This information is reprinted with permission from the DERAKANE NEWS ® , The Dow Chemical Company, Vol. 15, Issue 3, January 1997
Because physical inspection of a composite laminate tends to be destructive, visual inspection is usually the method of choice for evaluating composite equipment. This is a list of defects that may aid in the identification of fabrication problems, facilitating their correction & ensuring the ultimate strength & corrosion resistance of the composite part.
Potential Problem / Defect :
"Air Bubbles , Voids"
Nature of Defect :
Air entrapment between plies, non-interconnected spherical voids
Possible Causes :
(Whipping action during mixing) (Poor or dirty surface) (Air bubbles not rolled out during lay-up)
Potential Problem / Defect :
"Blisters"
Nature of Defect :
Rounded, sometimes sharply defined elevations of laminate surface
Possible Causes :
(Cure too rapid) (Moisture in resin, filler or glass)
Potential Problem / Defect :
"Impact Cracks"
Nature of Defect :
Separation of materials through thickness and visible on surface
Possible Causes :
(Impact) (Insufficient reinforcement) (High concentration of resin)
Potential Problem / Defect :
"Crazing"
Nature of Defect :
Pattern of fine cracks on or beneath surface
Possible Causes :
(Isolated resin-rich area) (Impact) (Intermittent service causing temperature differences) (Wet / Dry cycling) (Resin shrinkage)
Potential Problem / Defect :
"Delamination"
Nature of Defect :
Separation of layers
Possible Causes :
(Poor glass saturation) (Dirty surface) (Glass content too high) (Failure to remove air-inhibition coat before adding layer)
Potential Problem / Defect :
"Fisheye"
Nature of Defect :
Small globular mass not blended into surrounding material, particlarly evident in transparent or translucent materials
Possible Causes :
(Dirty surface) (Foreign matter falling on resin)
Potential Problem / Defect :
"Dry spots"
Nature of Defect :
Area of reinforcement not wetted with resin (usually at laminate edge)
Possible Causes :
(Not enough resin used, applies mostly to molding operations)
Potential Problem / Defect :
"Pimple"
Nature of Defect :
Small, sharp or conical pimple-like elevation on surface
Possible Causes :
(Dripped resin or small bubble) (Worked on area after resin has started to cure)
Potential Problem / Defect :
"Pit or Pinhole"
Nature of Defect :
Small regular or irregular crater on surface, usually with nearly equal width and depth
Possible Causes :
(Air bubbles that rise to surface which cure before smoothing out)
Potential Problem / Defect :
"Resin pocket"
Nature of Defect :
Apparent accumulation of excess resin in a small, localized area
Possible Causes :
(Improper lay-up in which glass separates and voids fill with resin)
Potential Problem / Defect :
"Scratch"
Nature of Defect :
Shallow mark, groove, furrow or channel
Possible Causes :
(Improper handling or storage)
Potential Problem / Defect :
"Wrinkle"
Nature of Defect :
reinforcement
Possible Causes :
(Improper lay-up) (Too rapid cure) (Use of old resin) (Fold in release film on the mold)