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Cosmetic Defect

Identification Guide
With
Cosmetic repair Guidelines

Paint Pops
Reverse Impact Crack
Generally appears as a line of
paint pops after top coat
application. Typically will see
faint line running through or
adjacent to pops.

The Reverse Impact crack is


caused by a strike/hit to the back
side surface of the part. It is very
difficult to see on IMC surface.
Topcoat solvents can wick into
this crack and volatize
generating what we call paint
pops.

Often evidence of a strike/hit


will exist on the inside of the
part (opposite of where the
paint pop occurs). If paint
pops such as this are
repetitive trouble shoot by
identifying origin of Strike/Hit
mark.

IMC Ferning/Pitting
Trapped air In its most
common form, ferning
literally looks like a fern
plant as seen here.
Careful sanding is
required to smooth the
part surface with out
destroying part contour.

Trapped air in its most


troublesome form take the
form of very small pits in the
coating.
They are very difficult to
detect.
Sanding dust fills them up
easily and gives an
appearance of complete
repair.
Recent process enhancements
have drastically reduced the
occurrence of this defect

<1.0 mm

Substrate Waviness
Surface waviness most prone to occur on
vertical molding surfaces where lack of molding
pressure exists. Can vary in severity from not
visibly noticeable to rejectable after topcoat.
Repair Method Block sand smooth to
eliminate wrinkles or waviness and prime where
necessary.

IMC Blister
IMC Blister gas trapped between substrate and
coating. Trapped air typically results in ferning but can
be a result in IMC blisters. It is can be driven by
several molding process factors to include:
shot size
open height.
Porosity filled with IMC coating can also generate a
coating blister as the IMC cures in the substrate pit.

Outline of blister
present.

Paint Pops
Porosity Part 1
Porosity related paint pops
exhibit bubbling of clear
coat from gases baking off
in oven prior to clear coat
being cured.

Cross Sectional view


shows the filling of
porosity pits by IMC.

Typical result of porosity on Topcoat Layer.


Typical cross-sectional view of porosity.
Impacts of porosity minimized/eliminated through effective
sealing capabilities of IMC coating.
Molding Process Focus is the reduced generation of this
specific defect.

Repair Methods and Defect Identification


techniques discussed on later pages.

Paint Pops
Porosity Part 2

Out of mold porosity can exhibit a


pitting condition as well as raised
wavy condition with pits as shown
here.

Solvents get trapped in the


interface crack. The
solvent turns to
gas.expands.and
generates a pop in the
clear coat as the gas seeks
path of least resistance.

To prevent this proper


repair must be completed

After sanding pits filled with IMC


are exposed. The interface
between filled pit and substrate
is where pop is generated.

Edge Pops
Edge pops are largely a function of two drivers:
Supplier Properly finessed and primed edges
Paint facility Heavy base/clear application/sags

Proper Edge Finesse hand


sanding with 400 grit
sandpaper minimizes the
potential for edge pops Part
edges must be smooth to
touch.

Heavy Base/Clear
can increase the
potential for trapped
solvents generated
pops as shown.

Both a function of heavy


application and gravity (sagging)
heavy coating effects shown.

Defect Source Identification

Red Base
migrates into
substrate
crack.

To destructively identify source of defect is impractical in the plant


environment. To quickly identify the source and repair part. Sand part
identify origin layer and repair using appropriate repair technique.

Clear Coat
Base Coat

IMC coating defect


Substrate Porosity/Crack

IMC

Substrate

BaseCoat origin

Desired surface repair


scenario
Minor Surface Defects can be sanded smooth without
going through the IMC. (Rubs, Dings, Light Porosity)
Not sanding through the IMC is beneficial because IMC is
resistant to solvent penetration and prevents solvents
from entering substrate and causing paint pops.

Method Keeping sander flat or using a sanding block


sand the defect until it is not visible. The key to making
this repair viable is minimizing the surface rate of change
to prevent the occurrence of sander gouge.
DO NOT TIP SANDER
Blend the sanding in beyond the local affected area
IMC sanded without going to
substrate. Gentle transition in
surface prevents sander
gouge

Major Repair Methods


Substrate Defect
(porosity) sanded down
to substrate

Repair area sanded down


additional with heavy grit
paper to: a) lower surface
b) promote adhesion.

After sanding repair is


blown out thoroughly to
promote adhesion and
ensure good repair.

Cross Sectional view of the intended impact of


sanding shown on following slide.

Cosmetic Repair
When repair is made going to
substrate minimize the excess
remaining high to surface so
excess sanding is not needed.

Cross Section noted above after


application of repair material.
Ensure application area clean
Thoroughly smooth repair material in.
Mininize excess application
Allow to dry thoroughly prior to sanding

Blend repair in using sander


or sanding block.
Maintain Integrity of part contour
Blow off and inspect for voids and
surface smoothness.
If defect remains repeat
repair material application..

Completed repair (prior to


prime application)
Contour maintained
Substrate concerns filled
Putty layer transitions to
substrate or IMC

IMC lift/Scratch/Surface Crack

This defect can originate from several different sources:


IMC lifting generally a result of a tooling condition
Scratch generally associated with product handling
Surface crack various potential causes

By sanding carefully through the layers (clear coat, base


coat, IMC and substrate a more reliable assessment can
be made.

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