Rheology of automotive adhesives during dispensing: A direct comparison of epoxy and rubber based systems via drag and pressure driven flows

Construction of vehicles requires adhesive dispensing for body-in-white assembly, hemming of closure panels, decking of windshields and the manufacture of battery packs. Knowledge of the rheological properties of adhesives applied using common dispensing systems is important for optimization of dispensing and application conditions. However, flow behavior of adhesives at shear rates used in dispensing is not well understood. Therefore, this study combines parallel plate and capillary rheology techniques to directly compare the rheological properties of an epoxy structural adhesive used in hemming applications and a rubber ‘topical sealer’ used to seal water leak paths across the range of shear rates observed in dispensing. Shear viscosity (η) and complex viscosity (η*) master curves were created from time-temperature-superposition (TTS) of steady shear and dynamic oscillatory data. Both adhesives did not follow the Cox-Merz rule. It was found that the Carreau-Yasuda model fit the steady shear viscosity master curve of the epoxy structural adhesive, while a simpler power law model fit the steady shear viscosity master curve of the rubber topical sealer. An inexpensive capillary rheometer was developed to simulate the adhesive dispensing process. Viscosity data was corrected for entrance pressure losses and a non-Newtonian flow front using Bagley and Weissenberg-Rabinowitsch corrections, respectively. It was observed that complex viscosity master curves better predicted viscosity during dispensing, as compared to steady shear viscosity master curves. Linear stress ramp measurements showed that the adhesives have widely different yield stresses, while the capillary rheometry measurements showed they have similar viscosities during dispensing. Furthermore, the capillary rheometer ‘shot meter’ pressures were related to the apparent and doubly corrected viscosity values through power law functions. A new quality control method based on the capillary rheology data is proposed.