ASE B3 - Plastic Repair Techniques

Thermoplastic

Plastic that can be heated and reformed multiple times

Thermosetting Plastic

Plastic molded with heat and pressure, cannot be reheated

ISO Codes

Set of code letters by ISO to identify various plastics

Rod Adhesion Test

Test to determine which welding rod works on a specific plastic

Flexibility Test

Test to match adhesive repair material flexibility to damaged part

Olefin

Thermal Polyolefins (TPO) used in automotive plastics

Plastic Welding

Process using welding gun and filler rod to repair plastic

Hot Air / Nitrogen Welding

Method using hot air or compressed Nitrogen gas for plastic repair

Tacking Tips

Nozzle type for tacking broken parts before final welding

Round Tips

Nozzle type for filling small holes and tight corners in welding

Speed Tip

Feeds welding filler rod automatically while preheating base material.

Airless Welding

Uses heated welding tip in direct contact with base material.

Welding Rods

Available in various plastics matching base material, with different colors and diameters.

V-Grooving

Process of tapering or sanding damaged area for welding or adhesive repairs.

Two-Sided Welds

Used when both sides of the part are accessible for welding.

Adhesive Plastic Repair

Involves two-part epoxies, urethanes, or cyanoacrylates for bonding plastic.

Melt-Flow Technique

Method for airless welding where shoe fills V-groove with melted filler rod.

Stitch-Tamp Technique

Technique for hard plastics where shoe mixes base plastic and filler rod.

Two-Part Adhesives

Consist of A and B parts mixed together for bonding.

Plastic Cleaner

Used to clean plastic before welding or adhesive repairs.

Heat Setting

Adjustable temperature setting on welder for specific materials.

V-Groove Depth

Determines the depth of tapering or sanding for welding repairs.

Cooling Bucket

Contains cool water and sponge to cool plastics during welding.

Die Grinder

Tool used for initial cutting in V-grooving process.

Filler Rod Preparation

Cut at a 60-degree angle for single-sided welding with hot air.

Plastic Blend Repair

Uses a piece of damaged part as a welding rod for repair.

Manufacturer's Recommendations

Guidelines provided by the manufacturer for using welder and tips.

Plastic Makeup Matching

Plastic welding rods available to match base material composition.

Welding Technique

Affects repair quality; pressure, speed, and cleanliness are crucial.

Welding Gun Maintenance

Requires clean feed tubes and shoes to prevent contamination.

Plastic Color Schemes

Varies by manufacturer based on plastic type for welding rods.

Adhesive Types

Include two-part epoxies, urethanes, and cyanoacrylates for plastic bonding.

V-Groove Repair Rule

Two-sided repair if backside accessible, single-sided if not.

Plastic Cleaning Process

Involves washing, brushing, and using a plastic cleaner before repairs.

Cyanoacrylates

Fast-curing adhesives like super glues with thin viscosity

One-Sided Repairs

Repairs for surface or one-sided damage on parts

Two-Sided Repairs

Repairs for damage through the part, using a reinforcing patch

Reinforced Plastic Repair

Repairing external panels with adhesively bonded reinforced plastics

SMC

Sheet molded compound used in reinforced composites

RIM

Reinforced Injection Molding method for plastics

Panel Bonding Adhesives

Adhesives for bonding panels to frames in repairs

Structural Patching Adhesive

Adhesive for repairing panels without attaching to frame

Backing Materials

Materials like unidirectional cloth used in panel repairs

Hot Air Welder

Device melting base plastic and filler rod for repairs

Filler Rod

Material used in plastic repairs, melted by hot air welder

Oxy Weld

Repair technique directing heat into base plastic and filler rod

Adhesive Backing Patch

Procedure for repairing rigid plastics with reinforcing fibers