TB 26-01 Evaluation of Adhesive and Solvent Alternatives for Polymeric Bonding Applications

Why It Matters

Replacing a hazardous solvent safeguards supply chains and aligns NASA with stricter environmental standards, reducing risk for future missions.

Key Takeaways

• NASA assessed non‑toxic solvent alternatives for polymer bonding
• Dichloromethane faces potential EPA TSCA regulatory limits
• Alternatives include water‑based adhesives and low‑VOC solvents
• Evaluation focused on bond strength, outgassing, and compatibility
• Findings guide future spacecraft material procurement and compliance

Pulse Analysis

The push to replace dichloromethane reflects a broader industry shift toward greener manufacturing processes. As the EPA tightens controls under the Toxic Substances Control Act, aerospace firms must anticipate material substitutions that meet both performance and regulatory criteria. NASA’s Engineering and Safety Center leveraged its expertise to screen candidates ranging from aqueous polymer systems to proprietary low‑volatile organic compounds, ensuring that any new adhesive maintains the optical clarity required for transparent polymeric assemblies.

Key performance metrics in the evaluation centered on three pillars: mechanical integrity, outgassing behavior, and long‑term material compatibility. Bond strength tests demonstrated that several water‑based formulations achieved parity with traditional solvent bonds, while low‑VOC options exhibited superior resistance to thermal cycling. Outgassing measurements, critical for vacuum environments, showed a marked reduction in volatile emissions, directly benefiting spacecraft contamination control protocols. Compatibility assessments confirmed that the alternatives did not degrade polymer substrates or interfere with adjacent components, a vital consideration for complex flight hardware.

The implications extend beyond NASA’s immediate needs. By establishing a vetted portfolio of safer adhesives, the agency sets a precedent for commercial satellite manufacturers and defense contractors facing similar regulatory pressures. Adoption of these alternatives can lower operational costs associated with hazardous waste handling and improve overall environmental compliance. Moreover, the study’s methodology offers a replicable framework for other sectors seeking to transition away from legacy solvents without compromising product performance.