Introduction to

Polymers, Properties &

Selection

1
What is a Polymer ?

• The word polymer comes from the Greek prefix poly-,

which means "many," and the suffix -mer, which means
"parts.“

• A polymer is a large molecule made up of chains or rings

of linked repeating subunits, which are called monomers.

• IUPAC definition
Polymerization: The process of converting a monomer or a mixture
of monomers into a polymer

2
Properties of Polymers

Every polymer has very distinct characteristics, but most polymers have
the following general attributes.

• Polymers can be very resistant to chemicals.

• Polymers can be both thermal and electrical insulators.
• Generally, polymers are very light in weight with significant degrees of
strength.
• Polymers can be processed in various ways.
• Polymers are materials with a seemingly limitless range of
characteristics and colors.
• Polymers are usually made of petroleum, but not always.
• Polymers can be used to make items that have no alternatives from
other materials.
• After expiry of useful life, recycling of polymers is a challenge
• Most of the polymers, donot decompose in nature

3
 Catalyst
INPUT OUTPUT
1.Monomers
2.Heat Polymerization Polymer +
(water)
3.Pressure

Polymerization Process

4
Monomer Molecules in Random Motion

Monomer

5
Polymerization

Polymer Chains

6
Polymerisation example

H H H H H H H H

c c c c c c c c

H H H H H H H H

ETHYLENE
Monomer
 Polymerisation example
Catalyst -heat, pressure and time

H H H H H H H

c c c c c c c c

H H H H H H H H

ETHYLENE POLYETHYLENE
monomer polymer
Polymer examples

Propylene Polypropylene
monomer polymer
Styrene Polystyrene
monomer polymer
Vinyl Chloride Polyvinylchloride
monomer polymer
Phosgene
Polycarbonate
Bis-Phenol Acetone
polymer
monomer
Effect of ‘n’ value on State of Polymer

n = DOP
H.D.S
> 3000
L.D Solid
n > 1000
Wax 26 < n < 50

Oil 12 < n < 14

Liquid 5<n<8

Gas n = 1

10
 Injection Molding grade of
Polymers
500 < n > 35,000

DOP Mechanical Melting Viscosity Processabilty

(n) Properties Point

11
Summary

Polymer chains have a coiled spring like structure.

About 5,000 times longer than their diameter.
Chains are upwards of 1,000,000 repeat units long.
Processing of polymers reduces the chain length and
hence the loss of properties when using regrind.
Classification of Polymers

13
 Polymer

Semi
Natural Synthetic
Synthetic
Shellac Butyl Cellulose
Rubber Derivatives

14
# PARTICULARS POLYMERIZATION

ADDITION CONDENSATION

1 Type of Reaction to Simple Addition Condensation

create chemical
linkages between
monomers

Frequency
Molecular Weight
2 Byproduct - Water

3 Example PE,PP Polyamide,

Polyester
Addition Polymerization(Chain Growth)

•Reaction of unsaturated monomers which links to form a

continuously increasing chain

•Initiation step is slow, Propagation & Termination Steps are Rapid

•Monomer Concentration decreases continuously during reaction

•Increased reaction time has no effect on avg. molecular weight

or chain length

•Eg. Polyethylene, Polypropylene,

Polyvinyl Chloride, Polystyrene

16
Polymerization of Ethylene into Polyethylene

Addition Polymerization

17
 CLICK
FOR
VIDEO
(VIDEO ON NATURE OF PLASTICS)

18
Classification of Polymers with Examples

19
Based on Type of linking monomers

Linear Polymers-
HDPE, PVC, PMMA &
etc

Cross Linked-
All Thermosets

Branched- LDPE
Network-
Epoxy, PU &
etc

20
Homo-polymers

The homo-polymer chains comprise of the same

repeat unit for their entire length.

Examples: HDPE, PA, POM, PVC, PS, PP.

Co-polymers

Co-polymer chains comprise of two or more

different repeat units, which are linked together.

Examples: ABS, SAN, POM, PP, HIPS.

(ABS – Acrylonitrile-Butadiene-Styrene)
Homopolymers and Copolymers

Homopolymers- ONE Type of monomer is used to get polymers

Eg ; PE, PP, PC, Nylon 6 & etc

Copolymers : More than TWO types of monomers are used in making the
polymers

Ex: ABS, Nylon 6/12, Nylon 4/6, POM

Advantages of Copolymers-

Modified Strength, Lubricity, wear resistance

23
Types of Structure of Copolymers

24
Classifying plastics

Commodity Engineering
Classifying plastics
Commodity Plastic Price/tonne
Polypropylene £600 - £950

HDPE £500 - £900

LDPE £600 - £900

Polystyrene £600 - £1200

SAN £600 - £1200

Acrylic £900 - £1500

ABS £1500 - £2500

Prices are only approximate

Classifying plastics
Engineering Plastic Price/tonne
PET £1000 - £1200
Acetal (POM) £1100 - £1900

Nylon (PA) £1600 - £2400

PBT £1800 - £2700

PC £2500 - £3500

PAI £35000 - £40000

PEEK £38000 - £69000

Manifold PA66 GF35
Prices are only approximate.
Classification of Plastics

Load ,
Temperature,Cost
Super
Plastics

Engineering
Plastics

Commodity
Plastics
28
Classification of Plastics

Load ,
Temperature &
Cost
Super
Plastics
PTFE, PEEK,LCP
110 MPa 200°C Rs 1000

Engineering
Plastics
60 MPa PA,POM,PC,ABS Rs.150
85° C

Commodity Plastics
23 MPa
PE,PP,PS,PVC
35° C Rs.50
Classification of Plastics
Plastics

Thermo Thermo set

Elastomers
Plastics Plastics

Semi
Amorphous
Crystalline
•PC , PS •PA , PE, •PF, MF, PU
PP UF
•PVC
30
Table of differences between
Thermo plastic & T.Set
# PARTICULARS THERMOPLASTICS THERMOSETS

1 Linking of Monomers Long linear chains Cross linked (3D)

(with side branches)
without cross linking
2 On application of Soften to from a Gel like soft
Heat viscous melt structure

3 Change on heating Physical Chemical

(Insoluble,
Infusible)
4 Analogy (Example) Ice, Water, Steam Egg & Omelet

5 Recycling Yes No

31
Thermoplastics
Amorphous Semi Crystalline

Branched Chain Linear Chain

molecules molecules

32
Structural changes of polymers
Molten state

Flow
Random structure Ordered structure
Amorphous Semi-Crystalline

COOL
Thermoplastics:

1.Become soft when heated

2.Easily moulded
3.Remolded without significant degrading
34
Classifying plastics
Thermoplastics

Example - Polyethylene
Heat Cool/remove heat

Melt
Flows under Solidification
pressure
Classifying plastics
Thermoplastics

Polyethylene

Polystyrene

Polycarbonate

Nylon

Polyester

(Physical change - Ice to water)

Classifying plastics

Amorphous versus Semi-crystalline!

What are the differences?

Classifying plastics

Thermoplastics

Amorphous Semi-crystalline
Polycarbonate Polyethylene
A.B.S. Polypropylene
Polystyrene Nylon
S.A.N. Acetal
Acrylic Polyester
 Amorphous
(a-morphous = without shape)
• Polymer chains in random arrangement
• Molecular structure incapable of forming
regular order (= not crystallized)
• Molecular arrangement randomly twisted,
kinked & coiled

Amorphous

Random order
Crystalline
•Polymer chains form a regular pattern
•Molecular structure forms regular order
(crystals) Regularly stacked in crystal-like fashion
Semi Crystalline
Amorphous

Crystalline
(Orderly)

40
# PARTICULARS THERMOPLASTICS

AMORPHOUS CRYSTALLINE
1 Order of Structure Random Aligned &
Closely packed
2 Volumetric Shrinkage Less More
3 Transparency Yes No
4 Melt temperature, Melt Less High
viscosity, Shrinkage

5 Toughness & Flexibility More Less

6 Strength in direction of ~Equal in all Higher*
molecules directions
7 Ease of Processing Easy Difficult
8 Example ABS, PC, PMMA, *PP, PE, Nylon
PS, PVC

41
# PARTICULARS THERMOPLASTICS
AMORPHOUS CRYSTALLINE
9 Softening with Over a broad range Sharp Melting Point
temperature of temperature

10 Bonding with Adhesives Easy Difficult

/ Solvents
11 Stress cracking Prone to Resistant

12 Fatigue Resistance Poor Good

13 Typical Applications Structural only Structural +

14 Bearing / wear No Yes

applications

42
Deformation Behaviour of Amorphous
Thermoplastics with Temperature
Tensile strength

Temperature
Tg –Glass Transition Temp. T f – Flow Temp. Td–Degradation Temp.
Deformation Behaviour of Crystalline
plastics with Temperature
Tg Tm Td

Rigid Thermo Plastic

Thermo
Brittle
Elastic
Tensile strength

Temperature

Tg –Glass Transition Temp. Tm –Melting Point Temp. Td–Degradation Temp.

44
 Flow behaviour

Semi-crystalline Amorphous plastics

(PA) Melt and solidify over a
WIDE temperature range.
+
Semi-crystalline plastics
Melt and solidify over a
NARROW temperature
Ease Amorphous range. (i.e they have a
of (PMMA) crystalline melting point)
flow

Temperature +
Thermo-sets

1. Rigid plastics
2. Resistant to higher temperatures
than thermoplastics
3. Once set cannot be remolded

46
Thermoplastics : Thermo - sets

Remolded without Once set cannot

significant be remolded
degrading

47
Elastomers

1.Loosly cross linked compared to

thermosets
2.More Elastic than thermosets
3.Once shaped cannot be reshaped

48
Alloys and Blends of Polymers

Sometimes to try to combine the benefits of two different types of polymers

by mixing them together in different ratios.

Mixing Acrylic and melt processable rubber increases the impact resistance of
the final product. It makes the Acrylic tougher.

If the two materials are not totally compatible, a compatibilizing agent needs
to be added to improve the properties and provide a homogenous mix.

An example of a compatibilizer is Pyrrolidinone which is used to improve the

properties of materials that are not normally compatible

Polymer blend (PB): Mixture of at least two macromolecular substances,

polymers or copolymers, in which the ingredient content is above 2 wt%.

49
Blends & Alloys

Blends
Two or more different polymers in the same matrix
but not linked.
Noryl PPO/PS
High Impact Polystyrene HIPS
Alloys
Two or more different polymers in the same matrix
plus a chemically adhesive additive.
Xenoy PC/PBT
Bayblend PC/ABS
Advantages of Blending
The advantages of blending fall into two categories:
1. Improvement of Product Performance
A. materials with desired properties at lowest cost
B. Extending the performance of Plastics by incorporation of less expensive polymers
C. Improvement of properties like
i. Brittleness
ii. Modulus and Dimensional Stability
iii. Solvent and Chemical Resistance
iv. Improvement in Biodegradability
v. Improvement ESD Performance of plastics
2. Improvement in Processing Parameters
i. Favourable Changes in Tg
Improvement of

51
Common trade names
Trade names Family names
Cycolac, Lustran, Terluran ABS

Delrin, Hostaform, Kematal Acetal (POM)

Plexiglas, Lucite (Perspex) Acrylic (PMMA)

Lupolen, Rigidex, Vestolen HDPE

Styron, Lacqrene HIPS

Ultramid A, Zytel 66, Maranyl A Nylon 66 (PA 66)

Santoprene, EPDM TPE’s

Principle Polymer blends in Market

53
General Properties of Plastics

54
Plastics are much lighter than metals.

Density of Metals ? Density of Plastics ?

Metals Density Plastics Density
Gm/ cc Gm/ cc
Gold 19.3 PTFE 2.1
Silver 10.5 POM (Acetal) 1.4
Copper 8.9 PC / CA 1.2
Iron / Steel 7.85 Acrylic / Nylon 1.15
Alluminium 2.7 ABS / PS 1.05
Magnesium 1.74 HDPE 0.96
LDPE 0.92
PP 0.90

55
Plastics are much lighter than metals

Which metal competes with Plastics?

56
Transparent package with excellent impact strength is moulded out of Acrylic

57
Plastics are much lighter than metals.

Density of Metals ? Density of Plastics ?

Metals Density Plastics Density
Gm/ cc Gm/ cc
Gold 19.3 PTFE 2.1
Silver 10.5 POM (Acetal) 1.4
Copper 8.9 PC / CA 1.2
Iron / Steel 7.85 Acrylic / Nylon 1.15
Alluminium 2.7 ABS / PS 1.05
Magnesium 1.74 HDPE 0.96
LDPE 0.92
PP 0.90

58
Transparency of Plastics

GLASS 90

PMMA 92

PC 89

87 88 89 90 91 92 93

59
 Optical Properties

Transparency Translucency Opacity

60
Note : AIR & PLASTICS are Heat Insulators

THERMAL CONDUCTIVITY OF MATERIALS

W/mK

COPPER

ALUMINIUM

STEEL 0.15 - 0.5

PLASTIC 0.05

AIR

0 100 200 300 400 500

Insulators ……………………Conductors

61
 Electrical Conductivity of Different Materials m/Ohm mm2

COPPER 58.5

ALUMINIUM 38.5

STEEL 5.6

PLASTIC

0 10-15
10 20 30 40 50 60 70

PLASTIC STEEL ALUMINIUM COPPER

Series1 5.6 38.5 58.5

62
•Reason for low thermal conductivity of
Plastics?
•Advantage of poor ?
•Disadvantage of poor ?

63
•Reason for low thermal conductivity of Plastics?
•Absence of free mobile electrons
•Advantage of poor ?
•Heat insulating Handles for utensils
•Disadvantage of poor ?
•Heat required for processing can only be
slowly introduced & it is difficult to dissipate
the heat upon completion of processing

64
Coefficient of Thermal Expansion

Material a (10-6/C)
at room T
• Polymers
Polypropylene 145-180
Polyethylene 106-198
Polystyrene 90-150
Teflon 126-216
• Metals
Aluminum 23.6
Steel 12
Tungsten 4.5
Gold 14.2
• Ceramics
Magnesia (MgO) 13.5
Alumina (Al2O3) 7.6
Soda-lime glass 9
Silica (cryst. SiO2) 0.4

65
Specific Heat

Material cp (J/kg-K)
• Polymers at room T
Polypropylene 1925 cp (specific heat): (J/kg-K)
Polyethylene 1850
Polystyrene 1170
Teflon 1050

• Ceramics
Magnesia (MgO) 940
Alumina (Al2O3) 775
Glass 840
• Metals
Aluminum 900
Steel 486
Tungsten 138
Gold 128
66
HDT of Polymers

• HDT means Heat Deflection Temperature or Heat Distortion Temperature.

• HDT is a measure of polymer’s resistance to distortion under a given load at
elevated temperature.
• HDT is a measure of the “stiffness” of the material as the temperature
increases
• The method is defined in ISO 75 and ASTM D 648

67
Vicat Softening Point

It indicates the temperature at which a circular indenter with a

cross-section of 1 mm² under a standard load of 10 N or 50 N will
penetrate the specimen precisely 1 mm deep.

The Vicat softening temperature is defined in ISO 306 and ASTM

D1525.

68
Thermal Properties of Polymers
Polymer Type Deflection Temperature Deflection Temperature Melting Point (°C)
at 0.46 MPa (°C) at 1.8 MPa (°C)
ABS 98 88 -
ABS + 30% Glass Fiber 150 145 -
Acetal Copolymer 160 110 200
Acetal Copolymer + 30%
200 190 200
Glass Fiber
Acrylic 95 85 130
Nylon 6 160 60 220
Nylon 6 + 30% Glass
220 200 220
Fiber
Polycarbonate 140 130 -
Polyethylene, HDPE 85 60 130
Polyethylene
70 65 250
Terephthalate (PET)
PET + 30% Glass Fiber 250 230 250
Polypropylene 100 70 160
Polypropylene + 30%
170 160 170
Glass Fiber
Polystyrene 95 85 - 69
Melt Flow Index Test (MFI)

Definition: It is defined as the measurement of the rate of extrusion

of molten resin through a die of specified length & diameter under
prescribed conditions of temperature and pressure in 10 min. The
unit of MFI is g/10 min.
Test Methods:
❖ASTM D 1238
❖ISO 1133-1991
Test Apparatus:
• Test Sample
• Steel Cylinder
• Die
• Heater
• Piston
• Load
• Thermometer
•Weighing Balance
 Dynamically
stressed
(Moderate)
parts

Fan Blade& Blower wheel moulded of

Mineral reinforced Nylon

72
High Strength to Weight Ratio

Dunnage Tray --- HDPE

Weight --- 13.5 Kg –
can carry pay load – 2.75 Tons

73
Temperature Resistance

Moulded Bakery Tray

Material : Glass reinforced
PP Less weight.

problem - Sticking of
baked items to Tray
avoided

74
Sandwich Structure

Solid Skin Solid Skin

Foamed Enlarged Photo of ‘Sandwich

Core moulded’ product

75
76
Varieties of parts with excellent mechanical, Chemical and
Electrical characteristics can be moulded from plain & glass
reinforced (ETFE) Fluro - polymer resins

77
Easy Formability of Intricate Shapes

HIPS Decorative Panel

Acrylic
Sink
*

HIPS Drawer

Thermoformed Products : --- a) Acrylic Sink b) HIPS drawer

c) HIPS Decorative Panel d) Wood-grained Plastic skin
Laminated to chip Wood base

*Wood-grained Plastic skin laminated to chip wood base

78
Finishability

Sailboat hull formed out of ABS

sheet & filled with expanded
Polystyrene for buoyancy

79
THERMOFORMED PARTS

80
THERMOFORMED PARTS

81
Easy Process-abilty

Removing ABS Boat-hull with PS foam

floatation from Press
82
Easy Assemblabilty

Tool & Tote Box vacuum formed of Polyethylene

83
Platability

Blow moulded Acetal copolymer aerosol container

84
Rotationally moulded
Poly Ethylene Hobby Horse

85
Light Weight & Durability

Stylish Ladies Boots Slush moulded from Plastisol --- Semi rigid heels &
soles Flexible uppers with expandable sides & Foam liner
86
87
Aesthetic Appeal

88
Barbie Dolls

89
 Rotomolded
Play Balls
out of
Plastisol

Rotomoulded Vinyl Ball -

Rotation moulded from Plastisol

90
Eg. Casserole

91
Seamless Nylon Fuel
Tank for Boats
Characterized by

1.Light weight
2.Corrosion
Resistance
3.Low Permeation
Treatment
92
Cast Polyester -- Chair back

93
GFR Epoxy Mold

8.3 meter Long weighing 2.75 Kg. (can withstand 2050C)

94
Non conductive Reinforced
Plastic Ladders &
Platforms protect linemen
constructing HT Transmission
lines
Very small to Very Large Parts

Mould for 75
Feet Reinforced
Plastic Yacht

96
 IMD?

In-mould Decoration of
Compression moulded Phenolic
Handles and inserts
97
 IMD

In mould Decoration of Injection

moulded Polystyrene cannisters

98
Automotive Applications:
•A.C Fan
•Oil Suction Tube
•Thrust Washer
•Oil Seal
•Switch Housing
• Bush Bearing………..

What mind can imagine….!

99
Pre-treatment of plastics
Hygroscopic -Property of Plastics which absorbs Moisture
-Moisture creates processing problems
-To be removed/ reduced to acceptable levels

Condensation: Moisture can condense on some plastic grains

surfaces. They should be treated to reduce moisture content

Damaged by water - needs drying.

Eg: PC, PET, PA, PBT, PUR

Not affected - drying not usually required.

Eg; POM, PE, PP, PS, PVC
Thank You