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Last updated on 2024年5月6日

How can you detect and prevent the most common material defects?

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Material defects can compromise the quality, performance, and safety of your products. They can also increase your production costs, waste, and rework. To avoid these problems, you need to know how to detect and prevent the most common material defects in manufacturing. In this article, we will cover four types of defects that affect metals, plastics, ceramics, and composites, and how you can avoid them with proper material selection, testing, and processing.

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1 Metal defects

Metals are prone to defects such as cracks, porosity, inclusions, and segregation. Cracks are fractures that occur due to stress, fatigue, or thermal shock. Porosity is the presence of voids or gas bubbles in the metal, which can reduce its strength and ductility. Inclusions are foreign particles or impurities that are trapped in the metal, which can affect its corrosion resistance and weldability. Segregation is the uneven distribution of alloying elements or phases in the metal, which can create variations in its properties and performance. To prevent metal defects, you should choose the right metal grade and composition, use appropriate heat treatment and cooling methods, and perform non-destructive testing (NDT) such as ultrasonic, radiographic, or magnetic inspection.

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2 Plastic defects

Plastics are susceptible to defects such as warping, sink marks, flash, and short shots. Warping is the distortion or deformation of the plastic part due to uneven shrinkage or cooling. Sink marks are depressions or dimples on the surface of the plastic part due to insufficient pressure or material. Flash is the excess plastic that flows out of the mold cavity along the parting line or ejector pins. Short shots are incomplete plastic parts due to insufficient material or injection pressure. To prevent plastic defects, you should select the right plastic material and grade, optimize the mold design and injection parameters, and perform quality control checks such as visual inspection or dimensional measurement.

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3 Ceramic defects

Ceramics are subject to defects such as cracks, pores, blisters, and pinholes. Cracks are breaks or splits in the ceramic material due to thermal stress, mechanical stress, or processing errors. Pores are small holes or spaces in the ceramic material that can affect its density, strength, and porosity. Blisters are bubbles or swellings on the surface of the ceramic material due to trapped gases or moisture. Pinholes are tiny holes or pits on the surface of the ceramic material due to incomplete sintering or firing. To prevent ceramic defects, you should choose the right ceramic material and composition, use proper mixing, drying, and pressing methods, and control the sintering or firing temperature and time.

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4 Composite defects

Composites are vulnerable to defects such as delamination, debonding, voids, and wrinkles. Delamination is the separation of the layers or plies of the composite material due to poor adhesion or interlaminar shear stress. Debonding is the detachment of the composite material from the substrate or core due to weak bonding or peel stress. Voids are air pockets or gaps in the composite material that can reduce its strength and stiffness. Wrinkles are folds or creases in the composite material that can affect its appearance and integrity. To prevent composite defects, you should select the right composite material and type, use adequate curing and bonding methods, and apply sufficient pressure and vacuum during the fabrication process.

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Forouz Behzadpour

Former Boeing Sr Technical Lead Engineer, Structural Analysis (Composites)
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contrary to common belief, composite defects including warpage are the direct result of bad layup selections and design details and cannot be corrected by modifying the curing process. The thick laminates should be and can be avoided at all costs.

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How can you detect and prevent the most common material defects?

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5

1 Metal defects

2 Plastic defects

3 Ceramic defects

4 Composite defects

5 Here’s what else to consider

Manufacturing

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How can you detect and prevent the most common material defects?

1

2

3

4

5

1 Metal defects

2 Plastic defects

3 Ceramic defects

4 Composite defects

5 Here’s what else to consider

Manufacturing

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