Category Archives: Surface Tips & Tricks
Think about your company’s manufacturing operation.
Now, think about fixing your adhesion problems simply by knowing a single number…
What do both of these statements about surface adhesion have in common?
- “We need to measure surface quality of the teeth on a gear to make sure the coating stays on.”
- “We need to make sure the coating on our tubing is uniform, but we can’t measure a curved surface with our current surface testing method.”
“We need to be solvent wiping our aluminum before it’s coated/painted/sealed/insert adhesion-intensive process here.”
Technically, that’s correct…you should be.
But is that understanding enough?
In some industries–including film and flexible packaging–dyne is the primary language. BTG Labs’ Surface Analyst uses water contact angle measurements as a fast easy, objective, and non-destructive alternative to dyne inks.
The main concern we hear from manufacturers is that both the suppliers and the customers speak dyne as their standard.
The answer is the Surface Analyst’s Dyne Mode. This unique feature takes the Surface Analyst’s default contact angle measurement and automatically converts the measurement into a dyne/cm readout, directly on the instrument. This mode allows manufacturers to maintain their investment in the dyne measurement language.
BTG Labs believes in dyne measurements, but not dyne inks. Manufacturers using dyne inks struggle with inaccuracy and subjectivity, leaving much room for error. Furthermore, because of dyne inks’ destructive nature, users can’t measure on the actual part. This leaves dyne inks virtually impossible for testing the part on the factory floor. …Read More
Of all the challenges manufacturers face, creating and optimizing critical surface processes for various materials can be very difficult. Traits such as location, size, shape, and texture can add to the challenge. The success of any critical surface process requires an in-line, fast, easy, and accurate verification method.
That’s why more and more manufacturers are turning to the Surface Analyst. Whether it’s bonding, painting, printing, cleaning, coating, or sealing, BTG Labs’ Surface Analyst optimizes critical surface processes and monitors surface treatment on virtually any surface so the product is guaranteed to deliver.
BTG Labs engineered the Surface Analyst to adapt to any application directly on the factory floor. Patented Ballistic Deposition deposits a stream of micro-droplets on the surface; these micro-droplets contain kinetic energy which allows the drops to overcome various textures and different angles without interfering with measurement accuracy. The drop size can also be adjusted so that measurements can be taken on any sized surface from a giant wind turbine to a minuscule medical catheter.
In 2014, a large manufacturer of automotive exteriors and interiors encountered a problem consistently adhering paint to their dashboards due to an inappropriate use of their flame treatment.
Flame treatment is a popular and notable procedure that can successfully modify the surface chemistry of a polymer, readying it for adhesion. Although flame treatment is an effective solution, determining the amount of treatment can be a delicate procedure. The over-flaming of these highly sensitive polymers can lead to polymer reorientation due to localized melting and ultimately, destruction of the surface.
In this case, however, the manufacturer was not utilizing flame treatment to monitor their surface cleanliness. Instead, they used it to deflash excess material on the edges of their dash boards. The edges of the dashboard were being over-flamed, hindering the polymer’s surface adhesion ability. This, in turn restricted paint from correctly adhering to the edges of the dashboard. The company needed a way to determine the appropriate amount of flame treatment.
BTG Lab’s recently held another successful webinar. Hosted by Products Finishing and presented by Dr. Giles Dillingham, the webinar emphasized the importance of monitoring cleaning processes and explored different ways to measure surface cleanliness.
In the webinar, Dr. Dillingham discusses measuring surface cleanliness as a way to quantify cleaning processes. By measuring the success of cleaning processes, manufacturers can determine the ideal solution for their application.
Precisely evaluating cleaning processes with water contact angle is a fast, easy, accurate, quantitative to way to gain ensure consistency and precision on the factory floor.
Challenges often arise when verifying critical surface processes on the factory floor when measuring hard to reach areas and varying angles. The Surface Analyst conquers those challenges with the unique ability to measure on vertical surfaces, which include assembled parts and hard to reach spots. This allows for easier surface analysis on the factory floor.
A few examples of the Surface Analyst’s ability to measure on vertical surfaces on the factory floor:
- Airplane wings prior to bonding, painting, and repair
- Canopy of jet fighters after cleaning
- Wind turbine blades prior to bonded repair
- Silkscreen bottles post flame treatment
- Ship hulls prior to painting and bonding
- Interior of automobile headlights prior to application of anti-fog coating
- Windshield bond lines prior to sealing
- Class A paint surface for decals applications and reapplications
- Measuring appliances after metal cleaning and prior to power coating
BTG Labs’ Surface Analyst is more than just a fast, easy, accurate, hand-held, non-destructive, objective surface cleanliness gauge. It encompasses features to personalize your application for measuring on different parts and for different purposes.
Because we work in highly diverse industries with countless applications from bonded nut plates on fighter jets to printed labels on packaging to hydrophilic coating on medical tubing our instrument is built to personalize your application.
The Surface Analyst features include charting results and statistics capabilities; modifiable material profiles for any application; auto drop detect for faster in-line operation; and adjustable drop size for easy measurements on any surface. These and other features of the Surface Analyst allow a manufacturer to personalize and optimize their surface critical processes.
Check out the list of features you should be using. …Read More
Thanks to advancements in powertrain manufacturing, sealing processes have improved assembly efficiency. Formed-in-place gaskets (FIPG) are replacing traditional mechanical fasteners as they are more cost effective, stronger, and easier to apply. However, adhesive bonding rather than mechanically fastening presents different challenges and requires new protocols.
Lead Sales Engineer Lucas Dillingham has presented “Defining Cleanliness in Powertrain Manufacturing for FIPG Applications,” at several events and automotive factories. BTG Labs works with numerous automotive manufacturers on surface chemical cleanliness and what it means for assembly.
Traditional millipore tests reveal particulate contamination, but on a sealing surface, one must detect chemical contamination. To adhere successfully, surface cleanliness on a chemical level is vital.
A byproduct of automotive manufacturing processes is contaminants that are detrimental to adhesion. Processes entailing unwanted contaminants include: