Polymers Materials Engineering

Shivan I. Abdullah
Mechanical Eng. Dep.
University of Zakho
October 2023
 Polymers
Polymer :- a substance which has a molecular structure built up chiefly or
completely from a large number of similar units bonded together, e.g. many
synthetic organic materials used as plastics and resins.

The molecular structure of plastics can be:-

• Linear chain
• Branch chain
• Cross-links

Molecules:- a group of atoms bonded together

Linear and Branch Chain

The bonding between adjacent molecules is secondary bonding or Van der

Waal forces of attraction. These can be weakened by heating.
Cross links

Primary bonding occurs with cross linking of adjacent molecules. This

results in a rigid, non-reversible structure.
 Classification of Polymers
Thermoplastics:- are composed of long chains produced by joining
together monomers; they typically behave in a ductile manner(method) . The
chains may or may not have (branches). There are relatively weak van der
Waals bonds between atoms of different chains. They are processed into
shapes by heating to elevated temperatures. Thermoplastics are easily
recycled.

Thermosetting polymers: are composed of long chains (linear or branched)

of molecules that are strongly cross-linked to one another to form three-
dimensional network structures. Thermosets are generally stronger, but more
brittle, than thermoplastics. They cannot easily be reprocessed after the
cross-linking reaction has occurred and hence recycling is difficult.
Elastomers: These are known as rubbers. They have an elastic deformation.
These may be thermoplastics or lightly cross-linked thermosets. The polymer
chains consist of coil-like molecules that can reversibly stretch by applying a

force.

Thermoplastic elastomers: are a special group of polymers. They have the

processing ease of thermoplastics and the elastic behavior of elastomers.
 Mechanical Behavior of Polymers
 The Strength of Plastics

Polymers respond to applied stresses in a unique fashion that reflects the nature
of their chemical bond and their molecular structure. Below figure shows the
stress-strain curves for a typical amorphous polymer at various temperatures.
The extremities of the curves represent rupture of the material.

Stress-strain curves for polymethyl methacrylate (PMMA) at

different test temperatures
 • We observe that, at 40°C, the material is brittle as glass: it breaks above a
certain strain without any plastic deformation

• With a modest increase of temperature (to 104°C), the material, still brittle,
shows a marked decline in elastic modulus.

- True stress-strain curves for several polymers above the glass transition
temperature TG. Insert shows uniform necking extension.
 Fracture of Polymers:- the fracture of thermosetting polymers is much like that
of other brittle solids.
 Creep of Polymers:-Creep is a slow and steady increase in the deformation of a
material subjected to a constant load. It takes place above the glass transition
temperature. Creep in polymers can take place at room temperature and even
below.
 Applications of polymers:- Polymers are so inexpensive, easy to manufacture,
light, and generally corrosion resistant that they find application in practically
all aspects of engineering, and their range of applications keeps increasing,
present some of the most important polymers and their applications.
 Composition and Uses of Thermoplastics
 Composition and Uses of Thermosetting Polymers
 Composition and Uses of Elastomers (Rubbers)
Some of the typical mechanical properties of typical thermoplastics are shown in
Table
 Processing plastics
• Calendaring – produces sheets by rolling into shape.

• Lamination – layers of materials (e.g. paper, cloth) are bonded with

a resin into a strong solid structure, often with heat and pressure.

• Foaming – expansion into sponge-like material by a foaming agent

(laborer).
Extrusion:-
• Produces tubes, rods and other shaped continuous form lengths.
• Heated polymer is fed into shaped die by a screw.
Injection Molding
• A measured amount of molten thermoplastic is driven by a ram past a
heating system into the mold.

• The mold is split (divided) to allow finished object to be removed after

cooling.
 Extrusion

Injection Molding
Advantages of Injection Molding:-
• Injection molding produces accurate and complex products with
high quality finish.

• Production is fast with little waste.

• Wide range of products including containers, toys, electrical parts

and car parts.

Blow Molding:-

• Used to make bottles and hollow toys.

• Air is blown into a plastic tube, called a parison, to take the shape of
the mold.

• PVC and polythene are often used.

Blow Molding
Compression Molding
• Thermoset plastics are shaped with heat and pressure causing
cross-linking.

• The polymer can be in powder or slug (cube) form.

• Products such as electrical fittings, bottle tops are often formed

out of formaldehyde plastics.

• High quality finishes are achieved with only the removal of ‘flash’
for finished products.

Transfer Molding

Thermoset polymers can be formed when a preset amount of material is

placed in a separate cavity and heated. A plunger moves the material into

the shaped mold with high pressure.

Typical forming processes for thermosetting polymers: (a) compression molding
and (b) transfer molding.
Rotational moulding
 Home work
 Metallic & Non-Metallic Materials Testing

References
 The Science and Engineering of Materials,. Sixth Edition. Authors
Donald R. Askeland, Pradeep. P. Fulay, Wendelin J. Wright.
Publisher, Global Engineering:. 949 pages

 Donald R.Askeland,Pradeep P. Phule, Textbook "The science and

engineering of materials", United State ,2006.

 Althouse , Turnquist , Bowditch , Textbook" Modern Welding,

Tinley Park, Illionis , United State , 2004.

 Rajender Singh, Textbook "Introduction to Basic Manufacturing

Processes and Workshop Technology" Daryaganj, New Delhi –
110002.