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c o m

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Viscosity
Viscosity is the measure of a fluids internal resistance to flow. The most common unit of measure is the centipoise. There are other units of measure to express viscosity along with some conversion factors: 100 Centipoise = 1 Centipoise = 1 Poise = Centipoise = 1 Poise 1 mPa s (Millipascal Second) 0.1 Pa s (Pascal Second) Centistoke x Density

For more processing Tips & Tricks please visit

http://www.crosslinktech.com/support/tips-and-tricks.html

Temperature conversions
To convert Fahrenheit to Celsius: 0 0 C = 5/9 ( F 32) To convert Celsius to Fahrenheit: 0 0 F = (9/5 x C) + 32

The higher the Centipoise the thicker the product.

Thixotropic materials are deigned to have body but are relatively easy to pump. Examples would be shaving cream, mayonnaise etc. The degree of thixotropy is usually expressed by a number called the Thixotropic index of a product. The higher the number, the thicker the appearance of the compound.

-65 -60 -55 -50 -45 -40 -35 -30 -25 -20 -15

-85 -76 -67 -58 -49 -40 -31 -22 -13 -4 5 14 23 32 41 50 59 68

100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185

212 221 230 239 248 257 266 275 248 293 302 311 320 329 338 347 356 365

Viscosities of some common products

Product
Water Milk SAE 10 Motor Oil Castor Oil Karo Syrup Honey Chocolate Syrup Ketchup Sour Cream Shortening

Viscosity in Centipoise
1 cps 3 cps 85 140 cps 1,000 cps 5,000 cps 10,000 cps 25,000 cps 50,000 cps 100,000 cps 1,200,000 cps

Epoxy and Urethane compounds can be heated to reduce viscosity however there are other handling issues to consider when heating these compounds.

-10 -5 0 5

Useful Epoxy/ Urethane handling Tips

Raising the temperature of a mix by 100C cuts the pot life in half. Increased gel temperature will result in an increase in shrinkage.

10 15 20

3|E p o x y / U r e t h a n e u s e r s h a n d b o o k | C r o s s l i n k T e c h n o l o g y I n c . | w w w . c r o s s l i n k t e c h . c o m 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 77 86 95 104 113 122 131 140 149 158 167 176 185 194 203 190 195 200 205 210 215 220 225 230 235 240 245 250 255 260 374 383 392 401 410 419 428 437 446 455 464 473 482 491 500

To calculate the Volume ratio (PBV)

10:1 Volume Ratio Volume Ratio Volume Ratio = 1.20 1.00 10 1.20 8.33 : 1

= =

Quick Conversion Factors

Volume
1 Fluid Ounce 1 Gallon (US) 1 Gallon (US) 1 Gallon (US) 1 Gallon 1 Gallon 1 Gallon 1 Gallon 1 Gallon (US) 1 Gallon (Imp.) 1 Litre 1 Litre 1 Litre 1 Cubic Foot 1 Cubic Inch 1 Cubic Centimetre 1 Millilitre = = = = = = = = = = = = = = = = = 29.57 cubic Centimeters 3785 Cubic Centimeters 3.785 Litres 128 Fluid Ounces 4 Quarts 8 Pints 16 Cups 231 Cubic Inches 0.83267 Gallons (Imp.) 1.20095 Gallons (US) 0.264 US Gallons 2.113 Pints (US) 1000 Millilitres 1728 Cubic Inches 16.387 Cubic Centimeters 1 Millilitre 1000 Microlitres

To convert mix ratio from parts by Weight to parts by Volume

PBW of A PBW of B x Sg. of B Sg. of A = PBV of part A to 1 part by Volume of part B

Legend
Sg. = Specific Gravity (as shown on technical data sheet. If a range is shown use the median figure). PBW = Parts by Weight PBV = Parts by Volume OR Weight Ratio Volume Ratio = Specific Gravity A Specific Gravity B

Weight
1 Kilogram 1 Kilogram 1 Pound 1 Pound 1 Ounce = = = = = 1000 grams 2.2 Pounds 16 Ounces 453.6 Grams 28.35 Grams

Example
Weight ratio (on tech. data) = 10:1 Sg. of part A = 1.1 - 1.3 Sg of part B = 0.9 1.1

Length
1 Centimetre 1 Inch 1 Inch = = = 10 Millimetres 2.54 Centimeters 1000 Mils

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AGING AMBIENT TEMPERATURE ARC RESISTANCE BOND STRENGTH

The change of a material with time under defined conditions, leading to either an improvement or deterioration of properties. The temperature of the surrounding air or other medium in contact with the specimen. The time required for an electrical arc to establish a conductive (carbon) path in a specimen. The amount of adhesion between two substrates. The overall bond strength is governed by the weakest component in the bonded structure. Also called "basic Insulation level" - an insulation level, expressed in kilovolts, at which electrical equipment will withstand a simulated lightening wave which reaches its peak in 1.2 microseconds and decays to half of the peak value in 50 microseconds. The magnitude of the voltage required to cause an insulating material to fail. The published figures must be referenced to the thickness of the specimen under test. Usually, the thinner the specimen the higher the volts/mil because there are less impurities in the thinner specimen. A manufacturing procedure where components are placed into moulds and the moulds are then filled with a thermoset material. After cure, the parts are removed from the moulds for service. Diagram The material that starts or speeds up a given reaction. Sometimes referred to simply as "Hardener". A catalyst could also be part of a hardener to further increase the speed of reaction. The unit used to express viscosity (the thickness of a liquid). The relative change in length of a material per degree of temperature change at constant pressure. CTE values are lower when materials are below their glass transition temperature as compared to when they are above it. The amount of compressive load at failure of a specimen in relation to its cross-sectional area. The amount of electric current passing through a unit cube of a material. Epoxies and Polyurethanes are considered insulators thus their conductivity is very low.

Other handy formulas

Multiply B.t.u. per sq. ft. per min. Centimeters per second Centipoise Circular mils Circular mils Circular mils Gallons ( US ) Gallons ( US ) Gallons ( US ) Grams per cm. Grams per cu. cm Grams Pascal second by 0.1221 1.968 1 X 10
-3 -6 -7

to obtain Watts per sq. inch. Feet per minute. Pascal - second Square centimeters Square inches. Square mils Cubic centimeters Cubic inches Liters
-3

5.067 x 10 7.854 x 10 0.7854 3785 231 3.785 5.600 x 10 0.03613 0.03527 1000

B.I.L. (Basic Impulse Level)

Pounds per inch Pounds per cu. inch Ounces Centipoise BREAKDOWN VOLTAGE

Formulated Epoxy / Urethane Compounds for:

Casting Potting Electrical Electronics Adhesives Tooling Custom Casting ..applications

CASTING

CATALYST CENTIPOISE COEFFICIENT OF THERMAL EXPANSION COMPRESSIVE STRENGTH

Terms and definitions

CONDUCTIVITY

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CORONA

A visible or invisible arc or arcs that develop in a material do to the surrounding voltage gradient exceeding a certain threshold value. Corona usually develops in areas of trapped air that is ionized by the voltage surrounding it. The length of time it takes an existing arc to develop a conductive path by carbonizing the material. Once the material is carbonized (burned), the arc is extinguished in that area because the surface carbon is conductive. The coupling of the molecules into a three dimensional structure as a result of the reaction between the resin and the hardener. The number of effective cross-links per unit volume. As a rule, the higher the cross-link density the harder the cured product. The temperature at which the necessary chemical reaction is initialized for the material to solidify. From the start of the reaction to the time when the specified properties are realized. Is the prescribed period of time and temperature for a material to develop its stated properties. Relates to the percentage of the stated properties reached through the curing process. Some products are extremely brittle after gellation but become quite tough and flexible after full cure. The weight per unit volume of a material. (grams/cm ) An insulating material (liquid, solid or gas). The capacitance developed by an insulating material placed between two electrodes as compared to only air between the same electrodes. The maximum voltage a given thickness of an insulating material can withstand without breaking down. It is usually expressed in volts/mil. As a rule, the thicker the specimen being tested the lower the volts/mil due to the increased number of impurities present. At the same time, the thicker specimen will withstand a higher voltage although the volts per mil is slightly lower. Dissipation factor is the ratio of the equivalent series resistance to the reactance in a dielectric device. The dissipation factor will be different at various frequencies, test temperatures and test conditions. This test would be a rough indication of the efficiency of HEAT DISTORTION TEMPERATURE GEL TIME
3

DIPPING

CORONA RESISTANCE

Immersing a component in a material for the purposes of penetrating its components usually for the purposes of insulation or environmental protection. Power factor is the ratio between the power applied to a device and the power output (exiting from) from the device. It is an indication of how much power is lost while transiting the dielectric components of the device. The amount of heat generated as a result of the chemical reaction. High exotherm usually increases the speed of reaction even further and results in increased shrinkage. The % increase in the length of a material being stretched just before it breaks. Enclosing a component in a plastic. The finished component is free standing, with the plastic forming the outside surfaces. The substance added to formulations to obtain certain desired properties. Depending on the type fillers can be highly abrasive or only slightly abrasive. The load a product is able to withstand before it brakes while 2 bending. Usually expressed as Pounds/in . The period of time it takes the material to begin its irreversible solidification. Gel time is usually measured from the time of mixing or, in the case of single component materials, from the time of first applying heat or other curing mechanism. The temperature at which a standard test bar with a standard load of 66 or 264psi deflects 0.010". Its importance is application dependent. For example: this property is less important if the material is not weight bearing or there is little force present while operating beyond its HDT, otherwise it is a critical consideration. The ability of a material to withstand impact without damage. To fill the voids and spaces. The maximum temperature at which electrical equipment can be operated to yield an average life of 20,000 hours, designated by the letters A, B, F and H as follows:

POWER FACTOR (PF)

CROSS-LINKING CROSS-LINK DENSITY CURE TEMPERATURE CURE TIME CURE CYCLE

EXOTHERM

ELONGATION ENCAPSULATING

FILLER

DEGREE OF CURE DENSITY DIELECTRIC DIELECTRIC CONSTANT

FLEXURAL STRENGTH

DIELECTRIC STRENGTH

IMPACT STRENGTH IMPREGNATE INSULATION CLASS

DISSIPATION FACTOR

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Insulation Class: A B F H LINEAR SHRINKAGE

Temperature Rating: 0 105 C 0 130 C 0 155 C 0 180 C

Shore A 25-30 35-45 45-55 55-65 65-75 75-85 85-95 95-100 -

86 90 Practical Hardness Reference Shore D 25-30 30-40 40-50 50-60 60-65 65-70 70-75 75-80

95 125 Feels like: White eraser Pink eraser Rubber stamp Hard eraser Medium rubber Rubber shoe sole Rubber Roller Garden hose Hard book cover Wood desk top Moulded plastic Wood yard stick White board

The reduction in linear dimension that occurs in materials during the process of solidification (cross linking), expressed as a percentage of the original dimension. Refers to the stiffness of a material and is defined as Load/Change in shape when loaded. It is expressed in p.s.i. or MPa. A material can be loaded in tension (Tensile Modulus), flexion or bending (Flexular Modulus), compression, torsion etc.

MODULUS

MOISTURE RESISTANCE The ability of a cured material to resist absorbing moisture. POT LIFE The period of time, after mixing or the application of heat, that the material remains useable (pourable) in the particular application. In some cases the recommended post cure consists of step curing at different temperatures for different periods of time. A manufacturing method where components are placed into containers and the containers are filled with a thermoset material. The containers remain an integral part of the assemblies in service. Diagram Is the reflection of the electrical losses (in the form of heat) at a specified frequency in an insulating material. The ability of an insulator to resist the flow of electric current through it. It is expressed in ohm-cm. Is the measured hardness of a cured material. Softer products are on the shore A scale, harder materials are on the shore D and Rockwell scales. Hardness Cross Reference Shore A 50 70 90 100 Shore D 10 15 32 45 74 78 82 Rockwell M 32 63 THERMAL CYCLE THERMAL CONDUCTIVITY

POST CURE

POTTING

SPECIFIC GRAVITY

The mass per unit volume of a material divided by the mass of the same volume of water at a standard temperature. Expressed in 3 grams/cm . The resistance to the flow of electric current on the surface of a specimen (between opposite edges). The pulling force required to break a standard size specimen. 2 Expressed in pounds/in . A measure of adhesive strength defined as the force required to break an adhesive junction in the form of a lap joint when a shear stress is applied to it. A lap joint is made by placing one substrate over another and bonding the overlapped sections together. The ability of a material to conduct heat. The amount of heat that passes through a specimen of a material in a period of time until the 0 difference in temperature between the two surfaces is 1 C. One or more gradual changes in the temperature of the medium in which the device operates. Always involves a transition time from hot to cold.

POWER FACTOR RESISTIVITY SHORE HARDNESS

SURFACE RESISTIVITY TENSILE STRENGTH

TENSILE LAP SHEAR STRENGTH

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(4)

THERMAL SHOCK

A sudden and marked change in the temperature of the medium in which the device operates. There is no transition time, the change is directly from hot to cold. A product that is, once solidified, is very difficult or impossible to reliquefy. As opposed to Thermoplastic materials that may be reliquefied usually by the application of heat. A polymer that is solid at room temperature or at another specified temperature but may be liquefied repeatedly when heated above that temperature. Unlike Thermosets which undergo a chemical change to form a three dimensional network, thermoplastic polymer molecules generally remain linear and separate after processing. Materials that have the ability to cling and build on surfaces. This property does not directly relate to viscosity. Examples of this are shaving cream, whipped cream etc. Is the measure of a liquid materials ability to flow. It is usually expressed in centipoises. (See Centipoise above) The resistance to the flow of electric current through a 1 cm cube of material. It is expressed as ohm-cm. A category of products that have been tested and certified by Underwriters Laboratories Inc. based on their use and intended application. UL recognized systems and components are listed yearly in the Recognized Components Directory and documented by the so-called "yellow card"

THERMOSET

THERMOPLASTIC

Excessive (5) Shrinkage

THIXOTROPIC

Mix ratio, proper resin and hardener mix, part pre-heat, cure, gel and post cure time/temperature, uniform filler content, incorrect cure temperature, trapped air bubbles or sharp edges on part. Significantly different wall thicknesses. Fillers not dispersed properly, incorrect preheat temperature, incorrect mix ratio, not thoroughly mixed, gellation or cure temperature too high

Mix ratio, lead lag problems, incorrect part temperature, sharp edges, trapped air bubbles, incorrect gel, cure and post cure temperatures, settled fillers. Significantly different wall thicknesses.

Off ratio, process temperatures, filler settling, improper mix and incorrect pre-heat temperature.

VISCOSITY VOLUME RESISTIVITY

Notes
(1)

YELLOW CARD

Most cure problems are mix ratio related. Accurate weighing of the resin and hardener followed by thorough mixing is very important. Dispense equipment can go off ratio through blocked lines, leaky seals and valves etc. Always hand mix a sample to confirm that the material hardens as it should. If it does, there is a dispense or handling problem that must be corrected. Most soft spots are due to improper mixing resulting in areas of excess resin or hardener. Lead/lag problems in dispense equipment and not thorough enough hand mixing are the most common problems causing soft spots. Air bubbles are most commonly caused by improperly filling the mould or the container. Ideally, the material should be poured into one corner and allowed to rise slowly pushing the air ahead of it. Bubbles can also be caused by moisture in the air or in the part being potted. An air conditioned room and drying the parts will solve this problem. The application of vacuum, either to the mix or to the part being filled, may be necessary depending on part configuration and complexity. Cracking is the result of internal stresses that develop in the material during the curing process. These stresses can be so great as to overcome the strength of the material. Cracking can also be caused by stressing a part in some manner before it is fully cured and had a chance to develop full strength. An example would be thermal cycling a component before the epoxy is fully cured or causing excessive shrinkage by shorter cure times at higher temperatures. Micro cracks caused by sharp edges embedded in the casting can propagate to form fully developed cracks.

(2)

EPOXY/URETHANE TROUBLESHOOTING TIPS

Symptom Not (1) Hardening Soft Spots
(2)

(3)

Air (3) Bubbles

Check for (Hand Processing) Weight accuracy of resin and hardener, not thoroughly mixed. Thorough mixing (longer, scraping the container bottom and sides) Moisture in the part itself or paper container or stir stick, mixing too violent.

Check for (Dispense Machine) Check weights just before mix head, not enough elements in static mix head, blocked line, leaky seal. Lead/Lag problems due to leaky valves, air in lines, leaky seals.

(4)

Leaky seals, part not dry, air in feed lines, filling the part to fast, moisture in the part.

8|E p o x y / U r e t h a n e u s e r s h a n d b o o k | C r o s s l i n k T e c h n o l o g y I n c . | w w w . c r o s s l i n k t e c h . c o m 4. 5. Avoid sharp corners and undercuts wherever possible as these are areas conducive to air entrapment. Provide uniform wall thickness (mass) throughout the tool to allow for uniform heating and to prevent large temperature variations due to different rates of cooling.

(5)

Too much shrinkage is most commonly caused by incorrect preheat temperatures in heat cure systems and too much localized exotherm in room temperature cure products. In every case, the epoxy or urethane will start to cure around the component at the highest temperature. Curing will progress from the hottest to the coolest area. Since shrinkage occurs during cure, the compound will replenish itself by drawing material from the cooler areas of the casting where gellation has not yet started. Built in stresses are higher if the material cures from the inside out or from the outside in. Ideally, the mass should start curing at the same time from the inside out and the outside in to yield the least amount of built in stresses and the least amount of shrinkage. ..

Viscosity
The lower the mixed viscosity the easier it is to process the epoxy. The mixed viscosity of two component epoxy compounds can be reduced significantly by separately heating the resin and hardener prior to mixing together or warming the mixture itself. Storing materials containing fillers under heat will require constant agitation to prevent filler settling and the possibility of an off ratio mix. Heating will normally result in shorter pot life.

Epoxy compounds are used to cast various shapes and sizes of components. Although epoxies are relatively simple to use, there are some basic steps that must be followed to establish a trouble free casting operation. Epoxy casting compounds must be carefully selected to suit the application at hand. The following are the basic considerations for selecting an appropriate epoxy compound: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Processing limitations Tool (mould) design Viscosity Reactivity Exotherm Vapour pressure Shrinkage Expansion characteristics Thermal shock capabilities Thermal stability characteristics

Reactivity

"For every 10 C rise in temperature the reaction rate doubles" This means that for every o 10 C rise in temperature, the pot life (the time during which the mixture remains pourable) is reduced by (half) 50%. For example; if an epoxy system is formulated to gel (become firm) in o o o o 30 minutes at 25 C (77 F), then if warmed to 35 C (95 F) it will gel in approximately 15 minutes.

Exotherm
Exotherm is the heat generated by the compound, above the cure temperature, during the reaction. The amount of heat (exotherm) generated depends on the epoxy formulation and the (mass) amount of product being reacted at one time. The exotherm generated by resins and/or hardeners heated to reduce the viscosity will be greater than without the application of heat. As a general rule, fast reacting epoxy systems generate higher exotherm during the reaction.

Vapour pressure
If a curing epoxy system becomes too hot, it will generate gas bubbles which, if the bubbles form just before gellation (hardening), can become trapped in the structure. Vapour pressure is also a key consideration for the use of vacuum to remove air from the epoxy mixture. Certain key ingredients such as accelerators or portions of the curing agent itself can be stripped out of the mixture under vacuum.

Processing limitations
Consideration must be given to the availability of appropriate processing equipment. Epoxy systems are available to suit hand casting, automated casting, heat curing and higher temperature (oven) curing. Epoxy compounds may contain fillers or may be unfilled liquids.

Tool (mould) design

The following are the basic considerations for tool design in casting with epoxy compounds: 1. The pour hole should be located for the shortest path into the cavity being filled. 2. Provide vent openings to allow air to escape as the epoxy fills the cavity. Air vents should be provided for all areas where air might be trapped such as flat surfaces and around intricate inserts. 3. A reservoir of material should be available to draw from as the epoxy shrinks during the gellation process. Most often the reservoir will be located over the pour hole which is usually the largest opening into the mould.

Shrinkage
Shrinkage is the reduction in volume during cure. Excessive shrinkage will cause internal stresses and serious degradation in the performance of the solidified epoxy. Epoxy systems containing fillers shrink less than unfilled epoxies. As a rule, the higher the filler content the lower the shrinkage. Providing a reservoir of product to replenish the shrinking epoxy improves the end result.

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Thermal expansion characteristics

This must be considered especially if the casting contains embedded component such as inserts within the cured epoxy. Large differences between the expansion characteristics of the epoxy and the embedded inserts can be the cause of cracking and reduced thermal cycling abilities. In general, the more flexible the cured epoxy the more it will expand and the higher the filler content the lower the rate of expansion.

Recommended actions based on symptoms experienced

Symptom Excessive shrinkage during gellation Bubbles in casting. Recommended corrective actions Reduce mould temperature, reduce mix temperature, increase reservoir size. Mix the resin and hardener together more gently avoiding turbulence, de-air the mix before use, pour slowly into one area, make sure inserts are dry and free of any volatile substances, avoid high humidity.

Thermal shock capabilities

The higher the elongation capabilities of the cured epoxy the better the thermal shock capabilities. Unfortunately, highly flexibilized systems exhibit rather poor thermal stability. The epoxy system must be formulated to achieve a suitable compromise between cured hardness, tensile strength and elongation to achieve the desired characteristics for the application.

Thermal stability
The thermal stability of a cured epoxy system is its ability to operate at elevated temperature while maintaining a specified set of minimum properties. A common test method to determine thermal stability is % weight loss in a period of time at a given temperature. Since every manufacturing process is somewhat unique and the parts manufactured must meet different performance requirements, it is not possible to provide hard and fast rules that could apply to all processes and materials. The following is a general set of trade-offs caused by specific changes in the handling of epoxy compounds: Result Action Heating the mix Cooling the mix Heating the mould Cooling the mould Mixed Viscosity Lower Higher Lower Higher Pot Life Gel Exotherm Shrinkage Time More Less More Less De-mould Time Shorter Longer Sorter Longer Prob. of Cracking Higher Less Higher Lower

Skinned over cavities in Reduce mould temperature, reduce insert temperature, increase the casting. reservoir size. Surface blemishes. Part sticking in tool. Cracking Soft spots in part Excessive yellowing of part after post cure. Clean tool surfaces, reduce the amount of mould release applied to the tool, slightly reduce the mould temperature. Clean tool surfaces from baked on deposits, apply a thin even layer of mould release. Reduce mould temperature, Reduce the difference between the insert temperature and the mould temperature. Probably an improper or off ratio mix. Mix resin and hardener more thoroughly scraping the sides of the mixing container. Some products will experience surface oxidization in post cure. For best results cure immersed in an inert oil.

Shorter Shorter Higher Longer Longer Lower NE NE Shorter Higher Longer Lower

Automated dispense equipment for Epoxy and Urethane compounds

Epoxy and urethane compounds are best processed through automated dispense equipment, especially in high volume production situations. From time to time, problems are encountered due to various causes, resulting in the improper cure of the epoxy or urethane mix.

Check List
o Check that the correct amount of resin and hardener is dispensed just prior to the mix head. This is best accomplished by removing the mix head and placing individual cups under each opening, dispensing the material and weighing the contents of each cup. Depending on the location of the ratio check valves, a simple

10 | E p o x y / U r e t h a n e u s e r s h a n d b o o k | C r o s s l i n k T e c h n o l o g y I n c . | w w w . c r o s s l i n k t e c h . c o m ratio check does not always reveal the problem because these valves are often located before lengthy feed lines and checks at this point will not reveal off ratio situations caused by back pressure. o Check that the mix head is clean and clear of obstructions. If the equipment has been functioning properly for some time and this problem has not been encountered before, it may be assumed that the mix head is doing its job. If the materials being dispensed are different from before or the system frequently encountered this problem all along, it may be worthwhile to consult the supplier of the mix head. Some products are harder to mix together than others. The number of elements, the diameter and/or the length may have to be increased. In the case of dynamic mix heads, the orifices or rpm may have to be adjusted. Check that the solvent flush valve is functioning properly. Leaky solvent flush valves can allow cleaning solvent to enter the mix and interfere with the reaction, cause bubbles and soft spots. On the other hand, valves that don't fully open will not allow the lines and/or mix head to be flushed clean, leaving residual amounts of mixed material to gel or cure causing partial blockages. Check the dispense lines for obstructions. Reduced dispense line diameter, due to settled fillers or gummed up material, could not only cause increased back pressure but also cause insufficient supply of the effected component, especially in the presence of the increased back pressure. Check the timing and synchronization of check valves. Some shut off valves are mechanically linked to each other while others are operated individually but in sync by electronics. If they are not exactly in sync, there will be extra resin or hardener in the line and the next shot will be off ratio. Some equipment manufacturers use solenoid valves for this purpose. Particles preventing the valve from seating properly are hard to detect. Just because the valve clicks does not mean that it is fully opened or fully closed. Check the timing and synchronization of dispense pistons. These pistons are mechanically linked on some equipment to facilitate changing the mix ratio. The ratio is changed by adjusting the amount of travel for each piston by adjusting a single linkage. Any worn part on this linkage could result in problems if the pistons do not start dispensing at the same time. Check for worn or leaky check valves. Leaky seals or worn components will allow one of the components to leak past the valve after it is shut off. The following shot of material will be off ratio. This condition could also change the balance between the dispense pressure and the back pressure with the result being random off ratio problems. Worn or damaged components can also result in the inclusion of air into the material. Air can be sucked in as the product flows through the valve. This included air can either cause the mix to go off ratio or exhibit itself as air bubbles in the curing material. The inclusion of moist air into moisture sensitive materials will make this problem worse. o Check for worn or leaky (dispense) pistons. Pressure begins to develop as soon as the material is pressed toward the mix head. Due to this pressure material will leak past the seals if they are worn or damaged. The result will be an off ratio mix and lead/lag problems. Check the temperature of supply lines. Some machines are equipped with heated supply lines to facilitate processing high viscosity (usually highly filled) materials. In order to prevent filler settling, it is paramount to keep the material moving through heated lines. Settled fillers will further compact as back pressure is developed and will result in partially blocked lines and an off ratio mix. Check resin and hardener reservoirs for filler settling. Reservoirs without agitation, especially those that contain filled materials, tend to encounter filler settling problems. Malfunctioning agitators, especially on heated reservoirs, will have the same problems. Some dispense equipment is designed to pump product directly from the material suppliers containers. It is critical to make certain that the fillers are thoroughly dispersed and are kept in suspension until the containers are emptied. Settled fillers will cause a resin or hardener rich mix (depending on which is filled or missing more filler) and therefore will be off ratio. Check vacuum shut off (if so equipped). Some material reservoirs are maintained under vacuum whenever the material is not being dispensed. The vacuum is shut off just before the dispense cycle begins. Any malfunction in this system could result in impeding material flow due to residual vacuum. Check compressed air supply lines and moisture traps. Equipment requiring compressed air is prone to problems caused by fluctuating line pressure. This problem could be complicated by excessive moisture in the air supply. Severe problems could arise if moist air comes in contact with moisture sensitive material components due to leaking valves in the system.

In our experience, the following symptoms are encountered most often:

The cured epoxy or urethane compound is too soft. The gel time is too long (longer than expected). The cured compound contains soft spots (lead/lag problems). The epoxy or urethane cures too quickly. The compound shrinks too much during cure. Air bubbles in the mixed product. The cured product appears to have streaks or blush on the surface.

General
Before anything else, for checking epoxy and urethane compounds, follow the Golden Rule

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Equipment related
Automated dispense machines are carefully designed to accommodate specific types of materials, specific types of fillers, mix ratios and the application requirements at hand. They must be maintained at regular intervals according to the manufacturers recommendation. Worn components such as seals, check valves and pneumatic components must be replaced regularly to insure proper, trouble free operation. In most cases, there is a delicate balance between the pressure that is required to dispense the material and the resistance that is presented against the flow of the products through the dispense lines prior to the mix head. Any blockages, improperly timed or leaky check valves or leaky piston seals will upset this balance resulting in problems. There are two basic types of mix heads in common use today. The static or motionless mix head is most common. These are usually made out of plastic containing spiral like elements and are disposable after use. Some are made out of stainless steel, employing the same principle of mixing, and are reusable. The dynamic mix head is the other most common type employed. This type of mix head has a built in mechanical blade that turns at a predetermined rpm to mix the components as they flow through the mixing chamber. For obvious reasons, it is critical to keep the mix head clean and free of blockages. In the case of dynamic mix heads, depending on the type of fillers employed in the formulation being processed, it is important that the mix blade is made out of a material having sufficient hardness not to wear too quickly. Dynamic mix heads also tend to generate heat during the mixing action. This heat can raise the temperature of the mixed material to unsatisfactory levels. In addition, the eroding mix blade can contaminate the mixed material with minute metallic particles that are detrimental in certain applications such as electrical or electronic device encapsulation. Proper design is extremely important. There are several variations of dispense mechanisms in use today. Many of these provide continuous material flow meaning that the back end of the piston is being filled while the material is dispensed in the forward motion. The reverse takes place while the pistons move backward. Other systems dispense only while the piston is moving forward and there is a period of time that is required to re-charge after the piston is emptied. Other systems employ electronically controlled auger type mechanisms. All these systems are capable of delivering highly accurate amounts of material in the correct ratio if appropriately maintained according to the manufacturers instructions. There are numerous variations in the type of adaptors available to deliver the mixed material from the mix head to the component being potted or encapsulated. These are usually in the form of flexible hoses or pipes equipped with the appropriate orifice to inject the mixed product. The length of these devices must be kept to the minimum and careful consideration must be given to the mixed viscosity and the available pot life during selection. Any restrictions to material flow and/or material nearing the end of its pot life residing in this device are both undesirable.

automated dispense equipment. The most significant properties affecting dispensability are as follows:

Miscibility (the ability to mix one component into the other) Abrasiveness. Vapour pressure. Component and mixed viscosity. Filler types (if any). Moisture sensitivity. Gel time. Processing temperature.

Materials that are harder to mix will require longer mix times or longer static mix heads with more elements. Abrasive products (abrasive fillers) will require hardened machine components. High viscosity products may require heat (heated reservoirs and supply lines) to process. Moisture sensitive products will require dry air and process conditions. Shorter gel times will require frequent discharge from the mix head to prevent freezing up.

The above represent a brief summary of possible corrective measures for problems encountered in casting with epoxy products. Contact us for specific solutions.

Before attempting anything else, confirm that the material is free of large solid particles and cures as it should by carefully weighing each individual component and hand mixing a sample. If it cures according to the manufacturers specification, the material is good, proceed with one or more of the following checks. To confirm that a lead/lag problem exists use the Bead Test.

Material related
There are numerous variations of formulated products that are processed through