Designation: D 1002 – 05

Standard Test Method for

Apparent Shear Strength of Single-Lap-Joint Adhesively
Bonded Metal Specimens by Tension Loading (Metal-to-
Metal)1
This standard is issued under the fixed designation D 1002; the number immediately following the designation indicates the year of

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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.
This standard has been approved for use by agencies of the Department of Defense.

INTRODUCTION

The accuracy of the results of strength tests of adhesive bonds will depend on the conditions under
which the bonding process is carried out. Unless otherwise agreed upon by the manufacturer and the
purchaser, the bonding conditions shall be prescribed by the manufacturer of the adhesive. In order to
ensure that complete information is available to the individual conducting the tests, the manufacturer
of the adhesive shall furnish numerical values and other specific information for each of the following
variables:
(1) Procedure for preparation of surfaces prior to application of the adhesive, the cleaning and
drying of metal surfaces, and special surface treatments such as sanding that are not specifically
limited by the pertinent test method.
(2) Complete mixing directions for the adhesive.
(3) Conditions for application of the adhesive, including the rate of spread or thickness of film,
number of coats to be applied, whether to be applied to one or both surfaces, and the conditions of
drying where more than one coat is required.
(4) Assembly conditions before application of pressure, including the room temperature, relative
humidity, length of time, and whether open or closed assembly is to be used.
(5) Curing conditions, including the amount of pressure to be applied, the length of time under
pressure, method of applying pressure (pressure bag, press platens, etc.), heat-up rate, and the
temperature of the assembly when under pressure. It should be stated whether this temperature is that
of the bondline or of the atmosphere at which the assembly is to be maintained.
(6) Conditioning procedure before testing, unless a standard procedure is specified, including the
length of time, temperature, and relative humidity.
A range may be prescribed for any variable by the manufacturer of the adhesive if it can be assumed
by the test operator that any arbitrarily chosen value within such a range, or any combination of such
values for several variables will be acceptable to both the manufacturer and the purchaser of the
adhesive.

1. Scope on a standard single-lap-joint specimen and under specified

1.1 This test method covers the determination of the appar- conditions of preparation and test.
ent shear strengths of adhesives for bonding metals when tested 1.2 The values stated in SI units are considered to be the
standard. The values given in parentheses are for information
only.
1
This test method is under the jurisdiction of ASTM Committee D14 on
Adhesives and is the direct responsibility of Subcommittee D14.80 on Metal
Bonding Adhesives.
Current edition approved Oct. 1, 2005. Published October 2005. Originally
approved in 1949. Last previous edition approved in 2001 as D 1002 – 01.

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 D 1002 – 05
1.3 This standard does not purport to address all of the more difficult if a different type of adherend is used in a larger
safety concerns, if any, associated with its use. It is the structural joint than was used in the small specimen.
responsibility of the user of this standard to establish appro- 4.4 The apparent shear strength measured with a single-lap
priate safety and health practices and determine the applica- specimen is not suitable for determining design-allowable
bility of regulatory limitations prior to use. stresses for designing structural joints that differ in any manner
from the joints tested without thorough analysis and under-
2. Referenced Documents standing of the joint and adhesive behaviors.
2.1 ASTM Standards: 2 4.5 Single-lap tests may be used for comparing and select-
A 109/A 109M Specification for Steel, Strip, Carbon, (0.25 ing adhesives or bonding processes for susceptibility to fatigue
Maximum Content Percent), Cold-Rolled and environmental changes, but such comparisons must be
A 167 Specification for Stainless and Heat-Resisting made with great caution since different adhesives may respond
Chromium-Nickel Steel Plate, Sheet, and Strip differently in different joints. See Guide D 4896 for further
B 36/B 36M Specification for Brass Plate, Sheet, Strip, and discussion of the concepts relative to interpretation of
Rolled Bar adhesive-bonded single-lap-joints.
B 152/B 152M Specification for Copper Sheet, Strip, Plate,
and Rolled Bar 5. Apparatus
B 209 Specification for Aluminum and Aluminum-Alloy 5.1 The testing machine shall conform to the requirements
Sheet and Plate of Practices E 4. The testing machine shall be so selected that

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B 265 Specification for Titanium and Titanium Alloy Strip, the breaking load of the specimens falls between 15 and 85
Sheet, and Plate percent of the full-scale capacity. The machine shall be capable
D 907 Terminology of Adhesives of maintaining a rate of loading of 80 to 100 kg/cm2 (1200 to
D 4896 Guide for Use of Adhesive-Bonded Single Lap- 1400 psi)/min, or, if the rate is dependent on crosshead motion,
Joint Specimen Test Results the machine should be set to approach this rate of loading,
E 4 Practices for Force Verification of Testing Machines approximately 0.05 in./min. It shall be provided with a suitable
pair of self-aligning grips to hold the specimen. It is recom-
3. Terminology mended that the jaws of these grips shall engage the outer 25
3.1 Definitions—Many terms in this test method are defined mm (1 in.) of each end of the test specimen firmly.
in Terminology D 907. 5.2 The grips and attachments shall be so constructed that
they will move into alignment with the test specimen as soon
4. Significance and Use as the load is applied, so that the long axis of the test specimen
will coincide with the direction of the applied pull through the
4.1 This test method is primarily comparative. However, it center line of the grip assembly.
does have application as a discriminator in determining varia- 5.3 The length of overlap of the specimen may be varied
tions in adherend surface preparation parameters and adhesive where necessary. The length of the specimen in the jaws,
environmental durability. The test method has found applica- however, must not be varied. The distance from the end of the
tions in controlling surface preparations, primer, and adhesive lap to the end of the jaws should be 63 mm (21⁄2 in.) in all tests.
systems for determining strength properties of tested systems.
4.2 The misuse of strength values obtained from this test 6. Test Specimens
method as design-allowable stress values for structural joints
6.1 Test specimens shall conform to the form and dimen-
could lead to product failure, property damage, and human
sions shown in Fig. 1. These shall be cut from test panels
injury. The apparent shear strength of an adhesive obtained
prepared as prescribed in Section 7. The recommended thick-
from a given small single-lap specimen may differ from that
ness of the sheets is 1.62 6 0.125 mm (0.064 6 0.005 in.). The
obtained from a joint made with different adherends or by a
recommended length of overlap for most metals of 1.62 mm
different bonding process. The normal variation of temperature
(0.064 in.) in thickness is 12.7 6 0.25 mm (0.5 6 0.01 in.).
and moisture in the service environment causes the adherends
6.2 Since it is undesirable to exceed the yield point of the
and the adhesive to swell or shrink. The adherends and
metal in tension during test, the permissible length of overlap
adhesive are likely to have different thermal and moisture
in the specimen will vary with the thickness and type of metal,
coefficients of expansion.
and on the general level of strength of the adhesive being
4.3 Even in small specimens, short-term environmental
changes may induce internal stresses or chemical changes in
the adhesive that permanently affect the apparent strength and
other mechanical properties of the adhesive. The problem of
predicting joint behavior in a changing environment is even

2
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Standards volume information, refer to the standard’s Document Summary page on
the ASTM website. FIG. 1 Form and Dimensions of Test Specimen

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 D 1002 – 05
investigated. The maximum permissible length may be com- 6.5 At least 30 specimens shall be tested, representing at
puted from the following relationship: least four different joints. However, if statistical analysis of
L 5 Fty t/t (1) data and variance is employed, it should be possible to reduce
this number.
where:
L = length of overlap, in., 7. Preparation of Test Joints
t = thickness of metal, in.,
Fty = yield point of metal (or the stress at proportional 7.1 It is recommended that test specimens be made up in
limit), psi, and multiples of at least five specimens, and then cut into indi-
t = 150 percent of the estimated average shear strength vidual test specimens (Note 1), Fig. 2 and Fig. 3. Cut sheets of
in adhesive bond, psi. the metals prescribed in 6.1 and 6.4 to suitable size. All edges
6.3 A variation in thickness of the metal, and the length of of the metal panels and specimens which will be within (or
overlap, will likely influence the test values and make direct which will bound) the lap joints shall be machined true
comparison of data questionable. For this reason, in compara- (without burrs or bevels and at right angles to faces) and
tive or specification tests, the thickness should preferably be smooth (rms 160 max) before the panels are surface-treated
1.62 6 0.125 mm (0.064 6 0.005 in.) and the length of overlap and bonded. Clean and dry the sheets carefully, according to
should preferably be 12.7 6 0.25 mm (0.5 6 0.01 in.), or not the procedure prescribed by the manufacturer of the adhesive,
in excess of the value computed in 6.2. For development tests and assemble in pairs. Prepare and apply the adhesive accord-
values could be different, but should then be constant. ing to the recommendations of the manufacturer of the adhe-
6.4 The following grades of metal are recommended for the sive. Apply the adhesive to a sufficient length in the area across
test specimens: the end of one or both metal sheets so that the adhesive will
Metal ASTM Designation
cover a space approximately 6 mm (1⁄4 in.) longer than the
Brass B 36/B 36M, C26800 (Alloy 8) overlap as selected in Section 6. Assemble the sheets so that
Copper B 152/B 152M, C11000 they will be held rigidly so that the length of the overlap will
Aluminum B 209, Alloy 2024, T3 temper
Steel A 109/A 109M, Grade 2 be controlled, as indicated in Section 6, within 0.25 mm
Corrosion-resisting steel A 167, Type 302 (60.01 in.), and the adhesive allowed to cure as prescribed by
Titanium B 265 the manufacturer of the adhesive.

FIG. 2 Standard Test Panel

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 D 1002 – 05
the jaws (see 5.3) and so that the long axis of the test specimen
coincides with the direction of applied pull through the center
line of the grip assembly. Apply the loading immediately to the
specimen at the rate of 80 to 100 kg/cm2 (1200 to 1400 psi) of
the shear area per min. Continue the load to failure. This rate
of loading will be approximated by a free crosshead speed of
1.3 mm (0.05 in.)/min.
10. Calculations
10.1 Record the load at failure and the nature and amount of
this failure (cohesion in adhesive or metal, or adhesion) for
each specimen. Express all failing loads in kilograms per
square centimeter (pounds per square inch) of shear area,
calculated to the nearest 0.06 cm2 (0.01 in.2).
11. Report
11.1 Report the following:
11.1.1 Complete identification of the adhesive tested, in-
cluding type, source, date manufactured, manufacturers’ code
numbers, form, etc.,
11.1.2 Complete identification of the metal used, its thick-
ness, and the method of cleaning and preparing its surfaces
prior to bonding,
11.1.3 Application and bonding conditions used in prepar-
ing specimens,
11.1.4 Average thickness of adhesive layer after formation
of the joint within 0.001 in. (0.025 mm). The method of
obtaining the thickness of the adhesive layer shall be described
FIG. 3 Optional Panel for Acceptance Tests Only
including procedure, location of measurements, and range of
measurements.
NOTE 1—Bonding specimens in multiple panels is believed to give
11.1.5 Length of overlap used,
more representative specimens. However, individual specimens may be
prepared if agreeable to the supplier or the purchaser of the adhesive. 11.1.6 Conditioning procedure used for specimens prior to
testing,
8. Preparation of Test Specimens 11.1.7 Number of specimens tested,
8.1 Cut the test specimens, as shown in Fig. 1, from the 11.1.8 Number of joints represented and type of joint if
panels, Figs. 2 and 3. Perform the cutting operation so as to other than single overlap,

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avoid overheating or mechanical damage to the joints (Note 2). 11.1.9 Maximum, minimum, and average values for the
For final preparation trim panel area according to Fig. 2. failing load, and
Measure the width of the specimen and the length of the 11.1.10 The nature of the failure, including the average
overlap to the nearest 0.25 mm (0.01 in.) to determine the shear estimated percentages of failure in the cohesion of the adhe-
area. sive, contact failure, and adhesion to the metal.
NOTE 2—A five-tooth, typesetter’s circular saw has been found suitable 12. Precision and Bias
for such purposes. 12.1 Precision and Bias does not exist for Test Method
D 1002. An ASTM supported interlaboratory study (ILS) is
9. Procedure
currently underway to develop a P&B statement for Test
9.1 Test the specimens, prepared as prescribed in Section 8, Method D 1002.. This study, and a complete P&B statement
as soon after preparation as possible. The manufacturer of the are expected to be completed by 2007.
adhesive may, however, prescribe a definite period of condi-
tioning under specific conditions before testing. 13. Keywords
9.2 Place the specimens in the grips of the testing machine 13.1 adhesives; metal-to-metal; shear strength; single-lap
so that the outer 25 mm (1 in.) of each end are in contact with joint; tension loading

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 D 1002 – 05
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