Durability and Corrosion Resistance Test of Adhesive Joints Using Two Adherence Promoters for the Connection of Aerospace Aluminum Alloys

This article presents the technology of making an adhesive joint using two primers: Corrosion Inhibiting Primer BR127 (previously used, containing chromium compounds) and, as a potential substitute, Structural Adhesives Primer EW 5000 AS (which does not contain any compounds harmful to the environment). An adhesive film and a sol–gel primer were used to make the joint of two aluminum sheets, and various technologies were used for applying adhesion promoters. The mechanical properties of the prepared samples were tested using two test methods: wedge tests and shear strength tests. In both cases, the samples were aged in laboratory conditions in tap water, and in a climatic chamber (with increased temperature and humidity). The obtained results indicate that the best technology for preparing the joint using each primer is the technology that assumes heating the primer and hardening the adhesive film in one operation. The results of the strength tests indicate that the samples made using the EW 5000 AS primer have higher strength properties under all tested seasoning conditions compared to samples made using the BR 127 primer. It was also confirmed that the presence of moisture and/or water reduces the mechanical strength of the adhesive joints independently of the primer used. The results of the polymer coatings tests to protect the aluminum substrate against corrosion showed that the coatings are only effective for a certain period of time, and, as a result of the NSS test, after 480 h, all the samples were subject to corrosion.