1、_SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising theref
2、rom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions.Copyright 2011 SAE International All rights reserved. No part of this pub
3、lication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-4970
4、(outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/J1573_201112SURFACEVEHICLERECOMMENDEDPRACTICEJ1573 DEC2011 Issued 1987-02Revised 201
5、1-12Superseding J1573 OCT2008 OEM Plastic Parts Repair RATIONALEJ1573 has been updated to reflect more current automotive plastics applications statistics and repair procedure examples which reflect the current state of plastics repair technology. 1. SCOPE This SAE Recommended Practice defines the i
6、nformation required to repair the various types of plastics found on modern light-duty highway vehicles. Information is included for the repair and refinishing of most plastic body parts, both interior and exterior. Repair information is described for all commonly used plastics including, but not li
7、mited to, polyurethanes, polycarbonate blends, modified polypropylenes, polyethylenes and nylons. Repairs can be made to these types of plastics using two-part (2K) repair adhesives, plastic welding, and other materials available from body shop suppliers. When a new type of plastic is being introduc
8、ed to the market through a new vehicle program, specific repair and refinishing procedures should be provided, following the format in this document. Sheet-molded compounds (SMC), fiber-reinforced plastics (FRP) and carbon fiber reinforced plastics can also be repaired using slightly different proce
9、dures and repair materials. 1.1 Purpose The average composition of plastics and composites in U.S. vehicles has increased from approximately 230 pounds in 1995 to 350 pounds in 2008, with several types being used for structural and mechanical applications. Interior and exterior plastic body parts ha
10、ve become an integral part of the automotive design, reducing overall weight to aid in increasing fuel efficiency. The use of plastic compounds for these parts has expanded to include many variations of plastics and blends of plastics over the years. This document is intended to guide vehicle manufa
11、cturers, material suppliers, and equipment suppliers in providing timely repair information to repairers and insurers. Providing this information prior to vehicle introduction is necessary to allow damaged vehicles to be restored to their pre-accident condition.SAE J1573 Revised DEC2011 Page 2 of 9
12、2. REFERENCES 2.1 Applicable Documents The following publications form a part of this specification to the extent specified herein. Unless otherwise indicated, the latest issue of SAE publications shall apply. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendal
13、e, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org.SAE J1344 Marking of Plastic Parts SAE J2376 New-Vehicle Collision Repair Information 3. REPAIRABILITY Determine the severity of damage to each part (Can the part be repaired?). Next determine the
14、cost of the part (Is it worth repairing?). Plastic body parts are either repaired or replaced with new OEM, Aftermarket, or Recycled Parts (Turn in old for a repaired part). 4. PUBLICATION REQUIREMENTS Requirements should conform to SAE J2376. 5. TECHNICAL CONTENTS 5.1 Regardless of the repair metho
15、d used, refer to the product suppliers instructions for proper application of the product being used. 5.2 Safety Precautions Include special warnings and procedures, related to vehicle repair, to avoid personal injury and property damage. It is not necessary to include standard industrial safety pra
16、ctices. 5.2.1 Personal Protection Include recommended safety equipment and precautions. 5.2.2 Hazardous Materials Include information on use of Material Safety Data Sheets, handling and disposal. 5.3 Tools and Materials Include information on recommended tools and materials. 5.4 Plastic Identificati
17、on Include methods of and special procedures for material identification. Examples include consulting manufacturers literature; locating ISO codes for plastic type on the back of the part (requires part removal); conducting a “floater test”, orconducting a visual inspection. Consult SAE J1344 for ad
18、ditional information. SAE J1573 Revised DEC2011 Page 3 of 9 5.5 Inspection for Damage Include information on conducting visual inspections, identifying the type of damage, and determining the appropriate repair procedure (i.e., one-sided versus two-sided repair). 5.6 Pre-Conditioning of Parts Includ
19、e information on recommended temperature and humidity conditions parts should be brought to before beginning repairs.5.7 Cleaning Include information on recommended cleaning materials and techniques, including the use of adhesion promoters or surface modifiers. 5.8 Removal of Distortion Include info
20、rmation on recommended equipment and techniques to remove distortions in flexible plastic parts, including hot water, hot-air guns or infrared lamps. 5.9 Grinding/Sanding Include information on recommended grits, featheredging techniques, size and shape of V-grooves, size of the area to be ground or
21、 sanded adjacent to the damaged area, how to stop running cracks in SMC panels, sanding psi and recommended sanding equipment. 5.10 Surface Preparation Include information on recommended adhesion promoters or surface modifiers and flame treating. 5.11 Alignment and Clamping Include information on re
22、commended alignment and clamping techniques. 5.12 Structural Reinforcement Include information on types of materials, application techniques, recommended sizes, and fabrication of backing (pyramid) patches and bridging strips. 5.13 Repair Materials Include information on recommended types of materia
23、ls, mixing, application tools and techniques, and recommended curing conditions. 5.14 Sanding Include information on recommended grits, tools and techniques. 5.15 Bonding Include information on types of bonding materials, tools, removal of bonded components, surface preparation, and application tech
24、niques.SAE J1573 Revised DEC2011 Page 4 of 9 5.16 Plastic Welding Include information on recommended equipment, welding tips, welding rod material compatibility, conducting a rod adhesion test, types of weld joints, operating temperatures, pre-heating of glass-reinforced thermoplastics, sectioning o
25、f damaged parts, application techniques, cooling of the joints, and inspection of weld quality. 5.17 Refinishing Include information on degreasing/cleaning, surface preparation, application of fillers, primer-surfacers, and adhesion promoters, use of flexible additives, masking, application of basec
26、oat/clearcoat, number of coats, and curing conditions. 6. NOTES 6.1 Marginal Indicia A change bar (I) located in the left margin is for the convenience of the user in locating areas where technical revisions, not editorial changes, have been made to the previous issue of this document. An (R) symbol
27、 to the left of the document title indicates a complete revision of the document, including technical revisions. Change bars and (R) are not used in original publications, nor in documents that contain editorial changes only. PREPARED BY THE COLLISION REPAIR COMMITTEE OF THE SAE SERVICE DEVELOPMENT
28、STEERING COMMITTEE SAE J1573 Revised DEC2011 Page 5 of 9 APPENDIX A A.1 TYPICAL PLASTIC PART REPAIR PROCEDURE (NOT FOR COMPOSITE PARTS) A.1.1 Repairs opposite object detection sensors Do not perform repairs in any zone that lies in the transmitting zone of an object detection sensor of any kind. A r
29、epair in these areas can compromise the performance of these systems. A.1.2 Grinding Technique Clean the damaged area of all dirt, grease, wax, and tar, using soap and water followed by solvent wash. Grind the damaged area with a 3”, 50 grit disc, operating at 5,000 rpm and observe the sanding chara
30、cteristics. If the plastic sands smoothly and cleanly, it is thermoset plastic and can be repaired using conventional two-part (2K) plastic repair materials. If the grinding causes the plastic to smear or melt, it is a thermoplastic and an adhesion promoter will be required. Be sure and follow the m
31、anufacturers instructions of the repair material and for best results stay with one system of products throughout the repair. Note that many manufacturers of repair materials now recommend using an adhesion promoter on all plastics, with the exception of composites. A.2 REPAIR PROCEDURES A.2.1 Prepa
32、ration Cosmetic damage to plastic parts like bumper covers is very common. The puncture in Figure A1 has penetrated the cover causing several deep scratches and gouges. The following are general repair procedures that should be used for cosmetic or nonstructural damage.FIGURE A1 - PLASTIC BUMPER COV
33、ER DAMAGE A.2.2 Surface Preparation If the piece has a distortion caused by the impact, it may be necessary to apply heat using a hot-air gun, while applying pressure to the affected area. After cleaning the damaged area with soap and water, grease and wax remover or suitable plastic cleaner, the su
34、rface is made ready for the application of a two-part (2K) repair adhesive or plastic welding. Note that instructions regarding cleaning vary greatly among suppliers. Suppliers instructions should first be followed. This is accomplished by grinding the damaged areas with a grade 36 grinding disc fol
35、lowed by grade 80 to remove the grade 36 scratches. It is important to vee out the area along a tear, around a puncture or gouge to expose more surface area for plastic welding. However, if making an adhesive repair, form a tapered, or dished out area to accept the repair material, rather than a vee
36、 groove. A vee groove will result in ghosting (read through). The paint is then featheredged back using a grade 180 disc on a random orbital (R/O) sander (Figure A2). SAE J1573 Revised DEC2011 Page 6 of 9 FIGURE A2 - SANDING DAMAGED AREA WITH A R/O SANDER A.2.3 Reinforcing a Two-Sided Repair If stru
37、ctural reinforcement is required, the use of fiberglass cloth reinforcing tape or fiberglass cloth/mat, saturated with two-part (2K) repair adhesive applied to the back of the repair is recommended. Clean the backside of the plastic component using soap and water and a plastic cleaner Next, grind 51
38、 mm (2 in) beyond the back edge of the damaged area with a grade 36 or 80 disc. Apply a light coat of adhesion promoter. Apply two-part (2K) adhesive to a piece of fiberglass cloth and apply it to the backside of the repair. Apply additional coats of the two-part (2K) repair adhesive to theglass clo
39、th and surrounding surface and allow to cure (Figure A3). There are also commercially available reinforcement patches with pre-applied adhesive. FIGURE A3 - APPLICATION OF FIBERGLASS CLOTH TO BACKSIDE OF COVER A.2.4 Repair Sand any repair material that may have oozed through to the front side of the
40、 repair area, blow and/or wipe off any dust Be sure that the repair area has been properly dished out and any paint feathered back from the repair area. Apply adhesion promoter and allow it to flash off. Mix and apply the two-part (2K) repair material to the outer surface to fill all voids and resto
41、re the surface to a level slightly higher than the original contour and allow to cure. (Follow repair material manufacturers instructions.) Figure A4. FIGURE A4 - APPLICATION OF REPAIR ADHESIVE After the repair material has cured, it should be sanded with a dual-action random orbital (R/O) sander us
42、ing grade 80 and 180 discs (Figure A5) to restore the original contour. Sand with grade 320 to remove the 180 scratches and restore the original contour. Vacuum sanding is recommended to reduce the amount of airborne dust. Sanding dust should be blown and/or wiped off with a tack cloth, and the surf
43、ace cleaned with a plastic cleaner. (Figure A6) SAE J1573 Revised DEC2011 Page 7 of 9 FIGURE A5 - SANDING THE REPAIR MATERIAL FIGURE A6 - REMOVAL OF SANDING DUST Use only adhesion promoters when called for by the adhesive supplier, and one that is designed for the particular repair system. Adhesion
44、promoters should be applied prior to the application of the repair material and again after sanding (following manufacturers instructions for adhesion promoters).Plastic welding can also be used to make repairs on plastic parts. Matching the type of plastic welding rod to the plastic part being repa
45、ired is very important. For structural repairs, welding should be done from both sides. Another critical point is the welding temperature. If the temperature is too high, the material will be damaged; however, if the temperature is too low, the welding rod and the piece to repair wont be mixed. To a
46、chieve a good repair, it is also important to take into account the pressure applied on the welding rod. To restore the contour and surface apply a two-part (2K) repair material. If the plastic is a polyolefin type, an adhesion promoter is needed in order to obtain adequate adhesion between the two-
47、part (2K) repair material and the plastic substrate. A.2.5 Refinishing The refinishing procedures for flexible components may require the use of elastomeric primers or additives in the primer and topcoats. The only glazing putties recommended are those specifically designed for flexible repair. Bloc
48、k sand the primer with grade 240 followed by grade 320.Follow paint manufacturers instructions when refinishing plastics. A.3 TYPICAL RIGID PLASTIC REPAIR PROCEDURE - SHEET-MOLDING COMPOUND AND FIBER-REINFORCED PLASTICS (SMC AND FRP) A.3.1 Repairs opposite object detection sensors Do not perform rep
49、airs in any zone that lies in the transmitting zone of an object detection sensor of any kind. A repair in these areas can compromise the performance of these systems. SAE J1573 Revised DEC2011 Page 8 of 9 A.3.2 Full Rigid Panel Replacement (Panels bonded on with adhesive) Remove damaged panels according to manufacturers recommendations, and remove any remaining adhesive from the body structure with a grade 36 disc. Prime any bare expo
