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How to Choose the Right Adhesive for Aerospace Applications

Posted 08 Nov 2024 by Lucas Erikson, Aerospace Product Market Manager

During World War I, aviators applied glue made from natural materials like milk extract to their aircraft for weatherproofing and structural integrity. Although the chemistry composition of adhesives has evolved considerably since then, bonding agents and sealants are still used extensively in the aerospace industry to ensure routes through the sky are completed safely and efficiently. This article covers:

  • The many uses of adhesives in aerospace
  • Industry requirements for adhesives
  • Benefits of using adhesives over other bonding methods

How Adhesives are Used in Aerospace

Adhesives bond materials for engine compartments, interiors, and exterior components in the aerospace industry. Sealants protect the exteriors of aircraft and spacecraft from extreme temperatures and pressure changes and coat interior components, such as fuel tanks, for protection from moisture or chemicals. Adhesives are also used to create the safety products used in commercial flights.

How Adhesives Benefit Aerospace Applications

Adhesives enhance aesthetics, improve the distribution of stress over bonded joints, provide superior aerodynamics, and protect aircraft components against corrosion. Moreover, adhesives can improve production time and reduce operational costs. Adhesives are flame retardant and a lightweight alternative to mechanical bonding (e.g., screws and bolts). They can be used for in-field repairs in any environment, eliminating the time it would take to transport aircraft to a facility for repairs.

The specially formulated chemical composition of aerospace adhesives allows high-performance products that withstand extreme conditions. From commercial flights to space exploration, adhesives provide the stability and reliability needed to protect passengers and keep components intact and operating optimally.

What Aerospace Applications Require of Adhesives and Sealants

Aerospace sealants require excellent resistance to jet fuel and aviation gasoline, as well as petroleum products and chemicals commonly used in aircraft manufacturing. Since any amount of deterioration can compromise aircraft performance, adhesives must also be resistant to corrosion and protect substrates from material degradation. In addition, aerospace adhesives must provide improved flexibility and excellent bond strength to most metallic substrates, including stainless steel, advanced composites, and aluminum.

Aircraft and space exploration craft experience uniquely difficult operating conditions. For example, some military defense aircraft fly at twice the speed of sound over 50,000 feet in the air, where temperatures can plunge to double digits below zero. Adhesives must also withstand the vibration, joint movement, and impact of flights.

Aerospace adhesives must meet regulatory requirements and standards to ensure passenger safety despite the extreme conditions. The United States Department of Defense and original equipment manufacturers have strict standards in place for adhesives. Also, adhesives used in space must be non-magnetic and meet NASA’s outgassing requirements, meaning they can’t lose a certain amount of mass when passing through extreme heat or vacuum.

Types and Examples of Aerospace Adhesives

Some of the most widely used aerospace adhesives include urethane and polychloroprene rubber, cyanoacrylates, epoxies, structural acrylic adhesives, adhesive films and tapes, and anaerobic adhesives. In addition to assembling aircraft components, adhesives are used in:

  • Avionics (electronic systems used on aircraft)
  • Passenger safety inflatables (rafts, slides, jackets)
  • Composite fabrication and repair
  • Sealing fuel tanks and fuselage
  • Cabin pressurization
  • Aerodynamic smoothing
  • Spacecraft panels and interiors

Partnering with H.B. Fuller for Aerospace Adhesives

H.B. Fuller manufactures a complete line of aerospace adhesives, sealants, and electronic material packaging for aircraft interiors. We rely on industry-proven techniques for both conventional and advanced technologies. Applications include commercial aviation adhesives, runway sealants, polysulfides, and adhesives for use in space exploration products and military aircraft components.

In addition to a diverse portfolio, H.B. Fuller also has a global supply network to provide timely delivery of adhesive solutions, no matter where customers are located. Adhesives and sealants meet numerous military and commercial qualifications and come in lightweight and rapid cure options. Examples of Fuller brands in this industry include:

Subscribe to our blog for more on the real-world uses of adhesives. You can also contact a specialist to explore adhesive solutions for your product’s challenges.

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