Dukane iq series User Manual page 131

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Problem
The parts are marking.
Probable Cause
The horn heats up.
There are high spots in the part.
Use of raised lettering.
The part does not fit the fixture
properly.
Oxide from the horn is being
transferred to the part.
The parts contain fillers.
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Problem
Welding process not in control (inconsistent weld results on a part-to-part basis).
Probable Cause
A mold release agent is used.
Incorrect part tolerances.
There are cavity-to-cavity variations.
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Dukane Manual Part No. 403-586-02
Welding
Solution
Check for a loose stud, tighten if loose.
Loosen and then retighten the horn tip.
(Refer to Section 7).
Reduce the weld time.
Ensure that the horn and booster are coupling well.
(Refer to Section 7).
Visually check the horn for cracks.
Check the part dimensions.
Check the fit of the horn to the part.
Use recessed lettering or relieve the horn around the
lettering.
Check the fixture for proper support.
Check for cavity-to-cavity variations.
Redesign the fixture.
Place polyethylene film between the horn
and the part.
Use a chrome-plated horn and/or fixture.
Check the processing conditions.
Reduce the amount of filler in the plastic.
Solution
Clean the mating surfaces.
If a mold release agent is necessary, use a
paintable/printable grade.
Tighten the part tolerances.
Check the part dimensions.
Check the molding dimensions.
Check the part dimensions and tolerances.
Check for cavity wear.
Check the molding conditions.
Section 9 - Troubleshooting
Continued
Page 123