A
weld line (also called a weld mark or a knit line) is formed when
separate melt fronts travelling in opposite directions meet. A meld
line occurs if two emerging melt fronts flow parallel to each other
and create a bond between them. Weld and meld lines can be caused
by holes or inserts in the part, multiple gates, or variable wall
thickness where Hesitation or race tracking occurs. If weld or meld
lines can't be avoided, position them at low-stress and low-visibility
areas by adjusting the gate position and dimension. Improve the
strength of weld and meld lines by increasing the local temperature
and pressure at their locations.
How
to tell the difference between weld and meld lines
Traditionally, the "meeting angle" is used to differentiate
weld lines and meld lines. A meeting angle smaller than 135º
produces a weld line; greater than 135º, a meld line. Note
that the weld line surface mark disappears when the meeting angle
reaches 120º to 150º. Normally, weld lines are considered
to be of lower quality than meld lines, since relatively less molecular
diffusion occurs across a weld line after it is formed.
Problems
caused by weld lines
Weld lines are generally undesirable when part strength and surface
appearance are major concerns. This is especially true with fiber-reinforced
materials, because the fibers do not bridge the weld lines and often
are oriented parallel to them.
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