Query on Poly Carbonate (PC) - Durability of the Product

vivkrish

Involved In Discussions
#1
Hello All..!

This is Vivkrish,

I have faced one problem on our product which was produced on Polycorbonate (Unfilled) clear color material.

During Durability of the product (After 40,000 Kms running of the vehicle) the product gets dull in visual, Not in whole area of the product (Some area only).

Why it gets dull in visual? any idea..! Pls share.


Regards,
Vivkrish.
 
Elsmar Forum Sponsor

howste

Thaumaturge
Super Moderator
#2
Since we don't know what your part's shape and function is and what kind of durability testing was done, I don't think we can answer your question without more information. Is it being subjected to some kind of bending force?

I assume you're talking about polycarbonate.
 

NikkiQSM

Quite Involved in Discussions
#3
More information pertaining to the type of testing you are conducting could help to answer.

But from what you have provided, it sounds as though the PC part is developing stress fractures at the point when you are apply pressure.

While PC is strong, it can stress, break and shatter if not properly processed. PC requires drying before being processed / molded. If it is wet during this process, you will surely lose physical properties and the part can become brittle.

Was the material properly dried before being molded? If so, what was the moisture level?
 

vivkrish

Involved In Discussions
#4
Since we don't know what your part's shape and function is and what kind of durability testing was done, I don't think we can answer your question without more information. Is it being subjected to some kind of bending force?

I assume you're talking about polycarbonate.
Hello Howste,

I will answer your question. My product is head light of the passenger car. After it sale to the end customer it was happened with 40000 kms runs the vehicle. Rather than atmospheric force no other force applied on it.

As per you statement it was right we are talking about Poly carbonate material which was used to produce Outer surface (Lens) of the product.

Thanks,
Vivkrish.
 

vivkrish

Involved In Discussions
#5
More information pertaining to the type of testing you are conducting could help to answer.

But from what you have provided, it sounds as though the PC part is developing stress fractures at the point when you are apply pressure.

While PC is strong, it can stress, break and shatter if not properly processed. PC requires drying before being processed / molded. If it is wet during this process, you will surely lose physical properties and the part can become brittle.

Was the material properly dried before being molded? If so, what was the moisture level?
Hello NikkiQSM,

As my statement above we are not applying any external stress on the product, rather than atmospheric pressure. We were doing pre-drying before molding. The moisture level of the material before molding is 0.01% which we accept because, as per our raw material manufacturer comments. They fixed the maximum moisture level before molding should be 0.02%.

I have mentioned durability is nothing but after the car sale we fixed some time duration as a durability period. We have faced the problem within this period.


Thanks,
Vivkrish.
 

Miner

Forum Moderator
Staff member
Admin
#6
My product is head light of the passenger car. After it sale to the end customer it was happened with 40000 kms runs the vehicle. Rather than atmospheric force no other force applied on it.

As per you statement it was right we are talking about Poly carbonate material which was used to produce Outer surface (Lens) of the product.
You are limiting your thinking to mechanical forces, which go beyond wind. You could also have abrasion from airborne particulates and gas pump window cleaning squeegees, vibration transmitted through the chassis, gravity causing creep, etc.

There are other forces that affect reliability such as thermal (internal heat from lamp/external ambient heat), electrical, radiation (e.g., UV light from sun) and chemical (e.g., car wash cleaners, gas pump window cleaners, road salt, bug guts).
 
Last edited:

vivkrish

Involved In Discussions
#7
You are limiting your thinking to mechanical forces, which go beyond wind. You could also have abrasion from airborne particulates and gas pump window cleaning squeegees, vibration transmitted through the chassis, gravity causing creep, etc.

There are other forces that affect reliability such as thermal (internal heat from lamp/external ambient heat), electrical, radiation (e.g., UV light from sun) and chemical (e.g., car wash cleaners, gas pump window cleaners, road salt, bug guts).
Hello Minor,

I agree with you. If I suspect your points is main root cause for the failure means, i need to get the dull shade in whole area.But Its not like that. I have the problem in small area only. That why I can't conclude. Any other factors please.


Thanks,
Vivkrish.
 

vivkrish

Involved In Discussions
#9
Is the small area immediately in front of the headlamp? If so, heat may be a cause, or an accelerating factor.
Hello Miner,

Yes, Small area only affected.

I have dismantled the product and verified. It looks like smoke formation inside the lamp.
While wiping by hand it sticking on the hand. But not in black color. It was in light grey.

Can we suspect with the electrical devices(Bulbs, Leveling device) inside the lamp.

Thanks,
Vivkrish.
 

kuyakut

Involved In Discussions
#10
Hi,

Your molded part may have mold in stress wherein if it is subjected to thermal stress such as heat for bulb and heat form the sun it becomes blurry on some areas.
We always do annealing at Tg temperature of the plastic if we found out our parts have extreme mold in stress.
 
Thread starter Similar threads Forum Replies Date
Proud Liberal Power Query to combine multiple tables of unequal number of columns Statistical Analysis Tools, Techniques and SPC 1
A Query regarding MS Excel usage Excel .xls Spreadsheet Templates and Tools 2
V Query on Rubber products (EPDM, Silicone, BR, NBR, Neoprene, TPE) Manufacturing and Related Processes 5
V Query on PA66+GF15% - Color variation (Natural to Yellowish) problem Manufacturing and Related Processes 20
P Internal Audit Matrix Process Query ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 38
M Technical Query (TQ) Nonconformance and Corrective Action 1
D minitab macro to pull access query with parameters Using Minitab Software 1
R Medical Device and Accessory Establishment Registration and Listing Query Other US Medical Device Regulations 7
B Query on Medical Device Electronics RoHS Certificate Statement RoHS, REACH, ELV, IMDS and Restricted Substances 3
A 7.5.1.3: Verification of job setup query, sample WI required. IATF 16949 - Automotive Quality Systems Standard 5
S Query regarding completion of MedWatch 3500 Form Other US Medical Device Regulations 3
A Query about ISO 9001 Certification Documentation for a Service company ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 4
N Controlling Records query that may cause some serious trouble for me ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 8
V Query on TS 16949:2009 Certification for a Tool and Die Sales & Service office IATF 16949 - Automotive Quality Systems Standard 3
C Creating a Multiple Table SQL (Structured Query Language) Query in Minitab Using Minitab Software 10
G Query on Capability of Stdev Specifications Capability, Accuracy and Stability - Processes, Machines, etc. 9
N Must Templates be controlled? Controlled Document Query ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 3
N Controlled Documents Distribution Query - Home Care Company ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 1
R Query on Concentricity Inspection Manufacturing and Related Processes 11
Q OEM (Original Equipment Manufacturer) PPAP Applicability Query IATF 16949 - Automotive Quality Systems Standard 4
J Reduction of Pull Off Test Inspection Frequency - Capability Query Quality Tools, Improvement and Analysis 1
P Query about TS 16949 and a Multi-Disciplinary Approach IATF 16949 - Automotive Quality Systems Standard 3
A Query on Certification Man Days for ISO 9001:2008 ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 10
T Titles for Quality Functions - Very small business quality department query ISO 13485:2016 - Medical Device Quality Management Systems 17
F Good Documentation Practices Training Materials Query Training - Internal, External, Online and Distance Learning 6
J Help with Microsoft Access ODBC Database Query Criteria Misc. Quality Assurance and Business Systems Related Topics 35
S Identification and Traceablity - Audit Query - AS9100 REV B - Clause 7.5.3 AS9100, IAQG, NADCAP and Aerospace related Standards and Requirements 3
S TS16949 Query on Subscribing and Non-Subscribing Customer IATF 16949 - Automotive Quality Systems Standard 2
J Need Some Access Query Help - Error message saying "Numeric field overflow" Quality Assurance and Compliance Software Tools and Solutions 2
D 7.4 Purchasing - Query on Indirect Material Qualification ISO 13485:2016 - Medical Device Quality Management Systems 0
J Question, query, poser, MMMMMMM QS-9000 - American Automotive Manufacturers Standard 6
C Cotton Swab Method Validation for clean uniforms, bins and poly bags Other Medical Device and Orthopedic Related Topics 4
M Jail Terms for Poly Implant Prothese Executives EU Medical Device Regulations 2
Z My first Gage R&R - Paper/Poly/Foil Material Bond Test, need help Gage R&R (GR&R) and MSA (Measurement Systems Analysis) 15
D Tracking infrequent defects - Compounded plastic (poly propylene + filler) injection Manufacturing and Related Processes 12

Similar threads

Top Bottom