6
Troubleshooting
Guide
49
6.1 Injection Molding
Bakelite® Molding Compounds are shipped ready for use. Any material with visible moisture or
other contamination should not be used.
Excess trapped gas is frequently the root cause of voids or cosmetic defects in the molded part.
Moisture in the molding compound can be a contributor, even for materials that are not known to
absorb water such as most engineering thermosets. Proper venting of the tool and adjustment of
the processing parameters will take care of most moisture-related problems.
However, entrained moisture from condensation can overwhelm even a well vented tool. Care
should be taken to equilibrate material to the molding facility environment before opening the
packaging to avoid condensation. Drying is not recommended for Bakelite® Molding Compounds.
If packaging has been damaged or visible moisture is apparent in the material, contact a Hexion
Bakelite® product representative for technical assistance.
Injection molding machine should be equipped with a non-compression screw (1:1 feed to noz-
zle) appropriate for thermosets with good temperature control over the feed and nozzle sections.
The tool heating system should be in good working order with heat control uniform throughout
the mold cavity: ± 5 °F ( ±2 °C ).
Figure 21. Injection Molding Machine for free-flowing thermosets
Heat Conduction Heat Conduction Frictional Heat
Mold Wall Temp Barrel-Nozzle Temp Back Pressure
Cure Time Dwell Time Screw Speed / Advance Time
Additional parameters to be considered
- injection pressure
- consistency of melt cushion
- dosing time
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Table 5. Part defects and containment avctions
Injection Molding Corrective Action
Defect Root Cause Mold Hold Hold Vent- Inject
Temp Press Time ing Speed
Dim / Cloudy Areas Trapped gas
é é é ê
Damaged mold surface
Mold over waxed
Lubricants blooming
Diesel Effect / Burns Trapped gas ê é ê
Cold Slug in Part Material curing in nozzle é
Dead spots in cavity
é
White and Color Streaks Pigment breakdown
ê ê ê
Moisture Streaks Unvented moisture ê
Flow Marks Weld lines, back areas é é
End of flow path
é é é
Grain Marks Incomplete melting and
é é é é
fusing of granules
Porosity Incomplete packing
é é é
Blisters Skin curing much faster
than core ê é
Hot spots in mold
Molding compound too
reactive
Cracks Differential shrinkage stress
é é
Stress at gate ê ê ê
Part geometry
Sink Marks Differential shrinkage é é é
Part geometry
Scratches on Ribs Mechanical marks on tool
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Nozz Feed Shot Back Screw Actions
Temp Temp Size Press Speed
Clean vents, increase venting
Repair mold surface
Clean surface, use less wax
Adjust process 1st, contact supplier
ê ê Clean vents and / or increase venting
ê ê Adjust shot size, reduce nozzle temp if defect persists
Radius sharp corners in tool, eliminate right angle transi-
tions in runners
Reduce shear pigment, minimize cure in barrel and check
ê ê ê ê
mold for hot spots
é é é Clean vents and / or increase venting
é é Consolidate melt fronts before cure, homogenize melt
Consolidate melt fronts before cure, homogenize melt and
fill faster
Properly melt and homogenize molding compound
é é
Properly fill and pack, increase injection pressure if neces-
é
sary
Reduce curing of outer skin
ê ê
Look at performance and location of cartridge heaters
Reduce reactivity of molding compound
Reduce factors that contribute to differential shrinkage,
é
check for uneven heat
Relieve injection caused stresses
Smooth thickness transitions, address areas of material
accumulations
Fully fill and pack before cure
Smooth thickness transitions, address areas of material
accumulations
Repair damage tool and / or add draft to scratched feature
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6.2 Compression Molding
Table 6.
Compression Molding Corrective Action
Defect Root Cause Mold Mold Cure Clamp
Temp Press Time Speed
Dim / Cloudy Areas Trapped gas
ê é é ê
Damaged mold surface
Mold over waxed
Lubricants blooming
Diesel Effect / Burns Trapped gas ê ê
White and Color Streaks Pigment breakdown ê é ê ê
Moisture Streaks Unvented moisture ê
Flow Marks Weld lines, back areas é é ê
Grain Marks Incomplete melting and
é é
fusing of granules
Orange Skin Differential shrinkage skin-core é é
Porosity Incomplete packing é
Blisters Skin curing much faster than core
ê é ê ê
Hot spots in mold
Molding compound not reactive
enough
Cracks Differential shrinkage stress
ê é ê é
Part geometry
Sink Marks Differential shrinkage é é
Part geometry
Scratches on Ribs Mechanical marks on tool
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PreHeat PreHeat Fill Actions
Temp Time Volume
Clean vents, increase venting
é é é
Repair mold surface
Clean surface, use less wax
Adjust process 1st, contact supplier
é ê Clean vents and / or increase venting
ê Reduce thermal exposure of pigment, check mold for hot spots
é é Clean vents and / or increase venting
é é Consolidate melt fronts before cure, homogenize melt
Properly melt and fill cavity before curing molding compound
é é
ê Cure evenly under pressure, check mold for hot spots
é Properly fill and pack
Reduce curing of outer skin
Look at performance and location of cartridge heaters
Contact supplier
Reduce factors that contribute to differential shrinkage,
check for uneven heat
Smooth thickness transitions, address areas of material accumulations
é é é Fully fill and pack during cure
Smooth thickness transitions, address areas of material accumulations
Repair damage tool and / or add draft to scratched feature
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6.3 Examples of Common Process Defects With
Troubleshooting Tips
Flow Mark
è Homogenize melt and consolidate melt fronts before cure, optimize filling,
holding pressure and / or change over point
Blister Caused by Flash Contamination
è Clean mold before cycling
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Flow Marks, Cloudy / Grey Surface
è Clean vents or increase venting, optimize filling, holding pressure and / or change over point
Orange Skin
è Cure evenly under pressure, check mold for hot spots
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Blister Because of Insufficient Curing in Core
è Improve curing time
Blister Because of Insufficient Curing in Core
è Improve curing time
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Color Streaks
è Reduce shearing of pigment, check mold for hot spots
Diesel Effect
è Clean vents or improve venting, improve filling process
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Flow Mark
è Optimize filling, holding pressure and /or change over point
Gas Streaks Due to Insufficient Venting
è Clean vents or increase venting
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Entrapped Air Due to Insufficient Venting
è Clean vents or increase venting
Contamination
è Clean mold, check material
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Cured Slug
è Adjust shot size, reduce nozzle temp if defect persists
Contamination
è Check material
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Color Streaks
è Reduce shearing of pigment, check mold for hot spots
Incomplete Melting of Granules
è Properly melt and homogenize molding compound
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Incomplete Melting of Granules
è Properly melt and homogenize molding compound
Blisters
è Reduce curing of outer skin, check mold for hot spots
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Knitline Cracks
è Relieve stresses caused by injection
Sink Marks
è Fully fill and pack
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