Repairs of plast plastics are Opravy jsou so ease ... see for tak snadn ... yourself!

p esv d te se sami!

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Contents

Page Introduction Conditions of repairs Classication of plastics Identication Marking of plastics Marking of products from plastics Welding Components for sticking Sticking Summary 4 5 7 8 9 12 13 15 18 22

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

Introduction

Introduction
The technology of repairs of plastic vehicle parts has a relatively short history. Therefore, 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 covers 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 technology 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, conservative 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 probably the most signicant reason will be ignorance of the latest state in the development and application 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 rst because repair is more advantageous than the mere replacement with a new part from nancial and environmental reasons. The change of this state as against past was caused by the continuing development of adhesives used, by the method of application of these adhesives, by the general trend of growing prices of spare parts and last but not least by the growth of costs of recycling of damaged plastic parts. 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.

Insurance companies observe carefully the technological and price level of repair technologies. They set differentiated insurance premiums according to costs of repairs for individual car manufacturers. The amount of insurance premium is also one of the factors inuencing decision of clients to buy a specic brand. The client will surely appreciate a high-quality, fast and price favourable repair and will be loyal to the brand SKODA in the future.

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

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Conditions of repairs

3. How to repair?

The following methods of repairs are applied in repairs of plastic parts:

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pasting welding laminating heat shaping

The most frequently used and rational method of repairs are pasting and heat shaping and therefore we will discuss rst these methods of repairs.

3. When to repair?

The work intensity in repair of plastic parts depends primarily on the scope of damage and to a lesser extent to the method of repair used.

To generalise, it can be sad that the average repair time of a large plastic part (bumper) by pasting will not exceed 2 hours including preparatory work and surface nishing.

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

Classication of plastics

Classication of plastics
The plastics are developed according to requirements on their diverse physical qualities, i.e. in particular mechanical, mechanical/heating, heating 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, innumerable 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 processed 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 removal from ame

The sample burns on after removal from ame

The sample burns with a yellow ame

The sample burns with a blue ame with a yellow tip

The sample burns with a blue ame

The sample burns with a blue ame with a yellow tip

The sample burns with a yellow ame

Positive reaction to the Beilsein test

Smell of phenols

The sample dissolves and drops- Smell of burnt wool or hair

Smell of formaldehyde

The sample will not dissolve

The sample dissolves and drops

Flocks of ash

Smell of humidity

Smell of burning stuff

Not attacked by tetra

Not attacked by tetra

PVC

PC

PA

POM

PMMA

Floats on water surface

ABS Often opaque Opaque

PVC PC PA POM PMMA PE PP PS ABS SB

- Polyvinylchloride - Polycarbonate - Polyamide - Polyoxymethylene - Acryl - Polyethylene - Polypropylene - Polystyrene - Acrylonibil - Butadiene - Styrene - Shock-resistant polystyrene

Mass less than 0.915g

Mass above 0.915g

Not colouring bromide water

Colouring bromide water

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
ABS EP PA6 PA11 PA12 PA66 PBT PES PET PC PE PF PMMA POM PP PPE PPS PTFE PUR PVC SAN

Description
Acrylnitrite-Butadien-Styrol Copolymerisat Epoxide Polyamide with 6 atoms of monomer grid Polyamide with 11 atoms of monomer grid Polyamide with 12 atoms of monomer grid Polyamide from 2 monomer grids with 6 atoms each Polybutylene-terephthalate Polythersulphonide Polyethylene-terephthalte Polycarbonate Polyethylene Phenole-Formaldehyde Polymethylmethacrylate (Acryl) Polyoxymethylene, Polyacetal Polypropylene Polyphenylenether Polyphenylesulde Polytetrauorethylene Polyurethane Polyvinylchloride Styrole/Acrylnitril-Copolymerisat

Marking of plastics

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

Abbreviation
GF GM GB T M WD Glass bres Glass wool Glass balls Talcum

Description

Mineral stiffeners Wood aggregate

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

Abbreviation
ACM AU BR CSM CR EPDM ECO FPM MVQ NBR NR SBR

Description
Copolymer from ethylacrylate Polyestherurethane-rubber Butadiene-rubber Chorosulphide polyethylene Chloroprene-rubber Terpolymer from ethylene Copolymer from ethylenoxid (oxiran) and chlormethyloxiran Rubber with uorine Silicone rubber with matyl- and vinyl groups on polymer chain Acrylnitril-butadiene-rubber Isoprene-rubber (natural rubber) Sterol-butadiene-rubber

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Marking of plastics

Examples of designation and use of plastics in SKODA vehicles:

Material
PP+EPDM PP+EPDM+T PP/PE+T PP/PE other PP PE ABS Fillings Tank Bumper Front panel

FELICIA

OCTAVIA
Wheel housing Bumper Pillar and sill lining, front panel Pull handles Fillings Tank Mask, heating control, steering linkage cover, electric drive cover Outer handles, clips Clips, cable connectors

Pillar and sill lining

Centre console, lamp body, ashtrays, ventilation slots, outer mirrors Pull handles, outer handles, handle of pocket cover, clips Clips Ceiling lamp, third brake lamp Lining of pocket cover

PA6 PA66 PC PPO PBT ASA

Instrument panel, ventilation slots, defrost grid Lamellas of ventilation slots, covers of wipers, plugs

Registration number lighting ledges, signs Handle of 5th door

Outer mirrors, registration number lighting ledge, mask, instrument panel foil

PC/ASA PC/ABS APEC

Rear lamps 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 b

a) Logo of manufacturer b) Part number c) Code of manufacturer

c
d) Abbreviation of manufacturer

d e f
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01 96 97 98 99 00 01 02 03 04 05 02 03 04 05 06 07 08 09 10 11 12

e) Code of material f) Country of origin

Example of table with date of production of a plastic part.

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

- for repairs of plastics

D 007 70
D 007 700

u Ne w ne uve 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 thoroughly.

plastic

part

completely

and

dry

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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 plastics 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 (60C70C/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.

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The upper surfaces are suitable for painting according to guidelines from manufacturers of varnishes after 1-4 hours.

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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 bayonet 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 hardened 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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