 CASE STUDY No. 1AUTOMOTIVE - DIFFERENTIAL
Application :
The application involved the sealing and secure fastening of truck rear axle assemblies. This included forming “liquid” gaskets and sealing flanges under compression between the differential gearbox and the rear axle housing. This also included sealing and securing all of the threaded fastening bolts and studs and sealing the bolt holes. Service Conditions are : -40° to +150°C
Requirements :
The client needed to ensure efficient flange gasket sealing and to secure all fasteners with an adhesive resin with good adhesion to all of the metal substrates. They also required a rapid cure time. The assembly needed the flexibility to handle differential thermal expansion and contraction and the client wanted to use the same product for the entire job for both thread-locking and for the gasket-making. A pre-formed gasket requires a much smoother finish on the metal surfaces of the flanges, so the use of a liquid gasket material would simplify assembly and present fewer problems.
Adhesive Type :
The type of adhesive technology required for this is : Anaerobic Adhesive.
Solution :
Permabond A136 was recommended. The customer tested it and found it to be ideal for both providing a formed in place gasket and for thread-locking. The client wanted to pay particular attention to sealing the boltholes.
Preparation :
Minimal preparation was required, only simple cleaning and degreasing.
Benefits :
- No re-torquing
- Reduced servicing
- Reduced machining costs
- Fills gaps, damage, pitting and scratches
- Better strength and stress distribution of the assembly
- Excellent resistance to automotive fluids such as oil and fuel
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 CASE STUDY No. 2AUTOMOTIVE - SUMP GASKETS
Application :
The client’s automotive application was for sealing the two flange faces between a block and a sump. The substrate materials were aluminium alloy castings with machine flange faces, mating with pressed steel sumps.
The joint design required machined flat flange mating surfaces suitable for compression of the gasketing material between surfaces to provide a continuous layer between faces which provides a high pressure seal against escape or ingress of gases or liquids.
Problem :
This assembly required close fitting mating parts where no gasket could be used and the mating parts were made of dissimilar metals with the potential for galvanic reaction corrosion. There was a need to ensure reliable operation over a long service life with minimum maintenance.
Adhesive Type :
The type of adhesive technology required for this is : Anaerobic Adhesive.
Solution :
Permabond LH197 was recommended. It provides reliable adhesion and sealing at temperatures from -40° to +150°C.
The customer requirements were for a rapid cure, good adhesion to both substrates, a good seal and flexibility of the gasketing adhesive to withstand differential thermal expansion and contraction of both metals on their new automotive assembly without gaskets.
Preparation :
Minimum preparation was required. The only surface preparation possible was to degrease the surfaces before application of the adhesive.
Benefits :
- No re-torquing
- Reduced servicing
- Reduced machining costs
- Better load and stress distribution
- Greater strength of the bonded assembly
- Gap filling of surface texture, scratches, pitting or damage
- Excellent resistance to automotive fluids such as oil, fuel and coolant water
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 CASE STUDY No. 3INDUSTRIAL - GEARBOX
Application :
The client’s automotive application was for Gearbox Repair Solutions. Industrial gearboxes play vital roles in processing and manufacturing. They must be designed and made to suit challenging demands and to ensure reliable operation over a long service life with minimum maintenance. The ultimate goal is to maximise machinery output, reliability and efficiency - without experiencing problems nor down-time.
Requirements :
A gearbox failure is a costly setback to operations. For example, leakages between gearbox flanges may be caused by fasteners working loose due to torque, thermal expansion, vibration and shock loads. Proactive maintenance will reduce expensive downtime and enhance reliability, but better design and planning for reliability will improve reliability and reduce maintenance.
The substrate materials were often dissimilar metals with the potential for galvanic reaction corrosion. This application required assembling close fitting parts where no gasket was used. The joint designs, assembly arrangements and fastening methods were simplified to provide reduced machining costs and assembly times.
Need to tolerate temperatures from -40° to +150°C.
The customer requirements were for a rapid cure, good adhesion, good sealing and flexibility to withstand differential expansion and contraction of the metals.
Adhesive Type :
The type of adhesive technology required for this is : Anaerobic Adhesive.
Solution :
A range of Permabond anaerobic adhesive resins to provide reliable adhesion, sealing and locking for example : Gasketing to seal against escape or ingress of gases or liquids – A136, etc; Retention to hold components in place such as bearings and seals – A134, etc; Thread-locking of bolts, nuts, screws and adjusters – A1042, etc; And, Thread-sealing of larger pipe threads – A1044, etc.
Preparation :
Minimal preparation was required, only simple cleaning and degreasing.
Benefits :
- No re-torquing
- Reduced servicing
- Reduced machining costs
- Better load and stress distribution
- Excellent resistance to automotive fluids such as oil, fuel and coolant
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 CASE STUDY No. 4MARINE - BOAT RIGGING
Application :
The client needs to seal threaded rigging screws fitted on sea going luxury yachts to prevent threads becoming damaged by salt water, grit and sand. There is also a need to ensure the secure locking of the rigging screws which are exposed to salt water spray and a moist or wet corrosive atmosphere.
Requirements :
The material must be capable of penetrating within joints and the threads of metallic parts. It needs to tolerate vibration and moist and salty environments. It must avoid the possibility of galvanic electrolytic reaction occurring on mating faces of exposed metal parts and thereby prevent galvanic corrosion.
The application also requires easy disassembly and reassembly to ensure effective and reliable future maintenance.
Adhesive Type :
The type of adhesive technology required is for Anaerobic Adhesive.
Solution :
The product formulation chosen to best suit this application, materials and environment was a rapid curing anaerobic thread-locking adhesive - Permabond A1042. This product was tested and approved for this task.
Preparation :
The material substrates are stainless steel fastened into other stainless steel parts. There was the possibility that the fasteners could not always be treated with a surface preparation before fastening.
Benefits :
- The adhesive makes assembly and tightening easier.
- The adhesive helps lubricate the threads when screwed together.
- The adhesive seals and protects the joint against air, water and grit.
- The sealed rigging screws can be undone later by using normal tools.
- The adhesive prevents the rigging screws working themselves loose.
- The rigging screw component lives are extended.
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