Feb 7]. https://en.wikipedia.org/

wiki/Materials_data_management. 

5. Qian Y, Adali S. Extended structural balance theory for modeling trust in social networks. In: 

Castella Roca J, Garcia Alfaro J, Jensen CD et al., editors. Proceedings of the 11th Annual 

International Conference on Privacy, Security and Trust (PST); 2013 July 10–12; Tarragona, 

Spain. p. 283–290.

6. Adali S. Modeling trust context in networks. New York (NY): Springer; 2013. DOI 

10.1007/978-1-4614-7031-1.

7. Headquarters, Department of the Army. Information management: the Army records 

information management system (ARIMS). Washington (DC): Department of the Army;

2007 Oct 2. US Army Regulation 25-400-2.

8. Headquarters, Department of the Army. Protective clothing and equipment. Washington 

(DC): Department of the Army; 1995 Sep 26. AMC-R 385-100, paragraph 4–5.

9. Occupational Safety & Health Administration. Eye and face protection. Washington (DC):

Department of Labor (US); 2009. OSHA 29 CFR 1910.133 [accessed 2014 Feb 27] 

https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id

=9778.

10. US Army Research Laboratory. ARL PPE selection guide. Internal document [accessed 2014 

Feb 27]. https://arlinside.arl.army.mil/inside/labops/Safety/default.cfm.

11. APG Regulation 385-4, Chapter 12, Paragraph 12–4 Eye Protection. Aberdeen Proving 

Ground (MD): Department of the Army (US); 1991 Aug 2.

12. ANSI/ISEA Z87.1-2010. American national standard for occupational and educational 

personal eye and face protection devices.

13. US Army environmental hygiene agency occupational vision guide.
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14. M&MSD SOP no. 6.4, Safety, emergencies and housekeeping.

15. APGR 200-60. Environmental quality – hazardous waste management.

16. Army Research Laboratory Internal Operating Procedures: L1032, L1035, & L1040-001 an 

IOP for scale & balance operations; L1035, L1036, & L1040-003 an IOP for fume hood 

operations; L1028-013 grit blast cabinet; L1044-008 safe operations for blue m ovens; L1086-

006 blue m humidity cabinet; L1035, L1036, 1040-003 fume hood operation; L1032, L1035, 

L1038, & L1040-001 scale & balance operation; L1040/44-003 digital hot plate with stirrer;

L1044-008 blue m ovens operation.

17. ASTM D1002-10. Standard test method for apparent shear strength of single-lap-joint 

adhesively bonded metal specimens by tension loading (metal-to-metal). West Conshohocken 

(PA): ASTM International; 2010. DOI: 10.1520/D1002-10.

18. Thinner substrate coupons may require the use of 180-grit aluminum oxide to avoid excessive 

heating and warping during grit blasting. Finer grit blasting media benefit from initial abrasion 

with a Scotch-Brite pad.

19. TT-C-490F. Chemical conversion coatings and pretreatments for metallic substrates (base for 

organic coatings. Aberdeen Proving Ground (MD): Army Research Laboratory (US); 2013

May 17, superseding TT-C-490F, 2013 Jan 31.

20. SSPC-SP 10/NACE No. 2. Near-white metal blast cleaning. Pittsburgh (PA): The Society for 

Protective Coatings; 2007 Jan 1.

21. Xu W, Yu H, Tao C. Damage and stress evolution in the bondlines of metallic adhesively 

bonded joints accompanied by bondline thickness effect. International Journal of Adhesion 

and Adhesives. 2015;59:86–97.

22. da Silva LMF, Rodriques TNSS, Figueiredo MAV, de Moura MFSF, Chousal JAG. Effect of 

adhesive type and thickness on the lap shear strength. The Journal of Adhesion. 

2006;82:1091–1115.

23. Moradi A, Leguillon D, Carrere N. Influence of the adhesive thickness on a debonding - an 

asymptotic model. Engineering Fracture Mechanics. 2013;114:55–68.

24. ASTM Standard E865-12. Standard specification for structural film adhesives for honeycomb 

sandwich panels. West Conshohocken (PA): ASTM International; 2012. DOI: 

10.1520/E0865-12.

25. MIL-STD-810G. Department of Defense test method standard: environmental engineering 

considerations and laboratory tests. Laboratory test method 507.5, humidity. Washington 

(DC): Department of Defense (US); 2008 Oct 31. 
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26. MIL-STD-810G. Department of Defense test method standard: environmental engineering 

considerations and laboratory tests. Laboratory test method 501.5, high temperature.

Washington (DC): Department of Defense (US); 2008 Oct 31.

27. Digital Imaging Standards, 2014. Hartford (CT): Office of the public records administrator, 

Connecticut State Library, State of Connecticut; 2014 [accessed 2016 Jan 20].

http://ctstatelibrary.org/wp-content/uploads/2015/05/DigitalImagingStandards.pdf

28. ASTM D5573-99. Standard practice for classifying failure modes in fiber-reinforced-plastic 

(FRP). West Conshohocken (PA): ASTM International; 2012. DOI: 10.1520/D5573-99R12.
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INTENTIONALLY LEFT BLANK.
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41

10.0 Appendix A. Test Panel Dimensions

For viewing ease and use with computer-aided design software, supplemental test panel and 

tooling fixture drawings (as PDFs and DXFs) are attached to this PDF. 
ARL-ADHES-QA-001.01 rev 2.2

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42

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43

11.0 Appendix B. Tooling Fixture Dimensions
ARL-ADHES-QA-001.01 rev 2.2

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44
ARL-ADHES-QA-001.01 rev 2.2

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ARL-ADHES-QA-001.01 rev 2.2

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46
ARL-ADHES-QA-001.01 rev 2.2

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ARL-ADHES-QA-001.01 rev 2.2

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49

12.0 Appendix C. Single-Lap-Joint Fabrication Checklist

Sample ID’s:_____________, _____________,_____________,_____________,____________

Date:__________________ Temperature:__________________ Humidity________________

Testing facility and operator:____________________________________________________

Adhesive, type, and form:_______________________________________________________ 

______________________________________________________________________________

Lot ID, manufacturer’s code, expiration date:______________________________________

_____________________________________________________________________________

Method of cleaning and preparing bonding surface:_________________________________ 

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

Adhesive preparation, application, and bonding conditions: 

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

Tooling fixture and bonding pressure notes: _______________________________________ 

______________________________________________________________________________

______________________________________________________________________________

Adhesive mixing to applied pressure time:__________________________________________

Cure cycle:____________________________________________________________________ 

______________________________________________________________________________

______________________________________________________________________________

Oven used (model and serial number):_____________________________________________

Conditioning procedure:________________________________________________________ 

______________________________________________________________________________

______________________________________________________________________________

Comments:____________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________
ARL-ADHES-QA-001.01 rev 2.2

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51

13.0 Appendix D. Single-Lap-Joint Mechanical Testing Checklist

Sample ID’s:_____________, _____________,_____________,_____________,____________

Test date:_______________ Test temperature:______________ Test humidity____________

Testing facility and operator:____________________________________________________

Test frame model and serial number:______________________________________________

Test frame calibration date:______________________________________________________

Load cell model and serial number:_______________________________________________

Load cell calibration date:_______________________________________________________

Crosshead speed: 1.3 mm/min (0.05 in/min), list other________________________________

Nature of failure and other comments:
ARL-ADHES-QA-001.01 rev 2.2

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ARL-ADHES-QA-001.01 rev 2.2

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53

14.0 Appendix E. Bondline Thickness Measurements

Aluminum grade:___________________ Mfg. nominal thickness:______________(mm – in)

Micrometer model, serial number, calibration date __________________________________

______________________________________________________________________________

Adherend A 

(A)

Adherend B 

(B)

Adherend A & B Plus 

Bondline (BL) 

(C)

Bondline Calculation 

(BL=C-(A+B))

(A1 Value) (B1 Value) (C1 Value) (BL1 Value)

(A2 Value) (B2 Value) (C2 Value) (BL2 Value)

(A3 Value) (B3 Value) (C3 Value) (BL3 Value)

(Avg. of A) (Avg. of B) (Avg. of C) (Avg. of BL)

Section Comments

Bondline thickness units (circle) – mm or in

 Sample ID:

Location 1

Location 2

Average 

Location 3

Area in 

Test Grips

Area in 

Test Grips Shear Area

Bondline

C1

C2

C3

A1

A2

A3

B1

B2

B3

Adherend (A) Adherend (B)

Adherends 

and Bondline 
ARL-ADHES-QA-001.01 rev 2.2

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54

Adherend A 

(A)

Adherend B 

(B)

Adherend A & B Plus 

Bondline (BL) 

(C)

Bondline Calculation 

(BL=C-(A+B))

(A1 Value) (B1 Value) (C1 Value) (BL1 Value)

(A2 Value) (B2 Value) (C2 Value) (BL2 Value)

(A3 Value) (B3 Value) (C3 Value) (BL3 Value)

(Avg. of A) (Avg. of B) (Avg. of C) (Avg. of BL)

Section Comments

Bondline thickness units (circle) – mm or in

 Sample ID:

Location 1

Location 2

Average 

Location 3

Adherend A 

(A)

Adherend B 

(B)

Adherend A & B Plus 

Bondline (BL) 

(C)

Bondline Calculation 

(BL=C-(A+B))

(A1 Value) (B1 Value) (C1 Value) (BL1 Value)

(A2 Value) (B2 Value) (C2 Value) (BL2 Value)

(A3 Value) (B3 Value) (C3 Value) (BL3 Value)

(Avg. of A) (Avg. of B) (Avg. of C) (Avg. of BL)

Section Comments

Bondline thickness units (circle) – mm or in

 Sample ID:

Location 1

Location 2

Average 

Location 3
ARL-ADHES-QA-001.01 rev 2.2

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55

Adherend A 

(A)

Adherend B 

(B)

Adherend A & B Plus 

Bondline (BL) 

(C)

Bondline Calculation 

(BL=C-(A+B))

(A1 Value) (B1 Value) (C1 Value) (BL1 Value)

(A2 Value) (B2 Value) (C2 Value) (BL2 Value)

(A3 Value) (B3 Value) (C3 Value) (BL3 Value)

(Avg. of A) (Avg. of B) (Avg. of C) (Avg. of BL)

Section Comments

Bondline thickness units (circle) – mm or in

 Sample ID:

Location 1

Location 2

Average 

Location 3

Adherend A 

(A)

Adherend B 

(B)

Adherend A & B Plus 

Bondline (BL) 

(C)

Bondline Calculation 

(BL=C-(A+B))

(A1 Value) (B1 Value) (C1 Value) (BL1 Value)

(A2 Value) (B2 Value) (C2 Value) (BL2 Value)

(A3 Value) (B3 Value) (C3 Value) (BL3 Value)

(Avg. of A) (Avg. of B) (Avg. of C) (Avg. of BL)

Section Comments

Bondline thickness units (circle) – mm or in

 Sample ID:

Location 1

Location 2

Average 

Location 3
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1 DEFENSE TECHNICAL

(PDF) INFORMATION CTR

DTIC OCA

2 DIRECTOR

(PDF) US ARMY RESEARCH LAB

RDRL CIO LL

IMAL HRA MAIL & RECORDS

MGMT

1 GOVT PRINTG OFC

(PDF) A MALHOTRA

1 DIR USARL

(PDF) RDRL WMM C

R JENSEN