Latest News

A Leap Forward In The Fight Against Corrosion.

Understanding corrosion.

Corrosion is defined as the degradation or destruction of metals and alloys in an environment by the process of electrochemical or chemical process. It affects all aspects of industry; automotive, construction, transportation, production, marine and manufacturing to name a few. A recent study by NACE International found corrosion costs $2.5 trillion globally, contributing to 3.4% of gross domestic product.

The term corrosion can be applied to the deterioration of plastics, concrete and wood, but is mainly used to define the chemical break down of steels (containing a high iron content).

There are five main types of corrosion:

1)     Uniform corrosion: whereby the surface layer of metal/alloy will rust due to environmental factors. This type of corrosion is most common amongst ferrous metals and alloys which are uncoated.

2)     Crevice corrosion: this form of corrosion is usually associated with a stagnant solution within the formed crevice of the metal. It is initiated through ionic changes in the crevice; changes in acid potential, a build up of ion species and a depletion of oxygen.

3)     Galvanic corrosion: this type of corrosion is driven by corrosion potentials of dissimilar metals when in an electrolytic solution (water). The lowest corrosion potential metal becomes the anode and the highest becomes the cathode.

4)     Electrolytic corrosion: similar to galvanic corrosion, the only difference being that the corrosion does not have to take place in an electrolytic solution. There must be an external source of electromotive (EMF), this could be from a battery or electric generator etc.

5)     Filiform corrosion: this is noticeable by a ‘bubbling’ effect on metals which are protected by lacquers, paints or coatings. The protective coating becomes susceptible to breakdown and the corrosion builds up underneath the protective layer.

The corrosion process is known as a reduction-oxidation (redox) reaction; the oxidation reaction takes place at the anode and the cathode is protected during the reduction reaction. This reaction requires four prerequisites:

–        An anode – negatively charged electrode which discharges negative ions (anions), forming into positive ions

–        A cathode – positively charge electrode which discharges positive ions (cations), forming into negative ions

–        An electron pathway – the flow of electrons from one electrode to another

–        An electrolyte – a substance which produces an electrically conducting solution when dissolved in a polar solution, i.e. water.

When considering the above process, it is helpful to visualise the reaction as part of an electrochemical cell:

There are four factors which control the rate in which corrosion occurs, these are as follows:

1)     pH of the environment; an increase in corrosion occurs when the pH falls below 4.

2)     Oxygen content; an increase in oxygen increases the rate of corrosion.

3)     Flow rate; increased flow of water and oxygen to the surface removes protective surface films and increases corrosion.

4)     Water type; natural waters (soft water) contains a higher concentration of chloride ions and sulphate ions which can interact with the surfaces of metals more readily.

There are a few ways which corrosion can be prevented, such as; coating/anodizing the metal surface, using corrosion inhibitors in cavities, removing the access of oxygen and controlling the electrochemical potential of metals in contact with each other. However, these methods may be time consuming, and expensive for mass production processes.

How can you protect your vehicle from corrosion?

Protecting your vehicle from corrosion can be extremely difficult, which is why Forgeway have developed a new anti-corrosive spray adhesive (Formoa 760-AC) to protect any metal from the electrochemical process of corrosion. This product has been developed to protect under vehicle bodies, cavity protection and areas which are at risk of water entrapment. It works by omitting a chemical around the surface of the metal where the adhesive has been applied and inhibits the redox reaction on the metals surface, thus prolonging and preventing the breakdown of the protective layer on the metal surface.

See the results.

The testing was conducted on 300 X 300 X 3mm (H X W X D) mild steel plates; mild steel has a high iron content, meaning its corrosion potential is high and will therefore corrode at a faster rate. Formoa 760-AC was sprayed onto the mild steel to coat the entire back of the plate. Then sprayed in a 200 X 200mm square on the front of the plate, this was so bare steel was exposed during testing. This process was repeated with standard Formoa 760 (containing no anti-corrosive inhibitor). The plates were extensively tested in a salt spray chamber for 500 hours, the parameters for testing are listed below:

–        Test Standard: ASTM B117-11.

–        Temperature of chamber: 35°C

–        Temperature of air saturator: 49°C

–        Salt concentration: 5% NaCl +/-1%

–        Samples were positioned 15 degrees from vertical

The images below show the dramatic improvement of the bare mild steel after 500 hours in salt spray and show the beneficial effect of using Formoa 760-AC as a protective coating on metals.

When taking into consideration the total cost corrosion has on industry, there is no time to waste when ensuring that your vehicles are protected from corrosion and increasing their time on the road. You can depend on Formoa 760-AC and be rest assured that your vehicles will be rust free.

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Increase Fuel Efficiency of Commercial Vehicles

There are some things that however unfortunate or annoying they just have to be dealt with! Fluctuating fuel prices is definitely one of the above, and whilst there is not a lot anyone can do about this, you can help yourself by ensuring that your vehicle is as fuel efficient as possible. Regardless of vehicle size below are some top tips to help you increase efficiency. Whether it be a car, a 40ft truck, or a home delivery vehicle – the same principles apply.

Remove excess weight

Did you know that 50kg weight reduction can reduce fuel consumption by 1%? Conduct a thorough analysis of what is weighing your vehicle down, what purpose it plays and if it is necessary. Unnecessary vehicle weight is not confined to the tool box or other paraphernalia that seems to collect in vehicles! Significant weight savings can be achieved during vehicle production, for example, in the home delivery vehicle sector by using lightweight composite panels and an innovative bonding system, manufacturers can significantly reduce vehicle weight.

Reduce drag

Vehicle aerodynamics play a huge part in vehicle efficiency.  Great aerodynamics lead to fuel efficiency and operational cost savings. By using a fully bonded system it means that lightweight deflectors and cappings can be used; further increasing vehicle efficiency.

Increase vehicle payload

This is especially important in the commercial vehicle sector. The more the vehicle can carry means less miles travelled, which in turn means increased fuel economy. By partnering with lightweight panel and floor manufacturers and using an innovative bonding system one company was able to increase their payload by 200kg!

Another example is from a truck body builder who had the knowhow to reduce weight and therefore increase payload. Together with a structural floor manufacturer, Forgeway came up with an adhesive system that allowed the removal of the chassis runners. The increase in payload allowed the company to fit an extra item on each delivery.

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Great Cost Saving in the Commercial Vehicle Industry

There are countless blogs and articles on how to reduce costs and as a commercial vehicle manufacturer there are many quick wins that can be achieved, resulting in a more efficient workplace and a more efficient product.

Here are just a few examples of how you can reduce costs…

Cost of Materials

Adhesives make it possible to use economical, lightweight and diverse materials. For example, Formoa 066 makes the use of ABS and other economical, yet hard to bond materials possible.

Another simple move that can save money is to switch from cartridges to foil packs. The foil pack stub takes about 1/24th of the space that a cartridge shell would take in a bin. By making the switch to foil packs, one company was able to change their skip collection from once per week, to every two weeks!

Labour Costs and Production Efficiency.

Significant time savings can be made by using a primerless bonding system. Many adhesive systems require extensive surface preparation in order to be effective. By using the Formoa bonding system one company was able to save 15 hours per vehicle. Their previous system meant they had to sand/ abrade and prime all the side panels, now all they have to do is clean and bond.

The handling strength of an adhesive is also very important when it comes to production efficiency. Adhesives such as Formoa with excellent handling strength mean that props and clamps can be removed earlier and vehicles moved on down the production lines. The leading UK bus manufacturer was able to reduce build hours on bus roofs by 7 hours by using Formoa polymer technology!

Another company in the truck body industry reduced build time by 42 hours by using Formoa 066 adhesives and one-piece panels and floors instead of traditional riveted constructions.

Warranty and recall

Avoid warranty claims by replacing mechanical fasteners with adhesive and using application best practises. A horsebox manufacturer was able to reduce water ingress and related corrosion by following best practises. “S” bead application of adhesive was leading to water ingress, which then got trapped resulting in corrosion and failure. When best practises were followed, applying the adhesive is two straight parallel lines, the issue was resolved.

Many manufacturers were finding difficulty in educating their workforces in which products should be used for which application. Language barriers were causing miscommunication between teams resulting in the wrong products being used in the wrong applications. Mistakes like these are expensive and avoidable; that is why Forgeway developed the colours concept. Colour is a universal language, it crosses barriers and means that regardless of nationality, language or ability, operators will use the right product for the right application. The Formoa bonding system is completely colour coded. Blue for sealing, Yellow for bonding, Green for high strength bonding and Red for glass bonding.

This list is by no means exhaustive, and there are many other ways that cost savings and efficiencies can be achieved. Ask us for an on-site audit and find out how you can save money.

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Forgeway at The CV Show 2017 – Stand 3D80

The CV Show is just days away and Forgeway are getting ready for their debut at the show!

As a UK based manufacturer, our aim is to stay at the forefront of adhesive technology and the latest regulatory demands. We produce high performance innovative products for our customers, enabling them to provide a first class service to theirs.

With a can-do attitude and strong belief in being smart with constant innovation, we believe real creativity is born from continuous learning and development. The whole team is committed to the never-ending search for not just the best, but continuously better solutions.

We’ll be promoting an array of products, ideas and concepts from the well-known and respected FORMOA® brand.   We want to share with you how this primerless bonding technology, that can be matched in any colour, can save you time and money and help you stay at the fore-front of your industry sector.

Alongside this, we will have some precision electronic scales on our stand so you can not only asses the performance and economics of your vehicles’ build, but check your health at the same time!

The team can’t wait to meet some current and prospective clients next week, and will be on hand to answer any questions about our bonding solutions for the duration of the show.

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Graphic Designer Vacancy at Forgeway Ltd

An exciting opportunity has arisen to join a rapidly expanding manufacturing business in Newton Abbot.

Forgeway are seeking an experienced Graphic Designer to work within the Marketing team to develop design concepts and use up to date software to produce art work for the website, brochure print and packaging.

You will have an understanding of graphic design concepts and best practices and have a high knowledge of the Adobe Creative Suite products such as Illustrator, InDesign and Photoshop.

The ideal candidate will have a passion for marketing, graphics, and all things creative! They will be tech-savvy and come brimming with great ideas to add to our existing marketing campaigns.

What else?

You’ll be experienced in creative design with the ability to work to deadlines and have a meticulous attention to detail. Finally, a recognised qualification in Graphic Design, preferably a degree would be advantageous.

In return you will receive a salary of £26,000 per annum, a free lunch each day and onsite parking.

This is a full-time position, 40 hours per week.

If this sounds like you please email your CV and a covering letter, stating your suitability for the position to our careers@forgeway.com.

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Get your free health check at the CV Show on Stand 3D80!

We’re exhibiting at the CV Show 25th – 27th April 2017. Demonstrating how we’ve helped manufacturers in the industry solve problems during the past 20 years. Barriers that were once insurmountable are now the “norm”; amongst these are, increased payload, improved vehicle aesthetics and reduced build hours. How can we help you? Visit us at Stand 3D80 to find out.

Whilst at our stand take advantage of a free personal “health check”. On the stand we will have a BMI Calculating Checkpoint courtesy of AXA PPP Healthcare and on Tuesday we will also have a physiologist available to answer your health related questions. From our side we will be offering free training on how to improve the “health of your vehicle or fleet”. We will also be launching our new ground-breaking training resource for operators, so ensure you keep an eye out!

Over the years’ manufacturers in the transportation industry have turned to Forgeway when challenged with… Take a sneak preview into some of the customer success stories we will be promoting at the show.

Reducing build hours, inventory and work in progress.

The handling strength of Formoa products means that props and clamps can be removed earlier and vehicles moved down the production line. Many of our customers have been able to make significant reduction to build hours by using Formoa products. Leading UK Bus manufacturer reduced build hours on bus roofs from 8 hours to 1 hour by using Formoa polymer technology.

Come and visit us if you’re attending the show and find out what we can do for you.

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Formoa Gb – Super Reliable Glass Bonding

Found in every continent of the world – bonding windows in people movers and road transportation – tens of thousands of vehicles, travelling more than 10 million miles per week, carrying more than 1 billion passengers per year.

The Formoa Gb range of adhesives are continuing to gain a reputation for successful bonding in transportation applications. A truly primerless adhesive bonding system that reduces build and total vehicle costs. For over 20 years Forgeway have led the market in producing primerless adhesives for bonding. Originally developed and launched in 2001, the Formoa Gb range has continued to maintain the critical balance between a simple process, end strength and long term durability.

The process is simply clean and bond. Easy to extrude at ambient temperatures with fast strength build up and cure. The high tack non-sagging formulations can support the largest of glass units found in modern vehicle manufacturing. Formoa glass bonding products can be used to bond many new generation “glass alternatives” giving huge potential in riot and custodial vehicles to increase protection and reduce weight. The lower shear modulus of the Formoa Gb product family ensures that any stress and strain are absorbed into the polymer matrix rather than transferred to the bond interface.

Never a company to stand still, and knowing there must be a solution to the lengthy and exacting processes associated with typical polyurethane technology glass bonding systems, Formoa Screen Extra 2 was developed. Formoa Screen Extra 2 is a fast curing glass bonding adhesive suitable for bonding and backfilling and meets the requirements of FMVSS212 2 hour drive away time/ double airbag test and the 1 hour NCAP. It provides the ultimate solution for both OEM’s and the aftermarket who desire excellent mechanical properties with a simple process and fast cure times.

All the Formoa Gb range allows manufacturers to simplify their processes; for one customer switching to Formoa meant 16 man hours per vehicle saved. Find out how much you could save.

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Is it possible to stop staining on vehicle sides?

A question we often find ourselves asking customers is “if we had a magic wand, what problem would you like us to solve?” Many OEMs in the transportation industry are facing similar issues. A issue that many manufacturers share is staining on vehicle sides; so, what causes it, and how can the problem be solved? In fact, most of this problem is caused by the products that are being used in certain applications. For instance, many manufacturers will use polyurethane adhesive to bond in the windows; then backfill the glass with the same product.

Causes of Staining

The key to this issue is UV Stability. UV light affects the chemical linkages in Polyurethane adhesives and causes the product to break down. There are several clear warning signs that an adhesive has been affected by UV light. The first evidence is discolouration, yellowing or chalking, which is then followed by cracks in the surface of the product. With Polyurethane adhesives, this degenerative process will begin within 1 to 2 years of the vehicle being in service. Once the adhesive starts to break down it means that water (i.e. rain) can penetrate the surface and can wash out the pigment contained within it. This pigment, which is typically black due to the application, will then run down the body sides causing staining. We already covered the importance of UV Stability in our technical insight 007.

How can you stop staining?

One answer, and the only true answer, is to change the product you are using for this application. Adhesives and sealants that use Formoa Polymer technology have much higher UV resistance than PU products, therefore have a much longer lifespan. They don’t degrade in the same way as polyurethanes therefore don’t cause staining on the body side of vehicles. Whilst PU adhesives have their place in certain applications, not all products were created equal! Use a polyurethane product for glass bonding and backfill and even your vehicle will cry black tears! Contact us to find out how we can help you solve problems.

 

https://www.linkedin.com/company/forgeway-limited/

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Summer Placements in the Forgeway Lab

Lab Assistant – SUMMER PLACEMENT (June 2017 – October 2017)

We have an exciting opportunity for a second year undergraduate to join our Research and Development Team for a four-month period during the summer break.

The position will offer the right student the opportunity to:

  • Assist in the development of new and existing products within the adhesive portfolio
  • Assist in the sales process by carrying out technical work relating to customer requirements
  • Validate production batch material by carrying out Quality Control tests against specific parameters
  • Contribute to the company’s technical knowledge base by completing an individual research / data generation project
  • Obtain industry experience in a modern chemical processing facility

Direction will come from the Research and Development Manager and the job function will involve looking at specified performance characteristics. Forgeway are looking for someone who is passionate, conscientious and disciplined with a ‘can-do’ attitude, who is innovative with a dedication to continuous learning and development. The right candidate must also be able to work independently, have excellent attention to detail and be able to navigate Microsoft Excel confidently.

In return you will receive an hourly rate of £7.50, free onsite parking and a free complementary lunch each day.

If this sounds like you, please email a copy of your current CV with a covering letter to careers@forgeway.com.

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Mould Part 1: Is it really that bad?

So, what exactly is mould?

Mould is a naturally occurring microscopic organism that is a vital part of nature’s recycling system. It destroys whatever it grows on as it feeds on and digests it. Mould can spread either by extension of tiny root hairs called hyphae, or it produces spores (tiny seeds) which can be carried by air or water.

Mould generally requires the following to grow: Any organic material; some synthetic materials such as adhesives, pastes and paints; moisture; oxygen and ideally warm temperatures. Whilst mould cannot live off inorganic materials such as concrete, glass and metal, it can grow on dirt, debris or hair on the surface of these materials. Moulds prefer wet or damp materials such as decaying wood, but they can also survive well in areas with high relative humidity – typically above 60%. This explains why mould survives so well in many bathrooms!

Is mould dangerous for health?

The NHS outlines the dangers of mould to human health thus:
“Moulds produce allergens (substances that cause allergic reaction), irritants and sometimes toxic substances. Inhaling or touching mould spores may cause an allergic reaction, such as sneezing, runny nose, red eyes and skin rash. Moulds can also cause asthma attacks.”

www.nhs.uk/chq/Pages/Can-damp-and-mould-affect-my-health

Find out more about preventing mould here

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Mould Part 2: What can you do about it?

Where does mould cause the most problems?

Although most of us know the dangers mould poses to our health, it is still found all around us. Statistics show that around one in five British homes suffer with problems of black mould. However, mould is not an issue that is confined to the home – it is also an ongoing issue for many operators and manufacturers in many industries.
Occasionally mould related horror stories hit the press. For example, in the Daily Mirror online “driver reveals photos inside filthy delivery van – store admits it ‘hasn’t met its own hygiene standards’”. Photographs shared on this news site show the inside of a home delivery vehicle fridge body covered in mould and dirt.

Prevention is better than cure.

Once mould gets hold of something it’s very difficult to eliminate it as it eats away the surface of whatever it has been growing on. Once a smooth surface has been destroyed by mould it is very hard to prevent regrowth. Whilst the use of chemicals such as bleach remove the mould, they also further increase the likelihood of recurrence as the chemicals cause further breakdown of the surface. A classic example of the effects of mould can be seen on soap dispensers in public toilets – over time the surface of the plastic is visibly eaten away.

To prevent, or at least significantly slow this degenerative process, it’s important to ensure that mould doesn’t have an opportunity to grow. Keep surfaces clean and ensure that there is adequate moisture control. Ideally, humidity should be kept between 30% and 60% to reduce the likelihood of mould growth. Another preventative measure that manufacturers can take to prevent mould growth inside truck bodies, is to ensure that the adhesives and sealants used are mould resistant. All the Forgeway Formoa range of adhesives and sealants are mould resistant and have low dirt-pick-up, which further reduces the likelihood of mould growth.

Looking for a solution for mould growth on sealants and adhesives? Look no further. Contact us to find out what we can do to help.

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Technical Insight 010: Application matters

Selecting the right adhesive for your application can be difficult, with many different factors that must be considered at the outset. Whilst the type of application influences which type of adhesive should be used – 2k, 1k, flexible, rigid, tape, etc – how it is applied is equally as important. Over our 20+ years of experience in the field, we’ve gained some useful insights into the importance of application, and there are some common misconceptions…

“Use lots of adhesive”
More adhesive is not necessarily better! The effects of excess adhesive on cure are significant. When too much adhesive is applied with 1k systems like our Formoa range, the excess will squeeze out and cause problems by reducing the effective strength build up at the bond interface, because the initial moisture from the air is absorbed in curing the excess. Therefore, we would always recommend that excess adhesive is removed. As Formoa polymers cure by absorbing moisture in the form of atmospheric humidity, removing the excess will assist in faster through-cure at the bond interface. Recent tests show the effects of excess adhesive on bond strength after 24 hours.

Effect-of-excess-on-lap-shear-strength

Fig.1: Effect of excess on lap shear strength at 24 hours
As a moisture curing adhesive system, Formoa polymer cures from the outside in. The graph above illustrates this. Lap Shear number 1 had the excess removed immediately after application. After 24 hours this has started to through-cure and the lap shear strength is significantly higher than the other two lap shear joints.

Get more tips on adhesive application here

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Technical Insight 010: Application matters continued…

“S” Beads

Adhesive should be applied in horizontal or vertical straight lines. “S” beads are always a ‘No No’ as they can act as a water trap. Two beads that flatten out to around 20mm wide each, with a space in between, are better than dispensing a large mass of adhesive.

Open Time

Open time is the timespan from when the adhesive is applied, to when it no longer bonds to another substrate – normally quoted in minutes. It is important to understand open time as it can mean the difference between two substrates bonding or not. A product’s open time is always stated on its technical data sheet.

A quick way of testing if a product is ‘still open’ is as follows:

Wearing disposable gloves, press your index finger into the adhesive and squash down to a 2-3mm bond line. Alternatively, use a clean stainless steel spoon or a spatula. If you get a good transfer of adhesive to your finger, the adhesive is still ‘open’ and an acceptable bond will be achieved.
If the transfer is reduced, the adhesive has started to skin over and the ultimate tensile strength and peel forces will be reduced.
If there is no transfer of adhesive to your finger, the adhesive has skinned over and an acceptable bond will not be achieved.

If you have any questions on how best to apply adhesive to ensure maximum performance, give us a call, or follow us on LinkedIn where we will keep you updated with Application Best Practice.

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Product Focus 010: Formoa Surface Activator

formoa-surface-activator-PDF

Formoa surface activator is a specially formulated cleaner and activator combined in one system. Used extensively in vehicle manufacture for over 20 years. The formulation is specially balanced to be effective in all climates and environments.

For use on all non-porous substrates, metal/ composites/etc. Formoa Surface Activator cleans and etches the surface to promote adhesion and increase durability.

Formoa Surface Activator Usage Guide:

1 Remove any surface dust, swarf or heavy contamination
2 Before use ensure that the surface activator is ‘crystal clear’
3 Wipe in one direction only
4 Allow 10 minutes to flash off
5 The white residue is correct – it is the adhesion promoter
6 Apply the adhesive within 4 hours

Care Points:

1 Keep lids on containers when not in use – the product will hydrolyse with prolonged exposure to air and lose its effectiveness.

2 It is not a remover cleaner and should not be used on finished surfaces e.g. floor coverings, gel coat, laminate side casings, etc.

3 Change the surface of your lint free cloth after every linear meter

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Technical insight 009: Cartridge Wastage

Tired of running out of cartridges even after working out how many you thought you’d need? Not only is this annoying and time consuming, but it’s also avoidable.

Instead of having to throw a half-empty tube away at the end of the day, extrude a centimetre or so of sealant out of the nozzle and walk away. Depending on how long you leave it before using the cartridge again, use one of the following methods:
If it is only a few hours up to a couple of days, simply pull the now cured centimetre off the top of the nozzle and you’re good to go. Any longer than a few days and you will have to change the nozzle. Cartridge nozzles are available to purchase – part number 53001. Typical Yields – To work out quantities (excluding wastage) use the following formula:

Yield per cartridge – 1k adhesive / sealant
Bead diameter (mm) Linear Metres per 290ml Cartridge
3 40.0
4 23.0
6 10.2
8 5.7

abi_3

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Bonding in Mass Transit and Commercial Vehicle Bodies with Formoa 017FE

As a manufacturer of both rigid and flexible adhesive systems, we have found that when it comes to bonding mass transit and commercial vehicles, our flexible Formoa 017FE is the best solution.

Using Formoa 017FE (with its 300 – 500% elongation) eliminates any concerns over twisting, bumping and rolling etc because the flexible adhesive absorbs movement within its internal structure, rather than transferring all force to the bond interface. Formoa 017FE adhesive has a lap shear strength of 2.5N/mm2 – equal to approximately 0.25kg/mm2. The bond area to secure the body to the chassis is 60mm x 4527mm x 2mm. If we assume a minimum bond width of 25mm, the force to remove the body (in shear) would equate to approximately 56,500kg!

All our Formoa products have superior durability and do not embrittle with age. We have been successfully bonding one-piece composite and plywood floors in buses for 12 years, and many of our buses and truck bodies have been put through full durability life-cycle testing at Milbrook and Altoona in the US. We conduct all our lap shear testing on-site at 6mm/minute as this represents the closest value experienced in real life vehicle tests we have conducted.

Formoa adhesives cure by a reaction with atmospheric moisture, however, we do not recommend spraying the bond/adhesive area with water as over saturation can actually prolong the adhesion build up values – the amount of moisture required to start a reaction is very small. Cure is from the outside to inside and full cure of a 25mm wide bond will typically take seven days. But with Formoa 017FE one third of end strength is reached in the first phase (24 hours).

Formoa adhesive chemistry will give you greater manufacturing process tolerance in the workplace, more consistent summer/winter performance, easy extrudability, and long term performance combined with economic viability. Get in touch if you want to use Formoa 017FE or any other of our Formoa products.

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Product Focus 009: Purok VX67-15

Our customers have been searching for a new way to disguise the bond line of components and composites without compromising on adhesion or production throughput. Enter VX67 – a unique hybrid structural adhesive with a long open time whilst maintaining a snap set fast cure speed.

Purok VX67-15 is a two component, hybrid toughened structural methacrylate adhesive designed for structural bonding of a wide range of solid surfaces, plastics, composites, quartz, granite and natural stone. Now available in any of your desired colours.

Developed after more than 15 years of manufacturing epoxy, polyurethane and Formoa polymer technology, the Purok VX67 series continues to gain recognition as an essential bonding solution.

This is not just another methacrylate adhesive on the market. The demand for very fast cure and high lap shear strength has inevitably resulted in severe witnessing and shrinkage as a result of high exotherm. This has led to no tenacity at the bond interface resulting in ‘cold crack’ and difficulty in achieving a good mix. With Purok VX67-15, these issues no longer need to be ‘lived with’ and accepted as the norm.

Purok VX67-15 is suitable for general purpose bonding of composite structures, metal brackets and GRP panels. It is fast curing and very easy to extrude whilst still being flow controlled. It has high bond strength and excellent chemical resistance with long term durability. Another feature, answering yet another of your bonding challenges, is that it can be colour matched to any colour reference or substrate.

If you are experiencing any current issues with bonding, we have bonding experts ready to help you please don’t hesitate to get in touch.

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The New and Improved Antimicrobial

We’ve all experienced the frustration of watching mould slowly take over our bathroom. However you try to clean it it’s a pain and usually to no avail – within weeks, you’re back where you started. But mould is not an issue confined to the home – mould proves problematic for refrigerated truck builders and operators that transport products for human consumption.

The bewildering selection of sealants on the market which supposedly protect against mould makes finding the right ‘mould free’ product difficult. There is only one solution – Formoa Antimicrobial is yet another breakthrough in adhesive technology from Forgeway.

Formoa Antimicrobial’s (AM) formula is the result of an extensive R&D programme to find effective antimicrobial technologies that combat fungi, mould, bacteria and microbe growth on sealants and adhesives. Formoa AM is a high performance polymer blend that has been rigorously tested to ASTM G21 test (Standard practice for Determining Resistance of Synthetic Polymeric Materials to Fungi). It displays outstanding antimicrobial and anti-fungal properties and provides the following benefits:

1. Long-life integrity by creating a surface on which microbes cannot survive. The antimicrobial technology remains active for a long period of time. It also protects and maintains the high quality aesthetic by eliminating odours, staining and sealant degradation.
2. Significant reduction in microbe growth, with a reduction in the possibility of harmful growth on the sealant, preventing the spread of fungi, mould and bacteria. Microbe levels are reduced within 2 hours of coming into contact with Formoa AM.
3. It is now possible to have an antimicrobial sealant without compromising on looks! Already available in a rainbow of over 160 colours matched to a large range of RAL, NCS, BS and Pantone colour standards, we also offer bespoke colour options to match your substrates.

To find out how you can use our new and improved Formoa Antimicrobial in your business, give us a call!

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Technical insight 008: The Significance of Temperature

As Winter marches on, you might want to keep a close eye on outside temperature. The temperature of both environment and substrate can cause havoc with cure speed when bonding or sealing. For every 8°C drop in temperature, the cure time doubles and likewise for every 8°C increase in temperature, the cure time is halved.

So, what does outside temperature mean for your adhesives?

Apart from significantly decreased or increased cure times, products may be more difficult to extrude, and may not behave as expected. For optimum performance, the substrate and the adhesive should be between 15°C and 25°C. If over or under this range, the product may display different characteristics.

So, how do you ensure that your adhesives perform correctly when the cold sets in?

There is a quick test that can be carried out to ascertain whether the adhesive is curing as it should do – gun out some beads of adhesive onto a sheet of paper, bring into the office (where it’s warmer) and test the open time. This is done by simply touching the surface of the bead at regular intervals to check how long the adhesive takes to skin over. Then compare this with the adhesive’s performance in the colder workshop environments.

There are lots of simple ways to ensure that your adhesive doesn’t catch a chill:

–       Keep it raised off the floor – even a pallet height can make all the difference!
–       Store in a warm/heated environment
–       Keep the heating on overnight
–       Keep roller-shutter doors down as much as possible to avoid too much heat escaping
–       Use foil pack/cartridge warmers – give us a call for pricing.

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Product Focus 008: Formoa 066 For Sticky Tricky Plastics

Since development of its earliest form in the 1850s, plastic has been continually evolving, with new breakthroughs and innovations every year. Usage is exponentially growing and plastics have become a fundamental part of our everyday lives. From the car you drive, to the phone in your hand, to the freezer in your kitchen – plastic is something we would struggle to live without.

The choice of plastics available for a diverse range of applications is huge. Passenger vehicle manufacturers are always looking to reduce the weight of their vehicles for enhanced efficiency and plastics have made this possible.

However, with the many benefits of an ever growing range of plastics, there are always new challenges to overcome. One is matching a suitable adhesive. Bonding plastics often proves difficult due to their low surface energies. ABS in particular, has inert nitrile particles on its surface, meaning that the plastic has a low surface energy and is difficult to bond. But fear not. Forgeway continues to be at the forefront of adhesive bonding solutions, particularly for plastics that are difficult to bond.

Formoa 066 is a high-performance polymer based adhesive/sealant developed in response to specific customer problem – interior panels on several passenger carrying vehicles were proving impossible to bond with other adhesive technologies. After the fulfilment of the customer’s initial wish list, the test programme was completed and Formoa 066 was made available to the market.

If you want to use Formoa 066 on your tricky-to-bond plastics, get in touch.

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Careers at Forgeway

Since our beginning in 1994 our aim has always been to solve our customers’ problems and offer enhancement to their products.   With that in mind and due to our continued growth, we are always on the lookout for high calibre talent to join us in various functions within the business, whether you have experience in a factory, customer service skills or have a background in chemistry or as a lab technician.All roles here have a vital part to play in our continuing success. In return we offer fantastic benefits including career development, competitive salary, free lunch and free parking.

If you are interested, please submit your CV with a covering letter to careers@forgeway.com

Please view our current vacancies below:

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Product Focus 007: The unsung heroes

Adhesives provide solutions in the assembly of an almost infinite range of products worldwide. There are a multitude of ‘unsung heroes’ which play a key role in ensuring that these adhesives are fit for purpose, namely applicators and other accessories.

The 600ml foil pack applicator, the step-leg nozzle and the bonding packer all play a vital part in the correct application of adhesive, assuring maximum bond. In other applications, the 2K applicator and the mixer nozzle are needed to provide a correct mix ratio of part A and B, thus providing a fully functioning adhesive.

As an integral part of providing intelligent solutions here at Forgeway, we stock an extensive range of applicators and accessories, from pneumatic and manual to battery operated, 600ml to 50ml, 1 component or 2 component, 10:1 or 1:1 and many more.

Solutions aren’t limited to applicators either – we also stock a range of accessories to improve the application process further. Bonding packers, cartridge cutters, nozzles, clean-up wipes and glass suction clamps make up just some of the accessories available. For a full list of options and pricing, give us a call.

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Forgeway the Movie

Check out our whistle-stop tour of how we meet a client challenge, from continuous development to high-quality on-site manufacturing, via vigorous testing and the highest level of quality control. Follow the journey to an intelligent solution.

And talking of journeys we’ve just returned from Euro Bus Expo 2016. We joined nearly 300 other exhibitors and met thousands of visitors, all heading to the NEC to discover what’s new and next in the passenger transport sector. 9,500 industry specialists gathered for the Euro Bus Expo 2016, we were amongst the almost 291 exhibitors representing their products and services at the NEC, Birmingham from 1-3 November. As expected, our handmade bus made entirely from our product packaging turned a few heads, but we were also impressed with some of the other stands exhibiting.

Visitors to Euro Bus Expo represented every link of the supply chain and were treated to a showcase of the latest innovations in the industry – from vehicles, accessories and equipment to cutting-edge technology, training and services, including, of course, our innovative range of bonding and sealant technologies.

Whilst touring the expo, it became a bit of a spot the Formoa game, we were excited to see many of the 120 exhibiting buses featured Forgeway products, namely our coloured Formoa.

This year’s expo had its sites set firmly in the future and visitors were wowed by Volvo’s B5LHC Double Deck Electric Hybrid. The environmentally-friendly red double decker features an impressive new cableless overhead charging system. Some great innovations improving transport where it’s needed most.

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Technical Insight 007: UV stability – Protecting your most valuable assets

The effects of ultraviolet radiation on vehicles can be seen daily on our roads. The most obvious example is the fading visible on red vehicles such as Post office vans. Whilst all colours are affected by UV, the effects on red and orange materials are most severe. As all industries strive to use more environmentally friendly products, UV protection is no longer a simple fix.

Ultraviolet radiation from sunlight causes damage to many materials such as plastics and polymers. The damage caused can take the form of chalking, cracking, peeling, fading and loss of colour. The severity of this damage varies depending on the material sensitivity and the environment that the materials are subjected to. The spectral sensitivity varies from material to material – eg. for durable materials shortwave UV is the primary cause of polymer degradation.
When UV radiation breaks a polymer down the surface is more susceptible to mould. Dirt pick up is increased, often causing pronounced staining of the sealant and body side of the vehicle.

Because of our planet’s inconsistent climate, it’s important that UV protecting products are tested rigorously to ensure that they are fit for purpose where they are actually used. There are many outdoor testing facilities around the world, but there is some debate over which environment is optimum for use as a benchmark.

In the Forgeway lab we carry out extensive testing on many different polymer chemistries to ensure our products are robust enough for their end use, wherever that may be. To test our products we use a QUV accelerated weathering tester which reproduces the damage caused by sunlight, rain and dew. This rigorous testing is yet another reason why our products aren’t just fit for purpose, they’re fit for tomorrow.

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All aboard the Forgeway Euro Bus

We’re all set to attend Euro Bus Expo 2016 at NEC in Birmingham 1-3 November.

Having decided to exhibit, the big question was how best to unveil our new brand. Of course we could have brought our rebranded products along and talked about their benefits and uses – but that was far too simple! We wanted something to do something different, something that would showcase all our products at the same time.

So we’ve decided to create a bus made entirely of our new outer packaging. Like you do.

Our products are used in many different industries (including the manufacture of buses and trams), and the giant lego-style double-decker will be built from our colour-coded product boxes and tubes – each referencing a different Forgeway range and its application in vehicle manufacture.

Along with our eye catching bus, we’ll be handing out ‘instruction manuals’ and hopefully starting conversations with thousands of industry professionals – from operators and suppliers, to local authorities and community transport organisations.

If you’re attending the Expo make sure you flag us down. We’d love to meet and perhaps we can work together in improving your business.

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Product Focus 006: Formoa 017FE – The Adhesive that Flexes to your Needs

Of all our high strength Formoa products, Formoa 017FE is the unsung hero and backbone of the range. Due to its fast cure, high strength and impressive durability, 017FE is responsible for holding together a diverse range of over 50,000 vehicles worldwide. Not that you’d notice…

All over the world, on any given day, it is probable that you will come within a few metres of Formoa 017FE. The truck you pass on your way to work, the bus you take into town, the underground train beneath your feet, and the plane that flies overhead, all have something in common – they could be bonded with 017FE.

Formoa 017FE is a high quality, single component adhesive/sealant, with high grab and adhesive strength. It is based on MS Polymer®, chemically neutral and fully elastic. Its overriding feature is its elastic structural bonding making it ideal for the manufacture of coaches, caravans, truck bodies and aerospace industries, where a tough flexible bond is required.

Other key product characteristics and benefits include; the product is isocyanate, silicone and solvent free and carries minimal health and safety labeling. It is over paintable wet on wet and can withstand powder coating ovens up to 200°C for a limited period. Formoa 017FE also withstands extreme climatic conditions making it suitable for all environments.

So, if you need a world class adhesive capable of flexing to your needs, Formoa 017FE is the answer.

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Technical Insight 006: The True Cost of Corrosion

When we ask our customers in commercial vehicle manufacturing what their biggest challenges are, corrosion is always mentioned – corrosion of the chassis, side and body panels, or a breakdown of paint and powder coatings and so forth. It costs the industry billions of pounds every year in equipment failures, rejects, price reductions, credits and short life spans.

Not only is corrosion a financial threat, it’s a danger too. Almost daily, reports of tragic accidents and product failures can be linked back to corrosion somewhere along the line. Controlling corrosion is therefore key to a manufacturer’s continued success. And with the ever increasing push towards environmentally-friendly chemical treatments and primers, corrosion prevention has never been so problematic.

Corrosion occurs when a material is affected by an external factor – this could be oxygen, air, humidity or temperature, salt, precipitation, chemicals etc. You can eliminate corrosion with a protective layer that completely coats and protects the surface from its source.

A lot of our Formoa adhesives have been proven to protect metal at the bond interface, eliminating corrosion and ensuring a long term durable bond. Some of the latest generations of Formoa adhesives contain active ingredients that form a molecular layer of protection on metal surfaces, creating a protected environment when used in enclosed areas. Formoa AC formulations allow bus/coach manufacturers to reduce panel edge corrosion and eliminate corrosion in the panel/body side cavity.

Give us a call and we’ll work together to protect your vehicles from corrosion.

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Formoa 760 – Is there anything it can’t do?

As onsite manufacturers, we like to think we know our products and their applications inside out. However, even we couldn’t have predicted the versatility of one of our most popular products, Formoa 760.

760 was originally created for commercial and mass transit vehicle manufacturers to solve issues with underbody and chassis protection materials. It has since been found invaluable in many other situations. Formoa 760 is a solvent and isocyanate-free coating material that can be sprayed without fume or particle extraction, and has minimal overspray. It also dries to form a tough, durable and protective layer (preventing water ingress and corrosion) with very good adhesion to metals, plastics and painted surfaces.

Formoa 760 can be applied from bulk containers or from a 290ml cartridge via a simple-to-use air-powered gun. This ease of application might explain why users have found so many other applications for Formoa 760 beyond underbody protection.

Reported uses of Formoa 760 from our customers include: keeping rabbits and dogs protected from the elements; coating the inside of a luggage compartment to protect cases from damage; restoring a trailer to its former glory; coating storage boxes to keep them from slipping; sound deadening for metal clad buildings under flight paths; and waterproofing a Victorian lead-lined shower. The list goes on…

If you have found any of our products beneficial in unusual situations, we’d love to hear from you. Give us a call, email or contact us on LinkedIn.

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Technical Insight 005: The significance of jaw separation speeds when testing adhesives using a Tensometer

In ensuring all our products are perfectly suited to their end use there are a number of factors we consider.

It’s important to take into account the mechanical properties of an adhesive, as well as establishing the forces or stresses that will occur within a bonded joint. Because of this, the design of the joint is also important in effectively withstanding the forces applied to it.
The ‘modulus’ or ‘tensile modulus’ also has an effect on the suitability of an adhesive. Tensile Modulus (also known as ‘Young’s Modulus’ or ‘Modulus of Elasticity’) is a measure of stiffness of an elastic material. The higher the modulus of a cured adhesive, the less it is able to stretch.

Tensile Modulus is defined as the “ratio of stress (force per unit area) along an axis to strain (ratio of deformation over initial length) along that axis” and can be measured using a tensometer. The jaw separation speed, measured in MPa (Megapascal), is the speed at which the adhesive is pulled apart. The effects of higher jaw separation speeds have less effect on the peak loading (load at break) during testing of lower modulus adhesives. This is due to the higher elasticity of the adhesive absorbing the shock loading.

If the joints are subject to rapidly moving forces or shock loadings, it is often important to simulate these shock loadings with the maximum jaw separation speed. However, to obtain the most consistent mechanical properties of an adhesive or sealant, then a slow jaw separation speed is beneficial. The peak load at break will be lower than that achieved with high separation speeds. The joint design will need to take this into consideration to ensure that the joints will not fail in service.
Tensile and lap shear tensile testing is just one more example of the rigorous testing we carry out at Forgeway.

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Product Focus 005: Forbond F5740C – Double Sided Tape to Fight Off The Cold

Summer is well and truly over and autumn is upon us. Whilst we may still be enjoying the last of our warm evenings, it’s important to remember that the first morning frosts are just around the corner. In most instances, no other external factors are felt stronger than temperature and weather conditions. Adhesives are not exempt.

The outside environment, as well as the temperature of the substrate, can have a significant effect on adhesives and sealants in a few different ways. The cure speed will likely be affected first, decreasing the overall bond strength. In temperatures below 15°C (well above our average autumn temperature of 10.9°C and winter temperature of 3.9°C) the lap sheer strength (strength of bond under extreme tension) of double-sided acrylic adhesive tape can be reduced by up to 50%.

It is for this purpose that we developed Forbond F5740C. F5740C is a double sided adhesive tape incorporating a black, closed cell, cross-linked polyethylene foam. It has a high performance, durable, modified acrylic adhesive on both surfaces and is protected by a LDPE (Low Density Polyethylene) liner. Forbond F5740C achieves the winning combination of good tack (at temperatures down to -5°C), excellent bond strength and high durability. It has excellent weathering properties as well as good bond strength to various substrates; plastics including poly-carbonate, PVC and glass, wood, metals and most automotive paints.

Whilst originally designed for bonding alloy wheel weights in Scandinavia, its high tack makes Forbond F5740C ideal for many applications including mirror mounting, bonding of truck roofs, and panel assembly. If you’re interested in weather proofing with Forbond F5740C in time for winter, give us a call!

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Technical insight 004: Temperature Resistance of Adhesives

Elevated temperatures have long been recognised as the number one enemy of organic adhesives, degrading their efficiency in a number of ways. There are two main reactions that cause a breakdown of bond strength at elevated temperature – thermal oxidation and pyrolysis.

Thermal oxidation starts a progressive chain scission of the molecules that make up the adhesive, resulting in loss of weight, strength, elongation and toughness within the body of the adhesive.
The materials or substrates bonded will have an impact on this rate of oxidation – some adhesive interfaces with certain metals will increase the rate of oxidation through a chemical process. This explains, for example, why aluminium will display higher levels of thermal stability than stainless steel when used with most structural adhesives.The addition or incorporation of anti-oxidants within the adhesive system will help to limit or slow down the rates of oxidation, providing increased performance at elevated temperature.

Pyrolysis is the thermal destruction of the molecular chain of the base polymer within the adhesive. The molecular chains undergo scission and molecular weight decreases, cohesive strength is reduced and embrittlement occurs.
Resistance to pyrolysis is determined by the inherent heat resistance of the polymer. Typically, epoxy adhesives using an aliphatic polyamine curing agent are only suitable for use in environments where the temperature will not exceed 65°C. However, the use of aromatic diamine curing agents will improve this significantly. The addition of high temperature resistant co-reactants and anhydride curing agents will further increase the thermal stability of the epoxy system. This can achieve temperature resistance of >150°C with potential short-term resistance of up to 230°C.

All of our products are suitably heat resistant for their end use, however Aerok 7205, 7001p and 7001LZ, have been tested in extreme conditions to ensure they are fit for the altitude and temperature they will be exposed to within the Aerospace industry.

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Product Focus 004: Aerok 8250FP – Adhesive Fit for the Skies

Whilst epoxy-based materials have an enormous range of applications, they play a particularly important role in structural adhesives. Excellent gel and handling times are just one of the benefits of using fast curing epoxy systems. However, they aren’t perfect.

Often their performance at elevated temperatures is poor, and they have a tendency to soften after prolonged exposure to high humidity environments.

Temperature performance of an epoxy adhesive or filler is measured by the ‘transitional glass temperature’. Glass transition temperature (Tg) is defined as the temperature at which the mechanical properties of an adhesive radically change due to the internal movement of polymer chains that form the adhesive.

For many structural adhesive applications, the low Tg of these epoxy systems is tolerable, but as the need for high performance composites for fuselage (the main body of an aircraft) increases, so do the service temperature requirements for epoxy adhesives and fillers. This could be partly due to the fact that composite structures are not as effective in dispersing heat as aluminium alloys.

At Forgeway we develop our products with their end use in mind, and always take into account relevant industry specifications. As well as meeting the FST requirements of ABD 0031 and FAR JAR 852.63, Aerok 8250 has been developed into a rapid setting, high performance structural two component epoxy. Combining ease of application with high performance, Aerok 8250’s strength figures are in excess of 32MPa at temperatures of 80°C.

Aerok 8250 is designed to be used for insert potting, filling and jointing of phenolic aramid and aluminium honeycomb panels. It is available in 200ml, 400ml cartridges and bulk dispense. Interested? Call us.

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Forgeway’s New Website Goes Live Today

Our commitment to continuous development means we never sit still. Even online. Having unveiled our new brand on pack and in print in April, we turned our attention to our presence online.

We’ve just flicked the switch on a whole new Forgeway website. But don’t expect gimmicks or indulgent widgets. In line with our approach to own our area of speciality, we’ve taken a measured approach – innovation with application.

Less is more, with the intention being to provide just the right information exactly where and when you need it. It’s not a social media platform, or Wikipedia. But it is exactly what our clients said they needed, and it makes a virtue of our bold new brand.

Take a look. You’ll have no problem navigating through our range of products, or discovering more about how they’re being used. You might also learn something new as we’ve dedicated space to sharing technical insights.

Of course, innovative solutions really begin with collaboration, so if our virtual self looks like it can help, pick up the phone and start a real conversation…

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Product focus 002: FORMOA 760 – The answer to underbody protection and more

Over the years, many commercial and mass transit vehicle manufacturers have encountered issues with underbody and chassis protection materials. In response, Forgeway has developed FORMOA 760, a polymer-based coating material that is solvent and isocyanate free, fixing the issue of underbody protection with a few added benefits for our clients…

Issues around underbody and chassis protection materials usually involve the protector drying out, a short half-life, the need for recoating, and have to apply within an extracted area due to solvent content. Extensive masking of underbody parts is also required, meaning yet more time and money.

We don’t think protecting vehicles should be this complicated, so we created FORMOA 760 – a solvent and isocyanate-free coating material. It can be sprayed without fume or particle extraction with minimal overspray. This eliminates the need to mask underbody parts that do not need to be coated. FORMOA 760 also dries to form a tough, durable and protective layer (preventing water ingress and corrosion) with very good adhesion to metals, plastics and painted surfaces. It can be applied from 20 and 200 litre bulk containers, or from a 290ml cartridge via a simple-to-use air-powered gun. Typical coat weight is approximately 200gsm.

In addition, FORMOA 760 has excellent sound deadening qualities resulting in quieter vehicles. It has greater impact resistance, doesn’t dry and crack, has high specific adhesion, attracts no hazardous waste disposal costs and has excellent sound deadening qualities. When you’re looking for underbody protection, choose FORMOA 760.

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Technical insight 002: VOC levels

Volatile Organic Compounds (VOCs) are found in a huge range of products from paints and finishes to deodorant. They are a cause for concern for the Environmental Protection Agency (EPA) and air quality boards across the USA and Europe. VOCs have been found to be a major contributing factor to the production of ozone, a common air pollutant proven to be a public health hazard. Does your current product measure up?

VOCs are defined as “any organic compound whose boiling point is in the range from (50°C to 100°C) to (240°C to 260°C), corresponding to having saturation vapour pressures at 25°C greater than 100kPa (World Health Organisation, as cited in ISO 16000-6).

Many manufacturers are being forced to reduce their VOC levels year on year. Therefore, as part of our commitment to continuous development, and prompted by a specific customer request, we sent our FORMOA 010 product for testing to determine the VOC level. The product was tested to the SCAQMD (rule 1168).

Products tested must have a VOC level of less than 70g/l in order to comply. In both tests FORMOA 010 fell well within the VOC parameters set out in this regulation. The gravimetric test result for FORMOA 010 was 18g/l and the GC/MS (more comprehensive) test result was 2.7g/l.

Clearly FORMOA 010 meets and exceeds the requirements of SCAQMD and also complies with LEED regulations – an internationally recognised third-party verification for green buildings.

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New Rose Gold Formoa – A Problem Solved

All Forgeway’s products start life as a response to a client’s problem. Whether it’s a product developed for a very specific customer application, or a hard-to-match coloured sealant, we pride ourselves on finding a solution for our clients. Our new Rose Gold colour swatch was no different.

In May this year, we were sent a sample of material from one of our aerospace clients, Jamco America. They use a coloured material for their interiors that they had previously been struggling to match with a sealant. The colour was a Metallic Rose Gold. Metallic colours are notoriously hard to match, the challenge was set. The product Jamco was having to use for the application was far from perfect. In order to get the correct colour, they had to mix paint with a clear sealant, thus voiding any guarantees from their supplier and rendering the sealant ineffective.

Within our Formoa range we now offer over 140 colours to match a variety of applications, with no diminution in performance, even in extreme conditions and demanding environments. Using our experience of colour matching we found a solution – adding a bespoke metallic pigment to Formoa crystal polymer base resulted in a perfect match. This new bespoke shade will now be listed as one of our Formoa Colours. If you have a colour that needs matching, come fly with us!

John Hatton, Manufacturing Engineer, Aircraft Seating at Jamco America, was delighted:
“Our customers, program managers, and production staff demand and expect quality from our aircraft interior products. We also operate under strict guidelines regarding the use of adhesives, sealants, and other possibly flammable consumable materials. Forgeway not only provided Jamco America with four off-the-shelf color-matched sealants for one of our high-volume products, but custom matched a metallic Rose Gold to the plated trim pieces of one of our highest-profile, most demanding customer’s interior. If it weren’t for Laila Buckley’s patient assistance in making the perfect match, we would be delivering a less-than-quality product. Not to mention that I’m patting myself on the back for finding what no-one else could – a company willing to go the extra mile to provide exactly the product we need no matter how precise we needed it.”

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Product Focus 003: Aerok 7205 1K Edge Filler does it all

Aerospace engineering is a dynamic industry. With regulations and standards changing regularly, it can be difficult to ensure aircraft compliance. Furthermore, engineers are continuously trying to make their aircraft as light as possible in order to reduce fuel consumption.

Currently, in order to ensure aircrafts are in step with the law, engineers must adhere to fire safety regulations – ABD 0031, the Airbus standard fire test, and FAR/JAR 25.853, the flammability requirement for aircraft interiors.

Forgeway are proud to offer our best-in-class Aerok range of structural adhesives, designed specifically for the aerospace industry. In particular, Aerok 7205 is a single component, heat cured, low density, void and edge filler based on modified epoxy technology and created specifically to meet the requirements of aircraft manufacturers, including ABD 0031 and FAR/JAR 25.853. It also has high specific adhesion to composite and metallic components typically found in aircraft construction.

In addition, Aerok 7205 is cured using elevated temperatures, enabling fabricators to achieve a fast turnaround for specific parts, and developed for application using bulk dispense equipment.

Ipeco Composites gives Aerok 7205 a big thumbs-up: “It’s used as our core filler of choice for our Aerospace interior products. Being a one part-heat curing filler, we find it easy to apply and exhibits excellent results following curing with low shrinkage, good stability and good machining characteristics.”

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Technical insight 003: Fire retardance

When developing a new product, fire protection is a fundamental consideration – there can never be any compromise on standards or product performance. Whilst the threat of fire is a constant across all sectors, each sector has its own rules and regulations.

In recent years, research and development of fire safe materials has focused on preventing ignition and fire growth, and reducing peak heat release rates. Flame retardants are a common solution to this. Flame retardants are used to interrupt the combustion process of a fire, allowing more time for people to escape.

There are several different flame retardant chemistries. Each works to stop the spread of fire by either promoting the formation of char, creating a glassy protective layer, forming an upper intumescent coating or terminating free radical processes in the gaseous phase. Flame retardants can also work by cooling the substrate through endothermic reactions, absorbing heat through the release of water or carbon dioxide and diluting the concentration of gases.

Fire protection across all sectors is measured using three factors – fire, smoke and toxicity (FST). Within these FST regulations, critical factors include the time to ignition, smoke development, flame spread, toxic gases release, corrosive chemical release, and heat generation.

Every sector has a different set of regulations on FST, with different parameters to fit their purpose. For example, a product that is compliant with BS 476 (British Standard fire test on building materials and structures) may not be compliant with FAR/JAR 25.853 (Airworthiness standard).

Many of Forgeway’s products are fire safe, but in order to give a definitive answer on FST properties of one of our sealants or adhesives, we need to be clear about the specific application and what requirements need to be met. For more information on fire safe products, or any of our high performance adhesives, sealants and coatings, give us a call.

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An innovative new Forgeway brand.

2016 is going to be a big year for Forgeway, and it began with the complete redesign of our brand. Obsessed as we are with continuous development, we’ve created a new identity which not only celebrates the chemical ingenuity behind our growing range of products, but also provides a solution to shop floor confusion.

The bonding and adhesive market is dominated by a few big players, but there’s no personality or intelligent collaboration within the supply chain. We are changing that.

We’ve created a stand-out brand based on the periodic table, and used the same principle of categorisation to deliver an innovative identification system to educate users. Identity and information combine to provide an intelligent, non-linguistic solution which ensures the right product gets used on the right job every time. We’re now rolling out the new branding on and offline, and publishing a new monthly newsletter.

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Product focus 001: Welcome to the colour revolution – FORMOA metallics

The Formoa Colours range now includes several metallic colours which have been specifically developed for those hard to match sealant applications where a flat colour doesn’t provide the desired depth. The range of metallic colours currently includes gold, silver, pyrite gold and azure blue.

Specially developed to cover a wide range of industries and applications including bonding and sealing joints on composite, GRP, polycoated steel, concrete, masonry, painted surfaces, flexible and rigid PVC/EPDM, etc. Formoa Colours is suitable for both internal and external use.

The technology we developed to produce the metallic arrange actually helped us deliver another solution for a customer. They wanted a very high gloss red sealant for application in a very demanding environment, but wanted the sealant to remain glossy regardless.

We utilised the same polymer base used to create our Formoa metallics with the addition of a red pigment was added. The result was a very high gloss product that even after QUV testing to ASTM G154 showed little if any reduction. That’s continuous development in application.

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Bonded body home delivery vehicles lighten the load

Clients ask us to help them improve the appearance, durability and productivity of their home delivery vehicles. Forgeway have met the challenge, supporting the manufacture of bonded truck bodies and delivering weight reduction, fuel savings, increased speed and, ultimately, increased productivity.

Old-style riveted body vehicles have been the industry standard for years, but we’ve been more interested in meeting the demand for bonded bodies. In comparison, the benefits are numerous. The appearance of bonded bodies is vastly improved by matching the adhesive to the body colour for a seamless finish. Bonded vehicles are proven to have improved durability and production speed, and vastly reduced water ingress in the finished vehicle.

Apart from being physically lighter, bonding allows manufacturers to use lighter panels and thinner extrusions. This means the end result is substantially lighter than its riveted counterpart, cutting manufacturing costs immediately and reducing running costs in the long term.

Forgeway makes sure its products are as efficient and technically advanced as possible – that’s why we’re not content with current levels of weight reduction. Our FORMOA bonding products are currently undergoing further development in order to make them even lower in density, thereby further decreasing the weight of a bonded body.

We can also offer over 140 colours to match your required body colour, and if you can’t find the right solution within our range, we’ll manufacture bespoke product specifically matched to your substrate or colour reference.

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Technical Insight 002: What are VOCs?

VOCs (Volatile Organic Compounds) are defined as “any organic compound whose boiling point is in the range from 50°C – 100°C to 240°C – 260°C, corresponding to having saturation vapour pressures at 25°C greater than 100kPa” (World Health Organisation, as cited in ISO 16000-6).

Where do you find VOCs?

VOCs are found in a huge range of products from paints and finishes to deodorant. They are a cause for concern for the Environmental Protection Agency (EPA) and air quality boards across the USA and Europe. VOCs have been found to be a major contributing factor to the production of ozone, a common air pollutant proven to be a public health hazard. Does the product you are currently using measure up?

Why are VOC levels relevant to manufacturers?

Many manufacturers are being forced to reduce their VOC levels year on year due to changes in legislation. Therefore, as part of our commitment to continuous development, and prompted by a specific customer request, we sent our FORMOA 010 product for testing to determine the VOC level. The product was tested to the SCAQMD (rule 1168).

Products tested must have a VOC level of less than 70g/l in order to comply. In both tests FORMOA 010 fell well within the VOC parameters set out in this regulation. The gravimetric test result for FORMOA 010 was 18g/l and the GC/MS (more comprehensive) test result was 2.7g/l.

Clearly FORMOA 010 meets and exceeds the requirements of SCAQMD and also complies with LEED regulations – an internationally recognised third-party verification for green buildings.

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Technical Insight 001: Overpaintability of high performance sealants

Today’s demand for higher performance regularly sees dissimilar advanced materials combined to create complex structures, delivering high functionality with aesthetic appeal.

In the automotive and mass transport industries the use of high performance adhesive sealants has grown significantly in recent years, with a technology shift away from mechanical fastenings towards fully bonded structures. The associated weight reductions have a two-fold impact, lowering fuel consumption and raising payloads.

Along with these advances in engineering design, the requirement for high quality livery finishes has increased dramatically with a plethora of fully branded home-delivery vehicles on our roads, servicing the boom in on-line shopping. One big challenge in maintaining the aesthetics of these fleets is the need to seal joints with a colour-matched sealant or indeed to have a sealant that can be successfully over painted.

For the chemists involved in sealant formulation, there is a significant challenge to get the paint to adhere to cured sealant – chemical compatibility between sealant and paint; differing levels of hardness; differing paint application processes and the effect of joint design on sealant bead profile, to name a few. In the building of mass transit vehicles much use is made of high-performance epoxy etch primers in conjunction with epoxy or PU 2-pack top coat finishes. It is very important for vehicle durability that a high level of adhesion is achieved to all substrates, particularly the sealed seams where differing materials join. Paint adhesion failure on the sealed joints will incur significant costs to operators.

The latest generation of seam sealants in the FORMOA range demonstrate very high levels of paint adhesion. To test the adhesion of various paint systems to our adhesives and sealants we use the Cross Hatch Test (DIN EN 2409, ASTM D3002, D3359). This determines the adhesion of a paint to any substrate, in this case the sealant. Each substrate is then given a score to determine the level of paint adhesion to that substrate. Ask us for the results when considering your next order.

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