INTERNATIONAL TRUCK & ENGINE CORPORATION

TMS NUMBER:

(TRUCK MATERIAL SPECIFICATION) TMS-6900

TITLE: Structural Adhesives – Part 1 and Part 2 REVISION: E

WRITTEN/EDITED BY: APPROVED BY: DATE ISSUED:
Materials Engineering Materials Engineering August 2001

PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION

This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of
the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine
the applicability of regulatory limits prior to use.
Change Notice: Added new materials and substrates, revised testing requirements.
Reference: File 30-1 Keywords: Adhesive, adhesive bonding, structural bonding, structural adhesive.

Part 1 – General, Property, and Performance Requirements

1.0 APPLICATION
Part 1 of this specification covers structural adhesive systems used for bonding parts in the
construction of truck and tractor cabs and components, such as: hood and fender assemblies, body
panels, roof components, air conditioning components, and other parts used in truck manufacture.
Part 2 covers the production process requirements for structural bonding systems.
2.0 SCOPE
This specification covers the material properties, performance requirements, production quality and
process control, supplier's responsibility, source approval and quality control, general information,
and sources for approved adhesive systems.
3.0 REFERENCE DOCUMENTS
Unless otherwise specified, the latest issue of all referenced standards applies. The following
specifications, standards, and regulations are referenced herein.
Quality System Standard QS-9000 (ISO 9001) SAE J-243 ASTM D2240
INTERNATIONAL IQR Quality Standard SAE J1523 ASTM D2294
INTERNATIONAL Manufacturing Std. D-13 SAE J1525 ASTM D1002
INTERNATIONAL Eng. Design Std. A-16 SAE J1553 ASTM D2919
INTERNATIONAL Test Method GT-7E INTERNATIONAL TMS-9543 ASTM D3163
INTERNATIONAL TMS-9522 INTERNATIONAL CEMS G-5 ASTM D5041
INTERNATIONAL CEMS D-28 INTERNATIONAL CEMS D-22 ASTM B117
INTERNATIONAL CEMS A-6 CFR-Title 29, Section 1910 ASTM E132
INTERNATIONAL CEMS C-10 ASTM D638

4.0 GENERAL REQUIREMENTS

Adhesive materials supplied to this specification shall bond the intended substrates to produce a
permanent and structural bond. The general properties of as received materials, in the uncured state,
are listed in Table 4. Adhesive materials supplied to this specification shall be compatible with all
subsequent cleaning, pre-treat and paint operations used in the Assembly Plant and with current
production materials for which the new adhesive approval is sought. It is the responsibility of the
adhesive supplier to insure compatibility of the new adhesive materials with the Assembly Plant’s
product materials and processes and obtain approval from the Production Process Manager of the
Assembly Plant for the use of new adhesive materials.
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Corporate Technical Standards. Suppliers are required to assume all patent liability. ¤2001 International Truck and Engine Corporation
AUGUST 2001 Page 1 of 14
NUMBER: TITLE REVISION:
TMS-6900 Structural Adhesives E

Part 1
4.1 General Properties
Properties are provided for reference only. Properties shall be reported on submitted test reports and
will be included in Table 4.
4.1.1 Uncured Properties
Specific requirements are to be determined between the material supplier, equipment supplier and the
applicator.
Requirement: Typical Test Method
Solids SAE J-243 Procedure ADS-7, Method A
Viscosity - Method A SAE J-243, Procedure ADS-1, Agitated -
Conditioning Method C, Pressure Flow Method
275 kPa (40 psi), 25 ± 1°C (77 ± 2°F), 20 g.
- Method B SAE J-243, Procedure ADS-1, Agitated -
Conditioning Method C, Test 2.2 Brookfield,
spindle 7, 50 RPM

4.1.2 Cured Material Properties

4.1.2.1 Tensile Strength-Ultimate (for materials which do not exhibit a definite yield point) or Yield
Strength (for materials which do exhibit this property).
Will be determined by ASTM D638 using the 0.2 percent offset method. Speed of test will be as
designated in the appendices of ASTM D638 or as agreed upon for material not listed.
4.1.2.2 Ultimate Elongation.
Will be determined by ASTM D638. Speed of test will be as designated in the appendices of ASTM
D638 or as agreed upon for material not listed.
4.1.2.3 Tensile Modulus.
ASTM D638 will determine tangent modulus of elasticity at 23ºC. Speed of testing will be as
designated in Table 1 of ASTM D638 or as agreed upon for materials not listed.
4.1.2.4 Poisson’s Ratio
Determine per ASTM E132.
4.2 Sample Preparation
A minimum of five samples shall be prepared for each condition tested. Prepare fiber reinforced
plastic (FRP) samples per SAE J1525 and metal samples per SAE J1523 except as indicated. See
Figure 1. The surface condition tested shall be representative of production conditions and fully
described in the test report. The bond line shall be between 0.25 and 1 mm (.010 and .040 inches) with
an overlap of 12.5 mm (.5 inch) for metal and 25 mm (1 inch) for plastic, unless otherwise directed.
The cure conditions* shall be described fully in the test report and should closely match the production
cure conditions. These cure conditions will be listed on the attached tables and shall be reproducible
for future testing.
* Times and temperatures should represent actual bond line conditions rather than the reported
temperatures of the heating elements or the oven air temperature.

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AUGUST 2001 Page 2 of 14
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TMS-6900 Structural Adhesives E

Part 1
4.3 Property And Performance Requirements
4.3.1 Lap Shear Strength
4.3.1.1 Method: Prepare samples as directed in 4.2 Sample Preparation. Test per ASTM D3163 or
ASTM D1002, as appropriate. Tensile machine jaw separation rate shall be 13 mm (.5 in) per minute.
Test overlap shear at the following specified temperatures after holding at temperature for 30 minutes.
Report the average of five tests and their failure modes.
4.3.1.2 Required: See Table 1A.
4.3.2 Cross Peel Test (FRP only)
4.3.2.1 Method: SAE J1553 test method shall be used, with an adhesive thickness of 0.75 mm (30 mil).
4.3.2.2 Required: See Table 1B, for required values.
4.3.3 Cleavage Fracture Strength
4.3.3.1 Method: Prepare samples as indicated in 4.2 Sample Preparation except for the geometry
requirements of ASTM D5041. Test per ASTM D1041. Test samples un-aged and after water-
immersion.
4.3.3.2 Required: A minimum of 75% fiber tear is required for FRP samples. Report peak load, failure
initiation energy and failure propagation energy. See Table 1A.
4.3.4 Stress Durability
4.3.4.1 Method: Test per ASTM D2919 using a fixture described in either ASTM D2294 or ASTM
D2919. Prepare samples as indicated in 4.2 Sample Preparation except for the geometry requirements
of ASTM D2919 or D2294. Load samples to 2 MPa (290 psi). See Table 1 for test conditions. Measure
time to failure or residual load per Overlap Shear Strength above.
4.3.4.2 Required: Report only, requirements are under development, see Table 1A for expected values.
Failures are expected to be cohesive.
4.3.5 Corrosion
4.3.5.1 Method: Test per ASTM B-117 salt spray on coupons prepared in 4.2 Sample Preparation for
shear strength test for 500 hours.
4.3.5.2 Required: See Table 1A.
4.3.6 Humidity
4.3.6.1 Method: Test per CEMS Test Method GT-7E on coupons prepared in 4.2 Sample Preparation
for shear strength test for 500 hours.
4.3.6.2 Required: See Table 1A.
4.3.7 Water Immersion
4.3.7.1 Method: Immerse coupons prepared in 4.2 Sample Preparation for shear strength test in
distilled water at 25°C (77°F) ± 2°C (3.6°F) for 500 hours.
4.3.7.2 Required: See Table 1A.
4.3.8 Shrinkage (Pumpables, only)
4.3.8.1 Method: Fill small, flat container 50 mm diameter x 6 mm height (2 in diameter x 1/4 in
height) with adhesive material and subject leveled product to maximum bake temperatures for 40
minutes. Observe at room temperature.
4.3.8.2 Required: Shall show no visible evidence of shrinkage, cracking or overflow.

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NUMBER: TITLE REVISION:
TMS-6900 Structural Adhesives E

Part 1
4.3.9 Volume Expansion/Shrinkage
4.3.9.1 Method: Test per GM9037P, or WSB M-18P11-A2 on coupons prepared in 4.2 Sample
Preparation. Obtain substrate test coupons that are dimensionally capable of supporting the entire
part. For sheet stock, extrusions or injection-molded samples, avoid cutting from the edges of the
sheet or part.
4.3.9.2 Required: Report only, requirements are under development.
4.3.10 Over-bake
4.3.10.1 Method: Prepare samples for lap shear as directed in 4.2 Sample Preparation and in 4.3.8
Shrinkage. Over-bake samples in re-circulating air oven for (4) hours at maximum bake temperatures.
Check hardness; per ASTM D2240, and lap shear strength.
4.3.10.2 Required:
4.3.10.2.1 After Over-baking: ± 3 points max change from original hardness.
4.3.10.2.2 Over-baked material shall not darken substantially or show other evidence of degradation.
4.3.10.2 3. Shall retain 95% of original strength by lap shear.
4.3.11 Heat-Aging
4.3.11.1 Method: Prepare samples for lap shear and cross peel as directed in 4.2 Sample
Preparation. Heat-Age in a re-circulating air oven for 500 hours at 90± 2°C (194± 3.6°F).
4.3.11.2 Required: Retain strength as indicated in Table 1.
4.3.12 Cyclic Aging
4.3.12.1 Method: Prepare samples for lap shear as directed in 4.2 Sample Preparation. Test overlap
shear after the environmental conditioning periods listed below, allowing samples to return to ambient
room temperature for 24 hours prior to testing. The 6-week cyclic aging shall be as follows:
4.3.12.1.1 16 hours humidity
4.3.12.1.2 2 hours -30± 2°C (-22± 3.6°F)
4.3.12.1.3 2 hours at ambient conditions
4.3.12.1.4 2 hours 70± 2°C (158± 3.6°F)
4.3.12.1.5 2 hours salt spray
4.3.12.1.6 Repeat cycle until 6-week period has elapsed - cycle may be interrupted for weekends and
holidays, in which case leave the samples in humidity for that period.
4.3.12.2 Required: See Table 1.
4.3.13 Weldability - only applicable when designated as a weld though adhesive.
4.3.13.1 Method: SAE J243 Weld-Through Test ADS-3, Method B.
4.3.13.2 Required: Shall meet tensile, flashing, electrode life, and electrode pickup, as specified.

5.0 QUALIFICATION
Material and processes submitted for approval to this specification shall include the following:
5.1 A detailed, signed test report documenting testing to this specification per TMS-9543.
5.2 Test coupons or photographs showing failure modes for each test.
5.3 The complete procedure used for preparing and curing materials for test, especially surface
preparation and condition of the test coupons.
5.4 Adhesive, substrate and any chemicals used for bonding.

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NUMBER: TITLE REVISION:
TMS-6900 Structural Adhesives E

Part 1
6.0 SOURCE APPROVAL AND QUALITY CONTROL
6.1 Supplier Requirements
Suppliers must conform to the requirements of the International IQR Quality Standard which includes
conformance to the QS-9000 (ISO 9001) Quality System Standard. A mutually acceptable Quality
Control Plan as described therein is required for source approval to the requirements of this
specification.
6.2 Approval
Parts supplied against contracts or purchase orders citing this specification shall be equivalent in all
respects to those samples which were approved by the purchaser. No changes in formulation or
processing practices are permitted without approval. In the event that changes in material, properties,
processing practices, construction, color, or labeling of the product are required, the
supplier shall notify Materials Engineering, Truck Development and Technology Center and
INTERNATIONAL Purchasing and Supplier Development of the proposed change(s). Test data
indicating conformance to all requirements of this specification, test samples, and new or amended or
updated Material Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be
submitted with the request for change.
6.3 Process Control
The supplier shall either perform and/or report results of tests on specific lots of parts produced or
provide statistical evidence of the lot having been produced in a state of statistical control and with a
process capable of providing all required properties. The part supplier and the plant metallurgist
and/or the quality control manager of the using International plant may determine testing and reporting
requirements on specific products.
7.0 SHIPPING, PACKING AND IDENTIFICATION
Loading, packing and identification shall be in accordance with Manufacturing Std. D-13.
8.0 DESIGNATION ON DRAWINGS
The drawing designation may be written in a general or specific manner depending on the requirements
of the situation. The specification for a bonded assembly may be written as:
8.1 Bond per TMS-6900: Or, a bonded assembly may specify a specific adhesive system:
8.1.2 Bond per TMS-6900, System A: This would specify the bonding requirements but limit the
adhesive system selection to system A as listed in Table 4.
8.2 Optional Drawing Call-out: Finally, a specific material may be specified on a part drawing for
the purpose of purchasing that material. That designation may be written as a description of the resin.
8.2.1 Material Call-out per Table listing: These designations refer to the specific material ID listed
in Table 4.
8.2.1.1 Adhesive Resin A1 per TMS-6900

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TMS-6900 Structural Adhesives E

Part 1

TABLE 1A: BOND STRENGTH (1) – Lap Shear

Material FRP to FRP Metal to Metal Glass to Metal Thermoplastic

DCPD-DCPD to
Thermoplastic
Condition MPa [psi] Min. MPa [psi] Min. MPa [psi] Min. MPa [psi] Min.
25± 2°C ** 4.8 [700]* (2)(3) 17.2 [2500]* (2)(3) 8.5 [1233]* (2)(3) 3.5(508) (2) (3)
% Retained, Min. % Retained, Min. % Retained, Min. % Retained, Min.
-40± 2°C ** 95 (2) 95 (2) 95 (2) 95 (2)
120± 2°C ** FRP 30 80 (2)(3) 80 (2)(3) 25 (2) (3)
DCPD 25
(2)(3)
Heat Age 90 (2) 95 (2) 95 (2) 90 (2)
Water Immersion 80 (2)(3) 80 (2) (3) 80 (2) (3) 80 (2) (3)
Humidity 90 (2) Not Required 90 (2) 90 (2)
Corrosion Not Required 80 (2) Not Required Not req’d
Cyclic Aging FRP 80 80 (2) 80 (2) 90 (2)
DCPD 90
(2)
Cleavage Report (3) Not Required Not Required Report (3)

TABLE 1B: BOND STRENGTH (1) – Cross Peel

Material FRP to FRP Thermoplastic to

Thermoplastic
Condition MPa [psi] Min. MPa [psi] Min.
25± 2°C ** 1.0 [150]* (2) 1.0 [150]* (2)
% Retained, Min. % Retained, Min.
Heat Age 90 (2) 90 (2)
Water Immersion 80 (2) 80 (2)

(1) Other materials may be qualified to this specification. In these cases use the test criteria for
FRP and the initial strength qualification values will be listed under Table 4
(2) Failure must be by cohesive failure of the adhesive or delamination of the substrate (fiber
tear) unless for DCPD to DCPD in which the failure must be cohesive, shear failure of the
substrate or stock break.
(3) Screening tests.
* These are general values. Specific values need to be established on the production-bonded
assembly and agreed on between the supplier and Materials Engineering at TDTC. See Table
2 for a list of values.
** Test at these conditions.

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TMS-6900 Structural Adhesives E

Part 1
TABLE 2: SUBSTRATES
ITEM DESCRIPTION SPECIFICATION COMPOUND DESIGNATION
1a Sheet Molding Type II, Grsde B, CEMS D22 FS 2802
Compound (SMC)
1b Open Molded FRP – Type III, Grade B, CEMS D22 Aropol Q6389 System
GoldShield
1c Open Molded FRP – Type III, Grade B, CEMS D22
MPI
1d Cold Molded – ETM Type IV, Grade B or C, per AOC 812 DM System
CEMS D22
1e Sheet Molding Type II, Grade B, CEMS D22 FS 35
Compound (SMC)
1f Sheet Molding Type II, Grade B CEMS D22 LP 100
Compound (SMC)
1g Sheet Molding Type II, Grade B per CEMS FS 2901
Compound (SMC) D22
1h Sheet Molding Type II, Grade C per CEMS PS 2905
Compound (SMC) D22
2a Cold Rolled (CRS) – Grade 1C per CEMS A-6, Part
See (1) below. I
2b Hot Dipped Galvanized Grade 1 GALV per CEMS A- 60G60GU
Steel 6, Part II
2c Electrogalvanized Steel Grade 1 GALV per CEMS A- EG60G60GE
(EGS) – See (1) below. 6, Part II
3a Aluminum 5052-H32 – CEMS C-10 Sheet
See (2) below.
3b Aluminum 5182-0 – CEMS C-10 Sheet
See (2) below
3c Aluminum 3003-0 – CEMS C-10 Extrusion, Sheet
See (2) below.
3d Aluminum 3004-0 – CEMS C-10 Sheet
See (2) below
3e Aluminum 6061-T6 – CEMS C-10 Extrusion
See (2) below
3f Aluminum 6063-T5 – CEMS C-10 Extrusion
See (2) below
3g Aluminum 6022-T4 – CEMS C-10 Sheet
See (2) below
4a E-coat CEMS G-5 Part V Grade -56 Cathodic E-coat – BASF U32AD175N /
U32AD605
4b Top coat – White CEMS G-5 Part II Grade -18 Acrylic base coat/ Urethane clear coat –
Color – 9219 White Akzo BHC54056H Clear
10BHU43536H Activator 10BHU41971
(This row is intentionally left blank)

(1), (2), ** See page 8 for footnotes

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TMS-6900 Structural Adhesives E

Part 1
TABLE 2: SUBSTRATES - continued
ITEM DESCRIPTION SPECIFICATION COMPOUND DESIGNATION
4c Top coat – Black CEMS G-5 Part II Grade -18 Acrylic base coat/ Urethane clear coat–
Color – 0001 Black Akzo 4BHC59405H Clear
10BHU43536H Activator 10BHU41971
4d Top coat - Gold CEMS G-5 Part II Grade -18 Acrylic base coat/ Urethane clear coat –
Metallic Color – 4587 Gold Metallic Akzo 12BHC54615C Clear
10BHU43536H Activator 10BHU41971
4e Top coat – Red CEMS G-5 Part II Grade -18 Acrylic base coat/ Urethane clear coat–
Metallic Color – 2503 Red Metallic Akzo 3BHC55203 Clear
10BHU43536H Activator 10BHU41971
4f Top coat – Low Gloss CEMS G-5 Part II Gr. -19HS High solids thermoset acrylic– Akzo
SBY Color – 4422 LG SBY 2BLC59009
4g Top coat – Low gloss CEMS G-5 Part II Grade High solids 2 component urethane–
Beige -17HS Akzo 7BLU58217
Color – 1944 LG Beige
4h Top coat CEMS G-5 Part II Grade -17 2 component urethane
5a Dicyclopentadiene TMS 7133 DCPD
6a ABS ABS, A64A65DE1050S82
/AE1, CEMS D-28
7a Acrylic PMMA,A6DE1190K57M27S
72,CEMS D-28
8a Polycarbonate, clear PC,
headlight lens. A6DD1200M20K58S120RA6
40, CEMS D-28
8b Polycarbonate, general PC,
purpose (opaque A4DD1200M20K58S120RA6
headlight housing). 40, CEMS D-28
9a Laminated Glass TMS-9522 Windshield
9b Tempered Glass TMS-9522 Side, back and drop glass
(1) Steel Surface Preparation: Two sets of five samples shall be made for each condition tested. Solvent (acetone)
clean samples thoroughly. The first set shall be tested clean. The second set shall have a light oil coating, as in
steps 5 and 6 listed below, under Aluminum Surface Preparation.
(2) Aluminum Surface Preparation: Three sets of five samples of aluminum test samples shall be made for each
condition tested. Solvent (acetone) clean samples thoroughly. The first set shall be tested clean. The second set
shall have a light oil coating, as in steps 5 and 6 listed below. The third set shall be prepared in the following
manner:
1) Clean samples thoroughly with acetone.
2) Apply Mill Oil (Ashland Tectyl 900)* liberally to the bonding surface.
3) Wipe oil off surface with a clean, soft, paper lab towel. A light oil residue should remain.
4) Bake samples for four (4) hours at 200°C (392°F).
5) Apply Drawing lubricant (Quaker 61AUS)** liberally to the bonding surface.
6) Wipe oil off surface with a clean, soft, paper lab towel. A light oil residue should remain.
7) Prepare test samples as required.
** Other lubricants will be used in production. Adhesives and lubricants shall be compatible with each other.
Testing compatibility shall be the responsibility of the supplier of the new material. The Metallurgist at the
International Body Plant in Springfield, Ohio maintains a list of approved lubricants.
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TMS-6900 Structural Adhesives E

Part 1
TABLE 3: CURE CYCLES
ITEM LOCATION CYCLE
1 Core Materials 1) Heated Fixture - 5 minutes at 150± 2°C (302± 3.6°F)
Corporation 2) Prime Cure - 20 minutes at 160± 2°C (320± 3.6°F)
2 Springfield Body & Paint 1) E-coat oven - 30 minutes at 175 ± 2°C (347± 3.6°F)
Facility 2) Sealer oven - 20 minutes at 149 ± 2°C (329± 3.6°F)
3) Top-coat oven - 30 minutes at 110 ± 2°C (227± 3.6°F)
3 Chatham Assembly Plant 1) Top coat oven - 20 minutes 110± 2°C (230± 3.6°F)
(Pre-paint assembly)
4 Escobedo Plant 1) E-coat oven - 30 minutes at 175 ± 2°C (347± 3.6°F)
2) Sealer oven - 15 minutes at 119 ± 2°C (247± 3.6°F)
3) Top-coat oven - 30 minutes at 120 ± 2°C (248± 3.6°F)
5 Assembly Plant - post Ambient cure conditions – follow and report manufacturer’s
paint recommended practice.
6 Field Repair Ambient cure conditions – follow and report manufacturer’s
recommended practice.
7 GoldShield Primer oven- 30 minutes at 106°±3°C (225°±5°F)
8 GW Fiberglass
9 ETM Primer Oven- 20-30 minutes at 120°C±2°C (250 ± 4°F), 3
passes
10 21st Century Primer oven-30 minutes at 180’ F
11 Aftermarket Repair Conditions as prescribed by the adhesive supplier

TABLE 4: MATERIALS AND GENERAL PROPERTIES

ID SUPPLIER/ CODE PART VISCOSITY OPEN SHELF TENSILE TENSILE POISSON’S COLOR
MATERIAL NUMBER(s) Cps TIME LIFE OR MOD. RATIO
@ 23°°C [Days] YEILD [MPa]
Minutes [MPa]
A1 Ashland Pliogrip 7000 18,000 15 Tan
Urethane Pliogrip 7020 15,000 Green
A2 Ashland Pliogrip 7000 18,000 15 Tan
Urethane Pliogrip 7030 15,000 Green
A3 Ashland Pliogrip 7300 24,000 45 Tan
Urethane Pliogrip 6660 10,000 Dk
Green
A4 Ashland Pliogrip 7400 15,000 12 Tan
Urethane Pliogrip 7420 10,000 Dk
Green
A5 Ashland Pliogrip 8000 24,000 7 Tan
Urethane Pliogrip 6611 10,000 Dk
Green
A6 Ashland Pliogrip 8000 24,000 45 Tan
Urethane Pliogrip 6660 10,000 Dk
Green
A7 Ashland Pliogrip 9100
Urethane Pliogrip 9115
A8 Ashland Pliocryl 2809
B1 ITW Plexus MA320 135,000 – 8 – 12 Off-
Adhesive 175,000 White

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 NUMBER: TITLE REVISION:
TMS-6900 Structural Adhesives E

Part 1
TABLE 4: MATERIALS AND GENERAL PROPERTIES (continued)
Methacrylate MA320 40,000 – 8 - 12 Off-
Activator 60,000 White /
Blue
B2 ITW Plexus AO420 100,000 – 4 –6 Off -
Adhesive 125,000 White
Methacrylate AO420 50,000 – 4–6 Off-
Activator 70,000 White /
Blue /
Black
C1 Ciba 3131
Epoxy
D1 Eftech WC-2219HT
Epoxy
E1 Dow BETAMATE 3506629R1 200,000 30 180 18.9 Black
Automotive 73312 resin
Epoxy
E1 Dow BETAMATE 3506630R1 114,000 30 180 18.9 Tan
Automotive 73313 curative
Epoxy
E2 Dow BETAMATE 3551591R1 270,000/ 90 17 5068 Black
Automotive 73305 310,000
Epoxy
E3 Dow BETAMATE 3551595R1 270,000/ 90 17 5068 Black
Automotive 73305GB 310,000
Epoxy
E4 Dow BETAMATE 9,000 5 180 13.1 96.5 Gray
Automotive 73100
Urethane
BETAMATE 9,000 5 180 13.1 96.5 Tan
73005
F1 Lord Corp. 7545 A 45,000/ 5-60 Brown
Urethane 380,000 min.
7545 B Off-
White
F2 Lord Corp. 660 A 200,000/ 30 min. White
Acrylic 45,000
660 B White
F3 Lord Corp. 403 200,000/ 3-25 Tan
Acrylic 175,000 min.
19 Off-
White
F4 Lord Corp. 406 200,000/ 3-25 Tan
Acrylic 175,000 min.
19 Off-
White
F5 Lord Corp. 410 200,000/ 3-25 Tan
Acrylic 175,000 min.
19 Off-
White
G1 Hysol H4000 Part A 90,000 – 8 20 Cream
100,000
Methacrylate H4000 Part B 160,000 – Pale
170,000 yellow
H1 Henkel Terorehm 50,000cps @ 21.7 1060 0.477 Black
2000 300F
H2 Henkel Terocore 90 15 800 .25 Gray
1010B
H3 Henkel Terocore Black
XR33-2
L1 L&L L-5020 3547423C1 90 13.8 645.7 0.62 Black
Products 3558411R1

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NUMBER: TITLE REVISION:
TMS-6900 Structural Adhesives E

Part 1

TABLE 5: APPROVED MATERIAL, SUBSTRATE AND CURE CYCLE

MATERIAL SUBSTRATE(S) CURE QUALIFIED APPROVAL COMMENTS

SYSTEM(S) (see Table 2) CYCLE(S) SHEAR LEVEL/
(see Table 4) (see Table 3) STRENGTH REPORT
(see Table 1) NUMBER
Mpa [psiI] [see below]
C1, D1 2a, 2b, 3a, 3b, 3c 2 17.2 [2500] A
E2, E3 2a, 2b, 2c, 3a, 3b, 3c 2 17.2 [2500] MN99-1338-2FR
E1 2a, 2b, 3a, 3b, 3c 2 17.2 [2500] MN99-1338-1FR
L1 2a, 2b, 2c, 3a, 3c, 4a 2 15.5 [2250]

Note 1: Only material and substrate combinations listed in this table are considered “Approved.” Letter
or report may approve material combinations during periods between specification updates.

Note 2: Approval levels are as follows:

INTERNATIONAL Report number – Full approval as documented in the INTERNATIONAL
report.
A – Grand-fathered approval. Current production applications are required to submit test
reports to this specification to maintain approvals.
B – Approved for prototypes and pre-production applications.

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AUGUST 2001 Page 11 of 14
NUMBER: TITLE REVISION:
TMS-6900 Structural Adhesives E

Part 2
STRUCTURAL ADHESIVES
Part 2 – Manufacturing and Assembly Process Controls

1.0 APPLICATION (see Part 1)

2.0 SCOPE (see Part 1)
3.0 REFERENCE DOCUMENTS (see Part 1)

4.0 PERFORMANCE REQUIREMENTS OF BONDED ASSEMBLIES

4.1 Section A - FRP Assemblies
4.1.1 Surface Preparation
Prior to the bonding process, the FRP bond joints shall be wiped clean to remove any surface
contaminants, such as dirt, dust, oil etc. This procedure can include, but is not limited to dry-rag wipe,
alcohol wipe, or air blow-off. Metal surfaces must be primed unless otherwise indicated on the
drawing. These surfaces must also be free of contaminants.
4.1.2 Assembly Process
Assemblies are to be constructed in a manner which produces parts in accordance with the drawing in
a production environment. Process methods should incorporate practices in accordance with the
adhesive manufacturer’s recommended procedure. This should include any post-bake operation and
paint ovens at the using International plant.
4.1.3 Bond Joint Properties
Adhesive squeeze-out must be trimmed, or de-roped, at visible edges so as to be flush or below in
order not to affect appearance or paint performance. This may be waived if the edge is not visible or if
the squeeze-out does not affect fit, form or function of the part.
4.1.3.1 The adhesive thickness, or bond gap, target should be 1mm, +1mm, -. 2mm. The adhesive
width target shall be 18 mm, ±5 mm.
4.1.3.2 There shall be no instance of bond-line read-through on the appearance surface of the part.
4.1.4 Destructive Testing: Teardown
Destructive testing of the assembly, or teardown, should yield 75% fiber tear minimum, with the
balance being cohesive. There should be no more than 50 mm in 250 linear mm with adhesive failure.
Bond voids greater than 25 mm in 250 linear mm are unacceptable. Photographically document results
(preferably with digital pictures) and include in report with electronic file.
4.2 Section B – Metal Assemblies
4.2.1 Surface Preparation
Prior to the bonding process, the bond joints shall be wiped clean to remove any excess surface
contaminants, such as dirt, dust, oil etc. This procedure can include, but is not limited to dry rag wipe,
alcohol wipe, or air blow off. The adhesive shall be compatible with normal amounts of process oils
on the metal. Any special preparation shall be duly noted.
4.2.2 Assembly Process
Assemblies are to be constructed in a manner, which produces parts in accordance with the drawing in
a production environment. Process methods should incorporate practices in accordance with the
adhesive manufacturer’s recommended procedure. This should include any post-bake operation and
paint ovens at the using International plant.

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NUMBER: TITLE REVISION:
TMS-6900 Structural Adhesives E

Part 2
4.2.3 Bond Joint Properties
Adhesive squeeze-out is desired but must be cleaned from any visible, cosmetic joints. The adhesive
thickness, or bond gap, target should be .25mm - 1.0mm. The adhesive width target shall be 18 mm,
±5 mm.
4.2.4 Destructive Testing: Teardown
Destructive testing of the assembly, or teardown, should yield 75% cohesive failure minimum. There
should be no more than 50 mm in 250 linear mm with adhesive failure. Bond voids greater than 25
mm in 250 linear mm are unacceptable. Photographically document results (preferably with digital
pictures) and include in report with electronic file.
5.0 QUALIFICATION
Each facility bonding material for INTERNATIONAL shall have at least one material qualified as a
“primary” qualification. A “primary” qualification shall be the dominant substrate and adhesive
combination used in that facility within a single class of material. A “secondary” qualification is a
material within the same material group as the primary. A secondary qualification may be limited to
just the “screening” tests on the qualification report. For instance, a facility bonding SMC will qualify
its dominant SMC compound as the primary qualification to the full and complete specification.
Lower volume compound variations may be qualified as “secondary” qualification. But, if the facility
starts to bond other materials (such as metal, thermoplastics, or other composites), uses a new
adhesive, or replaces its primary material (even reducing its usage to a lower volume level against a
secondary qualification but not eliminate it entirely), it shall submit another “primary” qualification.
5.1 Questions regarding qualification requirements, secondary and primary materials, and qualification
reports and test materials shall be directed to:
Manager of Non-Metallic Materials
Materials Engineering and Technology Development
Truck Development and Technology Center
PO Box 1109
Fort Wayne, IN 46801

A.0 GENERAL INFORMATION

The equipment and adhesive manufacturers can provide direction in setting maintenance schedules,
provide process checking methods, evaluate storage conditions, and instruct on proper stock handling
procedures. The following are general guidelines that are usually true for most materials.
A.1 Production Control
Proper maintenance and equipment checks are necessary to ensure that the material is dispensed
properly. Some techniques to assure the adhesive is properly mixed and hardened are to check the
mixture feeding into the gun by weight and to measure hardness at the edge of cured joints.

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NUMBER: TITLE REVISION:
TMS-6900 Structural Adhesives E

Part 2
A.2 Material Storage
Base resin and accelerators shall be stored at ambient temperature below 38°C (100°F) away from all
sources of heat and ultraviolet light. The adhesive resins and accelerators exhibit a marked decrease in
storage life when not stored under stated conditions. Materials stored at temperatures below 21°C
(70°F) shall be conditioned at ambient temperatures prior to application. Due to storage life
limitations, inventory must be rotated continually (first in-first out) and kept to a minimum.
Note: Resins and accelerators may be reactive with moisture in the atmosphere and, therefore,
should be stored in tightly closed containers to insure maximum shelf life.

A.3 Proper Mixing

When components are mixed, colors must blend to a smooth, uniform color. A noted change in
adhesive color or shade indicates whether proportions are mixed correctly. Thus, a visual check, at the
point of application, can be made to insure thorough mixing. Since this is not an absolutely reliable
means of control, a ratio measure by weight should be made at the start of each shift or at an interval
agreed upon by the material and equipment manufacturers.

OVERLAP SHEAR TEST SAMPLE

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AUGUST 2001 Page 14 of 14