Even in highly automated processes, machinery operators can still have a sizeable influence on the success and effectiveness of their machinery’s operation. However clear and well-written an instruction manual may be, wherever humans are involved, there is always going to be room for variation, making it important to find ways for various operators to be on the same page. The following looks at two examples where subtle variations in technique by the machinery operators caused variations in outcome, and ways that the problem was overcome.
From one shift to another, a customer was experiencing bond strength variations with a product that utilised surface-activated acrylic adhesives. The bond strength was well within the quality control limits the manufacturer had set, but the variation was still large enough to cause concern.
Stress cracks occur when the short-term mechanical strength of a plastic is subjected to adverse forces. Reducing or preventing stress cracks is accomplished with a careful design of compatible substrates and consistent manufacturing and assembly processes.
There are several areas to consider when looking for the cause of stress cracks in plastic components.
- Manufacturing/Extruding/Molding processes
- Thermal co-efficient compatibility of substrates
- Adhesive chemistry & application process
- Assembly processes
Frosting – Blooming – Chlorosis – Whatever you call it, we all recognize it as the unattractive white stuff that can sometimes occur when using instant adhesives.
The residue is a byproduct of the cure process of the adhesive. Once the monomer is in vapor form, it will react with moisture in the air, cure, and settle on the surface around the bond area.
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The troubleshooting process begins with a thorough knowledge of the processes leading up to, and including, the application of the adhesive.
There are many possible causes for failure of bonded components. Before suspecting air in the bond line as the source of failure, double check the adhesive selection, the application process and the working environment. Make any necessary corrections.
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There are two main things to consider when troubleshooting a threaded adhesive application that isn’t performing to specs.
- Correct Adhesive Selection
- Proper Adhesive Application