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Material Selection Guide
Material Selection Guide
Sales Offices:
California:
Michigan:
Engineering Polymers
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Material Selection
Illinois:
THERMOPLASTICS
AND
POLYURETHANES
(Polyurethanes)
Tennessee:
(Plastics)
Canadian Affiliate:
Ontario:
A Design Guide
Bayer Inc.
77 Belfield Road, Etobicoke, Ontario M9W 1G6
416 248-0771 Fax: 416 248-4496
Quebec:
Bayer Inc.
7600 Trans Canada Highway, Pointe Claire, Quebec H9R 1C8
514 697-5550 Fax: 514 697-5334
KU-F3024
INTRODUCTION
TABLE OF CONTENTS
Chapter 1
UNDERSTANDING ENGINEERING PLASTICS
Chapter 3
MECHANICAL PROPERTIES
23
23
25
Tensile Modulus
25
Blends
26
Elongation at Yield
10
26
10
Elastomers
26
Elongation at Break
10
Molecular Weight
26
Ultimate Strength
10
26
Ultimate Elongation
11
Shrinkage
27
Poissons Ratio
12
Additives
27
Flexural Properties
12
Combustion Modifiers
27
Flexural Modulus
12
Release Agents
27
12
Blowing Agents
28
Cut-Growth Resistance
12
Catalysts
28
28
29
Compressive Properties
Compressive Strength
Compressive Set
Chapter 2
MECHANICAL BEHAVIOR OF PLASTICS
29
Shear Strength
29
Tear Strength
13
Viscoelasticity
29
Impact Properties
14
Creep
32
Hardness Properties
15
Stress Relaxation
34
15
Recovery
34
Coefficient of Friction
16
Loading Rate
34
16
35
17
Processing
36
17
Thermoplastic Regrind
37
Stress Relaxation
17
Polyurethane Recycling
38
Fatigue Properties
18
Weld Lines
19
Residual Stress
20
Orientation
21
Water Absorption
22
Chemical Exposure
22
Weathering
Creep Properties
Chapter 4
THERMAL PROPERTIES
Chapter 6
ENVIRONMENTAL PROPERTIES
40
51
Water Absorption
41
51
Hydrolytic Degradation
41
Thermal Conductivity
52
42
Specific Heat
53
Chemical Resistance
42
54
Weatherability
42
55
Gas Permeability
43
Torsional Pendulum
44
44
45
Chapter 7
OTHER PROPERTIES
56
Density
56
Specific Gravity
Chapter 5
ELECTRICAL PROPERTIES
56
Specific Volume
57
46
Volume Resistivity
57
Refractive Index
46
Surface Resistivity
57
Oxygen Index
47
Dielectric Strength
57
Flammability Class
48
Dielectric Constant
59
Flash Point
48
Dissipation Factor
48
Arc Resistance
49
50
50
50
Chapter 8
PROPERTIES USED IN PROCESSING
Chapter 9
MATERIAL SELECTION: THINGS TO CONSIDER
60
69
Cost Considerations
60
70
Environmental Considerations
60
Viscosity
70
Load
60
Solution Viscosity
70
Temperature
61
70
Chemical Resistance
62
71
Weather Resistance
71
Material Properties
72
Processing
62
62
Thermoplastics
62
Melt Strength
73
Appearance
63
Spiral Flow
73
Agency Approvals
74
Actual Requirements
64
Polyurethanes
64
Hydroxyl Number
74
Prototype Testing
65
74
Resin Suppliers
65
Acidity
74
Systems Approach
67
Free-Rise Density
67
Cream Time
67
Gel Time
67
Tack-Free Time
67
Chapter 10
TECHNICAL SUPPORT
75
75
76
Technical Support
76
76
76
76
Regulatory Compliance
77
Regrind Usage
77
APPENDICES
78
80
Index
83
BACK POCKET
Chapter 1
Figure 1-1
H
R
C=C
H
H n
PLASTICS: ORIGINS
AND DEFINITIONS
To understand plastic materials, you
should have some insight into
polymers, the building blocks of plastics. Polymers, derived from the Greek
term for many parts, are large molecules comprised of many repeat units
that have been chemically bonded into
long chains. Silk, cotton, and wool are
examples of natural polymers. In the
last 40 years, the chemical industry has
developed a plethora of synthetic polymers to satisfy the materials needs for a
diversity of products: paints, coatings,
fibers, films, elastomers, and structural
plastics are examples. Literally thousands of materials can be grouped as
plastics, although the term today is
typically reserved for polymeric materials, excluding fibers, that can be molded
or formed into solid or semi-solid objects.
H H
R C C
H
H
H H
H
C=C
H
H
C=C
H H H H
+
C C C C R
H H H H
Figure 1-2
H2O O
C
CH3
C
H O
CH3
Bisphenol A
H O
H2O
O
CH3
Carbonic Acid
O
CH3
H + O
H
OH + H
CH3
C
O
CH3
CH3
O C O
CH3
THERMOPLASTICS AND
THERMOSETS
How a polymer network responds to
heat determines whether a plastic falls
into one of two broad categories: thermoplastics or thermosets. Thermoplastics soften and melt when heated and
harden when cooled. Because of this
behavior, these resins can be injection
molded, extruded or formed via other
molding techniques. This behavior also
allows production scrap runners and
trimmings, for instance to be
reground and reused. Because some
degradation or loss of mechanical properties can occur during subsequent
remelting, you should limit the amount
of recycled resin in the production resin
OH
Condensation
polymerization of
polycarbonate (PC)
via condensation of
water. Although
not a common
commercial
process, the
reverse of this
reaction is the
mechanism by
which PC can
degrade in the
presence of water
and high heat.
mix. This is particularly true if processing conditions are harsh. See specific
Bayer Product Information Bulletins for
the recommended maximum regrind for
a given resin.
Unlike thermoplastics, thermosets form
cross links, interconnections between
neighboring polymer molecules that
limit chain movement. This network of
polymer chains tends to degrade, rather
than soften, when exposed to excessive
heat. Until recently, thermosets could
not be remelted and reused after initial
curing. Todays most-recent advances
in recycling have provided new methods
for remelting and reusing thermoset
materials.
Chapter 1
ming than thermoplastics, they usually have less mold shrinkage and exhibit
superior chemical and heat resistance.
Figure 1-3
BAYDUR STR
Solid
Composites (SRIM)
BAYDUR STRF
Foamed
Composites
PRISM
Rigid
Solids
BAYDUR
Rigid
Foams
R
R
I
M
BAYFLEX
Elastomeric
Solids
00300
BAYFLEX
Elastomeric
Foams
0600
0900
1200
1500
Figure 1-4
Crystalline Structures
Amorphous Regions
In crystalline resins, a percentage of the polymer chains orient into
ordered, crystalline structures.
CRYSTALLINE AND
AMORPHOUS POLYMERS
Thermoplastics are further classified by
their crystallinity, or the degree of
order within the polymers overall
structure. As a crystalline resin cools
from the melt, polymer chains fold or
align into highly ordered crystalline
structures (see figure 1-4). Generally,
polymer chains with bulky side groups
cannot form crystalline configurations.
Chapter 1
Tc
Crystalline Resin
Figure 1-5
BLENDS
Blending two or more polymers offers
yet another method of tailoring resins
to your specific application. Because
blends are only physical mixtures, the
resulting polymer usually has physical
and mechanical properties that lie somewhere between the values of its constituent materials. For instance, an automotive bumper made from a blend of
polycarbonate resin and a thermoplastic
polyurethane elastomer gains rigidity
ELASTOMERS
Elastomers are a class of polymeric
materials that can be repeatedly
stretched to over twice the original
length with little or no permanent deformation. Elastomers can be made of
either thermoplastic or polyurethane
materials and generally are tested and
categorized differently than rigid materials. Commonly selected according to
their hardness and energy absorption
characteristics rarely considered in rigid
thermoplastics elastomers are found
in numerous applications, such as automotive bumpers and industrial hoses.
MOLECULAR WEIGHT
COPOLYMERS AND
TERPOLYMERS
Unlike blends, or physical mixtures of
different polymers, copolymers contain
repeat units from two polymers within
their molecular chain structure, such as
acetyl resin, styrene acrylonitrile
(SAN), and styrene butadiene. In terpolymers, polymers with three different
repeat units, individual components can
also be tailored to offer a wide range of
properties. An example is ABS, a terpolymer containing repeat units of acrylonitrile, butadiene, and styrene.
10
FILLERS AND
REINFORCEMENTS
Often, fibrous materials, such as glass or
carbon fibers, are added to resins to create reinforced grades with enhanced
properties. For example, adding 30%
short glass fibers by weight to nylon 6
improves creep resistance and increases
stiffness by 300%. These glass-reinforced plastics usually suffer some loss
of impact strength and ultimate elongation, and are more prone to warping
because of the relatively large difference
in mold shrinkage between the flow and
cross-flow directions.
Chapter 1
SHRINKAGE
As a molded part cools and solidifies, it
usually becomes smaller than its mold
cavity. Shrinkage characteristics affect
molding costs and determine a parts
dimensional tolerance limit. Materials
11
ADDITIVES
Combustion Modifiers
Release Agents
Blowing Agents
12
Catalysts
Chapter 2
VISCOELASTICITY
Plastics have a dual nature, displaying
characteristics of both a viscous liquid
and a spring-like elastomer, or traits
known as viscoelasticity. This duality
accounts for many of the peculiar
mechanical properties found in plastics.
Under mild loading conditions such
as short-term loading with low deflections and small loads at room temperatures plastics usually respond like a
spring, returning to their original shape
after the load is removed. No energy is
lost or dissipated during this purely
elastic behavior: Stress versus strain
remains a linear function (see figure
2-1). Increasing the applied load adds a
proportional increase to the parts
deflection.
Many plastics exhibit a viscous behavior under long-term heavy loads or elevated temperatures. While still solid,
Stress-Strain Behavior
STRESS ( ) INCREASING
Loading and
Unloading
Follow
the Same Path
STRAIN ( ) INCREASING
Figure 2-1
Elastic
Spring
Linear relationship
of stress and strain
idealized by elastic
spring.
13
Figure 2-2
= Stress Level
3
STRAIN ( )
CREEP
Viscous behavior
of plastics with
varying stress
levels over time.
Figure 2-3
Spring A
Maxwell
Dashpot A
Voight
Spring B
Dashpot B
Voight-Maxwell
model simulating
viscoelastic
characteristics.
14
Chapter 2
Figure 2-4
Creep Phenomenon
Total Deformation
at Time (t1)
L+d+C
L+d
Time (t1)
(d) Initial
Deformation
Time (t0)
Creep (C)
Consta
Force
nt
RECOVERY
Stress Relaxation
Figure 2-5
L+d
L+d
STRESS RELAXATION
Constant
Strain
ced
Redu
Force
Time (t1)
Time (t0)
15
Figure 2-6
Load
Removed
A
C
STRAIN ( )
Permanent
Deformation
LOADING RATE
TIME (t)
STRAIN ( )
Brittle
Figure 2-7
H
Lo ighe
we r T
r S em
tra per
in atu
Ra re
te
Ductile
STRESS ( )
Effects of strain rate and temperature on material behavior.
FACTORS AFFECTING
MECHANICAL PROPERTIES
Most of this manual defines and
explains material property data found in
material-specific data sheets. These
16
Chapter 2
Processing
Thermoplastic Regrind
adversely affect the mechanical and cosmetic properties. For these reasons, you
should limit the ratio of regrind to virgin
material and completely avoid using it in
critical applications or when resin properties must be equivalent to virgin-material
properties. Closely monitor part quality
when using regrind in the mix to assure
adequate material and end-use properties.
Polyurethane Recycling
17
Figure 2-8
Weld Line
Melt Front
Melt Front
Weld Line
Weld Line
Weld Lines
18
Chapter 2
Flow Stresses
Figure 2-9
Elevated
Stresses in
Last Areas to Fill
Elevated Flow
Stresses
Near Gates
Runner System
Filling-analysis
results showing
areas of high-flow
stress.
Residual Stress
19
Figure 2-10
Fiber Orientation
Polymer chains and fibrous fillers in the outer layers of molded parts tend to align in the direction of flow
during molding.
Orientation
20
The glass fibers in outer layers of glassreinforced plastics tend to align in the
direction of flow, resulting in higher
tensile strength and stiffness in this
direction. They also exhibit greater
resistance to shear forces acting across
the fibers. Generally, fiber-filled materials have much higher shrinkage in the
cross-flow than in the flow direction.
Cross-flow shrinkage can be as much as
two to three times greater. Address
Chapter 2
Water Absorption
Figure 2-11
Durethan B 40 SK
as molded
0.6%
water content 1.3%
water content 2.0%
water content 2.9%
water content 3.5%
water content 8.3%
200
160
120
80
40
-50
-20
-0+
20
50
90
TEMPERATURE (C)
Flexural stress vs. temperature at a given strain based upon the flexural test (DIN 53452) for
unfilled PA 6 with varying water contents.
21
Chemical Exposure
Weathering
22
Chapter 3
MECHANICAL PROPERTIES
Tensile Tester
Load
Measurement
Test
Specimen
Fixed
Head
Overall Length
Figure 3-1
Testing
Region
Gripping
Jaws
Movable
Head
Testing device and
typical dogbone
specimen used to
test the tensile
properties of most
plastics.
Head Moves at
Constant Rate
SHORT-TERM
MECHANICAL PROPERTIES
Short-term mechanical data, based
upon testing done over a short period of
time, does not account for long-term
phenomena, such as creep or stress
relaxation. This information should be
used only when loading or other stress
is applied for such a short period of
time that the long-term effects are
insignificant. All mechanical properties
are tested at room temperature (73F or
23C) unless otherwise stated.
Tensile Properties
23
Figure 3-2
100
Cast Polyester
Non-Reinforced
(rigid, brittle)
80
PC (ductile)
TENSILE STRESS () (MPa)
60
PU Elastomer
(rubber-like)
(95 Shore A)
ABS
(ductile)
40
20
0
0
10
//
20 20
200
400
600
800
1,000
ELONGATION () (%)
These curves illustrate the characteristic differences in the stress-strain behavior of
various plastics.
24
Dividing the breaking load by the original minimum cross-sectional area gives
tensile strength. For rigid structural
polyurethane foams, use ASTM D 638
(ISO 527).
Chapter 3
Specimen
Before
Testing
strain curves. When dealing with materials with no clear linear region, you can
calculate the modulus at some specified
strain value, typically at 0.1% (secant
modulus). For some applications, buckling analysis for example, it may be
more appropriate to derive a tensile
modulus from the slope of a straight
line drawn tangent to the curve at a
point on the stress-strain diagram
(tangent modulus).
Figure 3-3
Specimen
After
Testing
Tensile Modulus
Figure 3-4
Ultimate Strength
C
Yield Point
B
D
Elastic Limit
Proportional Limit
Break
Point
STRESS
STRAIN
Typical stress-strain behavior of unreinforced plastics.
25
Elongation at Yield
Figure 3-5
Test Span
h
Neutral
Axis
Outer
Fiber
Stress
Tensile
Ultimate Strength
Ultimate Elongation
Elongation at Break
Most useful for one-time-use applications that fail by fracture rather than by
deformation, elongation at break measures the strain at fracture as a percentage of elongation. Brittle materials
break at low strain levels; ductile and
elastic materials attain high strain levels
before breaking.
26
Chapter 3
Poissons Ratio
Flexural Modulus
Flexural Properties
Test values for tensile modulus typically correlate well with those of the flexural modulus in solid plastics, but differ
greatly for foamed plastics that form
solid skins. Foamed materials gain stiffness because of their sandwich structure
of a foamed core between plastic skins.
Figure 3-6
Pierced
Section
90
27
Cut-Growth Resistance
Used in the shoe-sole industry, cutgrowth resistance, a cold flex test, determines hole-propagation characteristics in
polyurethane materials. In the standard
test (ASTM D 1052), a 1/4-inch
(6.4 mm)- or 1/2-inch (12.7 mm)-thick
specimen with a small hole in its center
is placed in a Ross Flexing Machine (see
figure 3-6). The specimen is flexed until
the hole develops cracks that split the
sample. To test at temperatures other
than room temperature, the specimen is
Compression Tester
Figure 3-7
Hardened
Block
Test
Specimen
28
conditioned for a minimum of 30 minutes after reaching the specified temperature and before starting the test.
Compressive Properties
Compressive Strength
Chapter 3
Compressive Set
Shear Strength
Impact Properties
Tear Strength
29
Figure 3-8
Beam
Cantilevered
Impact
Impact
Point
Izod
Test Bar
Beam Simply
Supported
Clamp
Impact
Charpy
30
lost on impact. This loss of energy, calculated from the difference in beginning
and ending heights, determines the Izod
impact strength, measured in ft-lb/in, or
J/m. Samples may be notched on the
narrow face, with the notch facing the
impact side as specified in the test.
Results should note whether the sample
was notched and list sample thickness
and test temperature.
Chapter 3
Critical Thickness
Figure 3-9
20
18
16
14
140F (60C)
12
73F (23C)
10
8
-4F (-20C)
6
4
2
0
.100
.140
.180
.220
.260
.300
.340
Izod impact
strength of
Makrolon
polycarbonate vs.
thickness at various
temperatures.
THICKNESS (in)
Figure 3-10
16 to 18
ft-lb/in
R = 0.005 in
2 to 4
ft-lb/in
31
Figure 3-11
Pendulum
Arm
Test
Specimen
Impact
Stop
Anvil
32
Hardness Properties
Chapter 3
Figure 3-13
80
60
500
110
40
100
20
80
100
50
60
40
20
0
ROCKWELL B
80
0
ROCKWELL C
140
120
100
80
90
120
60
70
Figure 3-12
40
10
60
BARCOL
0
75
5
25
50
Pivot
80
20
ROCKWELL M
100
60
90
40
60
20
30
SHORE D
SHORE A
0
20
60
100
140
160
BS
BS
HARDNESS
SOFTNESS
100
90
70
50
30
100
80
60
40
20
ROCKWELL R
1
BRINELL
HARDNESS NUMBER
Weight
Steel Ball
Specimen
Elevating
Screw
33
Miscellaneous Mechanical
Properties
Coefficient of Friction
Material
On Self
On Steel
PTFE
0.10-0.25
0.10-0.25
PE rigid
0.40-0.50
0.20-0.25
PP
0.35-0.45
0.25-0.35
POM
0.25-0.50
0.15-0.35
PA
0.30-0.50
0.30-0.40
PBT
0.30-0.40
0.30-0.40
PS
0.45-0.60
0.40-0.50
SAN
0.45-0.65
0.40-0.55
PC
0.40-0.65
0.35-0.55
PMMA
0.60-0.70
0.50-0.60
ABS
0.60-0.75
0.50-0.65
PE flexible
0.65-0.75
0.55-0.60
PVC
0.55-0.60
0.55-0.60
Figure 3-14
Normal Force (FN)
Applied
Force (P)
= FR
FN
34
Published data on coefficients of friction should be used for estimating purposes only. In addition to being very
sensitive to speed, coefficient values
depend greatly upon the surface finish
and the presence of lubricants and
surface contaminants. Because of these
factors, generating a precise friction
coefficient for design calculations can
be difficult.
Chapter 3
LONG-TERM
MECHANICAL PROPERTIES
Time and ambient temperature affect
the long-term mechanical properties of
plastics, because they affect polymerchain mobility. Plastic parts under constant load tend to deform over time to
redistribute and lower internal stresses.
The mobility of polymer chains determines the rate of this stress redistribution. Higher temperatures increase the
free space between molecules, as well
as the molecular-vibration energies,
resulting in a corresponding increase in
polymer-chain mobility. Even at moderate temperatures, polymer chains can
reorient in response to applied loads, if
given enough time. Two long-term
properties creep, the added deformation in a part that occurs over time
under constant stress, and stress relaxation, the reduction in stress in parts
subjected to constant strain increase
significantly with time and temperature.
Figure 3-15
Creep
Recovery
i
0 ps
6,00
3
2
5,000
psi
4,000
psi
si
3,000 p
100
si
2,000 p
7
5
Load
Removed
3
2
STRAIN () (%)
10-1
7
5
3
10-1
100
101
102
103
TIME (hours)
Creep and recovery of Makrolon polycarbonate at 73F (23C).
35
Creep Properties
MPa
23C (73F)
50% RH
50
7,000
5,200
5,000
4,000
3,750
40
hours
10 -1
10 0
10 1
10 2
10 3
10 4
6x10 4
6,000
TENSILE STRESS ( )
psi
30
Crazing
3,000
2,800
20
2,000
10
1,000
0.5
2.0
2.5
STRAIN ( ) (%)
Isochronous stress-strain curves at 73F (23C) for Makrolon polycarbonate.
Figure 3-17
3.5
73F
3.0
2.5
750 psi
Figure 3-16
1,400 psi
2,800 psi
2.0
4,200 psi
1.5
1.0
10 - 2
10 - 1
10 0
10 1
10 2
10 3
TIME (hours)
Apparent modulus for unfilled Makrolon polycarbonate at various stress levels.
36
10 4
Chapter 3
Figure 3-18
176F (80C)
10
10-1
100
101
102
103
104
4,000
3,000
TENSILE STRESS ()
MPa
30
-2
2,000
hours
psi
Isochronous
stress-strain
curves at 176F
(80C) for
Makrolon
polycarbonate.
20
10
1,000
Crazing
0
0.5
1.0
1.5
2.0
2.5
STRAIN () (%)
Figure 3-19
Crazing
Stress Relaxation
37
Figure 3-20
48
7 Hz
Bending
44
7 Hz
40
Tensile
7 Hz
36
32
10 3
10 4
10 5
10 6
These curves also may show when crazing could occur in transparent polycarbonate resins (see figures 3-16 and 3-18).
Crazing tiny, reflective cracks (see
figure 3-19) that appear when a part is
subjected to long-term tensile loads
precedes larger cracks and ultimately
part failure. In figure 3-16, you can see
that crazing occurs at 2.5% strain at
room temperature after 10,000 hours.
Stress-relaxation modulus, calculated
by dividing the stress after a specific
load duration by the strain corresponding to the fixed strain, accounts for
stress relaxation in standard engineering
equations.
38
Fatigue Properties
Chapter 3
Figure 3-21
50
Loading: Dynamic
45
-20
40
0
23
C
40
60
35
30
Design Limit
Stress-strain
curves for
Bayblend T85MN
PC/ABS showing
limits at various
temperatures for
dynamic loading.
90
25
20
15
10
5
0
0
.25
.5
.75
1.25
1.5
1.75
2.25
STRAIN () (%)
39
Chapter 4
THERMAL PROPERTIES
DEFLECTION TEMPERATURE
UNDER LOAD (DTUL)
DTUL values are used to compare the
elevated temperature performance of
materials under load at the stated test
conditions. Sometimes referred to as
the heat distortion temperatures or
HDT, they do not represent the upper
temperature limit for a specific material
or application. Molding factors, sample
preparation and test bar thickness significantly influence DTUL values.
Compare data from different test labs
and suppliers cautiously.
Figure 4-1
Load
Thermometer
0
75
25
50
Oil Bath
Level
40
Depth
Gauge
Test apparatus
for deflection
temperature under
load (DTUL).
Figure 4-2
1.2
Thermal
conductivity vs.
polyurethane
foam density.
1.1
1.0
0.9
0.8
0.7
0.6
Material
in/in/Fx10-5
Glass
0.5
Steel
0.6
Composite RIM
0.8
Brass
1.1
Aluminum
1.3
Nylon GF*
1.3
Polyester GF*
1.4
PPS GF*
1.5
Polycarbonate GF*
1.7
ABS GF*
1.7
Polypropylene GF*
1.8
Acetal GF*
2.5
Acrylic
3.8
Polycarbonate
3.9
PC/ABS Blend
4.0
4.0
ABS
4.4
Nylon
4.5
Polypropylene
5.0
Acetal
5.8
Polyester
6.0
Polyethylene
7.0
Elastomeric
RIM Unfilled
7.8
K-FACTOR (Btuin/hrft2F)
0.5
Baydur
Structural
Foam
0.4
0.3
0.2
0.1
20
30
40
(lb/ft3) 10
0.4 0.5 0.6
Specific Gravity
50
60
1.0
70
DENSITY/SPECIFIC GRAVITY
THERMAL CONDUCTIVITY
Thermal conductivity, typically measured as Btuin/(hrft2F) or W/Km,
indicates a materials ability to conduct
heat energy. Thermal conductivity is
particularly important in applications
*glass-filled resins
41
Figure 4-3
Depth
Gauge
0
75
25
50
Load
Oil Bath
Level
Indenting
Tip
Test
Specimen
SPECIFIC HEAT
Vicat softening point test apparatus.
RELATIVE TEMPERATURE
INDEX (RTI)
Exposure to elevated temperatures
can reduce a plastics electrical and
mechanical properties over time. The
42
VICAT SOFTENING
TEMPERATURE
By definition, the Vicat softening temperature ranks the thermal performance
of plastics according to the temperature
that causes a specified penetration by a
lightly loaded probe. Often used as a
general indicator of short-term, hightemperature performance, the Vicat
softening temperature is less sensitive to
Chapter 4
Figure 4-4
Test
Specimen
Temperature
Control
Heater
Recorder
Light
Mirror
TORSIONAL PENDULUM
Figure 4-5
tan
3
2
Flywheel
103
8
6
4
3
2
102
8
6
4
3
2
Makrolon 8030
3
2
1.0
8
6
4
3
2
Makrolon 2800
0.1
8
6
4
3
2
Makrolon 2800
Makrolon 8030
101
8
6
4
3
2
-140 -120 -100 -80 -60 -40 -20 0 +20
tan
0.01
8
6
4
3
2
+60
+100
+140
+180
TEMPERATURE (C)
Shear modulus and mechanical power factor of Makrolon 2800 and Makrolon 8030 PC resins.
43
Figure 4-7
Figure 4-6
Temperature-Controlled Chamber
Insulation
Top Cold Plate
Top Auxiliary Heater
Sample
Sample
Base
Guarded-hot-plate apparatus.
THERMAL TRANSMISSION
PROPERTIES
Many applications use polyurethane
materials for thermal insulation. The
thermal transmission properties, therefore, are of great importance in these
applications.
44
The standard test for thermal transmission properties (ASTM C 177) measures the steady-state heat flux through
a flat-slab specimen, using a guarded
hot-plate apparatus. In the test, a hot
isothermal surface is placed between
two specimens, with two cold plates
placed on the specimens outer sides
(see figures 4-6 and 4-7). These three
isothermal units help to create a measurable, steady-state heat flux unidirectionally through the specimens. Sensors
measure heat transfer from the center
hot plate through the specimens to the
cold plates.
OPEN-CELL CONTENT:
FOAMED POLYURETHANE
MATERIALS
The percentage of open versus closed
cells in a foamed system affects its
insulation capability, an important
consideration in appliances and other
applications. For rigid foamed materials,
open/closed cell testing is done in accordance with ASTM D 2856 (ISO 4590).
This test determines open-cell content
by reducing the volume of a sealed
chamber containing a foamed specimen
and measuring the resulting increase in
pressure. For a given specimen size,
greater open-cell content causes lower
pressure increase.
Chapter 4
Typically, materials with a greater percentage of closed cells will offer better
insulation characteristics. Materials
with more open cells offer better
filtration characteristics.
HEAT (HIGH-TEMPERATURE)
SAG
Heat sag is an important consideration
for car manufacturers and others who
will have parts painted and baked, or for
parts that will be exposed to elevatedtemperature service.
Foam
Support
Vanes
Differential
Pressure
Measurement
High Range
Foam Test
Specimen
Medium Range
Figure 4-8
Low Range
Vacuum
Chamber
Figure 4-9
R-2
R-1
Base Plate
Device for high-temperature sag testing.
45
Chapter 5
ELECTRICAL PROPERTIES
Figure 5-1
1018
PC
1016
1014
Bayer materials are often used in applications that need electrical insulation.
Our Product Information Bulletins
(PIBs) list the electrical properties for
plastics used in the electrical and electronic industries. To use this information properly, you need to have a good
understanding of the terminology and
testing methods. This section describes
the most common methods for determining electrical properties and explains
how these properties are used to select
materials for electrical and electronic
components.
PBT
1012
1010
PA 6 Dry
108
106
0
50
100
150
TEMPERATURE (C)
Volume resistivity of three plastics as a function of temperature.
VOLUME RESISTIVITY
Volume resistivity, a measure of a
resins electrical insulating properties,
provides a means to compare plastics
used as insulators. A resins volume
resistivity should be at least 108 ohmcm to be considered an insulating
material. While plastics generally have
excellent insulating properties, their
electrical resistance decreases with
increasing temperature and moisture
content, sometimes by orders of magnitude within a parts given service range
(see figure 5-1). Always evaluate your
products volume resistivity at in-use
environmental conditions.
SURFACE RESISTIVITY
Important in applications with closelyspaced conductors such as terminal
46
DIELECTRIC STRENGTH
A resins dielectric strength, the best
single indicator of a materials insulating capability, measures the voltage an
insulating material can withstand before
Figure 5-2
AM P S
+ Electrode
Guard Ring
Specimen
Electrode
Figure 5-3
E
Electrode
Specimen
Electrode
Cross sectional
view of dielectric
strength test.
47
DISSIPATION FACTOR
DIELECTRIC CONSTANT
An important factor in high-power
and/or high-frequency applications,
the dielectric constant is dimensionless
and varies with temperature, moisture
levels, frequency and part thickness.
Specifically, the dielectric constant is
the ratio of the capacitance of a plate
electrode system with a test specimen as
the dielectric to the capacitance of the
same system with a vacuum as the
dielectric. A schematic of the standard
tests for measuring dielectric constants
(ASTM D 150 or IEC 250) is shown in
figure 5-4. Lower values indicate better
insulating characteristics.
ARC RESISTANCE
Dissipation factors generally increase
with increasing temperature. Excessive
heat can cause a cascading effect:
Increasing losses generate higher temperatures and further losses. This effect
can lead to material breakdown and
possible thermal ignition.
Figure 5-4
Specimen
Vacuum
Dielectric constant is the ratio of the system capacitance with the plastic specimen as the
dielectric to the capacitance with a vacuum as the dielectric.
48
Tested on the same apparatus as dielectric constant, the dissipation factor measures the ratio of the parallel reactance
to the parallel resistance of a test material at specified frequencies and temperatures. To avoid an excessive level of
implied precision and bias, UL 746 A
records results from this electrical test
and other tests that follow as Performance Level Category (PLCs) based
upon the mean test results rather than
recording the exact numerical results.
Chapter 5
Figure 5-5
Range-Mean Time
of Arc Resistance
Assigned
PLC
60 and up to 120
Less than 60
Assigned
PLC
COMPARATIVE TRACKING
INDEX (CTI)
Much like arc resistance, the comparative tracking index tests (UL 746 A,
ASTM D 3638, or IEC 112) measure
the voltage needed to make a conductive path between electrodes on the
surface of a specimen. The difference
between these tests is that in CTI the
sample is exposed to 50 drops of an
electrolytic liquid, to account for
surface contamination. In the IEC 112
test for CTI, the electrolyte drips onto a
specimen at a rate of 50 or 100 drops
per minute and the tracking voltage
increases in 25-volt increments, up to a
maximum of 600 volts.
49
Figure 5-6
12.5 mm
127 mm
HWI Range-Mean
Ignition Temp
(IT in sec)
Assigned
PLC
HAI Range-Mean
Number of Arcs
to Cause Ignition
Assigned
PLC
HVTR Range-TR
(in mm/min)
Assigned
PLC
0 through 10
60 and up to 120
60 and up to 120
30 and up to 60
30 and up to 60
15 and up to 30
15 and up to 30
Over 150
7 and up to 15
7 and up to 15
Less than 7
50
HIGH-CURRENT ARC
IGNITION (HAI)
Measuring the number of arc applications applied either to the specimen surface or at some specified distance from
it until the sample ignites, this test (UL
746) subjects specimens to high-intensity arcs at regular intervals. Results show
the number of arcs needed to initiate
combustion under standardized conditions. The UL card lists results as a PLC
rating as shown in table 5-4.
Chapter 6
ENVIRONMENTAL PROPERTIES
WATER ABSORPTION
HYDROLYTIC DEGRADATION
51
Figure 6-1
psi
10,000
MPa
60
8,000
3200 Grade
23C (73F)
6,000
50
40
30
4,000
3200 Grade
60C (140F)
20
2800 Grade
60C (140F)
2,000
TENSILE STRESS ()
6455 Grade
60C (140F)
10
3200 Grade
80C (176F)
1,000
Time-to-fracture
curves for various
grades of Makrolon
polycarbonate resin
immersed in water.
800
5
600
400
10 - 1
10 0
10 1
10 2
10 3
10 4
TIME (hours)
52
Chapter 6
CHEMICAL RESISTANCE
Figure 6-2
2 mm
0.2%
Strain
Radius R
2 mm
1.4%
Strain
Radius R
Multi-strain fixtures. Radius R is varied to give strain values from 0.2% to 1.4%.
53
Figure 6-3
700
600
500
400
UV-Stabilized PC
300
200
100
Unmodified PC
0
0
10
20
30
40
50
60
70
80
90
100
TIME (months)
WEATHERABILITY
Plastics in outdoor use are exposed to
weather extremes that can be devastating to the material. The most harmful
weather component, exposure to the
suns ultraviolet (UV) radiation, can
cause embrittlement, fading, surface
cracking and chalking.
Weatherability in plastics varies with
polymer type and within grades of a
particular resin. While many resin
grades are available with UV-absorbing
additives to boost weatherability, gener-
54
a series of exposure times (see figure 63). Because it shows how specific properties are affected over time, this data is
extremely useful when designing parts
for outdoor use.
Although outdoor testing is most common, accelerated data can be generated
in special test chambers with UV lights
and climate controls. Because of the
more severe environment in these testing chambers, the results are usually
listed at 1,000 hours, rather than years.
Chapter 6
GAS PERMEABILITY
Gas permeability measures of the
amount of gas typically carbon dioxide, oxygen or nitrogen that passes
through a material in a given time.
Permeability is an important concern in
many packaging and medical applications where the plastic must form a
barrier to gasses. Usually graphed as
permeability versus film thickness (see
figure 6-4), gas permeability also can
be shown as a single value for each gas
at a standard film thickness and temperature. Standard permeability tests exist
for a variety of conditions, such as for a
pressure-driven system with just one
gas present or for a constant-pressure
system driven by a gas concentration
gradient. Standard tests include DIN
53380, ISO 2556 and ASTM D 1434.
Figure 6-4
300
250
CO2
Gas permeability
as measured by
DIN 53380 with test
temperature at
22C (72F) for
Durethan B38F
polyamide resin.
GAS PERMEABILITY
( m2cm
)
daybar
200
150
100
O2
50
N2
0
10
20
30
40
50
60
70
55
Chapter 7
OTHER PROPERTIES
Material
ASTM Test
ISO Test
Flexible Foam
D 3574
845
Rigid Foam
D 1622
845
Semiflexible Foam
D 5308
845
Microcellular Materials
D 3489
868
DENSITY
SPECIFIC GRAVITY
56
SPECIFIC VOLUME
The reciprocal of density, specific
volume can be used instead of density
for weight and volume conversions.
Typically, it is measured in cubic inches
per pound (in3/lb) or cubic centimeters
per gram (cm3/g).
Figure 7-1
Glass Column
Ignition Flame
Burning
Specimen
Wire Screen
Glass Beads
in a Bed
Adjustable
O2 /N2 Supply
REFRACTIVE INDEX
Light passing through a gas, liquid or
solid travels slower than light passing
through a vacuum. The refractive
index, important in a variety of opticallens and light-pipe calculations, indicates the ratio of lights velocity in a
vacuum to its velocity as it passes
through a given substance. Published
values from ASTM D 542 or ISO 489
are for testing at room temperature. The
refractive index of plastics generally
decreases with increasing temperatures.
OXYGEN INDEX
FLAMMABILITY CLASS
57
58
Figure 7-2
127 mm
9.5 mm
305 mm
Chapter 7
Figure 7-3
125 mm
Specimen
100 mm
45
10 mm
Wire Gauze
Wire Gauze
13 mm
Flammability of
solid specimens
according to
ASTM D 635
(similar to UL 94).
Gas
FLASH POINT
The liquid components in a
polyurethane system can be extremely
flammable. ASTM D 93 determines the
flash point, the temperature at which a
liquid component will flame when
exposed to a spark. Called the PenskyMartens closed-cup test, this test must
be performed to meet OSHA and DOT
regulations for safety and transportation. A second test, ASTM D 3278, the
Setafalsh closed-cup test, may also be
used.
Flammability
Classification
Test Criteria
94V-0
94V-1
94V-2
10 s
30 s
30 s
50 s
250 s
250 s
no
no
no
30 s
60 s
60 s
no
no
yes
Specimen Thickness
1/8 in
1/8 in
Burning Rate
1 1-1/2 in/min
3 in/min
or material ceases to burn before flame reaches the second reference mark
59
Chapter 8
GENERAL PROCESSING
PARAMETERS
Part designers and mold makers must
address two common processing parameters shrinkage and viscosity
when planning to make any part out of
plastic. These two processing properties
are discussed below.
Viscosity
Mold Shrinkage
Solution Viscosity
Shrinkage =[(Mold Dimension) (Part Size)]
(Mold Dimension)
60
Figure 8-1
104
8
6
4
ABS200C
PE180C
2
PC300C
10
8
6
4
2
PBT260C
PA 6250C
102
4 6 8 101
4 6 8 102
4 6 8 103
104
Figure 8-2
Capillary
Thermometer
Measuring Tube
Ball
Figure 8-3
Weight
Reference
Marks
Insulation
Heating Bands
Piston
Thermocouple
Melt
Die
62
THERMOPLASTICS
Most of the concerns for processing
thermoplastic resins involve flow rates
and ability to properly fill molds. This
section outlines the relevant tests to
check flow properties, viscosity curves
and other processing parameters for
thermoplastic resins.
Melt Strength
Chapter 8
Because the test for melt flow is performed at a single temperature and single load value, it does not account for
the relationship of viscosity as a function of shear rate and temperature. Melt
flow rates do not reliably predict the
ease of flow in a mold and should not
be used to judge the relative flowability
of dissimilar resins, because the shear
rates used in testing are generally lower
than those found during actual injection
molding.
Melt flow rate is useful for differentiating grades of a resin family according to
viscosity and molecular weight. For
general-purpose polycarbonate resins,
melt flow rates identify at least six viscosity grades within the 4 to 19 g/10
min melt flow range. Also, because
melt flow rate is a good measure of viscosity differences or changes for a specific resin, you can use it to check uniformity in production batches or as a
quick check for degradation in molded
plastic parts. If the melt flow rate in
molded material has significantly
increased from that found in unmolded
pellets from the same batch, processingrelated degradation may have occurred.
Figure 8-4
Spiral Flow
Spiral-flow testing measures the distance a plastic travels through the long,
spiral-shaped channels of a special test
mold to determine a resins mold-filling
capability (see figure 8-4). The test
mold typically consists of a center sprue
gate feeding a 1/2-inch wide, rectangular cross-section flow channel that spirals outward to a length of approximately 50 inches. The spiral-flow length
records the resins flow length at the
stated thickness and processing conditions. Graphs of flow length versus
thickness (see figure 8-5) provide a
quick method for estimating such molding parameters as gate spacing and
required part thickness for filling.
Consider this tests conditions and limitations when applying spiral flow data
to actual molded parts. Difficult-to-fill
features and non-uniform thicknesses
can limit this datas usefulness in many
applications. Additionally, flow in
molds with restrictive runner systems
may be shorter than this data indicates.
You will also need to know if spiralflow data is based upon maximum or
typical processing conditions. In these
situations, consider using computerized,
mold-filling analysis.
63
Figure 8-5
1200
Bayblend PC/ABS
FR 90
Melt Temperature: 260C (500F)
Mold Temperature: 80C (176F)
Filling Pressure: 650 bar (9,425 psi)
1000
FR 110
800
T 64
T 65 MN
600
T 88-2N
T 88-4N
400
200
0
0
POLYURETHANES
Hydroxyl Number
64
Chapter 8
Figure 8-6
Acidity
65
66
Chapter 8
Free-Rise Density
Gel Time
Cream Time
Tack-Free Time
Moisture can be absorbed into the isocyanate component if containers are not
properly sealed. This moisture will react
with the isocyanate, forming ureas and
carbon dioxide, which contains the isocyanate. The carbon dioxide can pressurize the container, possibly causing a
perforation or explosive rupture.
67
68
Chapter 9
COST CONSIDERATIONS
A plastics contribution to final product
cost involves more than the per-pound
cost of the resin. Different materials
have different costs associated with
processing, finishing, productivity, and
quality control, which can alter costs
dramatically. Some examples:
In some painted automotive applications, a Texin thermoplastic
polyurethane resin that can be easily
painted without primer may be more
economical than a lower-cost resin
requiring special surface preparation
and primer.
69
Load
ENVIRONMENTAL
CONSIDERATIONS
Environmental conditions mechanical
loading, temperature extremes, exposure
to chemicals and the elements, for
instance play crucial roles in material
selection. When evaluating these conditions, consider more than just the intended, end-use environment: Plastic parts
are often subjected to harsher conditions
during manufacturing and shipping than
in actual use. To assure longevity and
durability, always test plastic parts under
all manufacturing, transportation and
end-use conditions.
70
Temperature
Chemical Resistance
Chapter 9
Weather Resistance
MATERIAL PROPERTIES
Radiation from indoor fluorescent lighting can also cause yellowing in many
plastics. Among the key reasons for the
popularity of Bayblend PC/ABS resin
blends in business machine housings is
their resistance to yellowing under fluorescent lights. Applications exposed to
other types of artificial radiation, such
as from high-intensity discharge lamps
71
PROCESSING
72
Chapter 9
AGENCY APPROVALS
APPEARANCE
The aesthetics of a finished part directly
affect the perception of quality. Many
people who purchase business machines
prefer the low-gloss, uniform appearance
of Bayblend PC/ABS blends for exposed
panels. For toys, housewares and medical
applications, Makrolon polycarbonate
resins are desirable, because of their
high-gloss finish, wide range of colors
and transparency characteristics.
73
ACTUAL REQUIREMENTS
Take time to ascertain your true part and
material requirements. Although the
problems associated with underestimating these specifications can be serious,
they usually can be identified and corrected during prototype testing. On the other
hand, because parts perform as designed,
the costs of over-specifying for an application normally go uncorrected. Such
oversights can increase part costs, while
reducing product competitiveness.
Some material requirements such as
product feel or appearance can be
subjective and imprecise. Others such
as flammability ratings or key thermal or
electrical properties are clearly specified by industry standards. Parts should
be designed with appropriate safety factors. Calculations and/or computer analysis may help determine some mechanical
or processing requirements.
74
When determining less-precise requirements, you may want to use comparisons. For example, your product may
have to be at least as hard as Baydur
polyurethane resin or have impact
strength comparable to unfilled
Makrolon polycarbonate resin. While
these comparisons do not precisely
define the material requirements, they
help you narrow your choices.
RESIN SUPPLIERS
Your resin supplier is an important member of your design team, providing technical and engineering support, as well as
test results and processing, design and
computer-aided engineering (CAE) services to help you. While many suppliers
offer these services, they can differ significantly in quality and availability. Bayer
has a reputation for providing quality
service throughout the projects life.
PROTOTYPE TESTING
Final material selection must be based
upon thorough product testing. Even
with the most complete planning and
engineering, opportunities for oversight
and miscalculations exist for any project. Prototype testing gives you an
opportunity to test and optimize part
design and material selection before
investing in expensive production tooling. Good prototype testing duplicates
the production conditions as closely as
possible, including prototype molds that
simulate production tooling; processing
and assembling techniques that are
identical to production; and testing
under the same range of mechanical,
chemical and environmental conditions
that the final part will endure.
Simplifying or eliminating prototype
testing increases the chances of unexpected problems that could lead to
delays and expensive modifications in
production tooling. You should thoroughly prototype test all new designs.
SYSTEMS APPROACH
In the systems approach, your team
consisting of designers, production and
processing engineers, and others who have
input on new products considers and
optimizes all of the steps involved in taking an idea from design to production.
This approach develops more options and
opportunities for improved material selection, design, and final production and processing techniques simultaneously. For
instance, selecting an easier-flowing material and modifying a parts design to maintain performance levels could solve processing problems before they develop.
Additionally, because the design is not
set in concrete when material selection
begins, you can compare designs that have
been optimized for the properties of each
material candidate. For instance, a material
with higher tensile modulus and good processing characteristics might be used in a
design with thinner wall sections. This
systems approach may help you select
material, because it compares the cost and
performance of the complete system.
Chapter 10
TECHNICAL SUPPORT
Appropriate literature has been assembled which provides information concerning the health and safety precautions that must be observed when handling Bayer products mentioned in this
publication. Before working with any
of these products, you must read and
become familiar with the available
information on their hazards, proper
use, and handling. This can not be
overemphasized. Information is available in several forms, e.g., material
safety data sheets, product labels, etc.
Consult your local Bayer representative
or contact the Product Safety Manager
for Polymers Division products in
Pittsburgh, PA.
Applicable government
or regulatory agency
test standards;
Tolerances that must be
held in the functioning
environment of the
part(s);
75
TECHNICAL SUPPORT
Product development
Dryer audits
Color matching
Start-up assistance
Prototyping
Material selection
Troubleshooting
Molding trials
Processing/SPC Seminars
Physical testing
Productivity audits
Concept development
Product/part review
Mold design review
Part failure analysis
Finite element stress analysis
Mold filling and cooling
analysis
Experimental stress analysis
Shrinkage and warpage
analysis
76
Chapter 10
REGRIND USAGE
For each grade of Bayers thermoplastic
resin, there is an upper limit on the
amount of regrind that may be used
with virgin material, depending upon
end-use requirements of the molded part
and provided that the material is kept
free of contamination and is properly
dried. These limits are published in
Product Information Bulletins and data
sheets. Any regrind used must be
generated from properly molded parts,
sprues, and/or runners. All regrind used
must be clean, uncontaminated, and
thoroughly blended with virgin resin
prior to drying and processing. Under
no circumstances should degraded,
discolored, or contaminated material
be used for regrind. Materials of this
type should be discarded.
The conditions of your use and application of our products, technical assistance and information (whether verbal, written or by way of
production evaluations), including any suggested formulations and recommendations, are beyond our control. Therefore, it is imperative that you
test our products, technical assistance, and information to determine to your own satisfaction whether they are suitable for your intended uses
and applications. This application-specific analysis at least must include testing to determine suitability from a technical as well as health, safety,
and environmental standpoints. Such testing has not necessarily been done by Bayer Corporation. All information is given without warranty or
guarantee. It is expressly understood and agreed that customer assumes and hereby expressly releases Bayer Corporation from all liability, in
tort, contract or otherwise, incurred in connection with the use of our products, technical assistance and information. Any statement or recommendation not contained herein is unauthorized and shall not bind Bayer Corporation. Nothing herein shall be construed as a recommendation to
use any product in conflict with patents covering any material or its use. No license is implied or in fact granted under the claims of any patent.
77
Appendix
Chapter 3
MECHANICAL PROPERTIES
Chapter 1
UNDERSTANDING ENGINEERING PLASTICS
Figure 1-1
Addition polymerization
Figure 3-1
Tensile tester
23
Figure 1-2
Condensation polymerization
Figure 3-2
24
Figure 1-3
Figure 3-3
25
Figure 1-4
Crystalline structures
Figure 3-4
25
Figure 1-5
Figure 3-5
Flexural test
26
Figure 3-6
27
Figure 3-7
Compression tester
28
Figure 3-8
30
Figure 3-9
Critical thickness
31
Figure 3-10
31
Figure 3-11
32
Figure 3-12
33
Figure 3-13
33
Figure 3-14
Coefficient of friction
34
Figure 3-15
35
Figure 3-16
36
Chapter 2
MECHANICAL BEHAVIOR OF PLASTICS
Figure 2-1
Stress-strain behavior
13
Figure 2-2
Viscous behavior
14
Figure 2-3
Voight-Maxwell model
14
Figure 2-4
Creep phenomenon
15
Figure 2-5
Stress relaxation
15
Figure 2-6
16
Figure 2-7
16
Figure 2-8
Weld line
18
Figure 2-9
Flow stresses
19
Figure 2-10
Fiber orientation
20
Figure 3-17
Figure 2-11
Flexural stress
21
Figure 3-18
37
Figure 3-19
Crazing
37
Figure 3-20
38
Figure 3-21
39
Table 3-1
34
78
Chapter 7
OTHER PROPERTIES
Chapter 4
THERMAL PROPERTIES
Figure 4-1
40
Figure 7-1
57
Figure 4-2
41
Figure 7-2
58
Figure 4-3
42
Figure 7-3
59
Figure 4-4
43
Figure 4-5
43
Table 7-1
56
Figure 4-6
Guarded-hot-plate apparatus
44
Table 7-2
59
Figure 4-7
44
Table 7-3
59
Figure 4-8
45
Figure 4-9
45
Table 4-1
Chapter 8
PROPERTIES USED IN PROCESSING
41
Chapter 5
ELECTRICAL PROPERTIES
Figure 5-1
Volume resistivity
46
Figure 5-2
47
Figure 5-3
47
Figure 5-4
Dielectric constant
48
Figure 5-5
Arc resistance
49
Figure 5-6
Hot-wire-ignition test
50
Table 5-1
49
Table 5-2
49
Table 5-3
50
Table 5-4
50
Table 5-5
50
Figure 8-1
61
Figure 8-2
61
Figure 8-3
62
Figure 8-4
63
Figure 8-5
64
Figure 8-6
65
Chapter 6
ENVIRONMENTAL PROPERTIES
Figure 6-1
Time-to-fracture curves
52
Figure 6-2
Multi-strain fixtures
53
Figure 6-3
Figure 6-4
Gas permeability
55
79
INDEX
compressive set, 29
abrasion, 32, 34
compressive strength, 28
fading, 54
acidity, 65, 66
condensation polymerization, 5, 6
addition polymerization, 5
copolymers, 10
fatigue, 38, 39
additives, 12
cost considerations, 69
fiber orientation, 39
aesthetics, 73
crazing, 37, 38
fiber reinforcements, 8
agencies, 73
cream time, 66
fillers, 10, 11
amine equivalent, 65
flame retardants, 12
amorphous polymers, 9
antioxidants, 12
flash point, 59
crystalline structures, 8
flexural creep, 36
apparent modulus, 36
crystallinity, 8
flexural modulus, 7, 27
apparent viscosity, 61
CTI, 49
appearance, 73
cut-growth resistance, 28
flexural stress, 21
flexural test, 26
D
flow stress, 19
blends, 9, 10
density, 56
blowing agent, 7, 12
design assistance, 75
break point, 24
dielectric constant, 48
free-rise density, 67
Brookfield viscometer, 62
dielectric strength, 47
Brookfield viscosity, 62
dissipation factor, 48
dry-heat aging, 52
gamma sterilization, 71
drying, 17
Gardner impact, 32
CAMPUS, 72
DTUL, 40, 41
gas permeability, 55
capillary viscometer, 61
Durometer, 32
gel time, 67
catalysts, 12
dyes, 12
chalking, 54
dynamic friction, 34
Charpy impact, 30
glycolysis, 18
chemical exposure, 22
GTI, 42
chemical resistance, 70
chlorofluorocarbons (CFCs), 12
elastic behavior, 13
CLTE, 41
elastic limit, 24
coefficient of friction, 34
elastomeric polyurethane, 7
coefficient of linear
elastomers, 10
HAI, 50
color shift, 22
hardness scales, 33
combustion modifiers, 12
embrittlement, 54
haze, 57
environmental conditions, 70
HDT, 40
viscometer, 61, 62
compression tester, 28
compressive modulus, 28
heat sag, 45
compressive properties, 28
80
high-temperature sag, 45
NCO percent, 65
humid aging, 52
rotary viscosity, 62
RTI, 42
S
safety factors, 23
HVTR, 50
safety margins, 23
HWI, 50
scratch resistance, 34
hydrolysis, 21, 51
orientation, 20
shear modulus, 43
hydroxyl number, 64
oxygen index, 57
shear rates, 61
shear strength, 29
impact strength, 29
part removal, 12
injection force, 9
skin thickness, 17
instrumented impact, 32
S-N curves, 39
solid polyurethane, 8
isocyanate viscosity, 62
pigments, 12
specific gravity, 56
Izod impact, 30
PLC, 48, 49
specific heat, 42
Poissons ratio, 27
specific volume, 56
polyol viscosity, 62
spiral flow, 63
polymerization, 5
K-factor, 42
polymers, 5
spiral-flow mold, 63
post-mold shrinkage, 11
static friction, 34
knit lines, 18
processing, 17, 72
steam autoclave, 52
proportional limit, 24
strain, 13
prototype testing, 74
strain limit, 53
L
loading rate, 16
strain rate, 16
stress, 13
luminous transmittance, 57
radiation, 71
stress-crack, 53
recycling, 17, 18
mechanical damping, 43
refractive index, 57
stress-strain curves, 24
melt strength, 62
reinforcements, 10
military (MIL), 73
surface cracking, 54
release agents, 12
surface resistivity, 47
moldability, 72
residual stress, 19
systems approach, 74
rigid polyurethane, 7
RIM polyurethane, 7
multi-strain fixtures, 53
81
Taber abrader, 34
tack-free time, 67
vertical-flame tests, 58
tear resistance, 29
Vicat softening, 42
technical support, 75
temperature, 70
viscoelasticity, 13, 14
tensile adhesion, 24
viscosity, 10, 60
tensile creep, 36
viscosity curves, 61
viscosity modifiers, 12
Voight-Maxwell, 13, 14
tensile strength, 24
volume resistivity, 46
tensile stress, 24
volume-resistivity test, 47
tensile test, 25
wall thicknesses, 10
terpolymers, 10
warp, 11
thermal aging, 52
water contents, 21
thermal insulation, 44
wear resistance, 32
thermoplastics, 6
weather resistance, 71
thermosets, 6
weatherability, 54
time-to-fracture curves, 52
weathering, 22
weld line, 18
transparent plastics, 9
Y
U
yield point, 24
82
ISO/IEC
Test Method
SI
Units
ASTM
Test Method
U.S.
Units
ISO 62:1980
D 570
ISO 62:1980
D 570
ISO 75-1:1993
D 648
ISO 75-2:1993
D 648
ISO 75-3:1993
D 648
ISO 178:1992
MPa
D 790
lb/in2
Flexural Modulus
ISO 178:1991
MPa
D 790
lb/in2
ISO 179-1eU:1993
kJ/m2
D 256
ftlb/in2
ISO 179-1eU:1993
kJ/m2
D 256
ftlb/in2
ISO 179-1eA:1993
kJ/m2
D 4812
ftlb/in2
ISO 179-1eA:1993
kJ/m2
D 4812
ftlb/in2
ISO 180-1eC:1993
J/m
D 256
ftlb/in
ISO 180-1eC:1993
J/m
D 256
ftlb/in
ISO 180-1eA:1993
J/m
D 256
ftlb/in
ISO 180-1eA:1993
J/m
D 256
ftlb/in
ISO 306:1994
D 1525
ISO 306:1994
D 1525
Tensile Modulus
MPa
D 638
lb/in2x103
MPa
D 638
lb/in2
D 638
D 638
MPa
D 638
lb/in2
MPa
D 638
lb/in2x103
D 638
ISO 868:1985
Scale-Value
D 2240
Scale-Value
ISO 899-1:1993
MPa
D 638
lb/in2x103
ISO 899-1:1993
MPa
D 638
lb/in2x103
ISO 1133:1991
ml/10 min
D 1238
ml/10 min
ISO 1183:1987
g/cm2
D 792
lb/in3
Hardness, Shore
Density
ISO/IEC
Test Method
SI
Units
ASTM
Test Method
U.S.
Units
ISO 1210:1992
Rating
(UL94)
Rating
ISO 1210:1992
Rating
(UL94)
Rating
ISO 2039-1:1987
Scale-Value
D 785
Scale-Value
Hardness, Rockwell
ISO 2039-2:1987
Scale-Value
D 785
Scale-Value
ISO 2557:1989
D 955
in/in
ISO 2557:1989
D 955
in/in
Melting Point
ISO 3146:1985
D 1525
ISO 3167:1992
1/K
D 696
in/in/F
ISO 3167:1992
1/K
D 696
in/in/F
ISO 4589:1984
D 2863
ISO 6602-1:1993
MPa
D 638
lb/in2x103
ISO 6602-1:1993
MPa
D 638
lb/in2x103
ISO 6603-1:1989
mm
D 3763
ftlb/in
ISO 6603-2:1989
D 3763
ftlb/in
ISO 8256:1991
kJ/m2
D 1822
ftlb/in2
ISO 10351:1994
Rating
(UL94)
Rating
ISO 10351:1994
Rating
(UL94)
Rating
IEC 93:1980
ohmcm
D 257
ohmcm
IEC 93
ohm
D 257
ohm
IEC 112:1979
Steps
D 3638
Steps
IEC 243-1:1988
kV/mm
D 149
V/mil
IEC 250
D 150
IEC 250
D 150
IEC 250
E-4
D 150
IEC 250
E-4
D 150
IEC 1006
D 3418
(UL746B)
(UL746B)
(UL746B)
(UL746B)
(UL746B)
(UL746B)
Flammability results are based on small-scale laboratory tests for comparison purposes only and do not necessarily represent the hazard presented
by this or any other material under actual fire conditions.
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A Design Guide
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