Why is an oxide layer needed when bonding aluminium alloys?

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    Aluminium Bonding
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Discussion Overview

The discussion revolves around the necessity and role of an oxide layer when bonding aluminium alloys. Participants explore whether a natural oxide film suffices or if a primer is required, as well as the chemical implications of these choices in the bonding process.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested
  • Experimental/applied

Main Points Raised

  • One participant questions the necessity of an oxide layer between the substrate and adhesive, seeking clarification on whether a primer is needed or if a natural oxide film is acceptable.
  • Another participant explains that aluminium develops a protective oxide layer that is adherent and impervious, similar to the protective layers found on stainless steel.
  • It is noted that anodising is a common industrial process used to enhance the oxide layer on aluminium, providing additional protection and improving adhesion for coatings.
  • A participant shares their experience using West System Epoxy, mentioning that an Aluminium Etch Kit containing phosphoric acid is used to prepare the surface, suggesting it cleans the surface for better oxide adhesion.
  • There is a discussion about the procedure for preparing aluminium surfaces, which includes sanding, etching, washing, and waiting before applying the adhesive, with a participant speculating that the waiting period allows for oxide formation.
  • Questions arise regarding the criticality of the waiting period for oxide formation after surface preparation.

Areas of Agreement / Disagreement

Participants express differing views on the necessity of a primer versus a natural oxide layer, and there is uncertainty regarding the importance of the waiting period for oxide formation. The discussion remains unresolved with multiple competing perspectives.

Contextual Notes

Participants mention various surface preparation methods and their implications for bonding, but there are no definitive conclusions about the optimal approach or the necessity of specific treatments.

brewnog
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Hi all,

When bonding aluminium alloys, an oxide layer is needed between (I think) the substrate and the adhesive.

Why?

And does this oxide layer have to be supplied by some kind of primer, or is a natural oxide film acceptable? Does anyone know what chemical purpose the primer provides, or is this still an industry secret?

Cheers

xxx
 
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Aluminium has very high resistance against corrosion because it develops an adherent, relatively impervious oxide layer. When aluminium is produced it is spontaneously covered by a thin but effective coating of oxide which protects the aluminium from further oxidation. If the coating of oxide is damaged mechanically this coating will be renewed immediately.

This is similar to stainless steel in which a thin layer of oxides of Ni and Cr protect the underlying Fe-based steel metal.

The industrial process most often used for oxidation of Al is Anodising (US - Anodizing). Anodising is a surface treatment which is used to give the aluminium product additional protection against corrosion, decorative surfaces with resistant colour and gloss, electrical insulating surfaces or foundations for gluing or painting. Anodising is an electro-chemical process that strengthens the natural oxide shift. Similar process is use to Ti-based alloys.

The oxide layer is generally rougher, and I believe organic coatings adhere better to the oxide layer. The oxide layer also protects the Al-metal substrate if the coating is damaged.

With respect to inorganic coatings, the oxide layer may also prevent undesirable impurities from diffusing into the Al metal. (I am speculating here).
 
I've used West System Epoxy for aluminium bonding. They recommend and specifically sell an Aluminium Etch Kit for preparing the aluminium surfaces before applying the epoxy. The main component of this is phosphoric acid, which is also the primary component of the PAN wet etch solution for aluminium. So, I suspect what this does is it provides a clean, fresh surface, which in turn helps the oxide adhere better to the metal. And if your adhesive is strong, then the weak link may be the adhesion of the oxide to the metal.
 
Last edited:
Cheers you two.

Gokul, this kit you use, aside from the etching (I presume once you've polished and etched your substrate you wash off those nasty etchy chemicals) are you supposed to provide a primer before you apply the adhesive itself?
 
brewnog said:
Cheers you two.

Gokul, this kit you use, aside from the etching (I presume once you've polished and etched your substrate you wash off those nasty etchy chemicals) are you supposed to provide a primer before you apply the adhesive itself?

No, I don't believe there's a primer involved.

The procedure is :sand -> etch -> wash -> wait -> glue away !
 
Last edited:
Interesting, I guess it's the "wait" stage which allows the oxide to form. Is the length of this "wait" critical?
 

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