Robotics Engineering
DoDEA - Career and Technical Education
Identifying Elements of Materials and
Structural Design
Worksheet 3 – Fasteners, Fastening and Bonding
Objective: After completing this exercise, you’ll demonstrate your knowledge and the proper use
of fasteners and fastening. You’ll model various types of fastening systems using
our robotics trainer. You’ll also become familiar with other methods the
manufacturing industry uses to fasten materials together.
Deliverables:
Copy and paste the required deliverables to another
document for submission. All deliverables must be word processed with the
required student ID information in the footer of the document. The header of
the document should contain the title of the assignment. Both the question and
answer must be included in the deliverable with the answers highlighted. All work
must be complete and accurate to receive credit.
1.
2.
Detailed definitions for each of the terms found in the Nomenclature section.
Detailed answers to the queries listed in the Questions section.
Information: Temporary and (various degrees of) permanent are the two basic types of fastening methods to
consider during product assembly. The method best chosen is determined by many factors. You certainly wouldn’t
want to weld or glue parts of an assembly together that may need to be taken apart later for maintenance or repair.
The same is true for using nails when the design specifically calls for woodscrews and glue. It’s very important to
follow the design specifications when selecting the fastener that’s appropriate for the work being done. The application
and types of materials being fastened together often determine the kind of fasteners that are used.
There’s one final distinction regarding the types of fasteners and fastening methods in regards to permanence… No
fastening method is actually permanent. Even welds and adhesives can be removed if there’s no regard for the
components that are fastened by them. When materials are fastened together, their joining is designed to form
continuity between the components. The goal is to make the components act as one. Therefore, it’s important to
consider the various mechanical stresses that manufactured products must endure without deformation or failure.
These forces are:
1. Compressive Stress results when an object is squeezed along the same axis.
2. Tensile Stress occurs when an object is being pulled along the same axis.
3. Shear Stress can be related to the stress caused by a pair of scissors as they cut through an object. Shear
stress is a sliding force represented by one material moving in parallel along another object.
4. Torsion Stress represents a twisting motion applied to an object.
It’s important to remember that the strength of joining materials together is only as strong as the fastener and material
that’s being joined. Bolting cardboard together seems inappropriate when you consider the metal fastener is thousands
of times stronger than the material surrounding it. Although the bolt itself may stronger, glue may be the better
fastening method in this situation.
Threaded Fasteners – These are pretty common fasteners that are available in a variety of sizes and are made from
array of materials including steel, stainless steel, brass or plastic depending on the application of the fastener. These
are temporary fasteners that are manufactured in the Imperial and Metric measurement schemes. Screws have
external threads and nuts have internal threads. The thread can be course or fine, but the actually thread sized is
standardized based upon the screws diameter and the pitch of its threads. It’s important for you to know the names of
these screws as well as their proper application. Caution: Most threaded fasteners use a right-hand thread meaning
the fastener will tighten if it’s turned to the right (clockwise) and loosen if it’s turned to the left (counter clockwise). The
old axiom is, “Righty Tighty… Lefty Loosey.” Over tightening any fastener can strip its treads. Some specification
require fasteners be tightened to a specific torque. In addition, using the wrong tool or the wrong size tool can damage
the head of the fastener making it difficult to install or remove.
Robotics Engineering – DoDEA Career and Technical Education
Identifying Elements of Material and Structural Design – Materials
Revised 16 March 2016
Socket Cap Screw
Cap Screw (Hex)
Machine Screw
Set Screws
The Socket Cap Screw typically
features a Hex or Torx head
socket allowing for a greater
transfer
of
power
during
tightening. This type of fastener
is also tamper resistant.
The common Hex Cap Screw
features a hexagonal head that
can be gripped with either a boxend, open-end, adjustable, or
socket
wrench.
Add
the
corresponding
nut
and
it
becomes the common bolt.
Machine Screws are available in
flat, pan, oval, round and button
head varieties using either
slotted
or
Phillips
driving
systems. They are the most
common type of screw used in
manufacturing coming in a vast
array of sizes. Some even come
complete with a built in lock
washer.
Tapping Screw
Wood Screw
Hex Standoff
Set Screws do not have a head.
They’re used in situations where
a head would interfere with the
product’s function. The top of
setscrew has a hexagonal socket
that fits an Allen Wrench or Hex
Key. The other end typically
comes to a dimpled point and
usually tightens so the point
drives into a recess or keyway.
Hex Nut
Is it called a bolt or is it a screw? It’s not a settled
argument, but essentially a screw becomes a bolt when it’s
used with a matching nut. Why? It’s due to U.S. trade and
tariff laws. It’s actually cheaper to import and export bolts
when they’re called screws.
Drive Styles
Phillips
Lock Nut
Head Styles
Socket Cap
The Tapping Screw is sometimes
called a sheet metal screw and has
sharp threads for cutting into the
material it’s securing. The threads
run completely up to the head of the
screw.
Wood Screws can have pan, flat,
round or oval heads with either a
slotted or Phillips recess for driving
the screw. The shaft of the screw is
partially threaded so the fastener
can draw the materials closer
together when the screw is
tightened. They’re not just for wood.
Hex Standoffs are a nifty little
invention that allows the designer
setup a platform that’s stood-off
from another surface. They’re
frequently used with printed circuit
boards (PCB) to keep the PCB
solder joints on the bottom of the
board safely away from a metal
chassis or case. They can be made
of insulating plastic (Nylon) or
conductive metal.
The Hex Nut is the female
counterpart to the screw or more
accurately, the bolt. It has internal
threads that match the diameter and
threads per inch (TPI) of the mated
screw. Nuts must be started at a
right angle to the screw otherwise
they’ll cross-thread
and bind
damaging both the nut and screw.
Some hex nuts include built-in lock
washers.
Locknuts are used to secure the
nut on to the bolt to keep it from
coming loose. The cap of the nut is
constricted requiring more torque to
tighten and loosen the nut. Some
locknuts are split while others use a
plastic insert to secure the nut in
place.
Tip Styles
Round
Cup
Slotted
Pan
Low Profile
Cone
Hex
Flat (Countersunk)
Hex
Flat
Torx
Oval
Note: It’s always best to turn the nut while holding the screw
instead of the other way around. The nut requires less torque to
tighten than the screw giving more accurate torque readings.
Robotics Engineering – DoDEA Career and Technical Education
Identifying Elements of Material and Structural Design – Materials
Revised 16 March 2016
Unthreaded Fasteners are permanent fasteners that require special tools for installation. Actually, these types of
fasteners can be removed but they often require cutting or drilling to do so. Unthreaded fasteners work by shortening
and deforming one end of the fastener to cinch the materials together. Although they require effort to install and
remove their degree of permanence and low cost may be most desirable for specific applications. Aircraft
manufactures prefer rivets over threaded fasteners because they are permanent, low cost, light weight, easy to inspect
and install.
Blind Rivet
Blind Rivet Nut
Blind Rivet Gun
Blind Rivets The term “Blind” means
that one end of the rivet is not
accessible during installation. To
install a Blind Rivet, a hole is first
drilled through the materials being
fastened. The rivet is inserted into the
hole and the Rivet Gun onto the
shank of the blind rivet. As the
handles of the rivet gun are
squeezed, the shank of the blind rivet
is drawn up through the rivet body as
its mandrel head deforms the rivet
body and draws the materials closer
together. After a prescribed force is
applied to the rivet gun, the shank of
the blind rivet will break at the break
notch and eject the remaining shank
making the popping sound. The Rivet
Nut can be installed just like a blind
rivet, but this device leaves behind a
threaded hole that accommodates a
machine screw. It’s a very cool way to
add a nut to a fastener point. To
remove blind rivets, you simply drill
off the head and punch the rivet out
with a drift punch and hammer.
Domed Head
Solid Rivet
Flat Head Solid
Rivet
Solid
Rivets
work
like
any
unthreaded fastener. It has a smooth
shank and a manufactured head.
They can be made from aluminum,
brass, copper or steel and may be
solid
or
hollow
tipped.
The
manufactured head can be either
domed, flat or countersunk, but
regardless of the rivet type or style,
solid rivets require a punch (setter)
and anvil to install them.
The anvil is used to form the tail end
of the rivet. The anvil is rigidly held in
place while the rivet is driven into a
recess on the surface of the anvil.
The shape of the recess determines
the shape of rivet’s tail. The punch is
used to drive the rivet through a hole
in the joined materials and then into
the recess on the anvil. The punch
(Setter) is struck with a hammer to
deform the tail of the rivet and in-turn
bind the materials together.
Flat (Countersunk)
Solid Rivet
Fabric
Snaps
are
installed
essentially the way rivets are set.
There is a male and female part of
the snap assembly and they both
require different punches and anvils
for installation. Otherwise, the mating
parts of the snap will become
deformed and will not be able to snap
Rivet Punch or Setting Tool
Rivet Anvil
Fabric Snap
together.
Application Note: It’s not a good idea to mix materials when using fasteners. Regardless of the type of fastener, all materials
expand and contract with variations in temperatures. If you use a brass nut with a steel bolt the fastener will tighten or loosen with
changes in temperature. Copper and aluminum fasteners can also deteriorate due to electrolysis if they are used with another
metal or alloy.
Miscellaneous Fasteners include hardware and other devices that are either used as or used with other fasteners.
There are nearly as many types of fasteners than there are things to fasten and more are being invented every day.
The purpose of this exercise is to expose you to the fasteners and fastening methods predominately used in robotics
engineering and technology.
Washer
Standard Washers are most often
used with screws or bolts. They are
designed to protect the materials that
are being fastened together by
distributing the crushing force of the
screw-head or nut. They also provide
a slipping surface for spinning
fasteners so they don’t damage the
joined material as they twist and
tighten.
Split Lock Washer
External Tooth Lock
Washer
Internal Tooth Lock
Washer
Robotics Engineering – DoDEA Career and Technical Education
Identifying Elements of Material and Structural Design – Materials
Revised 16 March 2016
Lock Washers are used to make it
more difficult for the nut or screw to
work its way loose through vibration
or stress. The lock washer creates
friction that works to keep the
fastener stationary. There are many
different types of lock washers and
they’re made of the same materials
that many nuts and screws are made
of.
Shim
Thrust Washer
Cotter Pin
Clevis Pin
Spring Pin
The Shim is more than just a thin
washer. Shims are added or taken
away from an axle to change the
distance between two surfaces while
still allowing them to rotate on the
axel. The height of a room door is a
good example. The door that swung
freely before the room was carpeted
can swing freely again when shims
are added to the door’s hinge to lift
the door.
The Thrust Washer is more than just
a thick washer. It’s designed as part
of a drive system for a wheel or gear
to keep it spinning without wobbling
when it’s under angular stress. The
thrust washer is sandwiched between
a drive gear or hub and the wheel or
gear it’s trying to turn. The trust
washer typically turns with the drive
system.
Cotter Pins are easily replaceable
fasteners that are passed radially
through holes in a wheel hub and
axle to hold the wheel in place. The
end of the pin is split and bent out to
keep the pin from sliding back
through the pin hole. The cotter pin
also acts as a safety device called a
shear pin. If the wheel jams and the
drive continues to turn, the cotter pin
with shear off and protect the drive
from binding.
The Clevis Pin is a smooth pin that’s
passed through holes in joining
materials or assemblies to make a
temporary joint. The clip on the end of
the pin keeps the clevis pin from
falling out of the hole. Pull the clip
and then the pin and the assembly
can be quickly disconnected.
Spring Pins are a more permanent
and low profile adaptation of the
cotter pin. It’s installed the same way
with matching holes in the wheel (or
gear) hub and axle except the
diameter of the pin is somewhat
larger than the hole in the hub and
axle. The spring pin is driven through
the holes with a hammer and drift
punch. It’s held in place by the
friction of the expanding pin. The
head and tail of the spring pin does
not extend beyond the outer diameter
of the wheel hub hence… low profile.
External Retaining
Ring
Internal Retaining
Ring
E-Ring
External / Internal
Ring Pliers
Push Nut
Adhesive Tape
Robotics Engineering – DoDEA Career and Technical Education
Identifying Elements of Material and Structural Design – Materials
Revised 16 March 2016
Retaining rings are used to secure
wheels and bearings to shafts or in
bores. Special tools called (oddly
enough) retaining ring pliers are used
to expand or compress retaining rings
for self-lock installation into groves
carved onto shafts or in bores or
housings.
There are three basic types of
retaining
rings.
The
External
Retaining Ring is spread apart,
slipped over a shaft or axle and then
locked into a grove on the shaft. ERings are shaped like the letter “E”
and are also external retaining rings.
They’re pushed onto shafts or axles
and self-lock into grooves carved
onto the shaft. Internal Retaining
Rings are compressed and inserted
into a bore (hole) or housing and
locked into place as it’s released to
expand into a groove.
E-Ring Installation Tool
Push Nuts are designed for specific
diameter shafts or axles. They’re
made of hardened spring steel and
are pressed onto the ends of axles to
keep wheels on the shaft. The teeth
of the push nut bite into the shaft to
keep it in place. You can use a nut
driver and hammer to tap the push
nut into place.
Adhesive Tape comes in a wide
variety of materials, adhesives and
applications. Most adhesive tapes are
named
appropriate
to
their
application. Masking tape is most
often used to mask off areas where
paint should not go. Electrical tape is
used to isolate and insulate electrical
connections. Duct tape is used to
seal the air-duct joints used in heating
and
air-conditioning
systems.
Whether it’s packaging, carpet, antiseizing, or sealing tape there is a
tape for nearly every fastening
requirement.
The Quick-Release Pin works
precisely like a clevis pin except there
is no clip to keep it in place. Instead
there is a spring loaded ball bearing
at the end of the pin. When the pin is
pushed into its hole, the ball bearing
locks into a groove holding it
temporarily in place. A good pull on
the ring pulls the ball bearing out of
the groove and the pin pulls easily out
of the hole.
Quick-Release Pin
Machine Key
The Cable Tie or Zip Tie was
invented
as
a
low-cost
and
disposable method to organize and
bind cables. They’ve become a
simple way to bind nearly anything
together and come in many sizes and
colors. Cable ties have a one-way
locking mechanism that prevents the
tie from loosening. They are simply
cut-off to remove them. Never use a
cable tie on a body. Since they can
only tighten, they have caused
serious injuries
Cable Tie
Machine Keys are used to transfer
torque between a shaft and a wheel
hub or gear. The key locks the wheel
hub to the shaft and is sometimes
held in place with a set screw.
Machine keys are inserted into a
lateral notch in the hub and shaft
called a key-way. If the machine key
is not installed or falls out, the wheel
would simple free-wheel. They come
in standard sizes and lengths and are
made of hardened steel.
Hook and Loop
Hook and Loop fasteners are
sometimes known by the trademark
name, Velcro. Lots of companies now
manufacture
Hook
and
Loop
fasteners providing the material in
various sizes, shapes, colors and
strengths. It comes in self-adhesive
and sewn applications. One side of
the fastener is covered with rows and
columns of tiny, stiff, plastic hooks.
The other side is covered with fabric
loops. The sides interlock when
pressed together but can be pulled
apart with some effort.
Adhesives – Glues have been around for thousands of years. Initially, adhesives were sticky biomaterials like
beeswax, tree sap, and tar, as well as animal hides and bones. As technology and materials manufacturing evolved,
other adhesives were created to meet the emerging needs of industry. From beeswax to superglue, adhesives are
fastening methods that are vitally important to the manufacturing process.
Glues have two properties; How well it sticks to materials (adhesion) and how well it sticks to itself (cohesion). When a
glue bond breaks at the surface of the material, it’s due to a failure in adhesion. When the bond breaks in the glue
itself, it’s due to a failure in cohesion. There are two prominent explanations describing how glue works. The Van der
Waals Forces describes how molecules in the adhesive align observing polarity to create a strong molecular bond
while Mechanical Bonding describes how glue fills even the tiniest nooks and crannies in the material to get a better
grip on the materials surface.
It’s important to note that some adhesives work better with specific materials. Matching the type of adhesive to a
particular material is an important consideration. However, the key to a successful adhesion and cohesion is the same
regardless of type of adhesive being used. Remove any interference to the Van der Waals Forces or Mechanical
Bonding affect. Note: The following images do not represent an endorsement for a specific product or brand name.



Material surfaces need to be clean before adhesive is applied.
Adhesives need to be used under the conditions prescribed by the manufacturer (Material, Temperature and Humidity).
The glue joint can’t be moved until the adhesive has fully cured.
Robotics Engineering – DoDEA Career and Technical Education
Identifying Elements of Material and Structural Design – Materials
Revised 16 March 2016
Thread-lock
Thread-lock is designed for the locking and sealing of threaded fasteners which require normal
disassembly with standard hand tools. The product cures with or without air. It prevents loosening from
shock and vibration. Thread-lock comes in a variety of colors indicating its strength and durability. Blue
is particularly suited for applications where disassembly is required for servicing. Red thread-lock
requires heat to disassemble the fasteners. Don’t have thread-lock, nail polish will work in a pinch.
Feature
Protects threads
Medium strength
Locks threads
Benefit
Prevents rusting of threads
Can be removed with hand tools
Prevents loosening of metal fasteners caused by vibrations
Safety Precautions: Keep out of reach of children.
Preparation:
Protect work area. Parts to be sealed must be clean and dry. Shake the product thoroughly before
use.
Note: To prevent the product from clogging in the nozzle, avoid touching the bottle tip to the metal
surface.
Application:
For Thru Holes - Apply several drops of the product onto the bolt at the nut engagement area.
For Blind Holes - Apply several drops of the product down the internal threads to the bottom of the
hole.
For Sealing Applications - Apply a 360° bead of product to the leading threads of the male fitting,
leaving the first thread free. Force the material into the threads to thoroughly fill the voids. For bigger
threads and voids, adjust product amount accordingly and apply a 360° bead of product on the female
threads also. Assemble parts and tighten as required. Sets in approximately 10 minutes and fully
cures in 24 hours.
For disassembly, shear with standard hand tools and remove with methylene chloride. In rare
instances where hand tools do not work because of excessive engagement length, apply localized
heat to nut or bolt to approximately 482°F (250°C). Disassemble while hot.
Cleanup:
Clean adhesive residue immediately with a damp cloth. Cured product can be removed with a
combination of soaking in methylene chloride and mechanical abrasion such as a wire brush.
Contact Cement
Contact Cement is a versatile high-performance adhesive sealant formulated for all-purpose projects
and repairs. This semi-flexible crystal-clear adhesive is designed to address the daily needs of the
homeowner, both indoor and outdoor.
Feature
All-purpose adhesive
Dries crystal clear
Thick gel-like consistency
Waterproof
Benefit
Great for everyday projects and repairs
Eliminates obvious bond lines achieving invisible repairs
Will not run or drip; Reduces clean-up
Forms a tight, waterproof, weatherproof bond for a superior seal;
Great for plumbing repairs
Dries to a semi-flexible bond Ideal for bonding flexible materials such as fabric or leather
Gap filling
Will fill and seal uneven surfaces
Safety Precautions: Wear gloves. Wash hands after use. For interior applications, use in a well ventilated area.
Preparation:
Protect work area. Surfaces to be sealed or bonded must be clean and free from grease. For improved
adhesion, roughen very smooth surfaces. Pre-fit all materials before applying product.
Application:
As an adhesive - Apply adhesive to both surfaces to be bonded. Wait for 5 minutes until adhesive is
tacky and then press surfaces together. Clamp if necessary. Sets in approximately 10 minutes and
dries in 24 hours. Dry time is dependent upon temperature, humidity and amount of adhesive used.
As a sealant - Apply a layer 1/4' (6 mm) thick bead over the area to be sealed. Tool if desired. Let dry
for 24 hours. If necessary apply a second coat.
Cleanup:
Clean tools and uncured product residue immediately with mineral spirits or acetone. Cured product
may be carefully cut away with a sharp-edged tool.
Spray Adhesive
Spray Adhesive is an aerosol version of Contact Cement. It dries clear and has strong adhesive and
cohesive characteristics. It dries quickly and is ideal for a wide range of projects including photo and
art mounting. Spray Adhesive will work on a variety of porous and nonporous substrates. It is
recommended for bonding paper, wood, metal, acrylic, foam, fabric, polyethylene and polypropylene,
PVC, cardboard, leather, felt, carpet, corkboard, glass, foil rubber and most plastics. Certain plastics
Robotics Engineering – DoDEA Career and Technical Education
Identifying Elements of Material and Structural Design – Materials
Revised 16 March 2016
and elastomeric substrates can exhibit bond failure due to plasticizer migration. High humidity and
high temperature can also promote bond failure.
Feature
Benefit
Repositionable or permanent bonding
Variety of applications
Dries clear and will not yellow with age Invisible bond
Can apply multiple coats
Increases bond strength
Does not bubble
No reworking
Acid Free
Will not damage photographs
Cleanup:
Safety Precautions:
Apply in a well-ventilated area, wash hands after use.
Preparation:
Apply adhesive between 65°F (18°C) and 95°F (35°C). Shake can well before using.
Surfaces must be clean, dry and free of foreign materials. Protect finished surfaces. Pre-fit all
materials. Testing of substrates for compatibility is recommended. Turn spray tip so that the black dot
is aligned with the nozzle.
Application:
Hold can in a vertical position. Point valve towards surface and spray from a distance of
8' to 10' (20 to 25 cm). Keep the can moving to create an even coat and avoid build-up on the surface.
Start and stop the spray just off the work to prevent runs and sags. For repositionable/temporary
bonds: Apply a very light even coat to one surface. After 15 seconds, join with light pressure only.
For a permanent bond: Apply a medium coat to one surface. Allow to dry to tack and join.
For stronger permanent bonds: Apply a medium coat to both surfaces. Allow to dry to tack (1 to 10
minutes). Porous surfaces will require more than one coat.
After use, invert spray can and spray for approximately 2 seconds (or until spray is free of adhesive) to
clear valve and spray tip. Clean spray tip with turpentine or mineral spirits. Note: When using solvents
for cleanup, use proper precautionary measure.
Rubber Cement
Rubber cement is a latex polymer combined with a solvent like acetone. It’s well suited for applications
that prefer relatively weak adhesion and cohesion. It’s predominantly used in graphic arts for
positioning and repositioning paper flatwork. Rubber cement is inexpensive and easy to use. Excess
glue or drips can be easily peeled away leaving no sign of the adhesive.
Feature
Application Brush In Cap
Repositionable or permanent bonding
Can apply multiple coats
Benefit
No additional tools required for use
Variety of applications
Increases bond strength
Safety Precautions: Apply in a well-ventilated area. Do not use near an open flame. Some rubber cement uses benzene, a
cancer causing agent.
Preparation:
Protect work area. Surfaces to be bonded must be clean and free from grease. For improved
adhesion, roughen very smooth surfaces. Pre-fit all materials before applying product. Use the
applicator brush to apply the adhesive.
Application:
Apply adhesive to one surface for a repositionable bond and on both surfaces for a more permanent
bond. Wait for 1 or 2 minutes until adhesive is tacky and then press surfaces together. Sets in
approximately 10 minutes and dries in 2 hours. Dry time is dependent upon temperature, humidity and
amount of adhesive used.
Cleanup:
Excess glue and drips can be peeled away.
Glue Stick
The glue stick is a solid Polyvidone adhesive that is delivered in a twist up or push-up applicator. The
Polyvidone adhesive has high adhesion and moderate cohesion affect well suited for paper and paper
products. The glue can be applied smoothly and evenly, and allows sufficient time to reposition the
object. The applicator helps keep fingers clean. An airtight cap+tube-system, the glue stick keeps
fresh and can be used for several years.
Feature
Twist-up or push-up applicator
Repositionable or permanent bonding
Non-toxic adhesive
Benefit
Clean and hands-off application
Variety of applications
Well suited for school and office use
Safety Precautions: Wash skin with soap and water.
Preparation:
Surfaces to be bonded must be clean and free from grease.
Application:
Apply adhesive to one surface for a repositionable bond and on both surfaces for a more permanent
bond. The adhesive sets in approximately 10 minutes and dries in 2 hours. Dry time is dependent
Robotics Engineering – DoDEA Career and Technical Education
Identifying Elements of Material and Structural Design – Materials
Revised 16 March 2016
Cleanup:
upon temperature, humidity and amount of adhesive used.
Excess adhesive on work surfaces or clothing can be cleaned up with soap and water.
Super Glue (Cyanoacrylates)
Cyanoacrylates can bond just about any plastic, metal and wood project. Because it bonds in seconds
it is well suited for impatient craftsmen that would normally have to use clamps. Super Glue is not
recommended for use on cloth, Styrofoam, vinyl or CLEAR PLASTIC parts. Super Glue can ignite
cotton, dissolve Styrofoam, and fog clear plastic. Super Glue bonds instantly to skin. Super Glue has
a similar molecular structure of the same adhesive that mussels use to cling to rocks in the ocean.
Scientists synthesized the natural protein and learned how to mass produce it for commercial use. Its
first uses were in medicine as a skin and organ adhesive for field surgery during the Vietnam conflict.
It had great tensile strength but can be easily twisted or sheared to break the bond. Baking soda can
be added to it to make it a filler.
Feature
Gel formulation
Dries transparent
Sets in seconds
Benefit
No mess, no drip formula; Ideal for vertical applications
Invisible repairs
No clamping required
Safety Precautions: Wear gloves (non cotton). Protect work area.
Preparation
Surfaces to be bonded must be close fitting, clean, dry and free from oil, wax and paint. For best
results, lightly roughen smooth surfaces. Pre-fit parts to be joined as you won’t have much time to set
them.
Application:
Puncture the nozzle and squeeze the bottle to dispense the adhesive. Only one drop of adhesive per
square inch of surface is required. Excess glue may take much longer to dry. Press surfaces together
immediately and hold for 60 seconds. Do not attempt to reposition the parts. Immediately after use,
clean tip with tissue and replace cap. For increased strength, leave the parts undisturbed for at least
10 minutes. Full cure in 24 hours. Note: Cure time is dependent upon temperature, humidity, porosity
of surfaces and amount of adhesive applied.
Cleanup:
Cured adhesive may be cut away with caution using a sharp blade, removed with mineral spirits or
with boiling water.
Epoxy and Epoxy Putty (5 Minute)
Epoxy and Epoxy Putty is a two-part adhesive consisting of an epoxy resin and a
hardener. When mixed in equal amounts resin and hardener react to produce a
tough, rigid, high strength bond, which starts to set in 5 minutes and reaches
handling strength in 1 hour. The resin and harder must be uniformly mixed for proper
bonding. It’s a great adhesive for a wide range of materials or for a versatile filler
(Putty), gap bonding, surface repairs and laminating. Epoxy does not shrink during
hardening and is resistant to water and most common solvents. It can be tinted with
earth pigments, cement or sand for color matching and can be sanded and drilled.
Feature
Benefit
Can be drilled
Will not crack when drilled
Can be tinted
Matches surrounding materials
Water resistant
Can be used outdoors
Does not shrink
One-time application
Sets in 5 minutes Quick completion of project
Safety Precautions: Mix and use in a well-ventilated area using gloves.
Preparation:
Protect work area. Surfaces must be clean, dry and free from oil, wax and paint. For better adhesion,
roughen smooth surfaces prior to cleaning. Pre-fit parts to be joined.
Application:
Dispense equal amounts of hardener and resin directly onto surface to be filled or bonded. Putty can
be cut into equal amounts and kneaded together to mix. Place objects together within 4 minutes of
adhesive application. Bond sets in 5 to 7 minutes at 68°F (20°C) to 77°F (25°C). For best results in
butt joints, apply adhesive as a reinforcing fillet or splint over the joint for additional support. Remove
any excess adhesive immediately with mineral spirits. Usable strength is obtained within 1 hour.
Warmer temperatures will shorten the set time and cooler temperatures will lengthen it.
Cleanup:
Clean excess glue immediately with mineral spirits or acetone. Cured adhesive may be cut away with
caution using a sharp blade. Prolonged immersion in paint stripper will soften the cured adhesive to
aid removal.
Acrylic Solvent Cement
Robotics Engineering – DoDEA Career and Technical Education
Identifying Elements of Material and Structural Design – Materials
Revised 16 March 2016
Use on Polystyrene and ABS plastic. Bonds plastic by dissolving and cementing. Precision plastic
needle, dropper, and brush applicator makes easy work of gluing even small intricate detailed parts.
Application can be drawn into seams through capillary action to make and clean and neat bond.
Feature
Clean and seamless adhesive method
Low viscosity
Nearly instant and strong bond
Benefit
Smoother and more complete bonding
Small amounts provide for strong bonds
Quick and clean assembly
Safety Precautions:
Keep out of the reach of children. Keep away from heat, spark, open flame
and other sources of ignition. Contact with hot surfaces may produce toxic effects. Keep container
closed when not in use. Store in the shade below 80ºF. Use only in adequate ventilation. Avoid
breathing of vapors.
Preparation:
Application:
Cleanup:
Preassemble parts without cement to insure proper fit. Trim or file where necessary so parts meet
without a gap. When cementing painted or plated parts, scrape away paint or plating from surfaces to
be joined.
Apply cement sparingly with a syringe, dropper or brush to one surface and press firmly together.
Avoid cement of finger tips, as glue smudged on areas not to be joined cannot be removed. It will also
discolor or “cloud up” clear parts. Do not use on clear parts.
Wipe solvent from work surface. Allow extra adhesive on bonded materials to cure. Do not wipe
excess.
Model Cement
Cement for plastic models is specially formulated polystyrene cement for joining all
polystyrene and ABS plastics. Cement for wood models is better choice for wood
models. Cement for models can be used in the construction of model kits and may
also repair many common household products.
Feature
Strong adhesion and cohesion
Polystyrene solvent
Benefit
Strong bonding
Welds plastics together
Safety Precautions: Keep out of the reach of children. Keep away from heat, spark, open flame and other sources of
ignition. Contact with hot surfaces may produce toxic effects. Keep container closed when not in use.
Store in the shade below 80ºF. Use only in adequate ventilation. Avoid breathing of vapors.
Preparation:
Preassemble parts without cement to insure proper fit. Trim or file where necessary to insure a gap
free interface.
Application:
Use solvent cements sparingly. Too much glue will dissolve plastic. When cementing painted or plated
parts, scrape away paint or plating from surfaces to be joined. Apply cement sparingly to one surface
and press firmly together. Avoid cement of finger tips, as glue smudged on areas not to be joined
cannot be removed. It will also discolor or “cloud up” clear parts. Do not use on clear parts.
Cleanup:
Cement can be cleaned from work surfaces with acetone or mineral spirits.
White / Wood Glue
Today’s white glue is primarily made from polyvinyl acetate latex (PVA), water and some “Elmer”.
Wood glues are made using a slightly altered formula called Aliphatic Resin. When the water in the
adhesive evaporates, the bond is made. White glue is sometimes called “Craft Glue” and is well
suited for crafts (Duh) while wood glue is primarily used in carpentry. These adhesives are
recommended for use on porous materials -- wood, cardboard, cloth, porous pottery, and wood-towood bonds. It is not water resistant. Because of wrinkling, it is not suitable for bonding light weight
paper. Do not allow these adhesives to freeze. Store them in a tightly closed container in a cool and
dry place.
Feature
Non-Toxic
Easy Cleanup
Benefit
Safe for children to use
Use water for cleanup
Robotics Engineering – DoDEA Career and Technical Education
Identifying Elements of Material and Structural Design – Materials
Revised 16 March 2016
Good construction adhesive
Good adhesion
Resists solvents, heat and moisture
Works well on porous materials
Precautions:
Some types of wood glue contain formaldehyde. Don’t use them if
possible. Work in a well ventilated area and avoid getting the glue on your skin.
Wash away with soap and water.
Preparation:
Use above 40°F (4°C). Surfaces must be clean, dry and free of frost,
grease, dust and other contaminants.
Application:
Apply the adhesive evenly to both surfaces to make a more secure
bond. Clamping is required for 30 minutes to 1 hour to set the glue; curing time is
18 to 24 hours. PVA glue dries clear.
Cleanup:
Cleanup with soap and water.
Construction Adhesive
Polyurethane construction adhesive is a one component, polyurethane based, moisture-curing
adhesive. It can be used for interior or exterior projects and is also waterproof, paintable and cures in
cold or warm temperatures. It is a strong adhesive and is ideal for wide range of construction projects
including sub floor installations.
Feature
Waterproof
Low odor
Strong and versatile
High strength
Broad Service Temperature
Benefit
Great for interior or exterior applications
No strong solvent odor; Great for interior use
Permanently bonds together almost any substrate
Stronger than many substrates it joins together.
Suitable for use in hot and cold environments
Safety Precautions: Wear gloves. Cured adhesive on bare skin will not come off immediately with washing and will cause
skin to darken. Cured adhesive and discoloration will come off in about 3 days.
Preparation:
Use above 40°F (4°C). Surfaces must be clean, dry and free of frost, grease, dust and other
contaminants. Pre-fit all materials and protect finished surfaces. If using cartridge format, cut nozzle at
a 45° angle to desired bead size and puncture inner seal. Be very careful not to allow construction
adhesive to cure on a finished (painted) surface.
Application:
Apply adhesive to one surface of the material being bonded. Press the surfaces firmly together.
Materials may be repositioned within 45 minutes after applying the adhesive. If bonding two nonporous surfaces (such as foam, metal and fiberglass), add water in the form of a very light or atomized
spray from a plant mister bottle to the extruded adhesive. The repositioning time will then be reduced
to less than 30 minutes. Use mechanical support or clamps for 24 hours while the adhesive cures.
Cleanup:
Clean tools and uncured adhesive residue immediately with mineral spirits in a well-ventilated area.
Remove cured adhesive by carefully scraping with a sharp-edged tool.
Silicone
Silicone is a multipurpose adhesive and sealant which creates a waterproof, protective seal that is
ideal for metal, glass, rubber, tile and porcelain. It is designed to be used indoors and outdoors to
repair everything from electrical connections to seams on boots to stop leaks in wet weather. Silicone
can be used to bond or repair saltwater or freshwater aquariums.
Feature
Extreme temperature resistance
Waterproof
No cracking, peeling or shrinking
Gap filling
Flexible bonds
Benefit
All-season use
Indoor and outdoor use
One-time application
Excellent for imperfect surfaces
Impact resistant and flexes with materials
Safety Precautions: Wear gloves. Respiratory, skin and eye irritation possible.
Preparation:
Use between -35°F (-37°C) and 140°F (60°C). Protect work area. Surfaces must be clean, dry and
free of old adhesive, grease, dust and other contaminants. Note: Paint will not adhere to silicone. If
desired, paint items prior to gluing. Remove cap. Puncture inner seal with other side of cap. Attach
nozzle and cut to desired bead size.
Application:
As an adhesive: Apply to one of the surfaces to be bonded. When bonding rubber or plastic surfaces,
lightly roughen surface for best results. Press materials together. If possible, clamp parts together for
full cure time of 24 hours. As a sealant: Apply with a steady pressure, forcing sealant into the joint.
Robotics Engineering – DoDEA Career and Technical Education
Identifying Elements of Material and Structural Design – Materials
Revised 16 March 2016
Tool within 5 minutes. Do not use in joints deeper than 12 mm (1/2") without the use of a backer rod.
Use in joints between 1/4" and 3/4" wide. For aquariums: Apply a 1/4" bead to the edge of glass,
covering the thickness of the glass edge. Set glass on base and repeat procedure for all sides. All
joints must be glass to sealant to glass with no entrapped air bubbles. Apply additional sealant to
inside joints. Do not use in aquariums larger than 30 gallons (114 L) and/or aquariums containing
water greater than 18" (46 cm) in height.
Clean tools and adhesive residue immediately with mineral spirits. Cured sealant may be carefully cut
away with a sharp-edged tool. There is no solvent for silicone.
Cleanup:
Hot-Melt Adhesive (Hot Glue)
Hot glue is a thermoplastic adhesive typically provided in solid cylinders which are commonly referred to
as glue sticks. Glue sticks come a few diameters and lengths designed to fit a specific type of hot glue
gun or pistol. The glue gun houses a heating element that heats the glue stick to a liquid while a trigger
mechanically advances the glue stick through the heater and out the nozzle of the gun. The temperature
required to prepare the glue depends on the makeup of the polymers in the glue stick. Adhesion also
varies depending on the materials being bonded. Cohesion can be strong, but some brands and types of
hot-melt adhesives are brittle in certain applications. Glue guns and adhesive come in low-temperature
and high-temperature varieties. Low temperature glue guns operate at 250°F (121°C) while hightemperature versions operate at 380°F (193°C).
Feature
Heat from hot air gun softens glue
Quick hardening
Insulator
Benefit
Disassembly and reassembly possible
Fast assembly
Safe for electrical stress relief
Safety Precautions: The temperature of a hot glue gun and the glue out of the nozzle is hot enough to cause serious
burns. Use leather gloves to protect hands and never touch the glue unless it has cooled. Do not leave
the hot glue gun plugged in for a prolonged period of time. Don’t use any electrical device with a
damaged power cord. Keep glue guns out of reach of children.
Preparation:
Protect work area. Surfaces must be clean, dry and free of grease, dust and other contaminants.
Application:
Insert a glue stick and plugin the hot glue gun allowing it to heat-up for about five minutes. Place the
glue gun on a non-combustible surface while plugged in. Place something under the nozzle to catch
the oozing adhesive. Place the nozzle on the surface being bonded and squeeze the trigger for the
desired amount of glue. Quickly press the materials together to make the bond.
Cleanup:
Hot glue can be removed with scraping. Heat from a hot air gun can make the job easier.
Research Resources: The www changes all the time. If you find a dead link, please report it to your instructor but
you should also use a search engine to find the information in another site.
Institution
Web Site
Description
Industrial Press
Gesipa USA Fasteners
YouTube
Valley Fastener Group
Mlevel3.com
YouTube
HowStuffWorks.com
Grainger
McMaster
http://buku-ku.com/machinerys-handbook-27th-edition/
http://www.gesipausa.com/blind_rivets_basics.html
http://www.youtube.com/watch?feature=player_detailpage&v=9aoX
mzdSf_I
http://www.valleyfastener.com/solid-rivets.html
http://www.youtube.com/watch?v=1hB3rIECtxM&feature=player_det
ailpage
http://www.youtube.com/watch?v=wvL0AC37NOw&feature=player_d
etailpage
http://home.howstuffworks.com/plastic-glues.htm
http://www.grainger.com
http://www.mcmaster.com
Machinery’s Handbook – Hardware Specifications
Online lesson on how blind rivets work.
Video - How Do Blind Rivets Work?
Online lesson on how solid rivets work.
Aircraft riveting video lesson
Glues for Plastic Models Parts 1 and 2 – Videos
describe how to properly use modeling adhesives.
Online tutorial regarding plastic glues and cements
Industrial supplier of hardware, tools & materials
Industrial supplier of hardware, tools & materials
Nomenclature: Research and develop a detailed (two to three sentences) definition for each of these terms. It’s
important to realize that many words have multiple definitions. Some of which may have nothing to do with this course
of study. Make sure your definitions fall within the context of this lesson.
 Screw
 Nut
 Retaining Ring
 Rivet
 Bolt
 Punch
 Lock Washer
 Pin
 Keyway
 Adhesion
 Cohesion
 Cyanoacrylates
 Polyvinyl Acetate
 Bead (of glue)
Robotics Engineering – DoDEA Career and Technical Education
Identifying Elements of Material and Structural Design – Materials
Revised 16 March 2016
Questions:
1. Research and develop a detailed definition for each of the terms found in the Nomenclature section of this
document. Many words have multiple definitions. Some of which may have nothing to do with the field of Robotics
Engineering. Make sure your definition falls within the context of this lesson.
2. Name three examples of threaded and non-threaded fasteners. Include images in your answer.
3. What’s the difference between a bolt and a screw?
4. Match the following action and bicycling activity with the appropriate terminology to describe the type of stress:
Action
Pulling or Stretching
Twisting or Turning
Squeezing or Pressing
Sliding or Cleaving
Activity
Cranking Peddle
Sitting on Seat
Rolling Tires
Using Hand Brake
Stress
Shearing
Tensile
Compressive
Torsion
5. Examine the inventory card that’s found in the cover of the Tetrix Robotics Parts Kit. Create a table listing the
correct names and quantities of the fasteners included with the kit. Include an image from this lesson identifying
the fastener into the table you created.
6. Describe three methods or fasteners used to keep a nut from vibrating loose.
7. Describe three methods or fasteners used to keep a wheel on the end of a shaft or axle.
8. Generally speaking… What three conditions must be met to insure the best possible adhesive bond?
9. Indentify three adhesives that are best suited to bonding a paper poster to a cardboard placard.
10. Describe the difference between adhesion and cohesion.
11. How do solvent and plastic cements work differently than adhesives?
12. What is the origin of Super Glue?
13. What types of adhesive are not appropriate for bonding clear plastic?
14. How do you remove silicone from a work surface or joint?
15. What type of adhesive will most rapidly lose cohesion when exposed to hot sunlight?
Conclusion:
Assembly is one of the final stages of the secondary manufacturing process. Complex manufactured products are
typically comprised of lots of individual components or parts that must be fastened together to build the final product.
Wheels and gears may need to be bolted or pinned onto shafts while electronic circuits may need to be soldered
together. Ultimately, covers and cases may have to be glued in place or perhaps they simply snap together to make
the final product safe and presentable for sale. Whether it’s bolting, screwing, pegging, pinning, gluing, soldering, or
welding knowing the proper fastener or fastening method can make component assembly safer for you and provide a
quality product to the customer.
Robotics Engineering – DoDEA Career and Technical Education
Identifying Elements of Material and Structural Design – Materials
Revised 16 March 2016