Solid Materials Metals Plastics Thermo settings Commodity Ceramics

Solid Materials Metals Plastics Thermo -settings Commodity Ceramics Thermoplastics Engineering www. cse-annauniv. weebly. com Specialty 1

PLASTICS THERMOPLASTICS • Linear or slightly branched polymer – addition/condensation • Repeated softened at elevated temperature and solidified on cooling • No chemical changes occur • Molecules are held by secondary forces THERMOSETTING PLASTICS • Do not form linear chain – forms 3 –dimensional structure • Hard and infusible and cannot be softened without decomposition • Molecules are held by primary forces. www. cse-annauniv. weebly. com 2

FAMILIES OF POLYMER MATERIALS SEMI-CRYSTALLINE (Structured) THERMOPLASTICS (Can be melted) AMORPHOUS (Random) PLASTICS THERMOSETS (Cannot be melted) www. cse-annauniv. weebly. com 3

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Polymers are a large class of materials consisting of many small molecules (called monomers) that can be linked together to form long chains, thus they are known as macromolecules www. cse-annauniv. weebly. com 5

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Amorphous Vs Crystalline An amorphous solid is formed when the chains have little orientation throughout the bulk polymer. The glass transition temperature is the point at which the polymer hardens into an amorphous solid. This term is used because the amorphous solid has properties similar to glass. In the crystallization process, it has been observed that relatively short chains organize themselves into crystalline structures more readily than longer molecules. Therefore, the degree of polymerization (DP) is an important factor in determining the crystallinity of a polymer. Polymers with a high DP have difficulty organizing into layers because they tend to become tangled www. cse-annauniv. weebly. com 7

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Thermoplastics From melt to solid www. cse-annauniv. weebly. com 9

Various Thermoplastics PI Specialty Polymers PSU PTFE LCP PES HPPA PPSU Engineering Polymers PC PPO Commodities ABS PMMA PS PVC SAN AMORPHOUS PA POM PBT TPE PP-GF PP PET PE-UHMW PE-LD PE-HD CRYSTALLINE www. cse-annauniv. weebly. com 10

Why Use Thermoplastics? n n n n Increased performance n Corrosion resistance n Weight reductions (specific strength & stiffness) n Cost reduction! n Parts consolidation & net shape formation n Process elimination (painting, machining, assembly) n Economics of injection molding Properties can be altered to suit the needs Good strength/weight ratio Tough & durable Non toxic Easy processability Chemical/Moisture Resistant Fire retardant Do not rust/corrode. Resistant to microbes Attractive colours Good weatherability Practically maintenance free Reusable / Recyclable www. cse-annauniv. weebly. com 11

Low Density Polyethylene (LDPE) www. cse-annauniv. weebly. com 12

STRENGTHS LIMITATIONS • Susceptible to environmental stress cracking • Very low cost • Excellent chemical resistance • Very good process-ability • High impact strength at low temperature • Low strength, stiffness and maximum service temperature • Excellent electrical insulating properties • High gas permeability, particularly carbon dioxide • Very low water absorption • FDA compliant • Can be transparent in thin film form • Poor UV resistance • Since it is non-polar, electrical properties are almost independent of temperature and frequency • Tg is well below the room temperature • Highly flammable • High-frequency welding and joining impossible • Poor scratch and abration resistance www. cse-annauniv. weebly. com 13

Processability General information The most common process used for LDPE is extrusion (tubes, blow and cast films, cables, . . . ). LDPE can also be processed by injection molding or rotomolding. Extrusion Melt temperature : 180 -240°C Higher melt temperatures are needed for extrusion-coating (280 -310°C). A three zone screw with a L/D ratio of around 25 is recommended. Injection molding Melt temperature : 160 -260°C Post mold shrinkage lies between 1. 5 and 3. 5 %. www. cse-annauniv. weebly. com 14

Applications Key performances Packaging Pharmaceutical and squeeze bottles Caps and closures Tamper evidents • Low cost • Processability • Flexibility • Low cost • High flexibility • Processability Liners Trash bags Films for food packaging (frozen, dry goods. . . ) Laminations • Low cost • High flexibility • Processability Consumer goods • Low cost • Processability • Flexibility Housewares Flexible toys www. cse-annauniv. weebly. com 15

Applications Key performances Agriculture • Low cost Agricultural films • Good mechanical properties • Processability, excellent drawdown Pipes & Fittings • Low cost Water pipes and hoses • Excellent chemical resistance • Very low water absorption • Processability Wiring & Cables Sub-conductor insulators Cable jacketing • Low cost • Good electrical insulating properties • Processability www. cse-annauniv. weebly. com 16

Linear Low Density Polyethylene (LLDPE) www. cse-annauniv. weebly. com 17

Strengths Limitations • Higher tensile strength than LDPE • Lower gloss than LDPE • Higher impact and puncture resistance than LDPE • Narrower temperature range for heat sealing than LDPE • Lower thickness films can be blown compared to LDPE • Lower processability than LDPE • Susceptible to stress cracking • Improved sealability • Lower stiffness than polypropylene • Excellent chemical resistance • High mold shrinkage • Very good processablity • Poor UV resistance • High impact strength at low temperature • Low heat resistance • Excellent electrical insulating properties • Very low water absorption • High environmental stress crack resistance • High-frequency welding and joining impossible www. cse-annauniv. weebly. com 18

General information The most common process used for LLDPE is extrusion (tubes, blow and cast films, cables, . . . ). LLDPE can also be processed by injection molding or rotomolding. Extrusion Melt temperature : 205 -260°C A three zone screw with a L/D ratio of around 25 is recommended. Injection molding Melt temperature : 160 -260°C www. cse-annauniv. weebly. com 19

Applications Key performances Packaging Bags and pouches Films for food packaging (frozen, dry goods) • Low cost • High flexibility • Processability Agriculture Agricultural films • Low cost • Good mechanical properties • Processability, excellent Drawdown Pipes & Fittings Water pipes • Low cost • Excellent chemical resistance • Very low water absorption • Processability Wiring & Cables Cable jacketing Cable insulators • Low cost • Good electrical insulating properties • Processability www. cse-annauniv. weebly. com 20

Applications of LDPE & LLDPE Green House Cable Sheathing www. cse-annauniv. weebly. com Bottle Caps Pouch 21

High Density Polyethylene (HDPE) www. cse-annauniv. weebly. com 22

Strengths Limitations • Higher notched impact strength than other PE • Higher wear resistance than other PE • Not melt processable • Higher energy absorption capacity at high stress rates than other PE • Higher Cost than PE • Higher heat deflection temperature than other PE • Higher stress crack resistance than other PE • Very low water absorption • FDA compliant • Good thermal stability • Tg is well below room temperature • High tensile strength, stiffness, creep resistance, abrasion resistance than LDPE • Non-polar in nature • Very good chemical resistance www. cse-annauniv. weebly. com 23

General information PE-UHMW is not melt processable, because of its extremely high viscosity. It can be processed by ram extrusion and compression molding. Applications Key performances Engineering Linings of bunkers, silos and hoppers Excellent sliding properties High wear resistance High toughness Conveying applications (bottling, packing and transport equipment) Low friction with metal High wear resistance High impact strength Noise reduction Pump casings Good corrosion resistance Excellent chemical resistance Practical heat resistance Abrasion resistance www. cse-annauniv. weebly. com 24

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Polypropylene (PP) www. cse-annauniv. weebly. com 26

Strengths • Low cost Limitations • Poor resistance to UV, need to • Good chemical resistance against most be stabilized inorganic acids, alkalis, and salts • Embrittles below -20°C • Good resistance to environmental stress • Low upper service temperature, cracking when in contact with alcohols, esters, detergents, or polar hydrocarbons 90 -120 C • Attacked by highly oxidizing • Very good fatigue resistance acids, swell rapidly in chlorinated • Very low density solvents and aromatics • Excellent dielectric properties • More rigid than PE and retains mechanical properties at elevated temperatures • Heat-ageing stability is adversely affected by contact with metals • Post moulding dimensional • Mechanical and electrical properties unaffected changes due to crystallinity by submersion in water effects • Can be FDA compliant • Limited impact resistance • Good resistance to steam sterilization • Low scratch resistance • Excellent hinge characteristics • Poor paint adhesion • Can be joined by hot-gas, hot-tool, induction, or friction welding www. cse-annauniv. weebly. com 27

General information These resins are not hygroscopic and may be used as received without need for drying. At temperatures above 220ºC, EVA resins can evolve toxic fumes. Injection molding Melt temperature : 180 - 300°C Mold temperature : 20 - 60°C. Higher the mold temperature then better the surface gloss. High injection pressure and speed are recommended. Extrusion A three-zone screw with a total L/D ratio of 20 -25 is generally recommended. Melt temperature is, generally, in the overall range of 240 -270ºC. Blow molding Melt temperature should lie between 190 and 220°C. Mold temperature should lie between 20 and 40°C. www. cse-annauniv. weebly. com 28

Applications Key performances Packaging Flexible packaging (Food and confectioneries, Tobacco, Clothin. . . ) Low cost Good barrier properties Good processability Good puncture resistance Rigid packaging (crates, bottles, pots. . . ) Low cost Good processing stability High strength Good surface finish Caps and closures for beverage and cosmetic applications Low cost Good processing stability High strength Good surface finish Fibers / Textiles / Carpets Nonwovens Film tapes Strapping. . . High flexibility Good resistance to rupture Good chemical resistance www. cse-annauniv. weebly. com 29

Applications Key performances Health Care • Sterilization resistance Syringes • Good chemical resistance • Transluscent Household products / Consumer goods • Good cost to impact balance Transluscent parts • Excellent processability • Transluscent Housewares Furniture Appliances Luggage Toys • Good cost to impact balance • Excellent processability • Long-term use www. cse-annauniv. weebly. com 30

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Polyvinyl Chloride (PVC) www. cse-annauniv. weebly. com 32

Strengths Limitations Rigid PVC • Low cost • Difficult to melt process • High stiffness • Becomes brittle at 5°C (when not • Intrinsic flame retardant modified with impact modifiers and/or • Suitable for transparent applications processing aids) • Better chemical resistance than plasticized • Limited solvent stress cracking PVC resistance • Good electrical insulation properties • Low continous service temperature of • Good vapour barrier properties 50°C • FDA compliant • Good dimensional stability at room temperature www. cse-annauniv. weebly. com 33

General information Thermal stabilization is required for processing rigid PVC, otherwise material may decompose during processing. PVC is sensitive to thermal history and the window of processing temperatures is quite small. Drying before processing is highly recommended, moisture rate should be lower than 0. 3%. Injection molding Melt temperature should lie between 170 and 210°C. Mold temperatures of 20 to 60°C are more suitable. Mold shrinkage lie between 0. 2 and 0. 5%. Screw with an L/D ratio of 15 to 18 is recommended. Extrusion temperatures are 10 -20°C below injection molding temperatures in order to avoid premature thermal degradation. www. cse-annauniv. weebly. com 34

Applications Key performances Electrical Insulation pipes Jacketing Electricity distribution boxes Switches Transparent distributor box housings Plug housings Battery terminals • Low cost • Good electrical properties • Stiffness • Inherent flame retardant Engineering Pressure pipes Ventilation ducts Thermostat housings Fittings Pipe connections Claddings Ventilators • Low cost • Versatile performance profile • Stiffness • Good chemical resistance www. cse-annauniv. weebly. com 35

Applications Key performances Building and Construction Waste water pipes and fittings Grating covers Fencing Decking Siding Drain pipes Roofing sheets Sanitary installations Window profiles Fascia boards • Low cost • Processability • Stiffness • Flame retardant Consumer goods • Low cost Toys Vases Cases • Stiffness • Processability www. cse-annauniv. weebly. com 36

Applications Key performances Packaging Disposable pots Spice and cream containers Ball point pen cases Blisters Capsules Trifolds Bottles for vegetable oil, juices, wine or non-food packaging (cosmetics. . . ) • Low cost • Practical stiffness • Transparency • Processability • Good chemical resistance Pipes & Fittings • Low cost • Practical stiffness and impact strength Pipes Fitttings • Good chemical resistance www. cse-annauniv. weebly. com 37

Strengths Limitations Flexible PVC • Properties can change with time, due to • Low cost plasticizer migration • Good resistance to UV • Tends to degrade at high temperatures • Flexible • Attacked by ketones; some grades • High impact strength • Good resistance to acids, alkalis, oils and many corrosive inorganic chemicals Good electrical insulation properties • Non-flammable • Easier to process than rigid PVC • Versatile performance profile swollen or attacked by chlorinated and aromatic hydrocarbons, esters, some aromatic ethers and amines, and nitrocompounds • Non suitable for food contact with some plasticizers • Lower chemical resistance than rigid PVC www. cse-annauniv. weebly. com 38

General information Drying before processing is highly recommended, moisture rate should be lower than 0. 3%. Injection molding Melt temperature should lie between 170 and 210°C. Mold temperatures of 20 to 60°C are more suitable. Mold shrinkage lie between 1 and 2. 5%. Extrusion temperatures are 10 -20°C below injection molding temperatures in order to avoid premature thermal degradation. www. cse-annauniv. weebly. com 39

Applications Key performances Electrical Cable and wire insulation Plugs Cable jackets Sockets Cable heads Distributors Flexibility Good electrical properties Low cost Engineering Gaskets Stuffing boxes Pipes Hoses Coatings Protective caps for pipes. Flexibility Versatile performance profile Low cost Building and construction Seals for windows and doors Swimming bath linings Flexibility Floor and wall coverings Good weathering resistance Roofing Low cost Doorstops Flame retardant www. cse-annauniv. weebly. com Wire coverings 40

Applications Key performances Consumer Goods Toys Handbags Tablecloths Cases Flexibility Good weathering resistance Low cost Processability Sports & Leisures Balls Ski sunglasse seals Inflatable dinghies Flexibility Good weathering resistance Low cost Footwear Shoe soles Boots Flexibility Good weathering resistance Low cost Gardening Garden hoses Flexibility Good weathering resistance www. cse-annauniv. weebly. com Low cost 41

Applications Key performances Automotive Car body seals Dashboard skins Artifical leather seats Sun visors • Flexibility • Good weathering resistance • Low cost Healthcare / Medical • Flexibility Blood storage bags Drainage tubes • Hemocompatible • Low cost www. cse-annauniv. weebly. com 42

Types of Profiles : Hollow Profiles Foam Profiles Doors : Aluminium Frame + Hollow Profile PVC Frame + Foam Sheet Door Frame Windows Sliding Casement Single Glazing Double Glazing Partitions False Ceiling Miscellaneous (Viz. . . Kitchen Cabinets etc. ) www. cse-annauniv. weebly. com 43

Versatility of PVC From Footwear…. . www. cse-annauniv. weebly. com 44

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Polystyrene (PS) www. cse-annauniv. weebly. com 46

Strengths Limitations • Brittle at room temperature • Low cost • Transparent • Poor mechanical properties above 70°C • High stiffness • Good dimensional stability • Good processability • Good electrical properties, low • Poor chemical resistance, especially to organic solvents • Susceptible to UV degradation dielectric loss • Excellent resistance to gamma • Highly flammable radiation • Limited resistance to organic solvents, when compared to polyolefins. • FDA compliant • Low moisture absorption • Low mould shrinkage • Very low thermal conductivity • Possesses tendency to stress cracking Low creep strength under repeated stress www. cse-annauniv. weebly. com 47

High Impact Polystyrene Strengths Limitations Tougher than PS crystal Reduced transparency compared to PS crsytal Low cost Reduced electrical properties compared to PS crystal Good dimensional stability Poor chemical resistance, especially to organic solvents Good processability Good electrical properties, low dielectric loss Susceptible to UV degradation Excellent resistance to gamma radiation Highly flammable and toxic smoke FDA compliant www. cse-annauniv. weebly. com 48

General information Crystal polystyrene can be processed by every conventional technique used for thermoplastics. Drying is normally not necessary. But if necessary (high transparency and high gloss required), the product can be dried for 2 hours at about 80°C. Injection Molding A melt temperature of 180 -280°C is recommended. Generally, mold temperature should lie between 30 and 50°C. For thin wall objects moulded at short cycle times it could be useful to cool down the mould down to 10°C. Mold shrinkage lies between 0. 4 and 0. 7% depending on the grade used. Extrusion Grades with a high viscosity are suitable for extrusion. A melt temperature of 180 -220°C is generally used. www. cse-annauniv. weebly. com 49

Applications Key performances Packaging Food packaging (dairy packaging, meat trays, egg cartons, fruit and vegetable trays) Consumer packaging (cassettes and CD shell and covers, jewel box. . . ) Industrial packaging (small foamed shapes . . . ) Low cost Ease of process and decoration Food contact approvals Possibility to be produced by lots Recyclability of the material High stiffness Low cost Ease of decoration Ease of process Possibility to be produced by lots Recyclability Ease of process Low cost Recyclability Possibility to be produced by lots www. cse-annauniv. weebly. com 50

Applications Key performances Consumer Goods Low cost Processability Available in a wide range of colors Low density Toys Cutlery Disposables (cups, forks, knives, spoons, plates…) Shower stalls Door lights Envelope frames. . . Low cost Recyclable Processability FDA compliant Low cost Ease of process Possibility of printing and design Safety when broken (contrary to glass for shower stalls for instance) Optics Light diffusers Transparency Low cost Processability www. cse-annauniv. weebly. com Stiffness 51

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POLYMETHYLMETHAACRYLATE (PMMA) www. cse-annauniv. weebly. com 53

Strengths Limitations • Outstanding transparency • Poor impact resistance • Excellent UV resistance • Limited heat resistance (80°C) • High color brightness and stability • Limited chemical resistance, attacked by organic solvents • Surface hardness • Poor wear and abrasion resistance • Half the weight of glass • Cracking under load possible • Good dimensional stability • Good insulating properties www. cse-annauniv. weebly. com 54

General information Pre-drying is not necessary if a vented cylinder is used but if a normal cylinder is used then PMMA must be processed dry and it is advisable to pre-dry the granules for up to 8 hours at 70 -100°C. Surface defects and blisters will form if damp granules are processed. Injection Molding Melt temperature : 200 -250°C Mold temperature : 40 -80°C High injection pressures are needed because of poor flow properties and it may be necessary to inject slowly to get the correct flow. Extrusion temperature : 180 -250°C A degassing screw with an L/D ratio of 20 -30 is recommended. www. cse-annauniv. weebly. com 55

Applications Key performances Building & Construction Windows Port-holes Domes High transparency UV resistance Surface hardness Optics Sunglasses Diffuser panels Watch glasses Optical properties Transparency UV resistance Surface hardness Good optical performance Resistance to weathering Hardness Chemical resistance High clarity Lower weight than glass High surface quality www. cse-annauniv. weebly. com 56

Applications Key performances Automotive Rear lights Indicators Optical properties Colorability Weathering resistance Dashboard covers High transparency and clarity Scratch resistance Chemical resistance Electrical Lamp covers Transparency and excellent optical properties Processability Chemical resistance Packaging Blister packaging Transparency Hardness Thermoformability www. cse-annauniv. weebly. com 57

Applications Key performances Automotive Pens Transparency Gloss Goods processability Plates Salad bowls Resistance to greases FDA compliant Good surface finish Healthcare / Medical Toothbrushes Good processability Transparency Chemical resistance Blood sample tubes Diagnostic dishes Optical clarity Biocompatible Resistance to sterilization Industrial Point-of-purchase displays High versatility Good compatibility with other materials Good surface finish www. cse-annauniv. weebly. com 58

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ETHYLENE VINYL ACETATE (EVA) www. cse-annauniv. weebly. com 60

Strengths • Highly flexible , even at low temperatures (-25°C) • Highly compatible with a lot of elastomers, TP and other materials (SBr, EPDM, TPE, PVC, asphaltum. . . ) • Better tear resistance than LDPE • Excellent resistance to environmental stress cracking Limitations Poor heat resistance • Reduced barrier properties compared to LDPE • Attacked by polar solvents, hydrocarbons, oxydants and strong acids • Reduced creep resistance, compared to LDPE • FDA compliant • Good UV and ozone resistance www. cse-annauniv. weebly. com 61

General information These resins are not hygroscopic and may be used as received without need for drying. At temperatures above 220ºC, EVA resins can evolve toxic fumes. Injection molding Experience has shown screws normally used for injection molding of low density polyethylene to be satisfactory. Melt temperature : 150 -200°C Mold temperature : 15 -40ºC Extrusion A three-zone screw with a total L/D ratio of at least 20 is recommended. Melt temperature is, generally, in the overall range of 95 -205ºC. The melt temperature depends upon the melt index of the resin, the % vinyl acetate and the part configuration. www. cse-annauniv. weebly. com 62

Applications Key performances Packaging • High flexiblity Stretch film for shrink wrapping • Good tear resistance • FDA compliant • Good sealability Sealable layer in multilayer food packaging • Flexibility • FDA compliant Personal safety/ Protection equipment • High flexibility Flexible gloves • Good resistance to rupture www. cse-annauniv. weebly. com • Good chemical resistance 63

Applications Key performances Automotive Sound proofing • Good sound absorption • Good adhesion with many substrates Footwear Soles (EVA foam) • Good impact absorption • Good adhesion with many substrates Wiring & Cables Wire coating • Good adhesion with many substrates • Highly flexible www. cse-annauniv. weebly. com 64

Seals, Toys, Helmet Parts Corrugated Tubes Shoe Components www. cse-annauniv. weebly. com 65

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