Idi Molding Troubleshooting Guide

TROUBLESHOOTING
MOLDINGPROBLEMS
MoldingGuideforBMC&SMC
IDICompositesInternational
May,2013
407 S. 7th Street | Noblesville, Indiana 46060 | (317) 773-1766 | Fax: (317) 773-3877 | www.idicomposites.com
Table of Contents
BondFailure..................................................................................................................................................4
BondReadout...............................................................................................................................................5
Chip...............................................................................................................................................................6
Contamination..............................................................................................................................................7
Crazing(SurfaceCracks)................................................................................................................................8
Dieseling........................................................................................................................................................9
Dirt..............................................................................................................................................................10
DullSurface.................................................................................................................................................11
EjectorCracks..............................................................................................................................................12
FiberPull.....................................................................................................................................................13
FiberTear....................................................................................................................................................14
FingerTracks...............................................................................................................................................15
FishEye.......................................................................................................................................................16
FlowMarks..................................................................................................................................................17
Fractures.....................................................................................................................................................18
Gouge..........................................................................................................................................................19
HangingFibers............................................................................................................................................20
KnitLines.....................................................................................................................................................21
Laking..........................................................................................................................................................22
MoldMarks.................................................................................................................................................23
MoldedPoly................................................................................................................................................24
NonFill........................................................................................................................................................25
PaintSags....................................................................................................................................................26
Porosity.......................................................................................................................................................27
PreGel.........................................................................................................................................................28
ResinRich....................................................................................................................................................29
Rib,PinandBossReadout..........................................................................................................................30
Ripple..........................................................................................................................................................31
SandThrough..............................................................................................................................................32
SanderScratches.........................................................................................................................................33
Scratch........................................................................................................................................................34
Separation(Phasing)...................................................................................................................................35
Scumming....................................................................................................................................................36
SinkMarks...................................................................................................................................................37
Sticking........................................................................................................................................................38
Streaking(Abrasion)....................................................................................................................................39
SurfaceWaviness........................................................................................................................................40
Undercure...................................................................................................................................................41
Warpage(DimensionalError).....................................................................................................................42
WaterSpots................................................................................................................................................43
WhiteSpots.................................................................................................................................................44
407 South 7th Street | Noblesville, Indiana 46060 | (317) 773-1766 | www.idicomposites.com
Page 2 / 44
Blisters
Ablisterisadelaminationthatproducesabulgeonthesurfaceofthepart.Thisbulgeisusually
regularinshapeandcanrangeinsizefrom1/8to10inches.Ablisteriscausedbythepresenceof
gasesunderpressurewithinthesubstrate,forcingtheskinawayfromtheglass.Canbeseenon
paintedorunpaintedparts.
ProbableCause
Material
Insufficientglasswetoutwithresin(dryglass)
Foreignobjects/contamination(film,flash,etc.)inoronthecharge
Wrinkles/pocketsindiscontinuoussurfaceofSMCchargepattern
Process
Tooling
AddingsmallSMCpiecestochargepatternwhichtrapair
InsufficientpressureonSMCduringcurecycle
Oventemperatureheatupratetoofast,especiallyincombinationwithahigh
moisturecontentpart
Improperchargepatter(toolarge,rolledorfolded)
Moldtemperatureoutofspec
Vacuumtoolow;impropervacuumcycle
Lowcuretime(undercure)
Pressclosurespeedtofast(airtrappedinlaminate)
Moldshearedgeistootight(notallowingairtobleedout)
ToolDeflection
CorrectiveAction
Material
Checkforfiberglasswetout
Checkmaterialforcontaminantsandcheckformoisturecontamination
Evaluateviscositylevelsaffectonblisters,lookathigh,mediumandlow
Uselessreactivecatalyst
Selectdifferentshrinkadditives
Verifymaterialisnotdriedout
Process
Increasematerialflowdistance
Increasemoldingpressure
Pyramidchargeincenterofthetool
Loadpattern,location,size,thickness
Appropriatevacuumamountandtiming(position)
Appropriatepressclosurespeeds
Appropriatemoldtemperatures
Appropriatecuretime
Donotusemakeuppiecesinthecharge
Becertainmoldshearsarecleanwithatleast0.004offlash
Tooling
Checkformolddeflection
CheckforPlatenparallelism
Page 3 / 44
BondFailure
Failureofabondedassembly,usuallyattheinterfaceoftheadhesiveandthesubstrate
ProbableCause
Material
OutofspecSMC
Process
Geltimeofadhesivetooshorttopermitproperbonding
Bondnotfullycuredbeforeclampsareremoved
Improperlypreparedbondsurfaces
Mixratioofthetwocomponentadhesiveisoff
Moisturecontaminationofadhesiveorsurfacetobebonded
Outofspecadhesive
Excessiveinternalorexternalmoldreleasein/ontheSMC
Shiftbetweeninnerandouterpanelsduringcuringoftheadhesive
Incompatiblesubstrateandbondmaterial
Introductionofairintodispensesystemcausinggaps,ratiovariations
Impropercurecycle
Improperheatingduringbondcycle
Tooling
CorrectiveAction
Material
Process
ImproveQCofadhesivematerial
Fullycureadhesivebeforepressureorclampingisremoved
Properlypreparesurfacestobebonded
Ensurethatperiodiccheckofthemixratioisperformed
Controltemperatureofadhesive
DOnouseexternalmoldreleaseonbondareas
Tooling
Page 4 / 44
BondReadout
Bondreadoutisasurfacedistortionsimilartoahumporsinkthatoccursoverabondline
ProbableCause
Material
Process
Mismatchofcompliancebetweenouterpanel,innerpanelandadhesive
IncompatiblethermalexpansioncoefficientsbetweentheSMCandthe
adhesive
Excessiveshrinkageoftheadhesiveduringthefixturingandcuringcycles
Excessivefixturingpressureinducedduetopartmismatchoftheouter/inner
panelsandthebondlinestandoffs
Excessivefixturingtemperatureduetononuniformheating
Hotspotsfromadhesiveexothermicreactionduetononuniformadhesive
thickness
Bondgapthickabove1.5mm
Bondgapthinbelow0.5mm
Outerpanelthin,lessthan2.0mm
Innerthicknessabovemaximum
Tooling
CorrectiveAction
Material
Process
Increasethethicknessofthebondingareaoftheappearancepanelorselecta
moreflexibleadhesive
Matchthethermalexpansioncoefficientsbetweenthesubstrateandthe
adhesiveasmuchaspossible
Selectanadhesivewithminimumpolymerizationshrinkage
Obtainmatchedouter/innerpanelsthroughbettertooling
Eliminatebondlinestandoffs
Useclosedloopfeedbacktemperaturecontrolsystemfortightertemperature
variationtoleranceofthefixture
Minimizeandcontrolclamppressure
Moldwarpfreeparts;donotuseadhesivebondfixturetostraightenparts
Checkadhesivethicknesstospecification
Checkouterthicknesstospecification
Checkinnerthicknesstospecification
Tooling
Page 5 / 44
Chip
Achipisdamagetothesurfaceofthepartthatresultsinsmall(lessthan/2inch)missingpieces.A
chipusuallyoccursneartheedge,andsinceitisnonstructural,itusuallyisrepairable
ProbableCause
Material
Resinrichedge
Process
Roughhandling
Roughbypass
Shippingrackslacknecessarypadding
Nouseofinprocessracks(partsarestackedoneachother)
Squarededgeonpartatmatingsurfacewithadjacentparts
Tooling
Improperlydesignedsecondaryfixtures(nonpaddedinallnecessaryareas)
Molddefectsonedgesorflashstucktoshearedge
CorrectiveAction
Material
Increasecompoundviscosity
Process
Utilizetransferlinesandotherhandsoffprocessingtechniques
Trainworkersinproperhandlingtechniques
Improveshippingproceduresandmonitorpartquality
Improveshippingrackrepairprocedures
Addexternalmoldreleaseandclean
Slowejectorspeed
Slowpressclosurerate
Relocatecharge
Decreasemoldingpressure
Tooling
Designsecondaryfixturesproperlyandcoatthemwithsoftmaterialstoabsorb
shocks
Preventativemaintenanceonmoldsandfixtures
Periodicallycleanflashonshearedgesandgummydepositsofstyrene
Polishtoolsurface
Page 6 / 44
Contamination
Foreignmaterialinthelaminate
ProbableCause
Material
ForeignmaterialinSMCcompoundorrawmaterials
Process
Foreignmaterialfromthemoldingpresses
Tooling
CorrectiveAction
Material
Checkforforeignmaterialsinmoldingcompoundandcutoutifnecessary
Checkforforeignmaterialsinrawmaterials
Process
Tooling
Page 7 / 44
Crazing(SurfaceCracks)
Crazecracksarehairlinecracksthatdonotgothroughtheentirethicknessofthepart.Thesecracks
usuallyoccuringroups.Crazecrackscanappearsimilartoporosityonpaintedparts.
ProbableCause
Material
Process
Mechanicaloverstressingcausedbypartstickinginthemoldorroughhandling
Poormaterialflowpatternaroundmashoffs,corepins,moldouts
Thermalstressesinducedbymoldtemperatureorbynonuniformpartcool
down
Chargepatternchangedbyaddingsmallpiecestomakeupweight
Ejectorpins
Thicktothinwallthicknessvariation
Tooling
Secondaryfixturesimproperlydesigned
Thicktothinwallthicknessvariation
Ribstoothickwithrespecttowallthickness
Coredholesorslidestoolowfromdesignatedsurfaceposition
CorrectiveAction
Material
Process
Coolpartsatauniformrate
Designchargepatterntominimizeimproperflowbehavior
Donotusemakeuppiecesinchargepattern
Minimizemashoffs
Slowejectionsystemtoreduceejectorpincrazing
Increasedifferentialtemperaturebetweencoreandcavity
Tooling
Designsecondaryfixturessotheydonotinducestressonthepartandcoat
themwithsoftmaterialstoabsorbshock
Polishshearedgesofcavity,eliminatebackdraftorundercuts
Ensuresmoothtransitionfromthicktothinsections
Page 8 / 44
Dieseling
Dieselingisaburntspotonthelaminate,oftenaccompaniedbynonfills
ProbableCause
Material
Process
Airentrappedinthetoolwhichburns
Tooling
CorrectiveAction
Material
Process
Slowpressclosure
Varymoldtemperaturedifferential
Increaseshearopening(assumesdieselingoccursneartheshearedge
Addventedejectorpins
Tooling
Page 9 / 44
Dirt
Dirtisaparticulatecontaminateunderorinanypaintfilmthatshowsupasaraisedbumpofthe
curedpaintfilm.
ProbableCause
Material
Process
Dirtonpartsasreceived
DirtcreatedbyrepairingSMCdefects
Dirtonthepaintrackthatisnotwashedoff
Dirt,hair,fibers,etc.fromworkers
Improperpaintshopcleanliness
Deionizedrinseoutofspec
Tooling
CorrectiveAction
Material
Process
Installationofappropriatepowerwasher
Automatepaintoperations
Propermaintenanceofpaintequipmentandpaintbooth
Removeandcleanoversprayonthepaintracksperagreeduponschedule
Analyzedirtparticlestoaccuratelydeterminesource
Cleanoverheadconveyor
Improvepaintshopcleanlinessprocedures
Tooling
Page 10 / 44
DullSurface
Lossofglossonoverallpartsurface
ProbableCause
Material
Highshrinkage
Process
Undercure
Lossofpressure
Tooling
Unacceptabletoolsurface
CorrectiveAction
Material
Checkforcatalystlevel
Checkresinreactivity
Selectdifferentshrinkadditivesorlevels
Process
Increasemoldtemperature
Increasecurecycle
Maintainconstantmaterialpressureinpress
Tooling
Polishandbufftoolsurface
Chromeplatetoolsurface
Page 11 / 44
EjectorCracks
Ejectorcracksaresmall,visiblesurfacecracksonthecavitysidesurfaceofthemoldedpart.These
areoftenfoundontheoppositesideofthepartaboveanejectorpin.Acracklocatedonthesurface
ofthelaminatethatdoesnotextendcompletelythroughthesubstrate.
ProbableCause
Material
ResinReactivity
Process
Thepartisstickingtothecore
Thepartisundercured
Curetimeistoolow
Moldtemperatureistoolow
Insufficientreleaseagent
Theejectorpinisplacedinapoorlocation,toofewfinsortoosmalladiameter
Tooling
Ejectionsystemistoofast
Blockedairtopopperpassage(partial)
Improperlysizedairsupplylinetoairpopper
Ejectionsystemleadingairpopperblowoff
Excessflasharoundejectionpin
Undercutsalongshear(actingashangers)
CorrectiveAction
Material
Process
Checktemperatureandcuretimes
Placeejectorpinsinareasleastsensitivesuchasbelowribsorbosses,increase
diameterornumberofpins
Verifycorrectloadpatternweight
Addexternalmoldrelease,moldonepart,thendiscardthatpart
Cleanshearedges
Tooling
Slowejectionsystem
Checkmoldforundercuts
Alleviatestressesholdingtheparttootighttothecore(undercuts,etc)
Propersequencingofairpoppersystem
Inspectmoldforbiasedejection,installflowcontrolordividers
Ifejectorsareonangledsurfaceaddskidgroovestotopofejectorpin
Page 12 / 44
FiberPull
FiberPullisadepressionleftbyremovingorlooseningoffiberglassstrandslocatednearthesurface
ofthelaminate.
ProbableCause
Material
Sticking
Process
Flashbuilduponthebypass
Tooling
Wornbypass
CorrectiveAction
Material
Process
Addexternalmoldreleaseandcleanbypass
Varymoldtemperaturedifferential(normallynarrowthedifference)
Decreasebypassopening
Correctejectoraction(areallejectorpinsworking)
Slowejectorspeed
Tooling
Page 13 / 44
FiberTear
Fibertearisasurfacedefectcausedbyfiberstearingawaypartofthesurfaceresin.Thesedefects
alwaysoccurneartheshearedgeofapart.
ProbableCause
Material
Process
Improperdeflashingofthepart
Ejectorspeedtoofast
Chargeweighttoohigh
Moldtemperaturedifferentialincorrect
Moldingpressuretoohigh
Moldingviscositytoolow
Shearedgetemperaturevariancetooliberal(causingexcessflash/leakage)
Moldingpressstripspeedtoofast
Flowparalleltoshears
Tooling
Improperlyfitorwornshearedges
CorrectiveAction
Material
Process
Usesandpapers,fileorautomaticroutertodeflashinsteadofaknife
Closerinspectionofpunchedanddrilledholes
Usehightechnologyprocesssuchasrouter,waterjet,laserorultrasonicsto
performdeflash,punchanddrilloperations
Verifycorrectloadpatternweight
Verifyappropriatetemperaturedifferentialbetweencoreandcavity
Verifyappropriatemoldingtemperature
Slowejectorspeed
Adjustchargetominimizeflowparalleltoshears
Tooling
Maintainpropershearedgeonmoldstominimizeflash
Page 14 / 44
FingerTracks
Fingertracksareshallowgrovesinthesurfacethatshowupafterprimeortopcoat.Thesegrooves
areusuallythewidthofafinger.
ProbableCause
Material
Process
Sandingthesurfacewithoutablockorbackuppad.Thepressuredirectlyunder
thefingersremovesmorematerialthanbetweenthefingersandleavestracks
thatshowuponthepaintedsurface
Itisgenerallyacceptedthattheeyecandetectsurfacedepressionsof0.0004
inchesorgreateroveraoneinchspan
Tooling
CorrectiveAction
Material
Process
Alwaysuseblockorpadwhensandingthesurface
Developsandingandfeatheringtechniquesthatblendsurfacechangesover
largeareas
Use400gritorfinersandpaper
Tooling
Page 15 / 44
FishEye
Afisheyeisacircularorellipticaldepressionintheprimer.Thereisnotanypenetrationintothe
substrate.Fisheyesareusuallycausedbysometypeofsurfacecontamination
ProbableCause
Material
Process
Oil,greaseorsiliconecontaminationinpaintsystem,airfeed,paintconveyor
lineorinthepaintitself
Ragscontainingoiloroilbyproducts
Excessmoldreleaseatsource
Insufficientcleaningofthepart
Oversprayofprimer
Mismatchofsolventwithpaintorprimesystem
Ensurepartsarenotbeingsprayedordrippedonatpressbyhydraulicoils(if
so,with50%IPAand50%DIwater)
Tooling
CorrectiveAction
Material
Process
Donotusesiliconecontaininghandcreamsorlubricantsduringhandlingat
presssideorbonding
ProperlyinstalledpowerwasherforallSMCparts
Propermaintenanceofequipment(filters,etc.)
Ensureproperuseofoilsandlubricantsinthepaintshop
ProperQCproceduresonallpaintmaterials
Fisheyereducingadditivestopaintareavailable.
Tooling
Page 16 / 44
FlowMarks
Flowmarksisthevisualorientationoffiberglassstrandsonthepartsurface
ProbableCause
Material
Process
Flowcondition
Tooling
Tooldesign
CorrectiveAction
Material
Evaluatemoldingviscosityeffect
Selectdifferentshrinkadditivesorlevels
Process
Decreasematerialflowdistance
Relocatechargepattern
Increasepressclosurerate
Tooling
Changepartwallthickness
Page 17 / 44
Fractures
AFractureisastructuralfailureinapartwhichextendscompletethroughthesubstrate
ProbableCause
Material
Insufficientglassreinforcement
Stickingorwedgingofpartinmold
Process
Mechanicalhangupfromflowrelatedknitlines
Roughhandling
Poormaterialflowpatternaroundmashoffs,etc.
Chargepatternchangebyaddingsmallpiecestoproduceproperweight
Inprocessracksnotusedorpoorqualitysecondaryfixtures
Pressopensaskew
Poorpartdesign(ifeverypartiscracked)
Impropercombinationofdrillspeedandfeedrate
Shippingdamage
Heaviershearononeedge
Dulldrillbitorwornoutsleeve
Undercutatpartinglinesorundercutinthemold
Shearstootight
Curetimetooshort
Parallelismofejectors
Tooling
Improperlydesignedsecondaryfixturesortooling
CorrectiveAction
Material
ControlSMCsheetweighttoallowuseofautomaticcuttingofchargepatterns
UseQConSMCglasscontent
CheckSMCflow
Process
Reducematerialflowdistance(reducetheflowfront)
Designchargepatterntominimizeimproperflowbehavior
Donotusemakeuppiecesinchargepatterns
Properlysupportpartinshippingcontainers
Evaluateproperpaintrackdesign
Checkshears
Changedrillbitorsleeve
Eliminateanyundercutsinthemold
Increasecuretime
Slowejectorspeed
Relocatecharge
Tooling
Designsecondaryfixturessothattheydonotinducestressinthepart
Drawpolishshearedgesinthecavity
Useparallelismcontrolonthepress
Page 18 / 44
Gouge
Agougeisalong,deepdepressioninthesurface,severeenoughtorequirearepairprocedure.
Gougescanbeseveralthousandsofaninchdeep.
ProbableCause
Material
Process
Roughhandling
Improperlydesignedsecondaryfixtures(notpaddedinallnecessaryareas)
Squareedgeonpartatmatingsurfacewithadjacentparts
Tooling
CorrectiveAction
Material
Process
Investigatepotentialsourceforgougesinprocessandcorrect
shocks
Periodicallycleanflashonshearedges
Repairusingapprovedrepairprocedure
Tooling
Page 19 / 44
HangingFibers
Hangingfibersareglassfibersthatarelefthangingfromthepartafteradeflashing,holdpiercingor
drillingoperation.Thesefiberscausedirttobecarriedintothepaintshop.
ProbableCause
Material
Process
Dullorimproperlyfitsecondarytooling(bits,mashoffs,punches,etc.
Impropersandingtoremovefibers
Tooling
Dulldeflashingtool
CorrectiveAction
Material
Process
Closerinspectionofpiercedanddrilledholes
Usehightechnologyprocesssuchasrouter/drillbitdesign,waterjet,laseror
ultrasonicstoperformdeflash,punchanddrilloperations.
Tooling
Propermaintenanceprogramneedformolds,piercediesandsecondarytools.
Page 20 / 44
KnitLines
Knitlineisatermforthemoldingconditionwhichrelatestoorientedfiberpatternsinthemolded
part.Theknitlineusuallyoccursattheedgesorcornersofthepartfurthestfromthecharge
placementposition.Itisanextremelyweakareainthemoldedpartresultingfromtwoflowfronts
meeting.
ProbableCause
Material
Process
Flowfrontsfromdifferentchargepatternpieces
ToofarofadistancefortheSMCtoflow
Chargepatternposition
Incorrectrateoftonnagebuild
SpiralflowofSMCtohigh/low
Moldtemperaturestoohigh
Tooling
Molddesign(deepverticalwalls),etc.
CorrectiveAction
Material
Process
Appropriateloadplacement
Properpressclosure
Properloadpatterndimensions
Consistenttonnagebuild
Checkoillevelinpress
Placechargedirectlyovercriticalorknitlineareaifpossible
Decreaseclosurespeed(reduceamountoforientation)
Eliminateseparatechargesifpossible
Verifycorrectmoldingtemperature
Tooling
Optimizemolddesignforbestflowconditions
Page 21 / 44
Laking
Lakingisanirregulardullareaonthesurfaceofthepart.Thedullareamaybeassociatedwith
porosity.Lakingcanalsobenoticedafterprimeassoakin
ProbableCause
Material
Differentialshrinkage
Process
Toolowapressureonthepartduringmolding(usuallyonverticalwalls
Moldingonstops
Loadpatternweighttoolow
Undercuredpart
Coldspotsonmold
Tooling
CorrectiveAction
Material
Selectdifferentshrinkadditivesand/orlevels
Process
Maintainpressureonmaterialduringmolding
Donotmoldonstopsorflash
Verifyloadweightiscorrectandnottoolow
Verifymoldtemperatures
Increasepressingspeed
Tooling
Equippresswithparallelismcontrol
Page 22 / 44
MoldMarks
Amoldmarkisalump,depressionorlinethatoccursinthesamelocationofeverypartduetoa
damagedmold
ProbableCause
Material
Process
Tooling
Damagetothecavityofthemoldduetoinsufficientprotection
Stuckpartsthatrequirescrapingoffthemold
Impropertoolsusedtocleanthemold
Thicknessvariationflowingthintothickcausingtoolwear
Hardmetalobjectmoldedintopartcausingmolddamage
CorrectiveAction
Material
ProperQCofSMCmaterialswillreducethestickingofparts
Process
Tooling
Repairmoldsasrequired
Regularmaintenanceprogramformolds
Makesureallcuttingutensilsaremadefromsoftmaterialsthatwillnot
damagethemoldsurface
Makesureallemployeesuseonlycopper,brass,woodorplastictoolsto
scrapethemoldsurface
Wiredownalllooseitemsonthecuttingtableandloading/unloading
equipment
Protectmoldsurfaceintransportandstorage
Automationshouldbeconstructedfromaluminumorothersoftmaterials
Page 23 / 44
MoldedPoly
Irregularshaped,smalldepressionsonthesurfaceofapartshapedlikecarrierfilmchips,but
recessedintothesubstrate.Thesedepressionsarenormallythecolourofthefilm.
ProbableCause
Material
Process
PiecesofcarrierfilmthataremoldedintotheSMCpart
Tooling
CorrectiveAction
Material
Process
Makesurethatallcarrierfilmisremovedfromthecharge,especiallywhen
automaticfilmstrippingisnotused.
Properrepairprocedurerequired
Frequentchangingofbladestoensurecleancuts
Checkforproperslittercutteralignmenttoshearguide.Improperalignment
willcauseasmallstriptoadheretotheedgeoftheSMCunnoticed.
Tooling
Page 24 / 44
NonFill
Anonfillisaseverevoidinthelaminate.Itisanincompletepartthatmustbescrapped
ProbableCause
Material
Process
Tonnagetoolow
Moldtemperaturestoohigh
NotenoughSMCchargeweight
Moldingonstops
Pressclosuretooslow(tonnagebuildratetooslow)
Moldtemperaturesofcavityandcorearetooclose(noflash)
Flash/debrisonthemoldshears/stops
SMCchargesitsonmoldtoolongbeforeclosure
SMCchargehastoflowtoofar
Tooling
Toolorplatendeflects
CorrectiveAction
Material
Decreasemoldingviscosity
Process
Verifyparameterstocontrolplan/processsheet(tonnage,loadpattern,load
placement,temperature,closurespeeds)
CheckSMCspiralflow
Verifymoldingoffstops
Cleanmoldshears/stops
Checkfordeflection
MonitorSMCviscositybuild
Verifyweightscalesarecorrect
Increaseclosurespeed
Ensurechargeweightsarebalanced
Checkoillevelinpress
Ventejectorpinsand/oraddventedejectorpins
Shortentoolloadtime
Tooling
Blendcorehalftoreducethintothickflowrestrictionsinareaofnonfill
Page 25 / 44
PaintSags
Asagisexcesspaintonapartthatshowsitselfasahumporripplethatdistortsthesurface.
ProbableCause
Material
Process
Oventemperaturetoolow
Viscosityofpainttoolow,toomuchsolvent
Filmbuildtoothick
Sprayguntooclosetopartbeingpainted
Inconsistentsandingofpartstobereworked(causingsagswhenpaintingwith
electrostatics)
Tooling
CorrectiveAction
Material
Process
QCpaintviscosityoneachshift
Monitorandcontrolultimateovertemperatureandheatuprate
Donotallowpainterstogetaheadorbehindjobsequence
Instructpaintersonproperspraytechniques
Preventativemaintenanceofsprayequipment
Implementautomaticpaintsprayingequipment
Verifyappropriateairpressure
Verifyappropriatepaintpressure
Increasedistancebetweenpartandgun
Usemorecoatsofpainttogetdesiredfilmbuild
Thoroughlyscuffsandreworkspriortopaint.
Tooling
Page 26 / 44
Porosity
Porosityisanobservableorunobservableconditioninanypart.Itconsistsofaclusterofholesthat
usuallyoccurswhentrappedairescapesduringthemoldingprocess.Thisclusterusuallycoversan
areanolargerthanaquarter,butcanbelarger,andcanoccurasasinglehole.Unfilledporosity
createsacratertypeconditiononatopcoatedpart
ProbableCause
Material
Excessstyreneloss
Process
InsufficientflowoftheSMC;toolarge/smallachargepattern
Pregel
Flashonshearedgepreventsadequateventingofgasses
Insufficientpressureonmaterialduringmolding
Improperpressclosurespeed
Moldtemperaturetoohigh
Vacuumtoolow;impropervacuumcycle
Undercure
Lowchargeweight
AddingsmallSMCpiecestochargepattern
Toomanyplies
Moldingonstops
Moisturecontamination
Tooling
CorrectiveAction
Material
Evaluateviscositylevel
Verifymaterialisnotdriedout
Process
Verifyvacuumamountandtiming
Verifyloadpatternlocation,size,thickness
Verifyappropriatepressclosurespeeds
Verifyappropriatetemperatures
Makesuremoldshearsareclean
Minimizenumberofpliesincharge
Checkchargeweight
Checkmoldingpressure
Cleanmoldstops
Tooling
Page 27 / 44
PreGel
Pregelcauseslocalizedareasofdull,rough,porosity,usuallywithdiscoloration
ProbableCause
Material
Tooreactiveresin
Tooreactivecatalyst
Process
Slowclosurerate
Tooling
CorrectiveAction
Material
Process
Shortentoolloadingtime
Increasepressclosurerates
Decreasemoldtemperature
Tooling
Page 28 / 44
ResinRich
Anareainthepartwherefiberglassstrandscontentislow.
ProbableCause
Material
Resinisnotcarryingfiberglassstrands
Process
Tooling
CorrectiveAction
Material
Increasematerialmoldingviscosity
Process
Slowpressureclosurerate
Tooling
Page 29 / 44
Rib,PinandBossReadout
Asurfacedepressionlocatedoverribs,bosses,ejectorpinsorthicksectionsofthepartthatappear
asalightercolorresultinginreadthrough.
ProbableCause
Material
Process
Lackofmaterialflow
Lackofcavity/coretemperaturedifferential
Lackofatonnagebump(decreasemoldingpressureafter30secondsinto
cycle)
Tooling
CorrectiveAction
Material
Process
Increasematerialflowdistance(donotloadoveraboss)
Increasemoldtemperaturedifferential(thehotterappearancesidewillgel
slightlyfasterandwillreducetheamountofsink)
Reducetonnageaftermoldfill(hightonnageheldthroughthecurecycle
increasessink.Reducetonnageby25%to30%after30seconds.
Tooling
Page 30 / 44
Ripple
SevereshorttermwavesintheSMC,almostalwaysontheedgeofapartorverticalwalls.
ProbableCause
Material
Improperviscosity
Materialtoooldandwillnotflowproperly
Higherpasteshrinkage
ImproperlymaturatedSMC
ExtremelyhighflowingSMC
Process
Inconsistentforceonthematerialduringmolding
Chargepatternplacedorcutimproperly
Temperatureofmoldtoohighordroppedtemperaturezoneofmold
Improperclosurespeed
Abruptthicktothinflowcondition
Reflowofmaterialduetononparallelclosure(leveling)
Tooling
Moldnotcenteredtopressplaten
Flowturbulenceresultingfromtooldesign
CorrectiveAction
Material
Investigateviscosityofpaste
VerifySMCiswithinappropriatespiralflow
Investigatepastshrinkage
Process
Increasetonnage
Verifychargeweight
Monitorandcontrolmoldtemperaturestospecs
Tooling
Mayneedtooffsetmold
Modifytooling
Page 31 / 44
SandThrough
Asandthroughisabreakthroughtheprimersurfaceresultingfromasandingoperation.
ProbableCause
Material
Process
Localizedsandingthatisdeeperandmoreseverethanisnecessary(finger
sanding)
Tippingpowersandertocutdeeperinoneareatoremovedirtorother
localizeddefects
Sandingwithtoocourseasandpaper
Tooling
CorrectiveAction
Material
Process
Alwaysblocksanddefects
Repairmoldwhenmoldmarksappeartominimizetheamountofsanding
Goalistoavoidusingsandpaper
Eliminateuseofpowersanders
Useonly400gritorfinersandpaper
Tooling
Page 32 / 44
SanderScratches
Scratchesinthesubstrateresultfromasandingoperation.Thesescratchesusuallyappearasvery
finecircularscratches.
ProbableCause
Material
Process
Sandingcurvedareasofpartwithaflatsander
Impropergritsizepaper
SandingClassAsurfacetoremovediemarks
Repairproceduresforalldefects
Poorflashremovalmethodswhichrequireadditionalsanding
Excessiveloadingofsandpaperwithsandingdebris
Tooling
CorrectiveAction
Material
Process
Establishspecificationdescribinggritsizeforspecificoperations
Handsandcurvedareasthatrequiresanding
Repairdiemarksonmold,notonparts
Automateflashremovaltoeliminateerror
Specifypapergritsizeforeveryrepairmethod
Specifysandpaperchangeinterval
Cleandebrisfromunloadingfixtureorracks
Tooling
Page 33 / 44
Scratch
Ascratchissimilartoagouge,butisnotdeepenoughtorequirefillrepairmaterial.Ascratchcan
usuallybefeathersandedout.
ProbableCause
Material
Process
Roughhandling
Improperlydesignedsecondaryfixtures(notpaddedinallnecessaryareas)
Squareedgeofpartamatingsurfacewithadjacentparts
Tooling
CorrectiveAction
Material
Process
shocks
shocks
Periodicallycleanflashonshearedge
Improveshippingprocedureandmonitorpartquality
Repairusingapprovedrepairprocedure
Tooling
Page 34 / 44
Separation(Phasing)
Anareaofhighthermoplasticcontentresultinginnonuniformityofcolor
ProbableCause
Material
Separationofthethermoplasticresinfrompolyester
Process
Tooling
CorrectiveAction
Material
Increasemoldingviscosity
Process
Shortendieloadingtime
Decreasemoldingpressure
Decreasemoldingtemperature
Tooling
Page 35 / 44
Scumming
Dullingorstreaksinthepart(generallytransfersasimilarpatternonthetoolsurface).
ProbableCause
Material
Incompatibleresinadditives
Process
Internalmoldreleasenotfunctioningatthemoldtemperature
Tooling
CorrectiveAction
Material
Usegreaterviscositymaterial
Process
Shortentoolloadingtime
Tooling
Page 36 / 44
SinkMarks
Asinkisadepressiononthepartsurfacethatwillnormallyoccuroverribsorbosses.Itispossibleto
getasinkontheedgeofaflangedpart.Sinkscanrangeindepthfrom0.0004toseveralthousands
ofaninchanywherealongariborboss.
ProbableCause
Material
Poorglassorientation
ExcessshrinkageoftheSMCoverathicksection
Process
Inadequatemoldingpressure
Temperaturevariationsduetovariablethickness
Tooling
Improperribdesign
CorrectiveAction
Material
Process
Flowmaterialfromathicksectiontoathinsectionsoasnottocreatesurge
flowpatternsinlocalizedareas(thesurgefloworientsglassfibersperpendicular
toadjacentareaswhichshowsupasasink).
Crosssectioningthewallsectionmaybenecessarytoproveathintothick
flowcondition
Controlaspectratioofribandboss(depthtothicknessratio);ribshouldnot
bemorethan0.075thicknessofattachedwall
Placeribsandbossesbehinddesignlines
Moldoffstops
Ifsinkisoveraboss,reducemassbyhavingalongcoredhole
Tooling
Modifytooling
Page 37 / 44
Sticking
Stickingoccurswhenthepartadherestothecavityorcoreandisnoteasilyreleasedorresultsina
crackuponremoval.
ProbableCause
Material
ReleaseproblemwiththeSMC
SMCshrinkagecontrolisincorrect
Process
Coreistoorough
Chargeweightisexcessive
Undercutsoncavityorcore
Partisundercured
Temperaturespreadondiestooclose
Pressstripistoofast
Contaminatedmoldsurface(oils,dirt,etc)
Tooling
Moldsurfaceiscorroded
CorrectiveAction
Material
CheckforSMCrelease
CheckSMCshrinkagedata
Process
Slowstripspeed
Cleanmoldsurface/runbreakinmaterial
Addexternalmoldrelease
Increasecycletime
Tooling
Evaluatemoldforundercutsandremovewherenecessary
Checkchromeplatingwear
Polishtoolsurface
Pyramidchargeinthecenterofthetool
Page 38 / 44
Streaking(Abrasion)
Darkareas,directional,inlineofflow,foundinpigmentedpartsandisgenerallylocatedover
fiberglassstrands
ProbableCause
Material
Process
Tooling
Toolabrasionorscuffing
CorrectiveAction
Material
Checkrawmaterial
Usegreaterviscositymaterial
Selectdifferentshrinkadditiveorlevel
Process
Tooling
Polishorbuffouttoolsurface
Chromeplatetoolsurface
Page 39 / 44
SurfaceWaviness
Shorttermwavinesshaswavelengthsfortooneinchlong.Longtermwavinesshaswavelengths
fromonetofiveinches.WavinesscausesdistortionofstraightlinesontheClassAsurfaceandis
mostreadilyobservedonapaintedpart.
ProbableCause
Material
Process
ImproperspiralflowofSMCsheetwhenmolded
Inconsistentforceonthematerialduringmolding
Partsmoldedwithimproperpressure
Chargepatterncutorplacedimproperly
Flowinterrupters(mashoffs,corepins,partgeometry)inmold
Partialcharge
Improperbondingtemperature(Undercure)whichcancausebondreadout,
causingwaviness.
Tooling
CorrectiveAction
Material
Process
Monitorspiralflowforappropriatevalues
Useproperpressuretomoldmaterial
Removeflowinterruptersfrommold
Monitorviscosityofpaste
Monitorandcontrolmoldtemperaturestospecs
Refertodesignguideforallowablethicktothintransition
Verifyclosurespeeds,loadpattern(location,size)andleveling
Monitorviscosityofpaste
Tooling
Page 40 / 44
Undercure
UndercureisanincompletecureorbakecycleoftheSMCinthemold.Thepartisoftenextremely
smoky,verydullandcanexhibitblownbossesorribs.Thispartisscrapped.
ProbableCause
Material
Unreactiveresin
Incorrectcurechemistry
Process
Lowtemperaturesand/orshortcycletime
Lossoftonnage
Tooling
CorrectiveAction
Material
CheckSMCforcuretime
Process
Checkmoldcoldspotsorbadstreamlinesandregulators
Verifycuretimes
Verifytonnageviaparametersheet
Tooling
Page 41 / 44
Warpage(DimensionalError)
Dimensionalerroristhefailureoftheparttofitthecheckingfixtureortomeetprinttolerancesdue
toWarpage,shrink,expansionortoolingerror.
ProbableCause
Material
Outofspecmaterial
Process
Unevencure
Excessivestressonthepartwhenunloadingorbonding
Notallowingtheparttocoolonfixturelongenough
Variablechargepatternorplacement
Improperexpansionfactorintoolforapprovedmaterial
Improperthermalexpansionmaterialmoldedinapprovedmold
Improperlydesignedpaintfixture
Degreeofcurebondline
Tooling
Tooltemperaturesnotwithinspec
CorrectiveAction
Material
VerifySMCforpropershrinkage
Process
Useheatmanagementdesignofmoldtopermitconsistentcuringofpart
Properplacementofejectorpinsreducesdemoldingstress
Evaluateprocessforsufficientcoolingtime
Controlchargepatternbyarea,notweight.Whenpossibleuselaserlightor
automationtopermitconsistentchargeplacement
Designpaintfixturestoproperlysupportpartduringbaking
Ifbondedassembly,reviewbondingprocess
Verifycuretimeversustooltemperaturecapabilityofmaintainingcorrect
temperaturethroughconsecutivemoldings.
Increasecuretimeortemperature
Increasechargepattern
Verifymoldtemperatures
Tooling
Propermolddesigntoensurethatthepartdoesnotsticktocoreorcavity
Workwithdesignengineersearlyinprogramsothatmoldisconstructedusing
expansionfactorsofthenewertechnologymaterials
Page 42 / 44
WaterSpots
Circularspotsonthepaintedsurfaceusuallyingroups.Thesespotsareusuallydepressionswitha
raisedringaroundtheedge.Waterspotscancausepaintfailureoftopcoats/
ProbableCause
Material
Process
Failuretofullydrythepartafterawashoperation
FailuretosueaDIwaterrinseafterwash
FailuretocleanandfilterDIwatertomeetspecifications
Partdesignswhichtrapwaterinpockets
Failuretousearinseadditivewhichensuresawaterbreakfreesurface
Tooling
CorrectiveAction
Material
Process
Drypartsthoroughlyafterallwashoperations
Designdrainholesintopartswhennecessarytopreventtheaccumulationof
waterduringthewashcycle
QCrinsewatertospecs
Useandmaintainarinseadditiveafterpartswashing
Tooling
Page 43 / 44
WhiteSpots
Agenerallightorwhitenedareaonapigmentedsurfacethatoccursasaresultofthermoplastic
separation.Theproblemisassociatedwithpittingoccurringinthewhitespottedarea.
ProbableCause
Material
LowviscositybuildsofSMCthroughmaturation
ThermoplasticincompatibilitywithSMCformulations
Flowrestrictions
Process
Tooling
CorrectiveAction
Material
Verifyday1viscosity
Recordoccurrenceandrollyardagewhenproblemoccurs
Recordmaterialratesandlotnumberwhenproblemoccurs
Verifyspiralflowofmaterial
Process
Verifyloadpatterniscorrectaccordingtoengineeringspecification
Reducediecoveragetoallowforincreasedflow
Tooling
Page 44 / 44

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