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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51
 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

63
 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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