Heat staking brass insert into XEnoy plastic

[fishforall]

I am looking for visual proof that when an insert is heat staked into plastic that there is disruption to the plastic. I have heard that this heat staking can cause a "ripple in a pool" affect around the area that the staking is taking place. My current process is showing failures between two staked inserts. The inserts are in a parrell line between each other approx. 1 inch apart. After the heat sink there is a failure crack showing between the inserts after time and use. The therory is that the heat staking is casuing a stress and this stress is the crack. I would like to see pictures of this ripple effect or video proof that this occurs. Can anyone help me out??

 

[MikeHalloran]

I've always considered heat staking of inserts as a short- run process, because process control for a giant hand- held soldering iron, the usual tool, is not real great.

Try giving the iron to a gorilla with smaller biceps.



Mike Halloran
Pembroke Pines, FL, USA

 

[unclesyd]

If the plastic has pretty good transparency you can use a very bright light and two Polaroid filters to possibly see the strain lines.

If you think this process is feasible you can get this done a local sign shop that makes Neon signs or a university glass shop.