Written and maintained by CASRAI Editorial Board
Last updated
Short answer
ASTM D1002 is the standard test method for the apparent shear strength of single-lap-joint, adhesively bonded metal specimens loaded in tension (metal-to-metal). It produces a comparative number, not a design value: ASTM states the method is not suitable for determining design-allowable stresses for structural joints.
Definition and scope
The full title is “Standard Test Method for Apparent Shear Strength of Single-Lap-Joint Adhesively Bonded Metal Specimens by Tension Loading (Metal-to-Metal)”. Its scope covers determining the apparent shear strength of adhesives for bonding metals, using a standard single-lap-joint specimen under specified conditions of preparation and testing. SI values are the standard; inch-pound values in parentheses are for information.
“Apparent” matters. The result is a property of one specific specimen configuration, the adherend metal, its surface preparation, the adhesive and the test conditions together. It is not a material constant of the adhesive alone.
How it is used in practice
ASTM describes the significance of the method as primarily comparative. It is useful for comparing variations in adherend surface preparation and the environmental durability of adhesives, and for controlling the surface preparation, primer and adhesive system used in a bonding process.
Testing laboratories describe the routine as follows (this is the lab’s description, not the standard’s text, from Micom Laboratories, checked 29 October 2026): two metal strips are bonded with a set overlap; for most metals the strips are 1.62 mm (0.064 in.) thick with a 12.7 mm (0.5 in.) overlap; at least five specimens are tested per adherend and adhesive combination; both ends are gripped and loaded at a constant crosshead speed to failure; and strength is the maximum load divided by the bonded overlap area. Aluminum and steel are the commonly cited substrates, with stainless steel, titanium alloys and copper alloys also named.
Which edition is current
| Designation | Status on the ASTM store |
|---|---|
| D1002-10(2019) | Active (last updated 30 April 2019) |
| D1002-05, D1002-01, D1002-99 | Historical |
Source: ASTM D1002 product page, checked 29 October 2026. Name the edition used when reporting D1002 results.
Why results are comparative, not design values
This is the point most summaries skip. The standard’s significance section carries three explicit cautions:
- Using the values as design-allowable stresses for structural joints could lead to product failure, property damage or injury (section 4.2).
- The method is not suitable for determining design-allowable stresses for joints that differ from the tested joint, unless a thorough analysis is done (section 4.4).
- Comparing fatigue or environmental behaviour from these specimens should be done only with great caution (section 4.5).
For the second and third points ASTM points readers to a companion document, ASTM D4896, “Standard Guide for Use of Adhesive-Bonded Single Lap-Joint Specimen Test Results”. Its scope is the safe and appropriate use of strength values obtained from single-lap adhesive joint test methods, with a focus on shear strength from small, thin-adherend specimens (ASTM D4896 page, checked 29 October 2026; the active version is listed as D4896-01R24). In practice D1002 gives the number and D4896 tells you how far the number can be trusted.
Where it matters for labs and supply decisions
- Process control. ASTM names controlling the surface preparation, primer and adhesive system as a use of the method.
- Specifying a test request. A request should state the edition, the adherend metal and thickness, the surface preparation, the adhesive and the conditioning, since the result depends on all of them.
- Reading a supplier datasheet. A lap shear figure quoted for one metal and preparation does not transfer to a different substrate or joint geometry without the analysis section 4.4 calls for.
D1002 compared with other ASTM adhesion and strength methods
| Method | What it measures | Guide |
|---|---|---|
| ASTM D1002 | Apparent shear strength of adhesive-bonded metal single-lap joints, by tension loading | This page |
| ASTM D4541 | Pull-off strength (adhesion) of a coating system, using portable pull-off testers | ASTM D4541 explained |
| ASTM D638 | Tensile properties of plastics | ASTM D638 explained |
| ASTM D412 | Tension testing of vulcanized rubber and thermoplastic elastomers | ASTM D412 explained |
The difference to keep in mind is the loading mode and the object tested: D1002 loads a bonded joint between two metal strips in lap shear, while D4541 pulls a fixture perpendicular to a coated surface.
Common misunderstandings
“The result is the shear strength of the adhesive.”
It is the apparent shear strength of that specimen. Adherend, preparation and test conditions are part of the result.
“A higher number means the joint can carry a higher design load.”
The standard says otherwise: it is not a basis for design-allowable stresses in structural joints.
“It applies to any bonded material.”
The title and scope limit it to adhesives bonding metals, metal-to-metal.
FAQ
What does ASTM D1002 measure?
The apparent shear strength of adhesives bonding metals, using a single-lap-joint specimen loaded in tension.
Can D1002 results be used as design values?
No. ASTM states the method is not suitable for determining design-allowable stresses for structural joints that differ from the tested joints without thorough analysis, and warns of failure, damage or injury if used that way.
Which edition of ASTM D1002 is current?
D1002-10(2019), listed as active on the ASTM store as of October 2026. D1002-05, D1002-01 and D1002-99 are listed as historical.
Which substrates are tested?
The standard concerns metal-to-metal bonds. Testing laboratories name aluminum and steel as common, with stainless steel, titanium alloys and copper alloys also tested.
Sources
- ASTM International, D1002-10(2019) product page and abstract, checked 29 October 2026.
- ASTM International, D4896 product page, checked 29 October 2026.
- Micom Laboratories, ASTM D1002 testing service description, checked 29 October 2026.
This page summarises published scope and significance statements. The standard’s full text is sold by ASTM.
