CHAPTER 13

COMPRESSION AND TRANSFER MOLDING

THERMOSET PLASTICS MOLDING
Thermosetting molding compounds (thermosets) that undergo a chemical reaction or cure (called polymerization or molecular growth) during the molding operation, include phenolic (phenol-formaldehyde), urea, melamine, melamine-phenolic, diallyl phthalate, alkyd, polyester, epoxy, and silicones. Thermosetting molding compounds processed from the individual heat-reactive resin systems are available in a wide range of formulations to satisfy specific end-use requirements. Depending on the type of material, products may be supplied in granular, nodular, flaked, diced, or pelletized form. Polyester materials are supplied in granular, bulk, log, rope, or sheet form, and polyurethanes are made in many forms, ranging from flexible and rigid foams to rigid solids and abrasionresistant coatings. Material temperature. Minimum cure time is a function of increased mold temperature and maximum material temperature when loaded in the mold. It is desirable to preheat most compounds. Extrudates are formed from screw feed material in a heated barrel. The temperature range is 180260 F (82127 C) depending on the type of preheat equipment. Molding pressure. The pressure causes the compound to flow within the confines of the mold cavities and forces it to completely fill out the part with minimum flash thickness. The required pressure is dependent on the method of molding. CHAPTER CONTENTS:
THERMOSET PLASTICS MOLDING 13-1 COMPRESSION MOLDING 13-8 TRANSFER MOLDING

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COMPRESSION MOLDING
In compression molding, the thermoset compound is placed in the open heated mold. The material may be in powder form or as a preform, a cold pressed slug that contains the exact charge weight required. As the mold closes, the heat and pressure cause the material to flow, compressing it to the required shape and density as defined by the mold. Continued heat and pressure produce the chemical reaction (polymerization or cure) that hardens the material. The thinner the part, the shorter the cure; conversely, thicker pieces take longer to cure. Part design should have as uniform a wall thickness as possible.

PRINCIPLES OF PLASTICS MOLDING

Thermosets, when placed in a heated mold under pressure, will conform to the shape of the mold and cure into a hard infusible product.

Molding Conditions
Successful plastics molding is dependent on good mold design and construction, the mold temperature, material temperature, molding pressure, etc.

Molding Methods
All of the thermoset compounds, except epoxies and silicones, may be molded by the following methods: compression, transfer, thermoset injection, and the runnerless injection/compression process. This chapter will only discuss compression and transfer molding. Table 13-1 lists factors to be considered in the selection of compression or transfer molding. The design and construction of the mold is the single most important factor in a plastics molding project. Without a mold built and engineered to produce good molded parts in an economical fashion, other factors are of little importance. Mold tempera t u re. Thermoset molding compounds may be molded in a temperature range of 285400 F (141204 C). Material suppliers should be consulted for recommended temperatures for a specific material and molding method. Molds may be heated by steam, hot oil, electric cartridge or strip heaters, or any combination of these.

Molding Equipment
The mold is fastened in a vertical molding press, either up-acting or down-acting, usually hydraulically driven. Small bench presses may be air driven. Presses may be self-contained or on a common hydraulic system. They have provision for an ejection system for the parts, usually both up-acting and down-acting. The press operation may be either automatic or semi-automatic, in sizes up to 2000 tons (17.9 MN). Preform presses, high-frequency preheaters, and preheat extruders are commonly used as auxiliary equipment in the compression-molding process.

Auxiliary Equipment
P reform presses. These are either hydraulic or mechanically operated, with various die sizes and shapes to squeeze the material in the cold state into a preform or briquette of the exact charge weight required. These presses work automatically.

The Contributors of this chapter are: F. Reed Estabrook, Jr., President and Senior Consultant, The Taim Corporation; Alan Low, Marketing Manager, Husky Injection Molding Systems. The Reviewer of this chapter is: F. Reed Estabrook, Jr., President and Senior Consultant, The Taim Corporation.

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A typical cycle, with the mold at recommended temperature and with adequate pressure available, would proceed as follows: 1. Air-clean the mold of all flash or foreign matter. 2. Load the material into the cavities. 3. Close the mold completely; or before closing it, interject a brief breathe cycle by opening the mold slightly to release any air and gases trapped in the molding compound. 4. Complete the cure time. 5. Open the mold and activate the knock-out assembly. 6. Remove the molded parts. 7. Clean the mold with an air blast. The cure duration is dependent on the type of molding compound, mold temperature, pressure on the material, and material temperature. Cross-sections 0.1250.500 in. (3.1812.7 mm) thick may cure in 30 seconds2 minutes when preheated material is used (which is always desirable). For thermosets, the material can be cold, but more often it is preheated close to the setting temperature. The mold is heated using steam or electric heaters, and remains closed until the part is cured or set; the hot part is then ejected. Typical parts produced using this technique are tires, components for the electrical industry, dinnerware, and under-the-hood automotive parts. For thermoplastics, the hot (melted) material is placed into the relatively cold mold; the mold closes and compresses the material into the desired shape. When the part has cooled down enough to be handled without deformation, it is ejected. With the materials processed by compression molding, the mold is open while the material is loaded. During the closing, it is unavoidable to have excess material escape at the parting line (flash). It is necessary to provide an excess of material with every shot, which is wasted (scrap) with thermosets, but can be reused with thermoplastics. In either case, the flash must be removed to provide a finished part, either by tumbling manually (parts permitting) or mechanically.

TABLE 13-1 Selection of Molding MethodCompression or Transfer Factors to Consider: AdvantagesLimitations Close tolerances, projected area Close tolerances, over flash line, minimum flash Lowest mold shrinkage Uniform shrinkage, all directions Maximum uniform density Reduced cure, thick sections No weld lines, less molded-in strains Small holes, longer length, through holes Extremely thin mold sections, telescoping No venting problems Impact strength Molds with movable sections or cores Molded-in inserts Large projected area parts Lowest mold-flash scrap Generally less mold maintenance Gate or sprue removal necessary Maximum number cavities per clamp force Mold erosion, sprues, runners, gates Generally higher mold cost Compression Transfer

Molding Conditions
Factors to be considered during compression molding include the type of molding compound, the mold temperature, and the molding pressure. Compound. When using a molding compound with the desired functional performance characteristics, the specifications should provide a bulk factor not greater than 3:1 (solid to liquid ratio), good funnel flow rating, and proper plasticity. Temperature. The mold temperature should be specified after consulting with the material supplier. As stated previously, temperatures range from 285400 F (141204 C). P ressure. Generally, all thermoset compounds recommended for compression molding require the same molding pressure. Polyesters are the exception and are considered low-pressure materials. Epoxy and silicone materials are not generally molded by compression. A material of recommended plasticity, at room temperature, requires pressures of 20003000 psi (13.820.7 MPa) on the projected molding and land area of each cavity. Parts greater than 1 in. (25 mm) in depth require an additional 600 psi (4.1 MPa) per inch of depth. Preheated material may reduce pressures 50% or more. The material supplier should be consulted when specifying molding pressure for polyesters.

High-frequency preheaters heat the preforms in the 200300 F (93149 C) range so the molding material is ready to flow as soon as it is loaded into the heated mold.

Molding Process
The mold consists of two halves, one containing the cavity or cavities (the female section) and one containing the force or forces (the male section). Each is mounted on press supports or grids which are in turn fastened to the stationary or moving platens. Generally, the cavities are in the lower half to permit easy loading of the molding compound. This operation may be manual or automatic. In the case of automatic operation, movable loading trays are incorporated, in conjunction with trays or forks to receive molded parts from the mold. A predetermined amount of molding material is placed into the open mold. By closing the mold and compressing the material, the desired shape is achieved. Both thermosets and thermoplastics may be compression molded; the process is used mostly for thermosets and thermoplastics containing significant amounts of fillers which reduce their viscosity (flowability), required for injection molding. (Examples: phenolics with up to 60% mineral fillers, for insulators; polysulfones up to 80% ceramic, for engineering uses.) Flashing is necessary to allow the air or gases to escape.

Mold Construction
Factors influencing mold construction include the mold cavity and forces, and the materials and method of construction.

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C avity and fo rces. The molds may contain a single cavity or multicavities. The number of cavities is determined by the production requirements, part size, type of material, and clamp capacity of the molding press. Determining factors that dictate design of the mold cavity and operational force include the type of material, part design, flash-line restrictions, part dimensions and tolerances, and end-use requirements. Shrinkage of material during curing and cooling is built into mold dimensions. Mold types. Five basic types of compression mold cavity and force are available for selection: Flash type. The flash-type mold, illustrated in Fig. 13-1, is simple in construction and low in cost. Disadvantages are that it creates minimal back pressure within the cavity (needed to control density and molded part dimensions) and it has high flash scrap loss. The flash mold is not recommended for parts requiring maximum density and strength. Semipositive, vertical-flash type. The semipositive, vertical-flash type mold, shown in Fig. 13-2, requires double fitting of force to cavity and is costly. It controls maximum density and critical dimensions as related to cavity and force, offers ease of flash removal on large parts, and leaves no flash line scar on the side of the part. Semipositive, horizontal-flash type. The semipositive, horizontalflash-type mold, shown in Fig. 13-3, controls conditions in a manner similar to that of the horizontal-flash type, but it is less costly and more popular. It is recommended for close-tolerance parts and assures minimum flash finish. Direct-positive type. The direct-positive-type mold, illustrated in Fig. 13-4, is used for high-bulk materials and deep-draw parts when maximum density is required. It is a single-cavity mold that uses an accurately weighed charge of material. Landed-positive type. The landed-positive type mold, shown in Fig. 13-5, is used as a single-cavity mold on a rotary press. Molding pressure is controlled at each station. Maximum density may be maintained by clearance between the side wall of the force and the cavity. Overall height of the part is controlled by land areas on mating surfaces of the force and cavity.

' $ & & ' $

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THERMOSET PLASTICS MOLDING
Mounting and retainer plates. Cavities and forces are assembled on mounting plates and may be held in the confines of a retainer plate. Heat sources are contained in one or both units.
Heat source Mounting plate Retainer Flash line Retainer Mounting plate Clearance 0.0030.005 in. (0.080.13 mm) 0.0080.012 in. (0.200.30 mm)

Fig. 13-2 Semipositive, ve rtical-flash compression mold. (Courtesy R. W . Bainbridge)

Clearance 0.0030.005 in. (0.080.13 mm)

Heat source

Mounting

Retainer

Land area

Retainer

Mounting

Mounting

Fig. 13-1 Flash-type compression mold. (Courtesy R. W . Bainbridge)

Fig. 13-3 Semipositive, horizontal-flash-type compression mold. (Courtesy R. W . Bainbridge)

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2 Land Straight wall Clearance 0.0080.012 in. (0.200.30 mm) 1 taper on cavity side wall

F ig. 13-5 Landed-positive-type compression mold. (Courtesy R. W . Bainbridge)

F ig. 13-4 Direct-positive-type compression mold. (Courtesy R. W . Bainbridge)

Pa rt-removal systems. A top and bottom knockout system is necessary in automatic operations. One set of pins may act as holddown or hold-up pins while the second set facilitates part removal. Mold design. Mold design is a special area and requires expertise in steel types and hardness specifications, machining methods, and other factors that may vary in the molds for producing different parts. Mold making. The principal kinds of steel used for making plastics molds are prehardened, carburizing, oil hardening, air hardening, stainless, and maraging. These materials are supplied in rolled, forged, and cast sections. The primary methods used to form cavities in steel molds are conventional machining hobbing and electrical discharge machining (EDM). Heat treatment is part of the mold-making process, unless a prehardened steel is selected. Finishing of the mold cavity surface is usually done by grinding and polishing. For additional information, refer to Volume 2 of this handbook series entitled Forming. See chapter 2 Die and Mold Materials.

press. A transfer press has a hydraulic clamp cylinder with a separate transfer cylinder applying pressure in the direction opposite to the clamp pressure. For automatic operation, a top-clamp force and a bottom-transfer force are desirable for ease of loading preheated preforms. Plunger-transfer presses are generally self-contained and have provisions for top and bottom knockout systems that are available for semiautomatic or automatic operations. Users should contact press manufacturers or molders for information on available press sizes.

Molding Processes

TRANSFER MOLDING

Transfer molding is a method of molding specific parts using a mold with two halves that is closed before any material is introduced. The material is loaded into a pot or transfer sleeve, and transfer pressure is applied to cause material to flow into the closed section of the mold. In a single-cavity mold, the material flows generally through a sprue bushing and is gated directly into the part. In the case of a multicavity mold, it flows from a sprue bushing or transfer sleeve into a runner system and is gated into each cavity and part. There are two distinct transfer methods of molding. One is known as pot-type transfer, and the other is the plunger transfer method. Pot-type transfer molding is generally done in a bottom-clamp compression press. Plunger transfer molding is done in a vertical

Molding Equipment

Depending on whether the molding method is pot-type or plunger, one of two mold types are employed in transfer molding. The mold cavity is closed (clamped), and connected at a gate via a runner to the transfer pot. The material is loaded into the pot and a plunger drives the material into the cavity. There is no flash on the part, but the runners and a certain amount of scrap (cull) remaining in the bottom of the pot must be removed before the next shot. This method is used almost exclusively for thermosets, requiring the pot to be heated. To reduce the molding time, the material charged into the pot should be well preheated, and as close as possible to the curing temperature of the material. Pot-type mold. A pot-type transfer mold as shown in Fig. 13-6 generally has one cavity. The mold consists of two halves with the cavity section assembled to the lower mounting plate which is fastened to the supports or grids and bolted to the movable lower platen. The lower platen is moved up and down by the clamp ram. The force section is assembled to the lower surface of the movable floating platen. The pot or chamber is contained in the upper area. These components are fastened together as a complete assembly. The plunger that enters the pot area is mounted to the head of the press or to the grids. In a typical cycle using the recommended mold temperature, the operator loads preheated preforms or extrudates into the pot area. Then the press is activated upward using low pressure, and the press picks up the floating member (see Fig. 13-6a) which engages the plunger. High pressure is applied, forcing the material

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Heat source Mounting plate Retainer plate Pot-plunger Sealing grooves cured molding compound Transfer pot Dovetail sprue puller Preforms-extrudates Retainer plate Force Sprue bushing Retainer plate Parting line Floating member Diaphragm gate Retainer plate Cavity Mounting plate Ejector pins (a) Beginning of cycle Cull Sprue Rods to hold floating plates Floating plates (fastened together) Part (b) End of cycle

Fig. 13-6 Pot-type transfer mold. (Courtesy R. W . Bainbridge)

through the sprue bushing directly into the cavity and force area (or through a diaphragm gate if it is a circular part). The cure cycle is completed under pressure, the clamp ram is moved downward, and the mold opens. The pot and plunger separate, and the

movable floating platen is pulled away from the lower half of the mold by rods fastened to the head of the press. The part-removal assembly raises the part from the cavity, and the operator removes the part. The operator removes cull and sprue from the plunger,

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uses an airblast to clean the remainder of the mold, and places the preforms in a preheater or activates the extruder for the following cycle, as shown in Fig. 13-6b. Plunger mold. A plunger transfer mold (shown in Fig. 13-7) consists of two halves, one containing the cavity or cavities and one containing the force or forces. The transfer sleeve and plunger are located in the center of the mold; the plunger is fastened to the transfer cylinder. The press design dictates location of the clamp ram and transfer cylinder. The halves of the mold are mounted on grids or support pillars in the proper location. In a typical operation with a bottom plunger transfer press and with molding performed at recommended mold temperature, the preheated preforms or extrudates are loaded into the transfer sleeve. The press is then closed. Activation of the transfer plunger forces material into the runner system, through a gate, into the mold cavity. After completing the cure cycle, the press is opened, and parts and runners are removed from the mold. The cull is removed from the top of the transfer plunger, and the transfer plunger is activated downward. An airblast is used to clean the mold and vents. The final step is to activate the preheater or extrudate equipment. Figure 13-7 shows a plunger transfer mold at the beginning (a) and the end of a cycle (b). The injection molding technology developed as an improvement of compression molding technique.
Vents Relieved 0.0320.045 in. (0.811.14 mm) Grid Heat source Mounting plate Force Cavity Mounting plate Ejector pins Grid Transfer sleeve Transfer plunger (a) Beginning of cycle Cull Force retainer plate Parts and runner Knockout pins Cavity retainer plate Preheated preforms or extrudates Mold openparts and runner removedmaterial loaded (b) End of cycle

Fig. 13-7 Plunge r-type transfer mold. (Courtesy R. W . Bainbridge)

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Molding Conditions
Factors to be considered during transfer molding include the type of molding compound, the mold temperature, and the molding pressure. Compound. The molding compound should be suitable for preforming and/or making extruded shapes in equipment using a screw to feed and preheat material in a temperature-controlled barrel. Temperature. Mold temperature can range from 285400 F (141204 C), depending upon the specific plastic materials used. P ressure. Technical considerations related to pressure specification differ for pot and plunger-type transfer molds. Polyester, epoxy, and silicone molding compounds require less transfer pressure than other materials. The plastics supplier should be consulted for recommended pressure. Pot-type transfer. The transfer pressure in this type of mold is the pressure developed within the pot area. The projected pot area must be equal to or 10% greater than the projected area of the part. Failure to provide sufficient area in the pot can cause the mold to blow open at the parting line of the cavity and the force. Recommended transfer pressure developed in the pot area is 600010,000 psi (4169 MPa). Plunger transfer. The transfer pressure recommended is 6000 8000 psi (4155 MPa). The significant area is made up of the combined projected areas of the parts and the transfer plunger, plus total runner and gate area of all cavities. Clamp force must be sufficient to keep the mold from flashing at the parting line of the cavities, runners, and cull area. Originally, operators were needed to load the raw material and to unload the molded articles. During the curing time, they removed the flash from the parts while attending one, two, or more machines. Later on, automation was introduced to both load and unload. At about the same time period, the use of thermoplastic materials increased dramatically and processing thermoplastics was performed using plunger machines. These are the forerunners of the present day injection molding machines.

Mold Design
The mold design engineer must consider part design, dimensional tolerances, gate location, type of material, type and size of molding presses, and mold design options before making the decision to mold a part either by pot-type or by plunger transfer. The majority of parts requiring transfer molding are suitable for the plunger transfer method. As in the case of compression molding, the final mold design is the result of considerable study. Types of steel, method of machining, and hardness vary for each part. Transfer molds must be supported well, especially in the center area, to keep the mold from flashing.

MOLDING PROCESS COMPARISON

A thorough evaluation should be made of the advantages and disadvantages of molding by the compression method as compared to the transfer method. It is desirable for the design engineer, process engineer, and material representative to meet and discuss all options before deciding on the best method of molding a particular part.

Pellets
For ease of handling, the powder-like molding material for phenolics and ureas is usually pressed cold into pellets (each one, or sometimes more than one, representing the part- or shot-weight). The weight of these pellets can be closely controlled during pelletizing. They are loaded, cold or preheated, by hand or mechanically, into each mold cavity or into the shooting pot. Preheating is done either in electric, steam, or microwave ovens. Because of the loading method for both compression and transfer molding, it is more practical to utilize gravity, that is, keep the mold parting line horizontal and use a vertical clamping arrangement. In some machines, the lower platen is fixed and the upper platen moves up and down. In others, the upper platen is fixed and the lower platen is movable. These differences in the design of the machines have no bearing on the molding process itself. The plunger is normally driven by a separate hydraulic cylinder mounted on the platen. It is possible to move either the lower or the upper platen, but usually, the platen with the transfer plunger is not moving. With a bottom-mounted plunger, the material is loaded into the pot while the mold is open; after the mold is closed, the plunger rises to push the plastic into the cavities. With a top-mounted plunger, the mold closes first, the plastic is loaded into the pot, and the plunger descends to push the plastic into the cavities. This is similar to injection molding. In another method, the plastic is extruded from a side-wall hole into the shooting pot from an extruder below the platen. In this process, the plunger must move below the opening to pick up the charge. The transfer method is the same as the two-stage injection molding system. Practically any injection pressure and shot volume can be achieved by varying the diameter of the plunger. (Smaller plunger, higher pressure but smaller volume, and vice-versa.) Of course, the shot volume also depends on the stroke of the plunger.

Compression Molding
Although it is the oldest method of molding, compression molding probably will continue to be a major technique for processing most thermoset molding compounds. The following applications are representative of the market areas for which many parts are molded by compression: Wiring deviceswall plates, outlet boxes and receptacles, switches. Closuresbottle and tube caps for drugs and cosmetics. Electrical switch gearhome and low-voltage circuit breakers. Automotive partsbrake and transmission parts, grilles and body parts, ignition parts. Dishwaremelamine dishware. Small appliancesknobs, handles, bases for motor mounts and cookers. Housingssanitary tubs, stall shower units or bases, electrical outlet boxes.

Transfer Molding
Because of part design, dimensional tolerances, mold design options, etc., many parts are well suited for molding by the transfer method. The following applications are representative of the market areas for which many parts are molded by transfer: Electronic devicescapacitors, transistors, integrated circuits, wire-wound power resistors, diodes, semiconductors, rectifiers, connectors, data processing devices. Electrical switch gear and motor startersheavy switch gear, circuit breakers, and related parts. Automotive partstransmission parts, solenoid covers, ignition parts. Cookwarehandles, stick handles, housings. Applianceshousings for motors, pumps, and timers.

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Other Methods of Molding

With the trend toward more automatic operations requiring no operators or one operator for several presses, there have been some conversions to the injection process and some new parts are being molded using it. Currently, the runnerless injection/compression

process is being adopted for some applications. Faster cycles are generally possible when the part and material are adaptable to this process. Process engineers must consider and evaluate the significant factors and parameters and make the decision as to the most suitable operation.

COMPRESSION MOLDING
The compression molding cycle is simple enough that problem solutions are generally obvious. Instrumenting load and thermal parameters can resolve many difficult problems. As in all casting processes, part design is a major factor in success. TABLE 13-2 Principal Compression Molding Parameters Material Type Form (powder, preform, other) Purity Uniformity Gassing properties Mold Basic design Material Ejection system Venting Dimensions Original Erosion/wear Setup Alignment Stroke Operating Characteristics Change volume Pressure (compression amount) Mold temperature Material preheat Machine Tool General construction Load capacity Size capacity Material loading system Part Requirements Design Surface requirements Internal integrity Dimensional requirements Operator Skill and Knowledge

PRINCIPAL COMPRESSION MOLDING PARAMETERS

Table 13-2 shows the principal parameters in compression molding. Material properties, part/mold design, and operating characteristics are the key essentials in problem solving.

TROUBLESHOOTING
Table 13-3 lists the types of problems found on parts1. Table 13-4 describes causes and solutions to many of the problems occurring in compression molding.1 Additional suggestions are presented in the Reference section at the end of this chapter.

TABLE 13-3 Types of Problems Found on Compression Molded Parts1 Surface Texture Blisters Scales Burns Scratches Chalking Sheeter lines Crazing Short Pinholes Sink mark Orange peel Warp Pimples Waviness Pits Weld mark Porosity Precure Internal Bubbles Crack Dry-spot Let-go Ream Slip plane Waviness Gloss Frosting Gloss loss Granularity Haze Lubricant-bloom Mica specks Dimension Dishing Doming Color Clarity loss Discoloration Dull-surface Filler specks Fisheye Foreign matter Mottle Segregation Stria Two-tone Other Optical distortion

TABLE 13-4 Common Faults, Causes, and Remedies in Compression Molding1 Problem Pieces blistered Possible Causes Molding cycle too short Air or gases trapped in mold Possible Solutions Increase time of cycle. Close mold more slowly; provide sprue grooves to allow escapement of gas; preheat* material.

(continued)

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TABLE 13-4(continued) Common Faults, Causes, and Remedies in Compression Molding1 Problem Pieces blistered Possible Causes Material has absorbed water by exposure Mold too hot Insufficient pressure Mold too cold Mold charge too bulky, contains too much air Nonuniform heating Piece designed with thick nonuniform walls Material too hard, does not flow freely Pressure insufficient Mold too hot resulting in precuring Mold closed too slowly, resulting in precuring Mold charge too great to allow proper escapement and closing of the mold Charge is insufficient Mold is closed too fast, splashing material from mold Mold allows too fast escapement of material. Piece is insufficiently cured Material has absorbed water by exposure Too much lubricant used on mold, causing material to be plasticized Temperature too high and resin fails to come to surface and cover it. (Common with mineral filled material.) Mold fouled by improper lubricant or previous materials. Phenolic material will stick after cellulose acetate has been used when molds are not chromium-plated Mold is undercut by scratches, dents, etc. Mold is poorly polished Mold is irregularly heated, leaving cold spots Pieces are undercuredtoo short a cycle or too low a temperature Possible Solutions Preheat* material. Reduce temperature. Increase pressure or adjust powder weights if multiple-cavity mold is used. Increase temperature. Preform material, or distribute in most suitable manner to allow air to escape. If powder, arrange in a pile similar to a mountain peak, rather than a volcano. Rearrange steam channels or place mold in press in a way to promote uniformity of heating. Tablet the charge; preheat* material; reduce molding temperatures. Use a softer material. Increase pressure. Lower temperature. Increase speed of closing by more rapid supply of pressure; preheat* material. Adjust charges properly or provide sprue grooves for escapement.

Parting line porous but bottom and flash thick. Finish good where piece is properly filled out and pressure is directly on it

Appearance as in previous problem, but bottom and fins of proper thickness

Increase charge to proper weight. Close more slowly, permitting material to soften and flow properly. When a flash mold is used, increase width of cutoff; where fit is poor between mold parts, it must be corrected; use a harder material; use abnormal charge of material. Increase curing cycle; if temperature is too low, raise it. Preheat* material. Reduce or do not use lubricant. Reduce temperature.

Molded piece is flexible on discharge

Molded piece sticks or adheres to mold

Clean surface of mold and polish.

Repair mold. Polish mold. Heat properly. Increase cycle; increase temperature.

(continued)

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TABLE 13-4(continued) Common Faults, Causes, and Remedies in Compression Molding1 Problem Molded piece sticks or adheres to mold Possible Causes Distortion caused by knock-out pins due to flexibility of piece Charge has trapped gas or air pockets, distorting piece and binding it to mold Mold too hot or too cold Mold improperly polished Mold stained by previous material Poor grade of steel used for mold Mold closed too fast under too high pressure Material too soft Material too coarse A number of preforms used for charge Material contains excessive moisture Material contains foreign matter, particularly oil or grease Mold too hot, causing precuring Material too hard and/or pressure too low Material too soft Mold closed too fast Material too soft (common) Too little charge or too much leakage Mold heated nonuniformly Material too soft Insufficient cure Mold too hot, causing casehardening of piece Piece of irregular wall thickness and shape resulting in complex flow, cure, and shrinkage Charge left too long in mold before closing Molding placed where it cools very unevenly; for example, on cold metal plate Material has absorbed moisture due to exposure Pieces cooled nonuniformly (one side cooling faster than the other after molding) Wall around inserts too thin Pieces strained on ejection Shrink plugs too large Possible Solutions Increase curing or use material with more rigidity at discharge. Slower closing of mold; breathe mold; preheat*; provide vents; use preform. Correct temperature. Polish mold. Clean and polish mold. Polish and chromium plate. Close mold more slowly; preheat* material and load hot. Use a harder material, or preheat* and load hot. Use a finer material, or preheat* and load hot. Use one preform or place preforms far apart and close mold slowly; preheat* material. Preheat* material. Protect material against contamination. Reduce mold temperature; tablet the charge. Increase pressure and/or use softer material. Use harder material. Close mold more slowly. Use a harder material; reduce temperature, which increases viscosity of flow. Increase charge; slower closing of mold; use stiffer material; preform to more accurately approximate shape of piece. Correct heating methods. Use harder material and/or preheat* material. Increase cycle. Decrease temperature. Use lower shrinkage material; adjust temperature of various parts of mold accordingly; preheat* material and load hot; redesign piece to uniform section. Close faster. Provide means for uniform cooling; provide shrink fixtures.

Surface of piece dull

Surface of piece orange peeled

Surface of piece pitted or has small fissures Surface of piece clouded and/or color segregated

Surface of piece has inverted blisters similar to dimples

Pieces warped

Preheat* material and load hot or cold. Cool uniformly.

Pieces crack at once or afterward in storage

Increase wall and/or use lower shrinkage material. Eject evenly. Correct plugs, mold and/or use lower shrinkage material.

(continued)

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TABLE 13-4(continued) Common Faults, Causes, and Remedies in Compression Molding1 Problem Pieces crack at once or afterward in storage Pieces have poor electrical properties Possible Causes Possible Solutions Where piece is cooled too much Reduce cooling cycle. in mold, strains are set up Pieces case-hardened by too rapid Close mold more slowly; preheat* material and load hot; reduce closing of mold and too high temperature. temperature Material has absorbed moisture Preheat* material. Pieces undercured Increase curing cycle. Foreign matter in material Protect against contamination. Pieces weak mechanically Pieces undercured generally due to Increase temperature and cycle. and have poor chemical too low temperature resistance, particularly to Pressure not sufficient on piece (a Increase pressure and/or charge. water and solvents common fault where charge is too low, escapement too great, or pressure is absorbed by abnormal landed areas on mold) Time of cure too short Increase time of cure. Surface has hard small Material contains foreign matter, Protect against contamination. spots on pieces similar to particularly wood splinters or small blisters, commonly metal chips known as pimples Material has hard particles in it Use softer and/or finer material. and/or is too coarse * Preheat: 180225 F (82107 C) for 20 minutes1 hour. Material should be loaded hot wherever possible.

TRANSFER MOLDING
Because transfer molding utilizes the same basic process as compression molding, most of the issues are the same. In this process, the transfer mold is closed before the previously plasticized compound enters it. In compression molding, the molding material is plasticized in the open compression mold prior to mold closing. In transfer molding, the plunger enters the die well as the press closes, the material is plasticized by heat and pressure and is forced through the sprue orifice, along the runners and into the mold cavity, which gradually fills under reduced pressure until the part formation is completed. Pressure is maintained on the mold until the cure period has ended. After this, the mold is opened and the part is ejected in a manner similar to that in compression molding.

PRINCIPAL TRANSFER MOLDING PARAMETERS

The parameters of this process are the same as compression molding. These parameters are listed in Table 13-2 .

TROUBLESHOOTING
Table 13-3 describes the problems found in both compression and transfer molding. The problems and solutions shown in Table 13-4 are also applicable to transfer molding. Additional troubleshooting guidance is shown in Table 13-5. Additional suggestions for transfer molding are presented in the Reference section at the end of this chapter.2, 3

TABLE 13-5 Problems, Causes and Solutions in Transfer Molding3 Problem Short molding (all powder cleared from pot) Short molding (cull left in pot) Possible Causes Insufficient molding powder Insufficient flow of material caused by incorrect temperature; insufficient pressure; flow of powder too stiff; or gates and runners too small Undercured Possible Solutions Increased charge to pot. Check and adjust temperature to proper range; check and adjust to proper pressures; use freer flowing powder; increase sizes of gates and/or runners. Increase cure time. Increase mold temperature. (continued)

Blisters or soft molding

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TABLE 13-5continued Problems, Causes and Solutions in Transfer Molding3 Problem Blisters or soft molding Excessive flash Gas marks Burn marks Possible Causes Undercured Transfer pressure too high Trapped gasparticularly with UF material Air trapped in mold Pot or mold temperature too high Molding cycle too long Preheating temperature too high Mold or pot too hot Time of dwell in pot too long before flow commences Uneven flow in mold Possible Solutions Preheat material. Reduce pressure or increase locking force. Preheat material prior to charging pot. Arrange for proper venting of mold. Reduce temperature. Reduce time cycle. Reduce time or temperature of preheating, use radio frequency heating, reduce power input. Reduce temperature. Apply pressure sooner after charging pot. Use a freer flowing powder and pre-heat. Apply pressure more slowly and thus reduce jetting.

Precure

Ripples or orange peel

References 1. Dennis Arthur Dearle, Plastic Molding Technique (New York: Chemical Publishing Co., 1970). 2. Raymond F. Veilleux, ed., Tool and Manufacturing Engineers Handbook, 4th ed., Volume 2, Plastics Forming, (Dearborn, MI: Society of Manufacturing Engineers, 1984), pp. 18-16 through 18-22. 3. John Brown and J. D. Robinson, Injection and Transfer Molding, and Plastics Mold Design (London: Business Books Unlimited, 1970). Bibliography Gillespie, LaRoux K., ed., Tool and Manufacturing Engineering Handbook, 4th Edition, Troubleshooting Manufacturing Processes (Dearborn, MI: Society of Manufacturing Engineers, 1988). High-temperature Plastics Thermosets: Expanding Material Options & Markets (Business Communications Company, Inc., 1991). Lin, Shiow-Ching and Pearce, Eli M., High Performance Thermosets: Chemistry, Properties, Applications (HanserGardner Publications, 1993). Isayev, Avraam I., ed., Injection and Compression Molding Fundamentals, (New York: Marcel Dekker, 1987). Wright, Ralph E., Molded Thermosets: A Handbook for Plastics Engineers, Molders, & Designers (Hanser-Gardner Publications, 1991). Wright, Ralph, Injection-transfer Molding of Thermosetting Plastics (Hanser-Gardner Publications, 1995).

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