To: Professor W.

Dai From: Hayden Benjamin, Christian Knebel Omer Hassan, Ryan OConnor, Matt Houppert Date: 10/31/13 Lab Session: Mon. 1:30 PM, Group 2 Subject: Lab Assessment 3- Compression Molding

Introduction: Using the process of compression molding, an ashtray was created out of Phenolic powder. The compression molding process consists of preheating the cast then quickly placing the phenolic powder in the cast. After this was done the cast was compressed to high levels while still being heated. The compression molding process requires the unique step called the breath cycle in which the cast is decompressed for one to two seconds before being compressed again. Sample Quality: The sample created using compression molding was an ashtray. The product was well formed, having smooth surfaces along all planes. The color aspect of the product was determined by the color of the phenolic powder used. In this case, the color used was burgundy. The sample was small and tough, with a cone-like shape. Due to the plastic properties and the extreme heat introduced to it, the phenolic powder did create a tough product, but this product was also brittle. Defects: Defects on the product came about because of multiple process issues that occurred during its forming. The biggest defect on the product found was a number of air bubbles found along part of its surface. This is believed to have been caused by

an error that occurred during the breathing cycle. Though we are unable to accurately pinpoint the issue, it was evident that the problem arose from the amount of time the product was in the breath cycle or the amount of decompression in the breath cycle. Improvement Recommendations: One recommendation to improve the process of compression molding, that may fix the various issues found, is to increase the time of the breath cycle to two to three seconds. This will give the material more time to release trapped air, therefore reducing if eliminating the surface blisters. Another possibility to resolve the found issues is to ensure a more even spread of the phenolic powder previous to closing the mold. This will reduce the chance of blisters on the surface of the product.

References/Bibliography: Kohser, R., Black, J.T. (2012) Degarmos Materials and Processes in Manufacturing.