Novel Method for Failure Modes Detection in UV-Cured Clear Coated Polymer for Automotive Interior Mechatronic Devices

Plastic parts used in automotive interior are difficult to coat, due to their low surface energies as well as their sensitivity to temperature and solvents, rendering the development of coating systems for such substrates challenging. Automotive customer requirements are explicit and clear, mainly f...

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Bibliographic Details
Published in:Polymers 2022-09, Vol.14 (18), p.3811
Main Authors: Braga, Ion Cristian, Udroiu, Razvan, Nedelcu, Anisor
Format: Article
Language:English
Subjects:
Adhesion tests
Automobile industry
Automobiles
Coating
Defects
Energy dispersive X ray analysis
Engraving
Equipment and supplies
Failure
Failure modes
Force and energy
Injection molding
Lasers
Manufacturing
Methodology
Methods
OEM
Plastics
Polymer industry
Polymers
Primers (coatings)
Protective coatings
Substrates
Surface defects
Surface tension
Taguchi methods
Tension tests
X ray analysis
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Summary:Plastic parts used in automotive interior are difficult to coat, due to their low surface energies as well as their sensitivity to temperature and solvents, rendering the development of coating systems for such substrates challenging. Automotive customer requirements are explicit and clear, mainly focused on functional and surface defects. A new failure modes detection methodology of UV clear coated polymers for automotive interior, obtained by a multi-step manufacturing process, is proposed. The polymer complex parts analyzed in this paper are manufactured in various steps as follows: two components plastic injection molding, primer coating, laser engraving, and UV-cured clear coating. The failure modes detection methodology of the parts within each process step is investigated using different tests and analyses as follows: surface tension test, painting adhesion test, optical 3D measuring, energy dispersive X-ray analysis (EDX), and microscopy. A design of the experiments (DoE) based on the Taguchi technique with the aim to detect the influence of the main factors that lead to surface defects was performed. The proposed methodology is validated by a case study. The results showed that the mold temperature and the laser engraving current have a significant influence on the surface defect occurrence. Additionally, a possible contamination of the molding tool can generate the defects. A solution to reduce the occurrence of the failures was proposed, reducing the defect rate from 50% to 0.9%.
ISSN:2073-4360
2073-4360
DOI:10.3390/polym14183811