879088-000 - TE Connectivity Aerospace, Defense and Marine

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Tyco Electronics Corporation

300 Constitution Drive

Menlo Park, CA 94025 USA

Specification

This Issue:

Date:

Replaces:

RT-1255

Issue 3

June 1, 2000

Issue 2

THERMOFIT® ADHESIVE S-1255-02

Fluid Resistant, High Temperature, One Part-Epoxy

1.0

SCOPE

This specification covers the requirements for one type of adhesive for use with heat-

recoverable, plastic and elastomeric tubing and molded components. When used as

specified with other compatible components, this adhesive is suitable for use in fluid

resistant, high temperature harness systems as described herein. The adhesive is suitable

for use in wire harness systems requiring resistance to the effects of nuclear, biological

and chemical agent exposure and decontamination as defined herein and in RT

-700.

APPLICABLE DOCUMENTS

This specification takes precedence over documents referenced herein. Unless otherwise

specified, the latest issue of referenced documents applies. The following documents

form a part of this specification to the extent specified herein.

2.1 GOVERNMENT-FURNISHED DOCUMENTS

Military

MIL-L-2104 Lubricating Oil, Internal Combustion Engine, Heavy Duty

MIL-H-5606 Hydraulic Fluid, Petroleum Base, Aircraft, Missile and Ordnance

MIL-T-5624 Turbine Fuel, Aviation, Grades JP-4 and JP-5

MIL-L-7808 Lubricating Oil, Aircraft Turbine Engine, Synthetic Base

MIL-A-8243 Anti-Icing and Deicing - Defrosting Fluids

MIL-C-43616 Cleaning Compounds, Aircraft Surface

Federal

O-S-1926 Sodium Chloride, Technical

VV-F-800 Fuel Oil, Diesel, Grade DF-2

SPECIFICATION RT-1255, ISSUE 3

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Page 2

2.2 OTHER PUBLICATIONS

American Society for Testing and Materials (ASTM)

ASTM D 149 Standard Test Method for Dielectric Breakdown Voltage and

Dielectric Strength of Electrical Insulating Materials at Commercial

Power Frequencies

ASTM D 257 Standard Test Methods for D-C Resistance or Conductance of

Insulating Material

ASTM D 570 Standard Test Method for Water Absorption of Plast

ics

ASTM D 910 Standard Specification for Aviation Gasoline

ASTM D 1002 Standard Test Method for Strength Properties of Adhesives in Shear

by Tension Loading (Metal-to-Metal)

ASTM D 2093 Standard Practice for Preparation of Surfaces of Plastics Prior to

Adhesive

Bonding

ASTM D 2651 Standard Practice for Preparation of Metal Surfaces for Adhesive

Bonding

ASTM G 21 Recommended Practice for Determining Resistance of Synthetic

Polymer Materials to Fungi

(Copies of ASTM Publications may be obtained from the American Society for Testing

and Materials, 1916 Race Street, Philadelphia, Pennsylvania 19103.)

Raychem Corporation

RT-555 Thermofit® 555 Tubing

RT-1330 Thermofit

® Fluoropolymer Molded Components

RT-700 Harness System Chemical Agent Exposure & Decontamination

Specification 55A 55 Wire and Cable

(Copies of the Raychem Corporation specifications cited above may be obtained from the

Literature Department, Raychem Corporation, 300 Constitution Drive, Mail Stop

527/6206, Menlo Park, California 94025-1164.)

3.0 REQUIREMENTS

3.1 MATERIAL

The adhesive shall consist of a one-part modified epoxy resin supplied in tape form, 0.75

inch (13 mm) wide and 0.010 inch (0.25 mm) thick, nominal.

3.2 COLOR

The color as supplied is black.

3.3 PROPERTIES

The adhesive shall meet the requirements

of Table 1.

SPECIFICATION RT-1255 ISSUE 3 Page 3

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3.4 SYSTEMS PERFORMANCE

The performance of harness systems fabricated with this material shall satisfy the

requirements of Systems Specification RT-700.

4.0 QUALITY ASSURANCE

PROVISIONS

4.1 CLASSIFICATION OF TESTS

4.1.1 Qualification Tests

Qualification tests are those performed on adhesive submitted for qualification as a

satisfactory product and shall consist of all tests listed in the specification.

4.1.2 Acceptance Tests

Acceptance tests are those performed on each production lot of adhesive.

Acceptance tests shall consist of the following

Visual inspection

Adhesive shear strength (Stainless Steel to Stainless Steel at 23ºC)

Other tests shall be performed as often as necessary to ensure compliance with all

requirements of this specification.

4.2 SAMPLING INSTRUCTIONS

4.2.1 Qualification Test Samples

Qualification test samples shall consist of not less than 100 ft (30 m) of adhesive

4.2.2 Acceptance Test Samples

Acceptance test samples shall consist of not less than 10 ft (3 m) of adhesive from each

lot. A lot shall consist of all adhesive from the same production run offered for

inspection at the same time

4.3 TEST PROCEDURES

4.3.1 Visual Inspection

Visually examine the test specimens for color, uniformity, and the presence of foreign particles or other

contaminants.

SPECIFICATION RT-1255, ISSUE 3

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Page 4

4.3.2 Adhesive Peel Strength

Adhesive peel strength is determined by a test procedure described in greater detail in

ASTM D 2671 with surface preparation methods based on ASTM D 2093 and ASTM D

2651. In this procedure, an inner and outer

substrate of specified materials are bonded

together and peel strength is determined in a tensile tester

4.3.2.1 Tubing or Molded Component to Stainless Steel

4.3.2.1.1 Substrate Preparation

Abrade the outer surface of an 8-inch (200-mm) length of 1-inch (25-mm) diameter AISI

Type 316 stainless steel pipe with a wire brush or dry sandblast and wipe with a lint-free

cloth or paper towel moistened with isopropanol (IPA).

Select three sections of 1-1/2 inch (38 mm) Thermofit® RT-555 Tubing or three uniform

tubular sections of Thermofit® RT-1330 Molded Components with an expanded internal

diameter approximately 1-1/2 inches (38 mm) and a recovered internal diameter of 3/4

inches

(19 mm) or less. Cut these sections to a width of 1-1/2 inches (39 mm) and prepare the

inner surface by abrading with a Number 320 Emory cloth followed by wiping with a

lint-free cloth or paper towel moistened with isopropanol (IPA).

4.3.2.1.2 Bonding Procedure

Spiral wrap the S-1255 adhesive tape with a 50 percent overlap to produce a double

thickness of adhesive over the inner substrate. Place a 3/4-inch (19-mm) wide piece of

masking tape lengthwise to 1) hold the adhesive in place and 2) provide unbonded ends

from the outer substrate to insert into a tensile tester.

Place the tubing or molded component substrates over the adhesive-coated inner

substrate and rapidly recover with a heat gun in accordance with the applicable

installation instructions. Finally, heat in an air circulating oven at 240 ± 5°C (464 ± 9°F)

for 15 minutes.

SPECIFICATION RT-1255 ISSUE 3 Page 5

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4.3.2.1.3 Tensile Testing

After cooling to ambient temperature, cut each of the three bonded outer substrates

radially into 1-inch (25-mm) wide strips. Then cut each strip axially along the edge of

the masking tape to free an unbonded end for rolling drum peel tensile testing.

Test at a jaw separation speed of 2 inches (50 mm) per minute. Take peel strength

readings at every 1/2-inch (13-mm) of incremental jaw separation after 1-inch (25-mm)

initial separation. Record the average peel strength for each specimen from the first four

readings. Report the average peel strength from five specimens as the sample peel

strength value

Additional detail on specimen geometries, tensile test fixtures and calculations is

contained in ASTM D 2671.

4.3.2.2 Molded Component to Tubing

4.3.2.2.1 Substrate Preparation

Heat recover a 6-inch (150-mm) length of 1-1/2-inch (38-mm) inside diameter

Thermofit® RT-555 Tubing onto a metal tube 1 inch in diameter. This recovery requires

the application of heat in excess of 250ºC (482°F) and can be accomplished with the heat

gun described in section 4.3.2.1.2 or an oven.

Allow the recovered tubing to cool to room temperature and prepare the outer surface as

described in 4.3.2.1.1.

4.3.2.2.2 Bonding Procedure

Follow the bonding procedure described in Section 4.3.2.1.2 recovering the Thermofit®

molded component (RT-1330) onto adhesive-wrapped tubing.

4.3.2.2.3 Tensile Testing

Cool the assembly to room temperature and cut lengthwise along one edge of the

masking tape to remove the bonded assembly from the mandrel. Cut a 1-inch (25-mm)

wide specimen suitable for T-peel testing from the center of each double thickness.

Insert the two unbonded ends in the tensile tester, and perform the remainder of the

procedure as described in Section 4.3.2.1.3.

4.3.3 Adhesive Shear Strength

Adhesive Shear Strength is determined using a procedure based on ASTM D 1002 and a

surface preparation method based on ASTM D 2651.

SPECIFICATION RT-1255, ISSUE 3

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Page 6

4.3.3.1 Specimen Form

The adhesive shear test is performed on assembly specimens formed by bonding two 1 x

5 x 0.050 ± .005 inch (25 x 100 x 1.27± 0.13 mm) AISI Type 316 stainless steel

substrates with a 0.50 to 0.56 inch (12.7 to 14.2 mm) bonded overlap. A minimum of five

assembly specimens are required.

4.3.3.2 Substrate Preparation

Abrade the stainless steel substrates with number 320 emery cloth and wipe with a lint-

free cloth or paper towel moistened with isopropanol (IPA).

4.3.3.3 Bonding Procedure

Make the specimen bonded overlap length 0.50 to 0.56 inch (12.7 to 14.2 mm). Cut the

adhesive tape and position to cover an area approximately 0.25 inch (6 mm) wider than

the specified overlap length.

Cure these assemblies for 15 minutes in an air-circulating oven heated to 240 ± 5ºC (464

± 9ºF) under a pressure of approximately 2 psi (0.14 MPa) using a suitable fixture (eg.,

wrap joint with teflon tape).

Specimens should be at 23 ± 3ºC (73 ± 5ºF) for at least 4

hours before testing.

4.3.3.4 Test Procedure

Test five specimens. Measure the bonded overlap area prior to testing; disregard any

excess adhesive outside the overlap area.

Use an appropriate tensile testing machine with an initial jaw separation of 4 inches (100

mm) and a rate of jaw separation of 0.05 inch (1.3 mm) per minute.

Calculate and record the failing stress in psi (MPa). Report the central (median) value of

the five breaking loads.

4.3.4 Volume Resistivity

Place two 5 x 5 - inch ( 127x 127mm) sections of 10 mil thick adhesive between two

Teflon®*-based sheets 5 x 5 inch (127 x 127 mm) and seal edges with Teflon tape. Place

the assembly between two 5 x 5 - inch (127 x 127 mm) metal plates and cure the

assembly for 15 minutes at 240°C (464°F). Test for volume resistivity in accordance

with ASTM D 257.

Teflon is a registered trademark of DuPont Corporation

SPECIFICATION RT-1255 ISSUE 3 Page 7

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4.3.5 Corrosive Effect

Individually test five 0.25 x 1.0 inch specimens cut from the adhesive tape in the

thickness supplied for corrosive effect in accordance with ASTM D 2671, Procedure A

(Copper Mirror). Condition the specimens for 15 minutes at 240°C (464°F) prior to

testing.

4.3.6 Water Absorption

Test five 3 x 1 x 0.010 - 0.015 inch (75 x 25 x 0.25 - 0.38 mm) cured specimens for water

absorption in accordance with ASTM D 2671 at the condition specified in Table 1.

Report the average of the three specimens. Condition the specimens for 15 minutes at

240°C (464°F) prior to immersion.

4.3.7 Fluid Resistance

Completely immerse three specimens, prepared by bonding Stainless Steel to Stainless

Steel in accordance with Section 4.3.3, in each of the fluids listed in the applicable

section of Table 1 for 24 hours at the specified temperature. After immersion, lightly

wipe the specimens and air dry for 30 to 60 minutes at room temperature. Test the

specimens for adhesive shear strength in accordance with Section 4.3.3. Report the

central (median) value of the three breaking loads

4.3.8 Rejection and Retest

Failure of any specimen of adhesive to comply with any one of the requirements of this

specification shall be cause for rejection of the lot represented. Adhesive which has been

rejected may be replaced or reworked to correct the defect and then resubmitted for

acceptance

5.0 PREPARATION FOR DELIVERY

5.1 PACKAGING

Unless otherwise specified, the adhesive shall be packaged on rolls in sealed packages

with a desiccant

5.2 MARKING

Each carton of adhesive, shall be identified with the manufacturer's name or symbol, the

product number, the lot number, and other appropriate information

SPECIFICATION RT-1255, ISSUE 3

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Page 8

TABLE 1

Requirements

PROPERTY UNIT REQUIREMENT TEST METHOD

PHYSICAL

Visual Appearance

Color as supplied

Homogeneous, no foreign

particles or contaminants

Black

Section 4.3.1

Adhesive Peel Strength

at 23 ± 3ºC (73 ± 5ºF)

RT-1330 to stainless steel (#316)

RT-1330 to RT-555

RT-555 to stainless steel

pli (N/cm)

20 minimum (35)

Section 4.3.2

ASTM D 2671

Adhesive Shear Strength

at 23 ± 3ºC (73 ± 5ºF)

RT-1330 to stainless steel

RT-555 to stainless steel

Stainless steel to stainless steel (304)

psi (MPa)

100 minimum (0.69)

1000 minimum (6.9)

Section 4.3.3

ASTM D 1002

HEAT RESISTANCE

336 hrs at 250 ± 3ºC (482 ± 5ºF)

Followed by test for:

Adhesive shear strength

at 23 ± 3ºC (73 ± 5ºF)

Stainless Steel to Stainless Steel

psi (MPa)

400 minimum (2.7)

Section 4.3.3

ASTM D 1002

ELECTRICAL

Volume Resistivity

ohm-cm

1 X 1011 minimum

Section 4.3.4

ASTM D 2671

CHEMICAL

Corrosive Effect (Copper Mirror)

16 hours at 200 ± 5ºC (392 ± 9ºF)

percent

Copper removal

5 maximum

Section 4.3.5

ASTM D 2671

Water Absorption

24 hours at 23 ± 3ºC (73 ± 5ºF)

percent

2 maximum Section 4.3.6

ASTM D 2671

Fungus Resistance --- Rating of 1 or less ASTM G 21

Continued on next page

SPECIFICATION RT-1255 ISSUE 3 Page 9

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TABLE 1

Requirements (continued)

PROPERTY UNIT REQUIREMENT TEST METHOD

Fluid Resistance

24 hours at 23 ± 3ºC (73 ± 5ºF) in:

Gasoline, Aviation Grade 100

(ASTM D 910)

Coolanol* 25

Followed by test for:

--- --- Section 4.3.7

Adhesive Shear Strength

Stainless Steel to Stainless Steel

psi (MPa)

1000 minimum (6.9)

Section 4.3.3

24 hours at 50 ± 3ºC (122 ± 5ºF) in:

JP-5 (MIL-T-5624)

Deicing Fluid (MIL-A-8243)

Cleaning Compound

(MIL-C-43616)

5% Salt Solution (O-S-1926)

Fuel Oil, Diesel (*VV-F-800, DF-2)

Followed by test for:

--- --- Section 4.3.7

Adhesive Shear Strength

Stainless Steel to Stainless Steel

psi (MPa)

1000 minimum (6.9)

Section 4.3.3

Fluid Resistence

24 hours at 75 ± 3ºC (167 ± 5ºF) in:

Hydraulic Fluid (MIL-H-5606)

Skydrol* 500

Lubricating Oil (MIL-L-2104)

Lubricating Oil (MIL-L-7808)

Followed by test for:

--- --- Section 4.3.7

Adhesive Shear Strength

Stainless Steel to Stainless Steel

psi (MPa)

1000 minimum (6.9)

Section 4.3.3

* Trademark of the Monsanto Company