Understanding the Effects of In-Service Temperature and Functional Fluid on the Ageing of Silicone Rubber

With an organic/inorganic hybrid nature, silicone elastomers are amongst the most versatile engineering materials, exploited in a wide range of applications either as end-products or in manufacturing processes. In many industrial machines, silicone components are exposed to in-service conditions, such as high or low temperatures, contact with functional fluids, mechanical loading, and deformations, which can adversely affect these components and reduce their lifespan, leading to machine failure in turn. The present study investigates the behaviour of a silicone component of a manufacturing equipment and the variations in the part’s properties due to in-service conditions (temperature, exposure to heat transfer fluid, and mechanical deformation) to develop a monitoring tool. An experimental design was employed to study the main and the interaction effects of temperature (22 °C, 180 °C), medium (air, synthetic heat transfer fluid), and strain (0%, 200%) on the silicone component’s properties. Results showed that while the chemistry of the component remains intact, its thermal and in particular mechanical properties are largely influenced by the in-service conditions. Consequently, leading to a physical rather than a chemical failure of the component and limiting its service life. Statistical analysis revealed that high temperature and the exposure to the heat transfer fluid have the most sever effects. Moreover, these two manufacturing parameters were found to have a significant interaction with one another, whose effect cannot not be neglected.

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).