Failure Case Library
Real-world adhesive failure cases, anonymized and shared to help engineers learn faster.
Cyanoacrylate Debonding on Aluminum-ABS Assembly
Production failure where CA bonds failed within 2 weeks. Root cause: surface contamination combined with thermal cycling.
Epoxy Cracking in High-Temperature Electronics
Structural epoxy developed cracks after thermal cycling. CTE mismatch between ceramic substrate and rigid epoxy caused stress fractures.
Polyurethane Adhesive Softening in Chemical Environment
PU adhesive degraded when exposed to gasoline. Chemical incompatibility caused bond strength to drop below threshold.
Silicone Sealant Discoloration from UV Exposure
Outdoor silicone sealant turned yellow after 6 months. Non-UV-stabilized formulation used in direct sunlight application.
Acrylic Bond Substrate Failure on Medical Device
Substrate failure on thin-wall polycarbonate housing. Bond exceeded substrate strength, causing housing crack during drop test.
Anaerobic Threadlocker Failure Under Vibration
Threadlocker failed on bolts subjected to high-frequency vibration. Insufficient cure time before assembly went into service.