Manufacturers face common adhesion problems that can disrupt production and quality. By addressing key mistakes in surface preparation and contamination control, they can significantly improve product reliability and efficiency.
Fremont, CA: Adhesion problems plague manufacturers as their surfaces fail to stick or adhesives do not work as they should. This constant battle against adhesion failure seems endless and unending, even after changing equipment and processes. Issues like a bond that doesn't hold, coatings that don't cover uniformly, and paint or ink that does not stick continue to plague manufacturers at a high cost of scrap, recalls, unhappy customers, expensive rework, and time lost getting products to the customer.
However, manufacturers can take action to counter these factors and increase productivity. Reviewing common mistakes would determine effective solutions for fighting adhesion failures.
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1. Lack of Material Knowledge
Problem: Most manufacturers are ignorant of the properties of the materials they use, which affects the bonding between them and others. This mainly occurs due to overdependence on suppliers who may not divulge all relevant information.
Solution: Manufacturers should fully understand the condition of all material surfaces coming into their plant and know which properties of a surface most affect adhesion.
2. Surface Preparation in Error
Problem: If they know their material, manufacturers may treat surfaces appropriately and prevent them from bonding correctly.
Solution: Know material properties and use the best possible preparation for every material and application.
3. Over or Under-Treatment of Surfaces
Problem: Surfaces can be over-treated or degraded by excessive treatment, such as over-abrading or insufficient plasma treatment.
Solution: Verification steps must be taken to ensure surfaces are prepared to the exact level needed for optimal adhesion.
4. Surface Aging
Problem: Surfaces age over time, particularly in manufacturing environments, resulting in adhesion problems if materials are stored too long before use.
Solution: Identify the proper timing for applying adhesives or coatings following treatment and checking surfaces following storage to adapt preparation steps as necessary.
5. Inadequate Use of Abrasion
Problem: Over- or under-roading surfaces or applying abrasion where it is not necessary can interfere with adhesion.
Solution: Confirm abrasion is needed for the material and use the appropriate amount with verification steps to ensure the surface has been treated appropriately.
6. Failure to Clean before Abrading
Problem: Abrasion without proper cleaning can spread or embed contaminants, negatively affecting adhesion.
Solution: Clean all surfaces with a parts washer or IPA wipe before abrasion and verify the cleaning was effective.
7. Reuse of Cleaning Materials
Problem: Reusing wipes or not changing cleaning solutions enough can spread contamination.
Solution: Use a new wipe for each surface and check parts regularly to determine when to change cleaning elements.
Building awareness and knowledge of surface preparation, material conditions, best practices, and sources of contamination will help address these common mistakes. Even minor adjustments to the systematic approach to preventing adhesion failures can significantly improve the manufacturing process and product quality.
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