Opravyof plast

Repairs plastics arejsou

so ease ...
tak snadn ... see for
yourself!
p esv d te se sami!

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 Contents

Page

Introduction 4

Conditions of repairs 5

Classication of plastics 7

Identication 8

Marking of plastics 9

Marking of products from plastics 12

Welding 13

Components for sticking 15

Sticking 18

Summary 22

This textbook and worksheet cannot be used as a workshop manual!

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Introduction

Introduction

The technology of repairs of plastic vehicle parts has a relatively short history. There-
fore, the workshop repair practice always brings along repeating questions why, how,
in what conditions and where to repair plastic parts.

With growing level of technology development, the
design of vehicles uses increasingly plastic parts,
which are often combined with other materials
due to design reasons. The area of their use cov-
ers in particular various surface parts of the car
body and its extension, panels and parts in the
interior.
The growth of proportion of plastic parts in the
total weight of the vehicle has not by far been
ended and in view of the current trend in air tech-
nology it can be expected that plastic and
composite components will begin gradually to be
applied to a far larger extent as load-bearing
components.
A general rule is that plastics can be well repaired
thanks to their physical qualities. However, con-
servative tendencies survive in the vehicle repair
industry and repairs of plastic parts are made only
exceptionally.
Bumpers are the most frequent damaged plastic
parts in vehicles with up to 70% frequency of
damaged plastic parts.
Although various alternatives of repairs exist,
repairs tend to be performed even in case of small
damage with the most convenient method, which
is in most cases replacement of the whole
bumper. There are more causes of this, but proba-
bly the most signicant reason will be ignorance
of the latest state in the development and applica-
tion of adhesives and imperfect care for the clients
and their nancial resources.
This worksheet thus aims at making workers in
the service network acquainted with reasons and
possibilities of repairs of plastic parts; therefore,
the following 4 questions must be rst answered in
brief.

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 Conditions of repairs

1. Why to repair?

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Repairs of damaged plastic parts must be made Insurance companies observe carefully the tech-
rst because repair is more advantageous than nological and price level of repair technologies.
the mere replacement with a new part from nan- They set differentiated insurance premiums
cial and environmental reasons. The change of according to costs of repairs for individual car
this state as against past was caused by the con- manufacturers. The amount of insurance premium
tinuing development of adhesives used, by the is also one of the factors inuencing decision of
method of application of these adhesives, by the clients to buy a specic brand.
general trend of growing prices of spare parts and
last but not least by the growth of costs of recy- The client will surely appreciate a high-quality, fast
cling of damaged plastic parts. and price favourable repair and will be loyal to the
brand SKODA in the future.
Another important nancial as well as time factor
is also the possibility of immediate repair without
necessity to have a part on stock or to wait for its
supply. In case of a minor damage to the bumper
it is not necessary even to make a complete
painting.

2. What to repair?

The most frequent repaired plastic parts on a

vehicle are the following:

- Bumpers (85%)
- Spoilers
- Covers and braces of headlamps
- Front grid
- Rear-view mirrors US3-03

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 Conditions of repairs

3. How to repair?

The following methods of repairs are applied in

repairs of plastic parts: US3-04

- pasting The most frequently used and rational method of

- welding repairs are pasting and heat shaping and there-
- laminating fore we will discuss rst these methods of repairs.
- heat shaping

3. When to repair?

The work intensity in repair of plastic parts To generalise, it can be sad that the average
depends primarily on the scope of damage and to repair time of a large plastic part (bumper) by
a lesser extent to the method of repair used. pasting will not exceed 2 hours including prepara-
tory work and surface nishing.

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A general rule: " Repair when possible, replace when unavoidable!"

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 Classication of plastics

Classication of plastics

The plastics are developed according to require-
ments on their diverse physical qualities, i.e. in
particular mechanical, mechanical/heating, heat-
ing and electric insulation, manufacturing/
technological, processing requirements, as well
as requirements on chemical stability, on toxicity,
on the possibility to perform surface adjustments,
dying, pasting, welding and last but not least on
recycling or removal. In the past 50 years, innu-
merable plastics have been developed, which are
in principle divided to two large groups:

1) THERMOPLASTS

With growing temperature, their mechanical qualities change signicantly, they come over to a plastic up
to liquid state. They are mostly processed by injecting to forms.

2) THERMOSETTING PLASTICS

With growing temperature, their mechanical qualities do not change signicantly. They are mostly proc-
essed by compression moulding to forms.

With growing share in the automotive technology,
the effort of all manufacturers has been growing to
reduce the number of used types of plastics as
much as possible.
The reason is simple: to reduce production costs
and costs of recycling.
In some countries (e.g. Sweden) laws came in
force according to which each manufacturer or
dealer is obliged, after the end of life of a product
to take it from the buyer and ensure its recycling.
The weight proportion of recyclable parts and
components is expected to grow up to 95% with
vehicles.

5%

- +

95 %
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 Identication

Identication of the most common types of thermoplastics

We hold the sample at the edge of a

ame for max 10 sec.

The sample will extinguish after The sample burns on after removal
removal from ame from ame

The sample The sample burns The sample The sample burns The sample burns
burns with a yellow with a blue ame with burns with a blue with a blue ame with with a yellow ame
ame
a yellow tip ame a yellow tip

Positive Smell of The sample dissolves Smell of The sample The sample Flocks
reaction to phenols and drops- Smell of formaldehyde will not dissolves of ash
the Beilsein burnt wool or hair and drops
dissolve
test

Smell of Smell of Not attacked Not attacked

humidity burning by tetra by tetra
stuff

PVC PC PA POM PMMA Floats on water ABS

surface
Often Opaque
opaque
PVC - Polyvinylchloride
PC - Polycarbonate
PA - Polyamide
POM - Polyoxymethylene Mass Mass Not col- Colour-
PMMA - Acryl less than above ouring ing
PE - Polyethylene 0.915g 0.915g bromide bromide
PP - Polypropylene water water
PS - Polystyrene
ABS - Acrylonibil - Butadiene - Styrene
SB - Shock-resistant polystyrene PC PP PS SB

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 Marking of plastics

Codes (abbreviations) of the most common types of plastics

Table 1 - Examples of use of basic polymers (Thermoplastics and Duroplastics) which are often
used in automotive industry

Abbreviation Description

ABS Acrylnitrite-Butadien-Styrol Copolymerisat

EP Epoxide
PA6 Polyamide with 6 atoms of monomer grid
PA11 Polyamide with 11 atoms of monomer grid
PA12 Polyamide with 12 atoms of monomer grid
PA66 Polyamide from 2 monomer grids with 6 atoms each
PBT Polybutylene-terephthalate
PES Polythersulphonide
PET Polyethylene-terephthalte
PC Polycarbonate
PE Polyethylene
PF Phenole-Formaldehyde
PMMA Polymethylmethacrylate (Acryl)
POM Polyoxymethylene, Polyacetal
PP Polypropylene
PPE Polyphenylenether
PPS Polyphenylesulde
PTFE Polytetrauorethylene
PUR Polyurethane
PVC Polyvinylchloride
SAN Styrole/Acrylnitril-Copolymerisat

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 Marking of plastics

Table 2 - Examples of use of lling and reinforcing materials often used in automotive industry

Abbreviation Description

GF Glass bres
GM Glass wool
GB Glass balls
T Talcum
M Mineral stiffeners
WD Wood aggregate

Table 3 - Examples of use of lling and reinforcing materials often used in automotive industry

Abbreviation Description

ACM Copolymer from ethylacrylate

AU Polyestherurethane-rubber

BR Butadiene-rubber

CSM Chorosulphide polyethylene

CR Chloroprene-rubber

EPDM Terpolymer from ethylene

ECO Copolymer from ethylenoxid (oxiran) and chlormethyloxiran

FPM Rubber with uorine

MVQ Silicone rubber with matyl- and vinyl groups on polymer chain

NBR Acrylnitril-butadiene-rubber

NR Isoprene-rubber (natural rubber)

SBR Sterol-butadiene-rubber

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 Marking of plastics

Examples of designation and use of plastics in SKODA vehicles:

Material FELICIA OCTAVIA

PP+EPDM Bumper Wheel housing

PP+EPDM+T Front panel Bumper
PP/PE+T Pillar and sill lining Pillar and sill lining, front panel
PP/PE Pull handles
other PP Fillings Fillings
PE Tank Tank
ABS Centre console, lamp body, Mask, heating control, steering
ashtrays, ventilation slots, outer linkage cover, electric drive cover
mirrors
PA6 Pull handles, outer handles, Outer handles, clips
handle of pocket cover, clips
PA66 Clips Clips, cable connectors
PC Ceiling lamp, third brake lamp
PPO Lining of pocket cover Instrument panel, ventilation slots,
defrost grid
PBT Lamellas of ventilation slots, covers
of wipers, plugs
ASA Registration number lighting Outer mirrors, registration number
ledges, signs lighting ledge, mask, instrument
panel foil
PC/ASA Handle of 5th door
PC/ABS Rear lamps
APEC Cap in rear lamp

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Marking of products

Example of marking of front bumper at OCTAVIA

The marking of plastics is standardised. It must be in the form of the so-called rubber stamp, which must
include prescribed data. The marking must be on each plastic product or component.

Signicance of individual marks:

a a) Logo of manufacturer

b) Part number
b
c) Code of manufacturer
c
d) Abbreviation of manufacturer
d
e) Code of material

e f) Country of origin

f
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01 02 03 04 05 06 07 08 09 10 11 12
96
97
Example of table with date of production of
98 a plastic part.
99
00
01
02
03
04
05

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E.g. marking <PP + EPDM - T20> means the following:

- PP - polypropylene

- EPDM - modied elastomer

- T20 - reinforcing material

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 Welding

Welding of plastic component

- by hot air

- by ultrasound

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Identication of plastic components

Before a plastic product is welded, it is necessary to detect material from which it has been manufac-
tured so a good quality connection is achieved. A connection can only occur if the basic and the additive
material are of the same type, which means that the product must contain the same additive substances.

- a heat test is the starting point of identication as the enclosed diagram includes
references to other tests performed

- to identify or establish type of a plastic product, cut a small piece from the part to be
welded

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Welding

Welding process

In order to achieve good welding result, one must take into account some difcult factors.

As already stated above, both the basic and the additive material must be clean and degreased. The
welding lament must further be sharpened from 45 to 60 for three reasons:

- so the tipped end of the lament can be pushed into the basic material softened by heating

- so that sharpening, which is set forward in the direction of welding, is ease to start, as the
lament will wind up across the sharpening

- so that a uniform, diagonal start arises when welding around, due to the sharpened end, which
will not cause problems when completing

During the whole welding process one must pay attention to the burning angle. It is necessary to hold the
tip of the ame so that the warm airow comes precisely in the direction parallel to the welding and at an
angle of about 45between the welding lament and the basic material. If this procedure is not followed,
the edges of the seam will be heated unevenly.

The welding temperature must be regulated at source rather than by changing quantity of air as in case
of large quantity of air in the welding zone there is danger of oxidising the material resulting in a bad
seam.

The types of burners applied are usually electrically heated. The air ows through a heating body and
while passing through the necessary welding temperature (20- 600C) is obtained. It is necessary that
the welding temperature is adequate to a specic type of plastic.

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Some deformations of plastic parts (bumpers) without damage of part structure can be
repaired by heat shaping - heating with hot air or in water with subsequent reshaping.

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 Components for sticking

Set (D 007 700) for plastic repairs includes:

Set (D 007 700)

- - for repairs of plastics

Kunststoff
Plastic repa- Reparaturset
Set de repa ir set
plastic ration pour

u
D 007 70
0 Ne w
ne uve
D 007 700 ne
1 Set

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2-component plastic adhesive (D 180 KU1 A1)

in double cartridge of 50 ml

- is applied to cleaned degreased surfaces

treated with primer

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Cleaner (D 195 850 A1) in a 100 ml bottle

- for cleaning and degreasing of bonded parts

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Components for sticking

Primer (D 822 150 A1) - 150 ml spray

- applied to bonded parts as a substrate for

adhesive itself

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Reinforcing foil with textile

- lls in punched holes

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Mixing tips

- enables easy blending of adhesive components

and its spread

- are t directly on the cartridge with adhesive

- are intended for a one-time use

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 Components for sticking

Wiper

- - for spreading of adhesive

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Metal stiffeners

- are put perpendicular to the bonded joint

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Dosing gun (VAS 5155)

- is not part of the set

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Sticking

Clean the plastic part completely and dry

thoroughly.

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Clean the repaired part from both sides with a

detergent.

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Wedge taper edges of the repaired spot

(1-2 cm/grain size 120)

Remove cracks and ssures at their

ends by drilling with a small diameter
borer to prevent their expansion.

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Roughen surface on both sides (grain size 120).

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 Sticking

Clean the repaired spot on both sides with a plas-

tics cleaner and air for about 10 minutes. Do not
touch the degreased surfaces or clean properly.

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Spray the spot repaired from both sides properly
and air for at least 10 minutes. Do not touch thus
prepared spot in any case.

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Spread adhesive on the inner (rear) part of the

repaired spot (stick the metal stiffeners to cracks).
Secure the mutual position of damaged spots with
a suitable clamp.

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Put the reinforcing textile (larger than the repaired

spot) on the inner side of the repaired spot,
spread adhesive all across the textile surface and
spread smoothly with a spatula.

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Sticking

In case of extremely large cracks/holes or in order to

accelerate the process it is recommended to harden
the adhesive by means of an infrared lamp (60C-
70C/15 min).

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Apply adhesive on the outer (front) side and spread

smoothly.

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Harden with infrared radiation (60-70C/15 min).

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After cooling and hardening, grind the redundant

adhesive and remove dust. The hardened adhesive
can be ground, drilled and threaded.

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 Sticking

For better adhesion of the varnish, spray the

primer on the front side.

This completes the repair of the plastic part.

US3-29

The upper surfaces are suitable for painting

according to guidelines from manufacturers of
varnishes after 1-4 hours.

US3-30

The structure of upper surfaces can be renewed

in a mixture with a paint hardener (e.g. D775 108 -
not part of supply).

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Summary

Some useful tips

An unmixed adhesive in an open double cartridge will endure about 8 months. Of course, applying tips
with hardened mixed preparation cannot be used. This is, however, a negligible quantity, which does not
mean any substantial loss or bad economy. A new tip will be used for the next repair.
Before new use of adhesive, do not x the tip on the double cartridge; instead rst remove the small bay-
onet closure and try with the dosing gun whether equal "beads" are leaving easily both cartridges,
otherwise it is necessary to clean both holes properly with a needle. After use, remove the tip from the
double cartridge and x on the cartridge the bayonet closer that seals well. However, a tip with a hard-
ened preparation can be left on the cartridge as well. The cartridge is stored (suspended along with the
gun) in a position with the tip being roughly in perpendicular position.

Summary and prospects

In sum, it can be stated that tests performed so far prove feasibility of repairs and durability of bumpers
expertly repaired. The ofcial manufacturer and system supplier proves approval of such repairs with a
certicate issued by an authorised test laboratory. The certicate is also an important aid for experts and
insurance companies in establishing damages.
When deciding whether a repair and replacement with a new part is to be made it is always necessary to
keep always in mind an issue of economy. The aspect of repair adequacy to the age of the vehicle plays
an important role.

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 Notes

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