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Plastic Part Failure Analysis - 2 Day Course

Course description
Time: 8:00 AM - 4:00 PM
Location: Akron Polymer Training Center, Akron, OH 44325-5404, U.S.A.
Cost: $900 USD
CEU's: 1.6
Instructor: Michael Sepe

Course Overview

This course covers elements of a successful plastic product; principles of plastic part design, mold design considerations, material selection, processing, failure analysis tools and failure analysis process.

Please note class times: First day of class - 8:00 a.m. - 4:00 p.m.; Second day of class - 8:00 a.m. - 2:30 p.m.

  1. Elements of a successful plastic product
    • Part design
    • Mold design
    • Material selection
    • Processing
  2. Principles of plastic part design
    • Nominal walls
    • Ribs and other projections
    • Holes and other depressions
    • Designing for manufacturing and assembly (DFMA)
    • Design properties versus inherent properties of materials
  3. Mold design considerations
    • Mold steel selection
    • Managing polymer flow in the mold - runners and gates
    • Cavitation and the effect on balanced flow
    • The economics of cavitation
    • Hot runners versus conventional cold runners
    • Mold temperature control
    • Draft angles and ejection
  4. Material selection
    • Defining the application environment - time, temperature, stresses, etc.
    • Amorphous and semi-crystalline polymers
    • The importance of molecular weight
    • Structural choices within a polymer family
    • Property modifiers and additives
    • Regulatory considerations - UL, NSF, FDA
    • Performance and processability
    • Establishing the cost/performance balance
  5. Processing
    • The fundamentals of polymer flow
    • The effect of material structure on sound processing decisions
    • Machine selection
    • Process control strategies
    • The quest for six sigma
  6. Failure analysis tools
    • Material testing - composition and degradation
      • Molecular weigh evaluations
      • Thermal Analysis - DSC, TGA, DMA, TMA
      • Spectroscopy - FTIR, EDS, XPS, SIMS
    • Microscopy - cross sections and scanning electron microscopy
    • Physical property evaluation - your part is not a tensile bar
    • FEA and its relation to the application environment
    • Advanced characterization of mechanical properties
  7. The failure analysis process
    • Gathering background information
    • Focusing on the four fundamentals of a successful product
    • Conducting the appropriate evaluations
    • Establishing root cause
    • Fixing what is broken
    • Understanding the interactions of multiple causes
    • The role of designs of experiment
    • The cost/benefit analysis of problem solving
    • Following up
  8. Case studies