ENGINEERING THERMOPLASTICS

CENTRAL INSTITUTE OF PLASTICS ENGINEERING

& TECHNOLOGY
 Definition of Engineering Plastics

•The thermoplastics plastics materials, which have the capacity

to withstand tensile pressure of more than 400 kg/cm2 and
temperature of more-than 100°C under specified fiber stress in
continuous use are considered as engineering plastics.
•They are capable of being formed or shaped to precise and
stable dimensions.
•The polymers like Nylon 6, Nylon 66, PET, PBT, PC, PPO
Poly-aceton etc. represent this group of plastics.
 Categorization of Engineering Plastics
Based on Chemistry of Origin
•Amide based engineering plastics

For example Nylon 6 and Nylon 66 belong to this category.

•Ester based engineering plastics
PET, PBT and PC belong to this class of materials.
•Acetal based engineering plastics

Polyoxymethylene (Polyacetal) material is classified to this

category.

•Ether based engineering plastics

Poly Phenylene Oxide (PPO) fall in this category. Since

its chemical name is Poly (1,4 (2,6 di-methyle phenyl)
ether)
 Preparation of Nylon 6

•Nylone 6 is prepared from  caprolactam in the presence of water (which

acts as a catalysts) and acetic acid as a molecular weight regulator.
•The typical combination is charged into the vessel and reacted under a
nitrogen blanket at 250°C for about 12 hours.

NH
nR opening 0f lactam ring ( NH-CO-)n
CO Nylon 6
n =5
 Manufacturing of Nylon 6

•The schematic diagrams of the continuous polymerization of  caprolactam to

produce nylon 6

Fig.1. Flow diagram of continuous production of Nylon 6

 Manufacturing of Nylon 6

•The so-called VK tube is used in the polyamide process.

•Reactive end groups are formed by hydrolysing the caprolactam to - amino
caproic acid.
•A lactam melt with a relatively high water content (~15%) is fed to the top of the
VK tube equipped with a stirrer and heating coil.
•The water vaporises at the top, when viscosity is still low, to give a residue of the
desired composition.
•In the lower part of the tube, the equilibrium degree or polymerisation is reached
with an increasing viscosity of the melt.
•The polymer is drawn off at the bottom and granulated. Its equilibrium content of
caprolactam and oligomers is about 10% at a final temperature of 270°C.
•The monomer and oligomers are extracted from the chips with hot water, and the
polymer is subsequently dried with hot gas in a ventricle cylinder hot dryer.
•Intensive drying can produce a further reaction in the solid state and according to
the poly condensation equilibrium a higher degree of polymerization reached.
 Properties of Nylon 6

•The properties of Nylon 6 whether moulded, extruded or otherwise

shaped vary with processing conditions to the degree that the physical
structure is altered.

•Poor polymer handling and fabricating procedures can introduce

contamination or cause chemical change that impair properties.

•Nylon moulded in normal fashion in standard equipment (injection

moulding machine) exhibit typical properties. Some variation both
above and below these values occurs routinely because exact
duplication of thermal history from one molding situation to another is
not to be expected.
 Properties of Nylon 6

Properties Units Values

PA-6
Specific gravity 1.13
Tensile strength MPa 80
Tensile modulus MPa 3000
Flexural modulus Mpa 2414
Elongation at break % 50-100
Impact strength izod, Notched, J/m 53
Hardness M86
Deflection temperature under load 0
C 55-75
(1.82 Mpa)
Coefficient of linear expansion mm/mm/0C 81 x 10-6
Water absorption, 24hrs % 3.0
Dielectric strength KV/mm 100
Dielectric constant 10-6 Hz 3.5
Volume resistivity Ohm.m 10-12
Power factor 0.023
Melting point C
0
220
Glass transition
Temperature C
0
50
Mould shrinkage % 0.7-1.5
 Properties of Nylon 6

•Modifications such as co-polymerization, plasticization, nucleation, reinforcements

and so forth significantly affect properties. Because of the large no of modifications
available the precise properties of specific compositions in particular end-use
situations must be obtained/known.

•The tendencies of the nylons to craze under chemical attack is evaluated by

immersing of stressed samples in zinc chloride solutions.

•The crystallinity of a nylon can be affected not only by processing technique but
also by subsequent dry annealing or accelerated moisture conditioning.

•Other secondary operations that follow the shaping process such as machining,
assembling and decorating can also alter the properties of nylon 6.

•Nylon absorb more or less water depending on the type of nylon, the relative
humidity and the crystallinity of the part.
 Properties of Nylon 6

•The absorption of water can induce significant changes in modulus of

elasticity, yield stress toughness and dimensions. These changes can be
rationalized in terms of the effect of water on secondary crystallization
and in particular on the Transition temperature (Tg, glass transition
temperature). Because of its dependence on the method of
measurement and its sensitivity to moisture, the reported transition
value vary .

•It is normally noted that parts made from crystalline nylon retain their
integrity and exhibit a measured modulus almost to the melting point.
This contrasts with the behavior of amorphous polymers such as
PMMA and PC which lose at their mechanical integrity above Tg.
 Properties of Nylon 6

•The nylon has been recognized as a tough plastic and has been used in
many applications requiring impact resistance. At the same time it has
been known as notch sensitive material.

•As expected nucleation causes an increase in hardness. Plasticisers such

as monomer in unextracted nylon 6 or water decrease hardness and glass
reinforcement increases hardness.

•Nylons have excellent fatigue resistance. Applications as diverse as gears

and brush filaments depend on this ability of nylon plastics to withstand
cyclic or vibrational stresses.
 General characteristics of nylon 6
• Hard and though thermoplastic
• Good abrasion resistance
• How co-efficient of friction
• High tensile strength
• Good dimensional stability
• Low tendency to work
• Smooth appearance of surface
• Average to high surface gloss
• Resistance to lubricants, engine fuels, grease etc.
• Good resistance to coolants, refrigerants, paints, solvent cements.
• Resistant to aquious solution of many inorganic chemicals.
• Posses high HDT
• Attached by strong acids, phenols, cresol at devoted temperature
• Poor or resistance
• High temperature resistance
• Low co-efficient of linear thermal expansion
• High water absorption
 Grades of Nylon 6

The Nylon 6 is available in various grades

• Un reinforced grade
• Heat stabilized grade
• Impact modified grade
• Flame retardant grade
• Mineral filled grade
• Fiber reinforced grade
 Process techniques of Nylon 6

The Nylon 6 can be processed by the following techniques:

• Injection moulding
• Extrusion
• Compression Moulding
• Foam Moulding
• Rotomoulding
 Processing of Nylon 6

•The material is processed with lot of precaution because

of it sensitivity to moisture.
•The material is predried at 80° C for a desired period
depending on the level of moisture.
•Then it is processed in the processing temperature range
of 230° to 290°C.
 Precautions while moulding of Nylon 6

•While pre-drying precaution of temperature and residence time

should be taken in order to avoid the degradation of colorants which
are polyethylene concentrate.
•The residence time for different nylons varies generally from 2 to 4
hours.
•Screw design is also very important for Nylon 6.
 Precautions while moulding of Nylon 6

•While molding nylon attention on the following points is essential.

.High Injection speed of the molding machine
.Control of shot or size
.Minimizing drooling by nozzle of reverse tapper type.
.Shrinkage of the part

•In general shrinkage of the part increases with increasing crystallinity so that
high mould temperatures and thick parts cause high shrinkage . On the other
hand increasing injection pressure tends to reduce shrinkage.

•Annealing is widely practised as a commercial process in molding plants.

For nylon 6 the parts with thickness less than 1.27 cm

•Annealing is ordinarily done in oil bath at temperature of 130° to 149°C.

Annealing is done in order to enhancement of properties or the parts.
 Serviceability

•The Nylon articles are found in applications where dimensional stability

is important. It is inherently resistant to lubricants, engine fuels, hydraulic
fluids, coolants refrigerants, paints, solvent, cleaners and aliphatic and
aromatic hydrocarbons.

•The weatherability of Nylon 6 is relatively poor, unless a suitable

stabilizer is incorporated. The nylon present no toxicological problems
because they are insoluble in body fluids and are biologically inert.

•Un-modified nylons are rated as selfextinguishing class - 2 according UL.

With modification it can be identified selfextinguishing class –0.
 Areas of applications of Nylon 6

•Appliances
•Automotive
•Business equipment
•Consumer products
•Electrical
•Hardware
•Machinery
•Packaging
 Areas of applications of nylon 6

Appliances

Laundry equipment
Cooking equipment
Dishwashers and disposers
Cooling equipment
Consumer electronics
Housecleaning equipment
Small kitchen appliances
Sewing machine
Personal care and grooming
 Areas of applications of nylon 6

Automotive

Chassis parts
Power plant
Decorative body parts
Functional body parts
Electrical parts
Fuel system
Instrumentation
Heating, ventilating, air-conditioning
Accessories
 Areas of applications of nylon 6

Business equipment

Business machines
Vending machines
Office equipment
 Areas of applications of nylon 6

Consumer products
Kitchen utensils
Toys
Sporting goods
Apparel fitments
Personal accessories Fig. 2. Football face guards are made of
Nylon 6 because of its great toughness
Photographic equipment

Musical instruments
Brush bristles
Packaging
Film for cooking
Fishing line

Fig.3. Tennis racquet

 Areas of applications of nylon 6

Electrical
Industrial controls
Wiring and associated devices
Industrial connectors
Batteries
Telephone parts
Switches
 Areas of application of nylon 6

Hardware

Furniture fittings
Door and window fittings
Tools
Lawn and garden implements
Boat fittings
 Areas of application of nylon 6

Machinery
Agricultural
Mining and oil drilling
Food processing
Fig.4. Caster Wheels
Printing
Textile processing
Engine parts
Pumps, valves, meters, filters
Air blowers
Material handling equipment Fig.5. Spur and Pinion gears
Standard components
Gears
Cams
Sprockets
Bearings
Gaskets Fig.6. Bushing and Bearing
Pulleys
Brushes
 Areas of application of nylon 6

Packaging
Aerosol
Film and coated substrates

Fig.6. Nylon 6 film for meat

packaging
 Preparation of Nylon 66

The Nylon 66 is prepared from nylon salt, which is prepared by reacting

the hexamethylene diamine and adipic acid in boiling methanol. The
comparatively insoluble salt (mp-190° - 191 °C) precipitate out from
methanol.

n HOOC-R-COOH +nH2 NR1 NH2

- +
COO H2N

nR R1 [OCRCO -NHR1NH] n +2nH20

HOOC NH2
 Manufacturing of Nylon 66

•The polymerization of nylon 66 is carried out in several different reactors

connected in series

Fig.8. Flow Diagram of Continuos Process of Nylon 66.

 Manufacturing of Nylon 66

The starting material is an aqueous solution of nylon salt (AH salt) containing
equivalent quantities of hexamethylene diamine and adipic acid

•The solution with about 60% solid content is fed into the first horizontal cylindrical
reactor then divided into several components where the water is drawn off as vapor and
precondensate of low mol. wt. is formed.

•This is pumped into the second reactor, which is a heated tube reactor with a gradually
increasing diameter.

•The Polycondensation proceeds here and vapor forms at falling pressure.

•The next step is the removal of water in a steam separator followed by feeding the
polymer melt by means of a screw conveyor into the last reactor, which consists of a
heated screw conveyor where water vapor is again withdrawn and the final poly-
condensation equilibrium is attained.
 Properties of Nylon 66

Properties Units Values

PA-6
Specific gravity ---- 1.14
Tensile strength MPa 90
Tensile modulus MPa 3400
Flexural modulus Mpa 2896
Elongation at break % 20
Impact strength izod, Notched, J/m 37
Hardness M90
Deflection temperature under load 0
C 104
(1.82 Mpa)
Coefficient of linear expansion mm/mm/0C 81 x 10-6
Water absorption, 24hrs % 2.8
Dielectric strength KV/mm 108
Dielectric constant 10-6 Hz 3.2
Volume resistivity Ohm.m 10-13
Power factor 0.025
Melting point C
0
225
Glass transition
Temperature C
0
60
Mould shrinkage % 1.0-2.5
 Properties and Characteristics of
Nylon 66

The key properties of Nylon 66 are

•Toughness
•Fatigue resistance
•Low friction
•Abrasion resistance
•Resistance to oil and solvents
•Stability at high temperature
•Fire resistance
•Creep resistance
•Draw ability
•Good appearance
•Good moulding economics
•The other characteristics are very similar to Nylon 6
•However it above more moisture than Nylon 6.
 Processing of Nylon 66

•The Nylon 66 is also processed with much precautions as like Nylon 6.

•The annealing temperature of Nylon 66 part is 149 – 177°C.

•The Nylon 66 is processed in the temperature range of 275-305°C.

•They are available in the similar grade as like Nylon 6.

•Injection moulding, Extrusion techniques, Compression moulding, Foam

moulding and Rotomoulding techniques are used for processing the
materials.

•While moulding nylon 66, the precautions what are taken for nylons 6 the
some should be taken for nylon 66.
 Serviceability

•Property comparisons among the commercial grades of Nylon 66 vary

widely, because so many formulations are available.

•In general they all have excellent fatigue resistance, a low co-efficient of
friction, good toughness (depending on their crystallinity), and resist a
wide spectrum of fuels, oils and chemicals.

•All nylons are inert to biological attack and have electrical properties
adequate for most voltages and frequencies.

•When UV stabilisers are compounded in nylon 66, it become in sensitive

to UV light.