Full definition
The process of permanently bonding vulcanized rubber to metal substrates during the vulcanization cycle, creating composite parts that combine the elasticity and damping of rubber with the strength and rigidity of metal. Process: (1) metal preparation — degrease, grit-blast to SA 2.5 profile (SSPC-SP5), apply primer coat within 4 hours to prevent re-oxidation; (2) apply bonding agent (single-coat or two-coat system — Chemosil/Chemlok by LORD Corporation, Thixon by Rohm & Haas); (3) place prepared metal inserts in mold with uncured rubber; (4) vulcanize under heat and pressure — the bonding agent cross-links simultaneously with the rubber, creating a chemical bond stronger than the rubber itself (bond strength exceeds rubber tear strength, verified per ASTM D429). Applications: anti-vibration engine and machinery mounts, suspension bushings, bridge bearing pads, expansion joints, bonded seals, rubber-lined pipes and vessels, and shock absorber bumpers. Critical quality factors: surface preparation (80% of bond failures trace to inadequate prep), adhesive selection per rubber/metal combination, and cure conditions. Brands: LORD (Chemlok/Chemosil), Henkel (Megum).