spore: profile
id: loctite-ea-9394
spore_version: '0.2'
family: epoxy
name: LOCTITE EA 9394 AERO (Hysol EA 9394) epoxy paste adhesive
abbreviation: EA 9394
role: two-part structural epoxy paste adhesive for bonding, potting and liquid shims
category: seals-adhesives
type: adhesives
summary: |
  LOCTITE EA 9394 AERO, also known as Hysol EA 9394, is a two-part epoxy paste that cures at room temperature. Henkel's bulletin prints a tensile lap shear strength of 28.9 MPa (4,200 psi) at 25 °C on bare 2024-T3 aluminium and a service temperature of 177 °C (350 °F). NASA's 1993 outgassing compilation lists the EA 9394 rows with total mass loss of 1.02 to 1.74 %, which is above the 1.0 % screening level used for low-outgassing materials.
best_for: Room-temperature structural bonding, potting and liquid shims where a 177 °C (350 °F) service temperature is needed, per Henkel
weakest_at: 'Outgassing and heat: all eight EA 9394 rows read in NASA''s listing are above 1.0 % total mass loss, and lap shear falls to 8.3 MPa at 177 °C'
identity:
  formula: 'Two-part amine-cured epoxy paste: a Part A epoxy resin with aluminium filler and a Part B amine hardener (composition ranges in story.recipe)'
  designations:
    - system: Trade name
      code: LOCTITE EA 9394 AERO
      source: henkel-tds
      where: Title block, first line
    - system: Trade name
      code: Hysol EA 9394
      source: henkel-tds
      where: Title block, KNOWN AS Hysol EA 9394
    - system: Trade name
      code: EA 9394
      source: nasa-rp1124
      where: Section I (Adhesives) listing, material column; manufacturer code HYS (Hysol)
  source: henkel-tds
  where: Henkel bulletin title block and Introduction; Part A SDS Section 1 and Part B SDS Section 1
tags:
  environments: []
  stresses:
    - vacuum-and-outgassing
  applications:
    - structures
properties:
  - benchmark: density
    label: Density, mixed adhesive (Part A plus Part B by weight 100:17)
    value: 1.36
    unit: g/ml
    scope: material
    conditions:
      state: mixed two-part paste
      temperature: not printed in the bulletin
    method: Typical value printed in the Uncured Properties table of the Henkel bulletin
    status: ground
    source: henkel-tds
    where: Uncured Properties table, Density (g/ml), Mixed column
  - benchmark: density
    label: Density, Part A (epoxy component)
    value: 1.5
    unit: g/ml
    scope: material
    conditions:
      state: Part A, uncured
      temperature: not printed in the bulletin
    method: Typical value printed in the Uncured Properties table of the Henkel bulletin
    status: ground
    note: The Part A SDS (Revision 006.3) prints relative density 1.49 with no unit or temperature. The bulletin value is kept here; the SDS value is not recorded as a property.
    source: henkel-tds
    where: Uncured Properties table, Density (g/ml), Part A column
  - benchmark: density
    label: Density, Part B (amine hardener)
    value: 1
    unit: g/ml
    scope: material
    conditions:
      state: Part B, uncured
      temperature: not printed in the bulletin
    method: Typical value printed in the Uncured Properties table of the Henkel bulletin
    status: ground
    note: The Part B SDS (Revision 005.2) prints density 1.0 with no unit or temperature. The bulletin value is kept here.
    source: henkel-tds
    where: Uncured Properties table, Density (g/ml), Part B column
  - benchmark: dynamic_viscosity
    label: Viscosity, mixed adhesive at 25 °C
    value: 160
    unit: Pa·s
    scope: material
    conditions:
      temperature: 25 °C
      spindle: Brookfield HBT Spdl 5 at 2.09 rad/s
      state: mixed two-part paste
    method: Brookfield HBT typical value as printed in the bulletin
    status: ground
    note: The same table gives 400 to 800 Pa·s for Part A and 20 to 70 Pa·s for Part B at 25 °C. The Part A SDS prints 400,000 to 800,000 mPa·s, which matches.
    source: henkel-tds
    where: Uncured Properties table, Viscosity 25 °C Brookfield, Mixed column
  - benchmark: pot_life
    label: Pot life, 450 g mass
    value: 90
    unit: min
    scope: material
    conditions:
      temperature: 25 °C (75 °F)
      mass: 450 g
      method_as_printed: ASTM D 2471 in water bath
    method: Typical value printed in the Handling section of the bulletin
    status: ground
    source: henkel-tds
    where: Handling, Pot Life (450 gram mass)
  - benchmark: shelf_life
    label: Shelf life when stored below 25 °C
    value: 1
    unit: year
    scope: material
    conditions:
      storage: below 25 °C (77 °F)
    method: Typical value printed in the Uncured Properties table
    status: ground
    source: henkel-tds
    where: Uncured Properties table, Shelf Life row
  - benchmark: max_service_temp
    label: Service temperature (1000 psi lap shear retained)
    value: 177
    unit: °C
    scope: material
    conditions:
      definition: temperature at which the adhesive still retains 1000 psi (6.9 MPa) tensile lap shear strength, ASTM D1002
      printed_as: 350 °F
    method: Service temperature definition as printed in the bulletin
    status: ground
    source: henkel-tds
    where: Service Temperature section
  - benchmark: lap_shear_strength
    label: Tensile lap shear strength at -55 °C
    value: 22.7
    unit: MPa
    scope: material
    conditions:
      test_temperature: '-67 °F / -55 °C'
      cure: 5 days at 25 °C
      standard: ASTM D1002
      adherends: 2024-T3 bare aluminium, phosphoric acid anodized per ASTM D3933
    method: Typical result printed in the bulletin (3,300 psi printed alongside)
    status: ground
    source: henkel-tds
    where: Bond Strength Performance, Tensile Lap Shear Strength table, row -67/-55
  - benchmark: lap_shear_strength
    label: Tensile lap shear strength at 25 °C
    value: 28.9
    unit: MPa
    scope: material
    conditions:
      test_temperature: 77 °F / 25 °C
      cure: 5 days at 25 °C
      standard: ASTM D1002
      adherends: 2024-T3 bare aluminium, phosphoric acid anodized per ASTM D3933
    method: Typical result printed in the bulletin (4,200 psi printed alongside)
    status: ground
    source: henkel-tds
    where: Bond Strength Performance, Tensile Lap Shear Strength table, row 77/25
  - benchmark: lap_shear_strength
    label: Tensile lap shear strength at 82 °C
    value: 20.7
    unit: MPa
    scope: material
    conditions:
      test_temperature: 180 °F / 82 °C
      cure: 5 days at 25 °C
      standard: ASTM D1002
      adherends: 2024-T3 bare aluminium, phosphoric acid anodized per ASTM D3933
    method: Typical result printed in the bulletin (3,000 psi printed alongside)
    status: ground
    source: henkel-tds
    where: Bond Strength Performance, Tensile Lap Shear Strength table, row 180/82
  - benchmark: lap_shear_strength
    label: Tensile lap shear strength at 177 °C
    value: 8.3
    unit: MPa
    scope: material
    conditions:
      test_temperature: 350 °F / 177 °C
      cure: 5 days at 25 °C
      standard: ASTM D1002
      adherends: 2024-T3 bare aluminium, phosphoric acid anodized per ASTM D3933
    method: Typical result printed in the bulletin (1,200 psi printed alongside)
    status: ground
    note: Above the 6.9 MPa (1000 psi) retention level that defines the 177 °C service temperature.
    source: henkel-tds
    where: Bond Strength Performance, Tensile Lap Shear Strength table, row 350/177
  - benchmark: lap_shear_strength
    label: Tensile lap shear strength at 204 °C
    value: 4.1
    unit: MPa
    scope: material
    conditions:
      test_temperature: 400 °F / 204 °C
      cure: 5 days at 25 °C
      standard: ASTM D1002
      adherends: 2024-T3 bare aluminium, phosphoric acid anodized per ASTM D3933
    method: Typical result printed in the bulletin (600 psi printed alongside)
    status: ground
    source: henkel-tds
    where: Bond Strength Performance, Tensile Lap Shear Strength table, row 400/204
  - benchmark: ultimate_tensile_strength
    label: Tensile strength, bulk casting
    value: 46
    unit: MPa
    scope: material
    conditions:
      form: 0.125 in (3.18 mm) bulk castings
      temperature: 25 °C (77 °F)
      standard: ASTM D638
    method: Typical value printed in the bulletin (6,675 psi printed alongside)
    status: ground
    source: henkel-tds
    where: Bulk Resin Properties, Tensile Strength row
  - benchmark: elastic_modulus
    label: Tensile modulus, bulk casting
    value: 4237
    unit: MPa
    scope: material
    conditions:
      form: 0.125 in (3.18 mm) bulk castings
      temperature: 25 °C (77 °F)
      standard: ASTM D638
    method: Typical value printed in the bulletin (615 ksi printed alongside)
    status: ground
    source: henkel-tds
    where: Bulk Resin Properties, Tensile Modulus row
  - benchmark: shear_modulus
    label: Shear modulus, dry
    value: 1461
    unit: MPa
    scope: material
    conditions:
      condition: dry
      temperature: 25 °C (77 °F)
    method: Typical value printed in the bulletin; test standard not printed (212 ksi printed alongside)
    status: ground
    source: henkel-tds
    where: Bulk Resin Properties, Shear Modulus dry row
  - benchmark: shear_modulus
    label: Shear modulus, wet
    value: 1027
    unit: MPa
    scope: material
    conditions:
      condition: wet
      temperature: 25 °C (77 °F)
    method: Typical value printed in the bulletin; test standard and wetting method not printed (149 ksi printed alongside)
    status: ground
    source: henkel-tds
    where: Bulk Resin Properties, Shear Modulus wet row
  - benchmark: elongation
    label: Elongation at break, bulk casting
    value: 1.66
    unit: '%'
    scope: material
    conditions:
      temperature: 25 °C (77 °F)
    method: Typical value printed in the tensile-properties block of the bulletin
    status: ground
    source: henkel-tds
    where: Bulk Resin Properties, Elongation at Break row
  - benchmark: shore_d_hardness
    label: Shore D hardness
    value: 88
    unit: Shore D
    scope: material
    conditions:
      temperature: 25 °C (77 °F)
    method: Typical value printed in the bulletin; test standard not printed
    status: ground
    source: henkel-tds
    where: Bulk Resin Properties, Shore D Hardness row
  - benchmark: glass_transition_temperature
    label: Glass transition temperature, dry
    value: 78
    unit: °C
    scope: material
    conditions:
      condition: dry
    method: Typical value printed in the bulletin; test method not printed (172 °F printed alongside)
    status: ground
    source: henkel-tds
    where: Bulk Resin Properties, Tg dry row
  - benchmark: glass_transition_temperature
    label: Glass transition temperature, wet
    value: 68
    unit: °C
    scope: material
    conditions:
      condition: wet
    method: Typical value printed in the bulletin; test method and wetting method not printed (154 °F printed alongside)
    status: ground
    source: henkel-tds
    where: Bulk Resin Properties, Tg wet row
  - benchmark: compressive_strength
    label: Compressive strength, bulk casting
    value: 68.9
    unit: MPa
    scope: material
    conditions:
      temperature: 25 °C (77 °F)
      specimen: 0.5 in (12.7 mm) wide, 1.0 in (25.4 mm) long, 0.5 in (12.7 mm) high
      standard: ASTM D695
    method: Typical value printed in the bulletin (10,000 psi printed alongside)
    status: ground
    source: henkel-tds
    where: Compressive Properties section
  - benchmark: dielectric_constant
    label: Dielectric constant at 1.0 kHz
    value: 7.51
    unit: '-'
    scope: material
    conditions:
      frequency: 1.0 kHz
      standards_as_printed: ASTM D149, D150
    method: Typical value printed in the Electrical Properties table of the bulletin
    status: ground
    source: henkel-tds
    where: Electrical Properties table, Dielectric Constant, 1.0 KHz column
  - benchmark: dissipation_factor
    label: Dissipation factor at 1.0 kHz
    value: 0.022
    unit: '-'
    scope: material
    conditions:
      frequency: 1.0 kHz
      standards_as_printed: ASTM D149, D150
    method: Typical value printed in the Electrical Properties table of the bulletin
    status: ground
    source: henkel-tds
    where: Electrical Properties table, Dissipation Factor, 1.0 KHz column
  - benchmark: thermal_conductivity
    label: Thermal conductivity
    value: 0.331
    unit: W/(m•K)
    scope: material
    conditions:
      bulletin_print: 7.92 x 10-4 cal/sec-cm-°C, with 0.331 W/(m•K) in brackets
      test_standard: not printed
    method: Bracketed SI value as printed in the bulletin
    status: ground
    source: henkel-tds
    where: Electrical Properties table, Thermal Conductivity row
  - benchmark: cte
    label: Coefficient of thermal expansion at 40 °C
    value: 55.6
    unit: µm/m°C
    scope: material
    conditions:
      temperature: 40 °C
    method: Value printed in the bulletin; test standard not printed
    status: ground
    source: henkel-tds
    where: Electrical Properties table, Coefficient of Thermal Expansion, first row
  - benchmark: cte
    label: Coefficient of thermal expansion at 100 °C
    value: 80.6
    unit: µm/m°C
    scope: material
    conditions:
      temperature: 100 °C
    method: Value printed in the bulletin; test standard not printed
    status: ground
    source: henkel-tds
    where: Electrical Properties table, Coefficient of Thermal Expansion, second row
  - benchmark: outgassing_tml
    label: Total mass loss, EA 9394 row GSC17063 (7 days at 25 °C)
    value: 1.71
    unit: '%'
    scope: material
    conditions:
      data_reference: GSC17063
      cure: 7 days at 25 °C
      atmosphere_as_printed: AIR
      standard: ASTM E595 (TML), as described in the compilation introduction
    method: Value listed in NASA RP-1124 Rev 3, Section I (Adhesives)
    status: ground
    note: Above the 1.0 % TML level that the compilation uses to define low-outgassing materials. Other EA 9394 rows in the same listing give 1.02 to 1.74 %.
    source: nasa-rp1124
    where: Section I (Adhesives) listing, EA 9394 row, data reference GSC17063, %TML column
  - benchmark: outgassing_cvcm
    label: Collected volatile condensable material, EA 9394 row GSC17063
    value: 0.04
    unit: '%'
    scope: material
    conditions:
      data_reference: GSC17063
      cure: 7 days at 25 °C
      atmosphere_as_printed: AIR
      standard: ASTM E595 (CVCM), as described in the compilation introduction
    method: Value listed in NASA RP-1124 Rev 3, Section I (Adhesives)
    status: ground
    source: nasa-rp1124
    where: Section I (Adhesives) listing, EA 9394 row, data reference GSC17063, %CVCM column
  - benchmark: outgassing_tml
    label: Total mass loss, EA 9394 row GSC17085 (7 days at 25 °C)
    value: 1.14
    unit: '%'
    scope: material
    conditions:
      data_reference: GSC17085
      cure: 7 days at 25 °C
      atmosphere_as_printed: AIR
      standard: ASTM E595 (TML), as described in the compilation introduction
    method: Value listed in NASA RP-1124 Rev 3, Section I (Adhesives)
    status: ground
    note: Still above the 1.0 % TML level. The second row for the same product gives 1.71 % (GSC17063), so the two rows disagree; both are kept.
    source: nasa-rp1124
    where: Section I (Adhesives) listing, EA 9394 row, data reference GSC17085, %TML column
  - benchmark: outgassing_cvcm
    label: Collected volatile condensable material, EA 9394 row GSC17085
    value: 0
    unit: '%'
    scope: material
    conditions:
      data_reference: GSC17085
      cure: 7 days at 25 °C
      atmosphere_as_printed: AIR
      standard: ASTM E595 (CVCM), as described in the compilation introduction
    method: Value listed as 0.00 in NASA RP-1124 Rev 3, Section I (Adhesives)
    status: ground
    source: nasa-rp1124
    where: Section I (Adhesives) listing, EA 9394 row, data reference GSC17085, %CVCM column
corrosion:
  - environment: Water, isopropyl alcohol, hydraulic oil and JP-4 fuel, 7 days at 25 °C
    headline: Lap shear strength stayed at 27.6 to 28.9 MPa after 7 days in four fluids, against 29.6 MPa for the unexposed control.
    effect: Henkel printed lap shear strengths of 28.2 MPa after water, 27.6 MPa after isopropyl alcohol, 28.2 MPa after hydraulic oil and 28.9 MPa after JP-4 fuel, each after 7 days at 25 °C, against 29.6 MPa for the room-temperature control. The bulletin gives no pass or fail limit, so the rating is an assistant judgement from these printed values.
    rating: low
    conditions:
      test: tensile lap shear, ASTM D1002, 2024-T3 aluminium
      exposure: 7 days at 25 °C (77 °F)
    source: henkel-tds
    where: Bond Strength Performance, After Exposure to/Test Temperature table
  - environment: Humid air during a long open time in large assemblies
    headline: Henkel recommends precautions against carbonate formation in large, humid assemblies left open for a long time.
    effect: The bulletin says special precautions are recommended to minimize carbonate formation in large assemblies subject to extended open times in humid environments, and that Henkel can supply a memo with suggestions on request. The bulletin prints no amount of carbonate and no test result.
    rating: unknown
    conditions:
      basis: statement only, no test data in the bulletin
    source: henkel-tds
    where: Handling, note after the Failure to follow paragraph (carbonate formation)
  - environment: Moisture absorbed by the cured resin
    headline: The glass transition falls from 78 °C dry to 68 °C wet.
    effect: The bulletin prints a glass transition of 78 °C dry and 68 °C wet, and a shear modulus of 1461 MPa dry against 1027 MPa wet, both at 25 °C. It does not say how the wet condition was reached or for how long.
    rating: moderate
    conditions:
      basis: bulk casting; test method and wetting method not printed
    source: henkel-tds
    where: Bulk Resin Properties, Tg dry and Tg wet rows; Shear Modulus dry and wet rows
  - environment: Elevated temperature in service
    headline: Lap shear strength falls from 28.9 MPa at 25 °C to 8.3 MPa at 177 °C and 4.1 MPa at 204 °C.
    effect: Printed lap shear values are 28.9 MPa at 25 °C, 20.7 MPa at 82 °C, 8.3 MPa at 177 °C and 4.1 MPa at 204 °C, after a 5-day cure at 25 °C and tested per ASTM D1002. Henkel defines the 177 °C service temperature as the point where lap shear is still 6.9 MPa (1000 psi).
    rating: moderate
    conditions:
      basis: tensile lap shear, ASTM D1002, 2024-T3 aluminium with phosphoric acid anodize per ASTM D3933
    source: henkel-tds
    where: Bond Strength Performance, Tensile Lap Shear Strength table; Service Temperature section
risks:
  hazards:
    - text: Part A is labelled WARNING with H315 (causes skin irritation), H317 (may cause an allergic skin reaction) and H319 (causes serious eye irritation), per the Henkel Part A safety data sheet, Revision 006.3, issued 03/26/2025.
      ghs:
        - H315
        - H317
        - H319
      source: henkel-sds-parta
      where: Section 2, hazard statements and signal word
    - text: Part B is labelled DANGER with H302 (harmful if swallowed), H314 (causes severe skin burns and eye damage) and H317 (may cause an allergic skin reaction), per the Henkel Part B safety data sheet, Revision 005.2, issued 06/20/2025. The SDS lists acute oral toxicity category 4, skin corrosion 1C and serious eye damage category 1.
      ghs:
        - H302
        - H314
        - H317
      source: henkel-sds-partb
      where: Section 2, hazard class table and hazard statements
    - text: 'PubChem aggregates ECHA C&L notifications for tetraethylenepentamine (CID 8197), the amine that the Part B SDS lists as a hazardous component at 30 to 60 percent. Printed statements: H302 (99.9%), H312 (90.7%), H314 (99.9%), H317 (> 99.9%), H318 (43.7%), H334 (31.1%) and H411 (93.1%), plus H311 and H330 with no percentage printed. Danger for H311, H314, H318, H330 and H334; Warning for H302, H312 and H317. Aggregated from 1834 reports by companies from 22 notifications to the ECHA C&L Inventory. This is the pure substance, not the mixed adhesive.'
      ghs:
        - H302
        - H311
        - H312
        - H314
        - H317
        - H318
        - H330
        - H334
        - H411
      source: pubchem-tepa
      where: GHS Classification, Aggregated GHS information (CID 8197)
    - text: 'PubChem aggregates ECHA C&L notifications for bisphenol A diglycidyl ether (CID 2286), a bisphenol A epoxy resin. The Part A SDS names an epichlorohydrin and 4,4''-isopropylidene diphenol resin, not this monomer. Printed statements: H315 (> 99.9%), H317 (> 99.9%), H319 (> 99.9%) and H411 (50.9%), all with the Warning signal word. Aggregated from 1027 reports by companies from 12 notifications to the ECHA C&L Inventory.'
      ghs:
        - H315
        - H317
        - H319
        - H411
      source: pubchem-badge
      where: GHS Classification, Aggregated GHS information (CID 2286)
  failure_risks:
    - mode: Uncontrolled heat build-up in a large mixed batch
      trigger: Mixing more than 450 g of Part A and Part B in one batch
      consequence: Dangerous heat buildup can occur, causing uncontrolled decomposition of the mixed adhesive and toxic fumes, which can cause personal injury, according to the bulletin.
      severity: high
      source: henkel-tds
      where: Application, Mixing
    - mode: Adhesive cures in the static mixer and blocks the cartridge
      trigger: Leaving the mixed adhesive in the static mixer unattended for more than 90 minutes, or applying high pressure to an overheated cartridge
      consequence: Curing in the mixer produces back pressure when the plungers are triggered again, which can cause cartridge failure. The bulletin also reports 200 ml kit failures when inlet pressure is set too high.
      severity: moderate
      source: henkel-tds
      where: Dual Cartridge Application
    - mode: Loading the joint before full cure
      trigger: Applying load at the 24-hour handling point
      consequence: Full bond strength is not yet attained at handling strength, so the bulletin says load application should be small at this time.
      severity: moderate
      source: henkel-tds
      where: Application, Applying
  side_effects:
    - text: On decomposition, both parts emit carbon monoxide, carbon dioxide, low molecular weight hydrocarbons and oxides of nitrogen, according to their safety data sheets.
      affects: People in the fire area and the enclosure
      source: henkel-sds-parta
      where: Section 10, Hazardous decomposition products (Part A); Section 10 of the Part B SDS in the same PDF
  handling:
    - text: Keep Part A in a tightly closed container in a cool, well-ventilated place, away from incompatible materials (strong acids, oxidizing agents and amines). Part B is kept away from strong oxidizing agents and strong Lewis or mineral acids.
      source: henkel-sds-parta
      where: Section 7 and Section 10 (Part A); Section 10 (Part B)
    - text: Use with adequate ventilation. Avoid getting it in eyes or on skin and avoid breathing vapors, and wash thoroughly after handling, per the bulletin's precautionary information. The bulletin says the material is for industrial use only.
      source: henkel-tds
      where: Handling Precautions and Precautionary Information, General
  mitigations:
    - text: Do not mix more than 450 g at once, and mix smaller quantities to minimize heat buildup, per the bulletin.
      source: henkel-tds
      where: Application, Mixing
    - text: Do not pre-heat dual-cartridge kits above 90 °F for more than four hours, and do not place assembled cartridges upright in the oven.
      source: henkel-tds
      where: Dual Cartridge Application
uses:
  - application: structures
    device: Structural bonding of aerospace aluminium parts
    example: Henkel describes LOCTITE EA 9394 AERO as a two-part structural paste adhesive that cures at room temperature, and states that it is qualified to MMM-A-132 Rev B, Type I, Class 3, Form 3, Group 1.
    source: henkel-tds
    where: Introduction
  - application: structures
    device: Potting, filling and liquid shims
    example: The bulletin lists potting, filling and liquid shim applications, and says the thixotropic paste has good gap-filling capability. It names no specific device.
    source: henkel-tds
    where: Introduction and Features
supply:
  - subject: LOCTITE EA 9394 AERO (Henkel Corporation product)
    abundance: 'Not applicable: a formulated two-part product, not an element. No feedstock tonnage for epoxy resin or amine hardener was found in any source read.'
    producers:
      - country: United States
    critical_lists: []
    recycling: Not found in any source read.
    substitutes: []
    source: henkel-tds
    where: 'Bulletin header and footer (Henkel Corporation Aerospace, 2850 Willow Pass Road, Bay Point, CA); Part A SDS Section 1 (Region: United States)'
  - subject: Aluminium, the metal in the Part A filler
    abundance: 'USGS smelter production in 2025, estimated, in thousand metric tons: China 45,000; United States 660; world total 74,000. The Part A SDS lists aluminum as a hazardous component, so the metal is part of this product.'
    producers:
      - country: China
      - country: United States
    critical_lists: []
    recycling: 'USGS: about 3.6 million tons of aluminum was recovered from purchased scrap in the United States in 2025, about 56% from new scrap and 44% from old scrap.'
    substitutes: []
    source: usgs-mcs2026-al
    where: Aluminum chapter, World Smelter Production and Capacity table (Smelter production 2025e column); Domestic Production and Use paragraph for recycling
documents:
  - title: LOCTITE EA 9394 AERO Epoxy Paste Adhesive, Technical Process Bulletin (Henkel, Rev. 7/2015)
    type: datasheet
    url: https://dm.henkel-dam.com/is/content/henkel/EA-9394-Aero
    year: 2015
  - title: LOCTITE EA 9394 AERO PART A safety data sheet, Revision 006.3 (issued 03/26/2025), hosted on a reseller CDN
    type: sds
    url: https://cdn11.bigcommerce.com/s-jifykode7m/product_images/uploaded_images/msds/SGP93319.pdf
    year: 2025
  - title: LOCTITE EA 9394 AERO PART B safety data sheet, Revision 005.2 (issued 06/20/2025), same PDF as Part A
    type: sds
    url: https://cdn11.bigcommerce.com/s-jifykode7m/product_images/uploaded_images/msds/SGP93319.pdf
    year: 2025
  - title: Outgassing Data for Selecting Spacecraft Materials, NASA Reference Publication 1124, Rev. 3
    type: report
    url: https://ntrs.nasa.gov/api/citations/19940017416/downloads/19940017416.pdf
    year: 1993
  - title: Aluminum, Mineral Commodity Summaries 2026 (USGS)
    type: report
    url: https://pubs.usgs.gov/periodicals/mcs2026/mcs2026-aluminum.pdf
    year: 2026
  - title: Tetraethylenepentamine, PubChem CID 8197, GHS Classification (aggregated ECHA C&L notifications)
    type: database
    url: https://pubchem.ncbi.nlm.nih.gov/rest/pug_view/data/compound/8197/JSON?heading=GHS+Classification
  - title: Bisphenol A diglycidyl ether, PubChem CID 2286, GHS Classification (aggregated ECHA C&L notifications)
    type: database
    url: https://pubchem.ncbi.nlm.nih.gov/rest/pug_view/data/compound/2286/JSON?heading=GHS+Classification
gaps:
  - 'Flight heritage: the candidate note says EA 9394 has flight heritage, but no source read in this run states that the adhesive has flown. Not recorded.'
  - No NASA flight, thermal-vacuum or ASTM E595 test report for EA 9394 beyond the 1993 compilation rows was read. Water vapor regained (WVR) values in the same rows (0.70 % and 0.33 %) are not recorded.
  - Part A relative density 1.49 and Part B density 1.0 printed in the SDSs have no unit or temperature, so they are not recorded as values. The bulletin's g/ml values are used instead.
  - Aluminium corrosion, galvanic compatibility and primer or surface-treatment data were not found in any source read.
  - 'Carbonate formation: the Henkel memo on minimizing it is available on request and was not read; no quantity or test result was found.'
  - Chemical resistance was read only for water, isopropyl alcohol, hydraulic oil and JP-4 fuel; other solvents and fluids were not found.
  - Test standards for glass transition, Shore D hardness, tensile modulus and shear modulus are not printed in the bulletin, so conditions give only the method stated.
  - 'Benchmark names not in the canonical list and used as short snake_case names: dynamic_viscosity, pot_life, shelf_life, lap_shear_strength, compressive_strength, shore_d_hardness.'
  - 'Aluminium critical-mineral listing: the USGS aluminum chapter read here does not print one, so critical_lists is empty. The USGS 2025 critical list and the EU list were not read for this profile.'
  - 'Supply: no market share, producer tonnage or critical-mineral listing for epoxy resin or amine hardener was found in any source read.'
  - Electronics potting data (dielectric values beyond 1.0 kHz, moisture-resistance tests and thermal shock) were not found beyond the bulletin's single-frequency values.
  - 'Volume resistivity of 4.05 x 10^13 ohm-cm (Henkel bulletin, Electrical Properties table) was dropped: the PDF text prints the exponent as a superscript that the value check cannot match, so the value was removed rather than kept unverified.'
  - 'Cure to full strength at elevated temperature: the bulletin gives only the single 1 hour at 66 °C cure for complete cure, with no mechanical data for that cure.'
sources:
  henkel-tds:
    title: LOCTITE EA 9394 AERO Epoxy Paste Adhesive, Technical Process Bulletin (known as Hysol EA 9394)
    id: Henkel Corporation Aerospace, Rev. 7/2015
    url: https://dm.henkel-dam.com/is/content/henkel/EA-9394-Aero
    year: 2015
    kind: datasheet
    license: manufacturer datasheet, linked not reproduced
  henkel-sds-parta:
    title: LOCTITE EA 9394 AERO PART A safety data sheet
    id: Revision 006.3, issued 03/26/2025, IDH number 2946077
    url: https://cdn11.bigcommerce.com/s-jifykode7m/product_images/uploaded_images/msds/SGP93319.pdf
    year: 2025
    kind: datasheet
    license: supplier SDS, linked not reproduced
  henkel-sds-partb:
    title: LOCTITE EA 9394 AERO PART B safety data sheet
    id: Revision 005.2, issued 06/20/2025, IDH number 937062, item AB9277016
    url: https://cdn11.bigcommerce.com/s-jifykode7m/product_images/uploaded_images/msds/SGP93319.pdf
    year: 2025
    kind: datasheet
    license: supplier SDS, linked not reproduced
  nasa-rp1124:
    title: Outgassing Data for Selecting Spacecraft Materials, NASA Reference Publication 1124, Rev. 3 (Campbell and Scialdone, 1993)
    id: NASA RP-1124 Rev 3; NTRS 19940017416; N94-21889
    url: https://ntrs.nasa.gov/api/citations/19940017416/downloads/19940017416.pdf
    year: 1993
    kind: report
    license: NASA public document
  usgs-mcs2026-al:
    title: Aluminum, Mineral Commodity Summaries 2026 (USGS)
    id: USGS MCS 2026, Aluminum chapter (2025 estimates)
    url: https://pubs.usgs.gov/periodicals/mcs2026/mcs2026-aluminum.pdf
    year: 2026
    kind: report
    license: US government publication, public domain
  pubchem-tepa:
    title: Tetraethylenepentamine, PubChem CID 8197, GHS Classification
    id: PubChem CID 8197, aggregated GHS notifications (ECHA C&L Inventory)
    url: https://pubchem.ncbi.nlm.nih.gov/rest/pug_view/data/compound/8197/JSON?heading=GHS+Classification
    kind: database
    license: PubChem, public domain
  pubchem-badge:
    title: Bisphenol A diglycidyl ether, PubChem CID 2286, GHS Classification
    id: PubChem CID 2286, aggregated GHS notifications (ECHA C&L Inventory)
    url: https://pubchem.ncbi.nlm.nih.gov/rest/pug_view/data/compound/2286/JSON?heading=GHS+Classification
    kind: database
    license: PubChem, public domain
  wikipedia-epoxy:
    title: Epoxy, Wikipedia
    id: Epoxy article, definitions and curing chemistry
    url: https://en.wikipedia.org/wiki/Epoxy
    kind: web
    license: CC BY-SA 4.0, linked not reproduced
license: CC-BY-4.0
updated: '2026-11-01'
review:
  status: draft
  method: assistant
  checked_values: 30
  unreachable: 0
  caveats: 3
  note: 'Values read by an AI assistant on 2026-11-01 from the Henkel bulletin (Rev. 7/2015), the Henkel Part A and Part B safety data sheets (Revisions 006.3 and 005.2) and NASA RP-1124 Rev 3, all fetched in this run. Caveats: the bulletin gives Part A density 1.50 g/ml against 1.49 printed in the SDS; the two NASA rows for the same product disagree on TML (1.71 % and 1.14 %); and no test standard is printed for Tg, hardness or modulus.'
story:
  recipe:
    line: LOCTITE EA 9394 AERO is a two-part paste. Part A is an epoxy resin with aluminium filler, and Part B is an amine hardener. Henkel's bulletin mixes them 100 parts Part A to 17 parts Part B by weight. The ranges below are per part, as printed in each safety data sheet, and the SDS says exact percentages may vary or are trade secret. Epoxy resins are reactive prepolymers with epoxide groups, and amine hardeners cross-link them into a network (Wikipedia, Epoxy).
    parts:
      - name: Aluminum (Part A)
        symbol: Al
        share_percent: 30
        share_high: 60
        role: Aluminium metal, listed as a hazardous component of Part A.
        source: henkel-sds-parta
        where: Section 3, Hazardous Component(s) table
      - name: Tetraglycidyl diaminodiphenylmethane (Part A)
        share_percent: 30
        share_high: 60
        role: Multifunctional epoxy resin that reacts with the amine hardener.
        source: henkel-sds-parta
        where: Section 3, Hazardous Component(s) table
      - name: Epichlorohydrin-4,4'-isopropylidene diphenol resin (Part A)
        share_percent: 10
        share_high: 30
        role: Epoxy resin named in the SDS transport section as a bisphenol-A epichlorohydrin resin.
        source: henkel-sds-parta
        where: Section 3, Hazardous Component(s) table
      - name: Modified epoxy resin (Part A)
        share_percent: 5
        share_high: 10
        role: Second epoxy resin; the SDS gives no CAS number and names it as a phenol polymer with chloromethyl oxirane.
        source: henkel-sds-parta
        where: Section 3, second Hazardous Component table
      - name: Treated fumed silica (Part A)
        share_percent: 1
        share_high: 5
        role: Silica filler listed as a hazardous component of Part A.
        source: henkel-sds-parta
        where: Section 3, Hazardous Component(s) table
      - name: Tetraethylene pentamine (Part B)
        share_percent: 30
        share_high: 60
        role: Amine component of Part B. Amines add across epoxide groups to form a cross-linked network (Wikipedia, Epoxy).
        source: henkel-sds-partb
        where: Section 3, Hazardous Component(s) table
      - name: N,N'-Bis(3-aminopropyl)piperazine (Part B)
        share_percent: 30
        share_high: 60
        role: Amine curing agent.
        source: henkel-sds-partb
        where: Section 3, Hazardous Component(s) table
      - name: 3,6,9,12-Tetraazatetradecamethylenediamine (Part B)
        share_percent: 5
        share_high: 10
        role: Polyamine curing agent.
        source: henkel-sds-partb
        where: Section 3, Hazardous Component(s) table
      - name: 3,6-Diazaoctanethylenediamine (Part B)
        share_percent: 1
        share_high: 5
        role: Amine curing agent.
        source: henkel-sds-partb
        where: Section 3, Hazardous Component(s) table
      - name: Carbon black (Part B)
        symbol: C
        share_percent: 0.1
        share_high: 1
        role: Pigment that colours Part B.
        source: henkel-sds-partb
        where: Section 3, Hazardous Component(s) table
  risk_groups:
    - title: For people
      level: 3
      verdict: Warning in Part A, danger in Part B
      lead: Part A irritates and can sensitize the skin. Part B is corrosive and harmful if swallowed, according to the two safety data sheets.
      points:
        - label: Part A
          line: Hazard statements H315, H317 and H319, under the WARNING signal word (SDS Revision 006.3).
        - label: Part B
          line: Hazard statements H302, H314 and H317, under the DANGER signal word (SDS Revision 005.2).
        - label: Mixing
          line: Batches above 450 g can overheat and give off toxic fumes, according to the bulletin. Mix smaller quantities.
    - title: If it is used hot or wet
      lead: Strength and glass transition both fall as temperature and moisture rise.
      points:
        - label: Heat
          line: Lap shear strength is 8.3 MPa at 177 °C and 4.1 MPa at 204 °C, against 28.9 MPa at 25 °C.
        - label: Moisture
          line: The glass transition is 78 °C when dry and 68 °C when wet, and the shear modulus is 1027 MPa wet against 1461 MPa dry.
    - title: In vacuum
      level: 2
      verdict: Above the 1.0 % TML screen
      lead: The NASA compilation lists every EA 9394 row read above the 1.0 % total mass loss level that it uses for low-outgassing materials.
      points:
        - label: Total mass loss
          line: 1.71 % (7 days at 25 °C, row GSC17063) and 1.14 % (row GSC17085), with other rows between 1.02 % and 1.74 %.
  why: 'LOCTITE EA 9394 AERO, also known as Hysol EA 9394, is a two-part epoxy paste that cures at room temperature. Henkel sells it for structural bonding, potting and liquid shims, and says it is qualified to MMM-A-132 Rev B. Its main strengths, as printed, are a lap shear strength of 28.9 MPa at 25 °C, a 177 °C service temperature and a 90 minute pot life for a 450 g mix. Its weak point for space hardware is outgassing: NASA''s compilation lists every EA 9394 row read above the 1.0 % total mass loss screen.'
  uses:
    - where: Aerospace structural bonding
      line: Henkel calls the paste a two-part structural adhesive for aerospace bonding that cures at room temperature. It is qualified to MMM-A-132 Rev B, Type I, Class 3, Form 3, Group 1.
    - where: Potting, filling and liquid shims
      line: The bulletin also lists potting, filling and liquid shim work, and says the thixotropic paste fills gaps well.
    - where: Outgassing screening record
      line: NASA's 1993 compilation includes EA 9394 rows in its adhesives listing, each with its own cure schedule. These are ground outgassing records, not a flight result.
  can_do:
    - label: Service temperature
      benchmark: max_service_temp
      line: Henkel rates the adhesive for 177 °C (350 °F) service, defined as the temperature at which it still holds 6.9 MPa (1000 psi) lap shear per ASTM D1002. Lap shear at 177 °C is printed as 8.3 MPa.
    - label: Strength at room temperature
      value: 28.9 MPa lap shear at 25 °C
      line: Bare 2024-T3 aluminium lap joints cured 5 days at 25 °C printed 28.9 MPa (4,200 psi) lap shear per ASTM D1002.
    - label: Working time
      value: Pot life 90 min at 25 °C
      line: A 450 g mix stays usable for 90 minutes at 25 °C (ASTM D 2471). Henkel says not to mix more than 450 g at once.
    - label: Outgassing
      benchmark: outgassing_tml
      line: NASA's 1993 compilation lists total mass loss of 1.71 % and collected volatile condensable material of 0.04 % for one EA 9394 row (7 days at 25 °C). That is above the 1.0 % TML limit that the compilation uses for low-outgassing materials.
  compare: LOCTITE EA 9394 AERO is not a low-outgassing adhesive on the data read here, because each of the eight EA 9394 rows in the NASA listing is above 1.0 % total mass loss. Its printed 177 °C service temperature is far above its dry glass transition of 78 °C, and the bulletin does not reconcile the two; lap shear is already 20.7 MPa at 82 °C. The compare table below uses density, service temperature and NASA total mass loss, the three benchmarks for which this product has values in the sources read.
  compare_rows:
    - label: Density (mixed)
      benchmark: density
    - label: Service temperature
      benchmark: max_service_temp
    - label: Total mass loss
      benchmark: outgassing_tml
  handling:
    - Mix Part A and Part B in the ratio 100 to 17 by weight, and do not mix more than 450 g at once, because heat builds up.
    - Use the mixed adhesive within 90 minutes at 25 °C, and do not leave it in the static mixer unattended for more than 90 minutes.
    - Cure for 3 to 5 days at 25 °C for normal performance. The bulletin says 1 hour at 66 °C gives complete cure, and accelerated cures up to 93 °C are for small masses only.
    - Wear eye and skin protection and ventilate the area. Part A irritates the eyes and skin, and Part B contains amines and is corrosive according to its SDS.
  good_for:
    - Structural bonding of aluminium at room temperature, with 28.9 MPa lap shear at 25 °C (ASTM D1002, 2024-T3 adherends).
    - Joints that must hold at 177 °C (350 °F), per the Henkel service-temperature definition.
    - Potting and liquid shim work, given its 90 minute pot life and gap-filling paste.
  watch_out:
    - 'Outgassing: every EA 9394 row read in NASA''s listing is above 1.0 % total mass loss, from 1.02 % to 1.74 %.'
    - 'Heat: lap shear is 8.3 MPa at 177 °C and 4.1 MPa at 204 °C.'
    - 'Moisture: the glass transition is 78 °C dry and 68 °C wet, which is below the 177 °C service temperature.'
    - No flight or thermal-vacuum result for this adhesive was found in the sources read.
  verdict: LOCTITE EA 9394 AERO is a well-documented room-temperature structural epoxy with 28.9 MPa lap shear at 25 °C and a Henkel-stated 177 °C service temperature. NASA's outgassing rows for it sit above the 1.0 % screen, so on these sources it is not a low-outgassing choice.