Transcript No Slide Title

Level One Apprenticeship
What you need to know
•
•
•
•
•
•
•
•
Ability to identify the type of plastic
Proper steps to achieve correct results
Which method of repair?
Will the repair be satisfactory?
Is it cost effective?
Do you have all the necessary materials?
Are we allowed to repair the part?
Is it a Thermoset, or a Thermoplastic?
Plastics Usage Through the Years
1970
1980
1990
2000+
Where are these plastics used?
 fascias
 bumper covers
 interior trim
 exterior trim
 fan shrouds
 batteries
 gas tanks
 wheel housings and
liners
 exterior body panels
 valve covers
 composite plastic
floor tunnels
 virtually anywhere
Viper...
Is a perfect example of
Plastics and performance
Future Technology
Methods of Identification
•
•
•
•
•
•
ISO Code
Body Repair Manual
Sanding Test
Float Test
Flexibility Test
Rod Adhesion Test
ISO Code Identification
Other means of Identification
PET(E)
PP
HDPE
PS
PVC
Other
LDPE
The Mitchell Manual
is another source for
plastic identification
information
What is TPO, ABS or PUR ?
Plastic Locations
Oldsmobile Aurora
Saturn Station Wagon
PE / Polyethylene
PP/Polypropylene
Saturn
Hummer H2
Thermoset vs. Thermoplastic
Repairing Plastics
Identifying the Extent of Damage
• One sided Repair
- Nick, Scratch or gouge
• Two sided Repair
- Puncture, Rip or Tear
• Reshaping with Heat
- Dents or distortion
Damage Identification
Repair Methods
• Welding
– Hot Air Welding
– Airless Welding
– Ultrasonic
• Adhesive
–
–
–
–
Olefin
Non-Olefin
Rigid
Flexible
Repair Method Recommendations
Steps for Welding or Adhesive
Repair
• Thoroughly wash part with soap and water
– Warm soapy water
– Aids in cleansing water soluble materials
– Secondary damage becomes apparent
• Wax and Grease remover
– Cleans surface of waxes and silicones
– Removes non-water soluble materials, such as
road tar
• Once clean, use heat if necessary to reshape
panel and remove any distortion
– Heat gun
– Heat lamp
• Make repair decisions
– One sided repair?
– Two sided repair?
• Which method of repair will be appropriate?
– If cosmetic, Adhesive repair will suffice
– If torn, a two sided repair will be needed
• Will an Adhesive or a Welding repair be
stronger?
Safety First!
- With the vast
amounts of chemicals
found in plastics and
adhesives today,
following the proper
safety precautions
should be first and
foremost when
performing any repair
procedure
Do Not Repair!
Types of Adhesive Repairs
Adhesive Repair
• Tools needed for a one-sided repair
– Sander (D/A or Single action)
– Sanding block
– Air nozzle
• Materials
–
–
–
–
Plastic cleaner
Adhesion promoter (if polyolefin)
Repair material (2-part)
120-180 grit sandpaper
One Sided Repair
One Sided Repair Procedure
• Featheredge the nick, scratch or gouge to
the base of the damage
• Clean area by blowing away leftover dust
• Clean sanded area with approved plastic
cleaner (Do not mix systems)
• Wash clean and dry
• Apply adhesion promoter if necessary
• Mix chosen repair material correctly and apply
• Sand material to desired finish
Two Sided Procedure
• Tools
–
–
–
–
–
–
Die grinder
Small grinder (50 grit)
DA sander
Blow gun
Spreaders
Clamping devices
• Materials
– Backing materials
– Repair Adhesive and adhesive promoters
– Abrasives
Two Sided Repair
Two Sided Repair
Repair Materials
Do not intermix materials!
Cleaners
• Plastic cleaners are
important for a couple
of reasons
– They aid in removing
surface contaminants left
from the manufacturing
process
– Help cleanse the surface
of contaminants left from
the sanding and grinding
process
Repair Adhesives
• Procedures vary from manufacturer to
manufacturer
• Materials and their characteristics will vary as
well
• Can be made up of Epoxies, Urethanes or
Acrylics
• All have different curing times and sanding /
handling times
• Procedures are all brand and material specific
Curing times
Example only
Applicators
Using the Mixing Guns
•
•
•
•
•
Insert Cartridge into applicator gun
Remove protective cap from cartridge
Purge cartridge to equalize contents
Install new mixer tip
Gun out approximately 1 1/2 - 2 inches of
mixed material to ensure proper mixing on
waste material
• Apply material to repair area, keeping the
mixing tip in the applied adhesive
• Once all Material needed has been applied,
leave used mixing tip in place on cartridge
• Release pressure from cartridge and remove
cartridge from applicator gun
• Store leftover cartridge in a cool, dark
environment
• Shelf life of a used cartridge is
usually one month, an unused
one is a year
Reinforcement Materials
• Can consist of mesh materials
– Loose Fiberglas mesh
– Woven Fiberglas cloth
• Can consist of materials consistent with the
material being repaired
– Leftover or discarded plastics
of similar makeup
Adhesion Promoters
• Are used primarily for
improving the adhesion
characteristics of Olefin
based plastics
• Improve adhesion by
chemically changing the
surface of the Olefin plastic,
allowing an adhesive to bond
with it
• Other methods include a
flame treatment to promote
adhesion
Minor Repairs
• Instant Adhesives, or
‘crazy glue’ have their
place in the bodyshop
as well as 2-part
adhesives
• Serve well for minor
replacement of broken
tabs or mounting
hardware
• Limited strength
Plastic Welding
Hot Air and Airless
Plastic Welders
Hot Air Welding
Hot Air Welding Tips
Speed Welder (Hot Air)
Hot Air with Speed Tip
Fanning Nozzle
Temperature Settings
ISO Code
(identifier)
ABS
Welding Temperature
PE
300° C (572°F)
PVC
PP
Hard 300° C (572°F)
Soft 400-500° C (752-932°F)
300° C (572°F)
PA
400° C (752°F)
350° C (660°F)
Airless Welder
Welding a Thermoplastic
1
2
3
Welding a Thermoset
Two Sided Unreinforced
Shop Practicals
• Adhesive repair
– Olefin
• two sided
– Non-olefin
• one sided
• Welding repair
– ABS
• one and two sided
– Polyethylene
• one and two sided