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Insert molding

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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001593
EISBN: 978-1-62708-234-1
...Abstract Abstract A failure analysis was conducted on a flow-sensing device that had cracked while in service. The polysulfone sensor body cracked radially, adjacent to a molded-in steel insert. This article describes the investigative methods used to conduct the failure analysis...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.homegoods.c0090445
EISBN: 978-1-62708-222-8
... in conjunction with an electrical appliance, failed during assembly with the mating components. The failures were traced to a particular production lot of the covers and occurred during insertion of the screws into the corresponding bosses. The parts had been injection molded from an ABS resin to which regrind...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.auto.c0090442
EISBN: 978-1-62708-218-1
... (butylene terephthalate) (PBT) resin. After molding, electronic components are inserted into the sleeves, and the assembly is filled with a potting compound. A retained lot of parts, which had not cracked, were available for reference purposes. Tests and Results Conclusions Selected Reference...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c0090463
EISBN: 978-1-62708-234-1
... contact inserts. Investigation supported the conclusion that the switch housings failed via brittle fracture, likely through a creep mechanism. The failure was caused by severe embrittlement of the housing resin associated with massive molecular degradation produced during the molding process. A potential...
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001378
EISBN: 978-1-62708-215-0
... Fig. 4 Improved design with stress-relieving groove Fig. 1 Insertion of stud bolt into die block. (a) Existing condition. (b) Improved condition Fig. 2 Micrograph of stud bolt, showing crack at root of thread and nonmetallic stringers. Unetched. 38× Fig. 3 General...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003508
EISBN: 978-1-62708-180-1
... in the mold (chills, inserts, chaplets, etc.) Blowholes, adjacent to inserts, chills, chaplets, etc. B 113 (a) Like B 111, but accompanied by slag inclusions (G 122) Slag blowholes B 120: Class B 100 cavities located at or near the casting surface, largely exposed or at least connected...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.homegoods.c0090457
EISBN: 978-1-62708-222-8
... the tab from a nonfailed part in a manner consistent with the insertion of the corresponding metal slide. The laboratory fractures exhibited surface features that were in excellent agreement with those exhibited by the failed parts, as apparent in Fig. 1 . Fig. 1 Scanning electron images showing...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c0089646
EISBN: 978-1-62708-235-8
.... The burrs rise above the surface from 4 to 13 μm. Etched with nital. 220x Abstract Abstract Nodular cast iron crankshafts and their main-bearing inserts were causing premature failures in engines within the first 1600 km (1000 mi) of operation. The failures were indicated by internal noise...
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001130
EISBN: 978-1-62708-214-3
... at an elementary school was investigated. The seat contained a perforated reinforcing sheet metal (galvanized type 430 stainless steel) insert covered by an elastomeric material. Specimens of the reinforcing sheet from the failed seat were examined using SEM fractography, tensile and ductility tests...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0001814
EISBN: 978-1-62708-180-1
... • Young W. , “Are You Getting Maximum Performance From Your Die Casting Dies?,” Technical Paper CM68-587, American Society of Tool and Manufacturing Engineers , Dearborn, MI , 1968 • Young W. , Better Performance from Die Casting Dies , Precis. Met. Mold , Vol 23 , May 1965 , p...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003525
EISBN: 978-1-62708-180-1
... sleeves used in an automotive application cracked after assembly but prior to installation into the mating components. The sleeves were specified to be injection molded from a 20% glass-fiber-reinforced poly(butylene terephthalate) (PBT) resin. After molding, electronic components are inserted...
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001184
EISBN: 978-1-62708-235-8
... into the liquid steel. But more probably the metallic inclusions originate in floated base places of carbon-deficient steel, such as are inserted into the mold in casting from the above for the protection of the bottom. In any case, irrespctive of their origin, they must be regarded as casting defects...
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006765
EISBN: 978-1-62708-295-2
... thermosetting resins include phenolic, diallyl phthalate, and epoxy, while methyl methacrylate is the most commonly used thermoplastic mounting resin. Both thermosetting and thermoplastic materials require heat and pressure during the molding cycle, but, after curing, mounts made of thermoplastic resins must...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003532
EISBN: 978-1-62708-180-1
... after heat treatment. Specimen etched with Marble's reagent As a final example of a heat-treatment-related failure, Fig. 34 shows the microstructure of an AISI D2 draw die insert that exhibited galling and chipping after limited service. Examination of the microstructure revealed...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003501
EISBN: 978-1-62708-180-1
... to be performed for stresses, vibrations, heat flow, and so forth? Manufacturability: Can the selected manufacturing process hold the tolerances that will be needed for the configuration to meet the required functionality? Does the configuration allow for ease of handling and insertion for assembly...
Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006783
EISBN: 978-1-62708-295-2
... to that of the active metal Insert an electrically insulating gasket between the two dissimilar metals Seal the junction from any available electrolyte Another possibility is coating the cathodic material for corrosion control. Where metallic coatings are used, there may be a risk of galvanic corrosion...
Book Chapter

Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003548
EISBN: 978-1-62708-180-1
... metals with the least difference in “uncoupled” corrosion potentials Minimize the area of the more noble metal with respect to that of the active metal Insert an electrically insulating gasket between the two dissimilar metals Seal the junction from any available electrolyte Another...
Book Chapter

Series: ASM Handbook
Volume: 11
Publisher: ASM International
Published: 15 January 2021
DOI: 10.31399/asm.hb.v11.a0006790
EISBN: 978-1-62708-295-2
... carbide inserts in a steel matrix), the individual components of which vary in their mechanical properties. Under some abrasive wear conditions, removal of the softer phase (usually the matrix) can occur by one or more of the previously mentioned mechanisms. This process then leaves the harder phase...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003560
EISBN: 978-1-62708-180-1
... or that are made up of two or more component phases (e.g., a composite-type material, such as a high-chromium white iron, or a composite drill bit, such as diamond or tungsten carbide inserts in a steel matrix), the individual components of which vary in their mechanical properties. Under some abrasive wear...
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003509
EISBN: 978-1-62708-180-1