Designation: D 3164 – 03

Standard Test Method for

Strength Properties of Adhesively Bonded Plastic Lap-Shear
Sandwich Joints in Shear by Tension Loading1
This standard is issued under the fixed designation D 3164; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (e) indicates an editorial change since the last revision or reapproval.

1. Scope* Joint Specimen Test Results2

1.1 This test method is intended to complement Test Method E 4 Practices for Force Verification of Testing Machines3
D 1002 and Test Method D 3163 and extend its application to
3. Terminology
single-lap-shear adhesive joints employing plastic adherends.
The test method is useful for generating comparative shear 3.1 Definitions—Many terms in this test method are defined
strength data for joints made from a number of plastics. It can in Terminology D 907.
also provide a means by which several plastics surface treat- 4. Significance and Use
ments can be compared.
1.2 The values stated in SI units are to be regarded as the 4.1 Due to the increased use of adhesively bonded plastics
standard. The values given in parentheses are for information as a result of the inherent advantages afforded by bonded rather
only. than mechanically fastened joints, particularly the alleviation
of stress risers and stress cracking, there is a need for standard
NOTE 1—A complete metric companion to Test Method D 3164 has tests by which joints of various substrates and adhesives can be
been developed - D 3164M. compared. This test method is intended to meet such a need.
1.3 This standard does not purport to address all of the 4.2 This test method is limited to test temperatures below
safety concerns, if any, associated with its use. It is the the softening point of the subject adherends, and is not
responsibility of the user of this standard to establish appro- intended for use on anisotropic adherends such as reinforced
priate safety and health practices and determine the applica- plastic laminates.
bility of regulatory limitations prior to use. 4.3 The misuse of strength values obtained from this test
method as design stress allowable values for structural joints
2. Referenced Documents could lead to product failure, property damage, and human
2.1 ASTM Standards: injury.
D 907 Terminology of Adhesives2 4.4 The apparent shear strength of an adhesive obtained
D 1002 Test Method for Apparent Shear Strength of Single- from a given small single-lap specimen may differ from that
Lap-Joint Adhesively Bonded Metal Specimens by Ten- obtained from a joint made with different adherends or by a
sion Loading (Metal-to-Metal)2 different bonding process. The normal variation of temperature
D 2093 Practice for Preparation of Surfaces of Plastics Prior and moisture in the service environment causes the adherends
to Adhesive Bonding2 and the adhesive to swell and shrink. The adherends and
D 2651 Guide for Preparation of Metal Surfaces for Adhe- adhesive are likely to have different thermal and moisture
sive Bonding2 coefficients of expansion.
D 3163 Test Method for Determining Strength of Adhe- 4.5 Even in small specimens, short-term environmental
sively Bonded Rigid Plastic Lap-Shear Joints in Shear by changes can induce internal stresses or chemical changes in the
Tension Loading2 adhesive that permanently affect the apparent strength and
D 3164M Test Method for Strength Properties of Adhe- other mechanical properties of the adhesive. The problem of
sively Bonded Plastic Lap-Shear Sandwich Joints in Shear predicting joint behavior in a changing environment is even
by Tension Loading [Metric]2 more difficult if a different type of adherend is used in a larger
D 4896 Guide for Use of Adhesive-Bonded Single Lap- structural joint than was used in the small specimen.
4.6 The apparent shear strength measured with a single-lap
specimen is not suitable for determining allowable design
1
This test method is under the jurisdiction of ASTM Committee D14 on stresses for designing structural joints that differ in any manner
Adhesives and is the direct responsibility of Subcommittee D14.40 on Adhesives for
Plastics.
Current edition approved Aug. 10, 2003. Published September 2003. Originally
approved in 1973. Last previous edition approved in 1997 as D 3164 – 97.
2 3
Annual Book of ASTM Standards, Vol 15.06. Annual Book of ASTM Standards, Vol 03.01.

*A Summary of Changes section appears at the end of this standard.

Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.

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 D 3164 – 03
from the joints tested without thorough analysis and under- The recommended length of overlap is 12.7 6 0.25 mm (0.5 6
standing of the joint and adhesive behaviors. 0.01 in.). The thickness of the plastic in the metal/adhesive/
4.7 Single-lap tests may be used for comparing and select- plastic/adhesive/metal sandwich configuration may vary de-
ing adhesives or bonding processes for susceptibility to fatigue pending on the type and manufacturer but thin films of 0.354
and environmental changes, but such comparisons must be mm (0.010 in.) or less are recommended. An upper limit of
made with great caution since different adhesives may respond 1.62 mm (0.064 in.) plastic thickness is suggested.
differently in different joints. See Guide D 4896 for further 6.2 The surface preparation used on the adherend depends
discussion of the concepts relative to interpretation of adhesive on the subject plastic adherend. Methods such as those recom-
bonded single lap joints. mended in Practice D 2093 serve as a useful guide.
6.3 Apply the adhesive in accordance with the manufactur-
5. Apparatus er’s recommendations. Choose the adhesive such that the cure
5.1 Testing Machine, conforming to the requirements of and temperature does not adversely affect the mechanical proper-
having the capabilities of the machine prescribed in Test ties of the adherend.
Method D 1002 and has an accuracy of 61 % when calibrated 6.4 Cut test specimens from the bonded panels pictured in
in accordance with Practices E 4 requirements. Likewise the Fig. 2. Cutting the specimens must be accomplished without
grips are capable of securely grasping the specimen throughout overheating or otherwise physically damaging the adherend or
the test without allowing the specimen to slip. The grips are bonded interface. Individual test specimens may also be
also self-aligning. prepared if desired.
5.2 Temperature and Relative Humidity Controlling Equip-
ment, capable of maintaining the test temperature to 63°C 7. Procedure
(65°F) and the relative humidity to 63 %. If ambient labora- 7.1 Condition the test specimens for definite periods of time
tory conditions are employed the same degree of control is under specified conditions before testing if desired. After
required. conditioning, it is recommended that all specimens be stabi-
lized in the test environment for 1 h before testing.
6. Test Specimen
7.2 Place the test specimens in the grips of the testing
6.1 Make specimens that conform to the form and dimen- machine so that the applied load coincides with the long axis of
sions shown in Fig. 1. It is recommended that the test the specimen. Load the specimen to failure at a rate of 8.3 to
specimens be cut from the test panel depicted in Fig. 2, but 9.7 MPa (1200 to 1400 psi) of shear area per minute.
individual specimens may be prepared if preferred. The rec-
ommended metal substrate is Alloy 2024-T3 aluminum, 1.62 6 NOTE 2—The thickness of the plastic insert used will influence the joint
strengths obtained in this test due to the added offset. Thermal stresses
0.125 mm (0.064 6 0.005 in.). A surface treatment such as introduced in the joint by elevated temperatures bonding dissimilar
Method A of Guide D 2651 is recommended for the aluminum. materials will also offset ultimate joint strength. Direct comparison of
If a metal substrate other than aluminum is employed, then one results is possible only for the same thickness and composition of insert so
of the other surface preparations in Guide D 2651 is suggested. as to minimize differences resulting from offset or thermal stress.

FIG. 1 Form A—Dimensions of Test Specimen

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 D 3164 – 03

FIG. 2 Standard Test Panel

8. Calculations 9.1.5 Ambient conditions at time of bonding (temperature,

8.1 Calculate the bond area to the nearest 0.06 cm2(0.01 humidity, etc.).
in.2). Record both load at failure and type of failure (percentage 9.1.6 Length of overlap used.
cohesive and apparent failure in adhesion). Calculate failing 9.1.7 Conditioning of joint prior to testing.
stress as megapascals (or pounds-force per square inch) of 9.1.8 Maximum, minimum, and average values of the fail-
shear area. It should be noted that while the results are given in ing load.
terms of the average shear stress, the maximum shear stress 9.1.9 Number of specimens tested.
may be far from this average and the cleavage stresses in the 9.1.10 Type of failure. This should include estimated per-
joint may be even larger. See Guide D 4896 for more detailed centages of cohesive failure in the adhesive unbonded area,
information. apparent failure in adhesion, and failure in the adherend.
9.1.11 Test temperature employed.
9. Report 9.1.12 The average thickness of adhesive layer after forma-
9.1 Report the following: tion of the joint shall be reported within 0.0127 mm (0.0005
9.1.1 Complete identification of the adhesive tested, includ- in.). The method of obtaining the thickness of the adhesive
ing type, source, date manufactured, manufacturer’s code layer shall be described including procedure, location of
number, form, etc. measurements and range of measurements.
9.1.2 Complete identification of the metal used, its thick-
ness, and method of cleaning and preparing its surface prior to 10. Precision and Bias
bonding. 10.1 A precision and bias statement does not exist for this
9.1.3 Complete identification of the plastic used, its thick- test method because resources necessary for round robin
ness, and the method of cleaning and preparing its surface prior testing have not been forthcoming.
to bonding.
9.1.4 Method of adhesive application (brush, spray, roller 11. Keywords
coat, tape, etc.), amount of applied adhesive, open-time, 11.1 adhesive bond; lap-shear; sandwich joint; shear;
close-time, press pressure, and press-time. tension

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 D 3164 – 03
SUMMARY OF CHANGES

Committee D14.40 has identified the location of selected changes to this standard since the last issue
(D 3164 - 97) that may impact the use of this standard.

(1) Added Practices E 4 to Section 2 Referenced Documents (5) Added to 9.1.4 – more application method data for the test
(2) Added to 5.1– a statement that refers to Practices E 4. report.
(3) Added to 5.2 – a relative humidity tolerance.
(4) Added to 8.1 – a statement of information and reference to
Guide D 4896.

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