LevelLevel One ApprenticeshipOne Apprenticeship

What you need to knowWhat you need to know

• Ability to identify the type of plasticAbility to identify the type of plastic• Proper steps to achieve correct resultsProper steps to achieve correct results• Which method of repair?Which method of repair?• Will the repair be satisfactory?Will the repair be satisfactory?• Is it cost effective?Is it cost effective?• Do you have all the necessary materials?Do you have all the necessary materials?• Are we allowed to repair the part?Are we allowed to repair the part?• Is it a Thermoset, or a Thermoplastic? Is it a Thermoset, or a Thermoplastic?

Plastics Usage Through the Plastics Usage Through the YearsYears

1970 1980 1990 2000+ 1970 1980 1990 2000+

Where are these plastics Where are these plastics used?used?

fascias fascias bumper covers bumper covers interior trim interior trim exterior trim exterior trim fan shroudsfan shrouds batteriesbatteries gas tanks gas tanks

wheel housings and liners exterior body panels valve covers composite plastic floor tunnels virtually anywhere

Viper...Viper...

Is a perfect example of Is a perfect example of Plastics and performancePlastics and performance

Future TechnologyFuture Technology

Methods of IdentificationMethods of Identification• ISO Code• Body Repair Manual• Sanding Test• Float Test• Flexibility Test• Rod Adhesion Test

ISO Code IdentificationISO Code Identification

PETPET(E)

HDPE

PVC

LDPE

PP

PS

Other

Other means of IdentificationOther means of Identification

The Mitchell Manual is another source for plastic identificationinformation

What is TPO, ABS or PUR ?What is TPO, ABS or PUR ?

Plastic LocationsPlastic Locations

Oldsmobile AuroraOldsmobile Aurora

Saturn Station WagonSaturn Station Wagon

PE / PolyethylenePE / Polyethylene

PP/PolypropylenePP/Polypropylene

Saturn

Hummer H2

Thermoset vs. ThermoplasticThermoset vs. Thermoplastic

Repairing Plastics Repairing Plastics

Identifying the Extent of Identifying the Extent of DamageDamage

• One sided Repair One sided Repair - Nick, Scratch or gouge- Nick, Scratch or gouge

• Two sided RepairTwo sided Repair - Puncture, Rip or Tear- Puncture, Rip or Tear

• Reshaping with HeatReshaping with Heat - Dents or distortion- Dents or distortion

Damage IdentificationDamage Identification

Repair MethodsRepair Methods

• WeldingWelding– Hot Air WeldingHot Air Welding– Airless WeldingAirless Welding– UltrasonicUltrasonic

• AdhesiveAdhesive– OlefinOlefin– Non-OlefinNon-Olefin– RigidRigid– FlexibleFlexible

Repair Method Recommendations

Steps for Welding or Steps for Welding or AdhesiveAdhesive

RepairRepair• Thoroughly wash part with soap and Thoroughly wash part with soap and

waterwater– Warm soapy waterWarm soapy water– Aids in cleansing water soluble materialsAids in cleansing water soluble materials– Secondary damage becomes apparentSecondary damage becomes apparent

• Wax and Grease removerWax and Grease remover– Cleans surface of waxes and siliconesCleans surface of waxes and silicones– Removes non-water soluble materials, such asRemoves non-water soluble materials, such as

road tarroad tar

• Once clean, use heat if necessary to Once clean, use heat if necessary to reshape panel and remove any distortionreshape panel and remove any distortion– Heat gunHeat gun– Heat lampHeat lamp

• Make repair decisionsMake repair decisions– One sided repair?One sided repair?– Two sided repair?Two sided repair?

• Which method of repair will be Which method of repair will be appropriate?appropriate?– If cosmetic, Adhesive repair will sufficeIf cosmetic, Adhesive repair will suffice– If torn, a two sided repair will be neededIf torn, a two sided repair will be needed

• Will an Adhesive or a Welding repair be Will an Adhesive or a Welding repair be stronger?stronger?

Safety First!Safety First!

- With the vastamounts of chemicalsfound in plastics andadhesives today,following the propersafety precautionsshould be first andforemost when performing any repairprocedure

Do Not Repair!Do Not Repair!

Types of Adhesive RepairsTypes of Adhesive Repairs

Adhesive RepairAdhesive Repair

• Tools needed for a one-sided repairTools needed for a one-sided repair– Sander (D/A or Single action)Sander (D/A or Single action)– Sanding blockSanding block– Air nozzleAir nozzle

• Materials Materials – Plastic cleanerPlastic cleaner– Adhesion promoter (if polyolefin)Adhesion promoter (if polyolefin)– Repair material (2-part)Repair material (2-part)– 120-180 grit sandpaper120-180 grit sandpaper

One Sided RepairOne Sided Repair

One Sided Repair ProcedureOne Sided Repair Procedure

• Featheredge the nick, scratch or gouge toFeatheredge the nick, scratch or gouge to

the base of the damagethe base of the damage• Clean area by blowing away leftover dustClean area by blowing away leftover dust• Clean sanded area with approved plasticClean sanded area with approved plastic

cleaner (Do not mix systems)cleaner (Do not mix systems)• Wash clean and dryWash clean and dry• Apply adhesion promoter if necessaryApply adhesion promoter if necessary• Mix chosen repair material correctly and Mix chosen repair material correctly and

applyapply• Sand material to desired finishSand material to desired finish

Two Sided ProcedureTwo Sided Procedure• ToolsTools

– Die grinderDie grinder– Small grinder (50 grit)Small grinder (50 grit)– DA sanderDA sander– Blow gunBlow gun– SpreadersSpreaders– Clamping devicesClamping devices

• MaterialsMaterials– Backing materialsBacking materials– Repair Adhesive and adhesive promotersRepair Adhesive and adhesive promoters– AbrasivesAbrasives

Two Sided RepairTwo Sided Repair

Two Sided RepairTwo Sided Repair

Repair MaterialsRepair Materials

Do not intermix materials!

CleanersCleaners

• Plastic cleaners are Plastic cleaners are important for a important for a couple of reasonscouple of reasons– They aid in removing They aid in removing

surface contaminants surface contaminants left from the left from the manufacturing processmanufacturing process

– Help cleanse the Help cleanse the surface of surface of contaminants left from contaminants left from the sanding and the sanding and grinding processgrinding process

Repair AdhesivesRepair Adhesives

• Procedures vary from manufacturer to Procedures vary from manufacturer to manufacturermanufacturer

• Materials and their characteristics will Materials and their characteristics will vary as wellvary as well

• Can be made up of Epoxies, Urethanes or Can be made up of Epoxies, Urethanes or AcrylicsAcrylics

• All have different curing times and All have different curing times and sanding / handling timessanding / handling times

• Procedures are all brand and material Procedures are all brand and material specificspecific

Curing timesCuring times

Example only

ApplicatorsApplicators

Using the Mixing GunsUsing the Mixing Guns

• Insert Cartridge into applicator gunInsert Cartridge into applicator gun• Remove protective cap from cartridgeRemove protective cap from cartridge• Purge cartridge to equalize contentsPurge cartridge to equalize contents• Install new mixer tipInstall new mixer tip• Gun out approximately 1 1/2 - 2 inches of Gun out approximately 1 1/2 - 2 inches of

mixed material to ensure proper mixing mixed material to ensure proper mixing on waste materialon waste material

• Apply material to repair area, keeping theApply material to repair area, keeping the

mixing tip in the applied adhesivemixing tip in the applied adhesive

• Once all Material needed has been Once all Material needed has been applied,applied,

leave used mixing tip in place on cartridgeleave used mixing tip in place on cartridge• Release pressure from cartridge and Release pressure from cartridge and

remove cartridge from applicator gunremove cartridge from applicator gun• Store leftover cartridge in a cool, dark Store leftover cartridge in a cool, dark

environmentenvironment• Shelf life of a used cartridge isShelf life of a used cartridge is usually one month, an unusedusually one month, an unused one is a yearone is a year

Reinforcement MaterialsReinforcement Materials

• Can consist of mesh materialsCan consist of mesh materials– Loose Fiberglas meshLoose Fiberglas mesh– Woven Fiberglas clothWoven Fiberglas cloth

• Can consist of materials consistent with Can consist of materials consistent with the material being repairedthe material being repaired– Leftover or discarded plasticsLeftover or discarded plastics

of similar makeupof similar makeup

Adhesion PromotersAdhesion Promoters

• Are used primarily for Are used primarily for improving the adhesion improving the adhesion characteristics of Olefin characteristics of Olefin based plasticsbased plastics

• Improve adhesion by Improve adhesion by chemically changing the chemically changing the surface of the Olefin surface of the Olefin plastic, allowing an plastic, allowing an adhesive to bond with itadhesive to bond with it

• Other methods include a Other methods include a flame treatment to flame treatment to promote adhesionpromote adhesion

Minor RepairsMinor Repairs

• Instant Adhesives, or Instant Adhesives, or ‘crazy glue’ have ‘crazy glue’ have their place in the their place in the bodyshop as well as bodyshop as well as 2-part adhesives2-part adhesives

• Serve well for minor Serve well for minor replacement of replacement of broken tabs or broken tabs or mounting hardwaremounting hardware

• Limited strengthLimited strength

Plastic WeldingPlastic WeldingHot Air and AirlessHot Air and Airless

Plastic WeldersPlastic Welders

Hot Air WeldingHot Air Welding

Hot Air Welding TipsHot Air Welding Tips

Speed Welder (Hot Air)Speed Welder (Hot Air)

Hot Air with Speed TipHot Air with Speed Tip

Fanning NozzleFanning Nozzle

ISO CodeISO Code

(identifier)(identifier)Welding TemperatureWelding Temperature

ABSABS 350350° C (660°F)° C (660°F)

PEPE 300300° C (572°F)° C (572°F)

PVCPVC Hard 300Hard 300° C (572°F)° C (572°F)

Soft 400-500° C (752-932°F)Soft 400-500° C (752-932°F)

PPPP 300300° C (572°F)° C (572°F)

PAPA 400400° C (752°F)° C (752°F)

Temperature SettingsTemperature Settings

Airless WelderAirless Welder

Welding a ThermoplasticWelding a Thermoplastic1

2

3

Welding a ThermosetWelding a Thermoset

Two Sided UnreinforcedTwo Sided Unreinforced

Shop PracticalsShop Practicals

• Adhesive repairAdhesive repair– OlefinOlefin

• two sidedtwo sided– Non-olefinNon-olefin

• one sidedone sided

• Welding repairWelding repair– ABSABS

• one and two sidedone and two sided– PolyethylenePolyethylene

• one and two sidedone and two sided