Cathodic Disbondment of Rubber/Steel Adhesive Bonds Modeled as Liquid-Solid Reactions

Under cathodic conditions, rubber/steel adhesive bonded joints have been documented to ‘weaken’ due to attack by the generated alkali. If this were to occur under the action of cleavage mechanical loads, the bonds are likely to completely ‘delaminate’ causing the bonded constituents to physically separate. These two modes of disbondment are referred to as ‘weakening’ and ‘delamination’, respectively. Previously, Hamade and coworkers have implemented empirical and semi-empirical approaches to modeling cathodic disbondment of adhesive joints. Here, a method is presented to simulate bond weakening progress via numerical solutions. Bond degradation is modeled as a liquid-solid chemical reactor due to the attack by the alkaline medium. Specifically, the diffusion and chemical reaction processes involved in weakening are mathematically represented via a simplified, 2 partial differential equations (p.d.e.) boundary value problem (BVP). This is a reduced version of the more complex electrochemical formulation needed to fully describe the chemistry at the bondline under cathodic conditions. The weakening model is capable of simulating weakened bond lengths vs. time as function of electrolyte type (artificial sweater, ASW, or 1N NaOH), cathodic potential, and temperature. Furthermore and to model bond delamination, a mechano-chemical failure criterion is incorporated into the weakening formulation effectively coupling fracture mechanics principles with those of cathodic degradation. A fracture mechanics parameter, applied strain energy release rate, G, is used to represent the effect of externally applied loads. The failure criterion stipulates that the bond will delaminate if the applied G exceeds that of the degraded bond’s residual resistance. Both, the weakening and delamination formulations are validated against experimental data of bond weakening and delamination under a variety of conditions. As such, the numerical simulations developed in this work may be used to provide first order estimates of the life of rubber/steel bonded joints (weakened or delaminated lengths vs. time) as function of cathodic parameters and applied G (if the joint is loaded in the case of delamination).