Fracture toughness of injection molded glass fiber reinforced polypropylene

The fracture behavior of polypropylene reinforced with 30% by weight of short glass fibers was studied using single and double feed plaque moldings. Plaques were injection molded using several gate types and gate positions. Fracture toughness K_c, was calculated at different positions in the plaque moldings using single edge notched tension specimens. Fracture toughness was assessed in the directions parallel and perpendicular to the mold fill direction through measurements of the load to produce complete fracture. Results indicated that the value of fracture toughness is affected by the type of gate as well by size of gate. Position of the specimen also affected fracture toughness. Generally, specimens taken from positions near cavity walls gave higher toughness values than those taken from the center of the moldings. Furthermore, fracture toughness in the transverse direction was consistently higher than in the melt flow direction. Finally, in the case o double feed moldings, a much higher fracture toughness was obtained when the initial crack was perpendicular to the weld line than when it was placed inside the weld line.     

Surface resistivity and mechanical properties of rotationally molded polyethylene/graphite composites

Antistatic polymers are required to dissipate static charges safely from component surfaces. Our overall objective has been to develop cost‐effective flame‐retarded and antistatic polyethylene compounds suitable for rotomolding. This communication considers the surface resistivity and mechanical properties of rotationally molded linear low‐density polyethylene (LLDPE)/graphite composites containing natural Zimbabwean graphite, expandable graphite, or expanded graphite. Dry blending and melt compounding were employed to obtain antistatic composites at the lowest graphite contents. Dry blending was found to be an effective mixing method for rotomolding antistatic LLDPE/graphite composites, thereby eliminating an expensive compounding step. Dry‐blended Zimbabwean graphite composites showed the lowest surface resistivity at all graphite contents, with a surface resistivity of 10⁵ Ω/square at 10 wt% loading. Although rotomolded powders obtained following the melt compounding of Zimbabwean graphite exhibited higher resistivity values, the variability was much lower. Injection molding resulted in surface resistivity values above 10¹⁴ Ω/square for all compositions used. The rotomolded composites exhibited poor mechanical properties, in contrast to injection‐molded composites. The Halpin‐Tsai model showed good fits to the tensile modulus data for injection‐molded Zimbabwean and expandable graphite. J. VINYL ADDIT. TECHNOL., 19:258–270, 2013. © 2013 Society of Plastics Engineers     

Relationships between impact performance and structures of rotationally molded crosslinked high-density polyethylene

Crosslinked high-density polyethylene (XL-HDPE) is a preferred material for chemical and fuel tanks due to its superior environmental stress crack resistance and impact strength. The impact performance of rotationally molded specimen is important for final products. In the research the drop weight impact strength (defined as ARM impact strength) of rotationally molded XL-HDPE is tested between −40°C and 25°C. The crosslinking content, crystallization characteristics, and dynamic mechanical properties (DMA) of different thickness gradients are examined to illustrate the relationships between the impact strength, brittle-ductile transition (BDT) and microstructures. The innermost surface layer (about 0.3 mm) has lower gel content, higher crystallinity, and average lamellar thickness compared with the body part. The ARM impact strength is about 1 J/mm at −40°C and −30°C, and about 29 J/mm at −20°C ~ 25°C. There is a BDT between −30°C and − 20°C. After removing the innermost surface layer, the sample breaks in ductile manner in the entire tested temperature range, and the ARM impact strength is about 24 ~ 26 J/mm. The DMA results show that the BDT is consistent with the structure transition of the innermost surface layer. The microstructures of rotationally molded XL-HDPE in the innermost surface layer dominate the low temperature impact performance.     

Flame retarding effect of graphite in rotationally molded polyethylene/graphite composites

Linear low‐density polyethylene (LLDPE) compounds containing 10 wt % graphite fillers were rotationally molded into flat sheets. Flame retardancy was studied using cone calorimeter tests conducted at a radiative heat flux of 35 kW/m². Only the expandable graphite, an established flame retardant for polyethylene, significantly reduced the peak heat release rate. Compared with the neat polyethylene, it was easier to ignite the LLDPE composites containing carbon black, expandable graphite, and exfoliated graphite. However, rather unexpectedly, the inclusion of flake graphite increased the time to ignition by up to 80%. Simulations conducted with the ThermaKin numerical pyrolysis software suggest that increased reflectivity was mainly responsible for this effect. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 41472.     

Fracture toughness of filled polypropylene copolymer systems

The impact strength to stiffness balance of a toughened polypropylene copolymer was modified through the addition of mineral fillers. The stiffness was improved over the base resin value for all formulations. However, the impact strength exhibited complex behavior. The fracture toughness G_c calculated using the linear elastic fracture mechanics theory was indicative of the materials resistance to crack propagation. The G_c values were modified significantly with the addition of fillers and for some formulations was greater than the base resin value. The LEFM analysis indicates that this is due to an increase in the damage zone size r_p where the energy absorbing mechanisms are concentrated. However, the specific energy absorbed per unit volume decreased with the addition of fillers. The total energy to fracture measured using unnotched samples was indicative of crack initiation and crack propagation energies. This upper bound value decreased for all formulations indicating a reduction in the crack initiation resistance, in the presence of stress concentrating heterogeneities in the filled systems.     

Impact fracture toughness of polyethylene/polypropylene multilayers

In a number of applications, a brittle polymeric surface layer is deliberately molded onto a tough substrate for decorative or protective purposes. This can increase the susceptibility of the tough polymer to premature failure. Similar problems arise when a surface layer becomes embrittled by environmental effects. Choosing a surface material that has good mechanical properties without having this effect can be difficult. In this work the fracture resistances of two polyethylenes and an ethylene/propylene copolymer, and of symmetrical two‐component multilayers of these polymers, were determined as a function of temperature, using instrumented impact tests. The law of mixtures accounts adequately for the fracture resistance of multilayer structures where there is no mechanical interaction between skin and core. However, it gave misleading results for a structure in which high skin modulus at low temperatures appeared to influence the fracture resistance of the core through a constraint effect. Polym. Eng. Sci. 44:1627–1635, 2004. © 2004 Society of Plastics Engineers.     

Mechanical properties of rotationally molded nyrim

Rotational molding is used primarily for the manufacture of products from powdered plastics. However, there are many advantages to be gained from the use of a liquid plastic feedstock. This paper describes the results of an investigation to study the effect of process variables, such as mold temperature, on the morphology and mechanical properties of parts manufactured by the rotational molding of a reactive liquid nylon, caprolactam plus a diol. Initial mold temperature has a significant effect on the degree of crystallinity, levels drop off sharply at mold temperatures in excess of 140°C, while spherulite size increases after this point. Flexural properties improve with increasing degree of crystallinity while impact strength decreases. A similar trend is observed in moldings containing fillers. A brief study of water uptake and dimensional stability of molded parts is also described.     

Fracture toughness of interface of polyethylene modified in bulk

The fracture toughness of the interface, G_a, of the self‐healed joints of poly(ethylene) (PE) was measured using the wedge method. Samples of PE modified by mixing with three additives (branched low‐molecular weight PE, a graphite filler, and polypropylene oil) were investigated. The development of the strength of partially healed joints formed by several hours of contact at a welding temperature of 105°C can be represented in all cases by the linear dependence of the G_a parameter on the square root of time, in accordance with the diffusion mechanism of the interface formation. The presence of the additive in samples was found to enhance the fracture toughness of a joint for a given welding time. In the graphite composites, an induction period of welding was observed. In contrast, an instant nonzero strength occurred in joints of PE with PP oil samples. The results confirmed that the concept of the chain entanglement control of fracture toughness developed originally for the glassy polymers is well transferable to the semicrystalline PE. However, additional mechanisms due to the crystallization of PE upon cooling are also effective in the development of the joint strength. These mechanisms denoted as cocrystallization, transcrystallization, local crystallization, mechanical interlocking, etc., are substantially affected by the concentration of additives. © 1999 John Wiley & Sons, Inc. J Appl Polym Sci 74: 1009–1016, 1999     

Tailoring toughness of injection molded bar of polypropylene random copolymer through processing melt temperature

In this study, a facile route to realize the superior toughness of injection molded polypropylene random copolymer (PPR) is reported. The toughness of PPR is increased about twofold when the processing melt temperature increases from 180 to 250 °C. Systematic and detailed structural characterizations have been carried out to establish the structure–property relationships by using polarized light microscopy, scanning electron microscopy, infrared microscopy and dynamic mechanical analysis. It is found that increasing the melt temperature is beneficial for the coalescence of rubbery domains and enhanced molecular mobility which are mainly responsible for the improvement in toughness. Other factors, such as molecular orientation, crystallinity and so on, seem to have little effect. The vital role of enhanced molecular mobility in improving toughness is further demonstrated by the annealing of injection molded samples at elevated temperature, i.e. 110 °C. Copyright © 2011 Society of Chemical Industry     

Optimizing the impact strength of rotationally molded parts

Rotational molding of thermoplastics has become an important process in industry. However, the optimization of this technique has been essentially based on a trial‐and‐error process. In this report, an L'16 experimental matrix design based on the Taguchi method was conducted to optimize the impact strength of rotationally molded parts. Oven temperature and oven time were found to be the principal factors affecting the impact property of rotationally molded thermoplastics. Density and melt flow index measurements were also employed to identify the material and structural parameters. The part density increased with increasing total energy transmitted into the molding system. The melt flow index provides an easy indication of the mechanical properties of rotationally molded parts.     

Effect of the compatibility on toughness of injection‐molded polypropylene blended with EPR and SEBS

The effect of the compatibility between a dispersed phase and a matrix polymer and the annealing on improvement in the toughness of injection‐molded isotactic polypropylene (i‐PP) blended with elastomers was studied. Two grades of ethylene‐propylene copolymer (EPR(A) and EPR(B)) and styrene‐ethylene‐butadiene‐styrene tri‐block copolymer (SEBS) were used as elastomer. EPR(B), which has lower strength than EPR(A), was able to improve the toughness of i‐PP more effectively than EPR(A). However, SEBS, which has higher strength than EPR(B), was more effective than EPR(B). This result contradicts the toughening mechanism of relaxing the strain constraint due to void formation. Two reasons are probable. First, the volume fraction of the dispersed phase of the i‐PP blended with EPR(B), hereinafter referred to as EPR(B)/i‐PP, is much lower than that of the i‐PP blended with SEBS (SEBS/i‐PP) because of the high compatibility between EPR and i‐PP. Second, it is possible that the dissolved i‐PP in EPR increases the strength of the dispersed phase. In this case, the void formation from the dispersed phase is restricted. Therefore, the efficiency of toughness improvement by relaxing the strain constraint is decreased. The annealing improves the phase separation. As a result, the strength of the dispersed phase is decreased, and therefore the toughness is improved. The effect of the annealing of EPR(B)/i‐PP is higher than that of SEBS/i‐PP because of the high compatibility between EPR and i‐PP. POLYM. ENG. SCI., 46:29–38, 2006. © 2005 Society of Plastics Engineers     

An investigation into the relationship between the impact performance of rotationally molded polyethylene products and their dynamic mechanical properties

In this paper, a study of the relationship between the impact performance of rotationally molded polyethylenes and their dynamic mechanical properties is carried out. A wide range of conventional linear low density polyethylene powders and met‐allocene catalyzed linear low density polyethylene powders were rotationally molded and tested. Instrumented falling weight impact tests were carried out over a temperature range of ?60°C to 20°C. Dynamic Mechanical Thermal Analysis (DMTA) tests were also carried out between ?100°C and 90°C, at a frequency of 100 Hz. Comparisons between the impact performance of metallocene catalyzed LLDPEs and Ziegler‐Natta LLDPEs are made. The transitions evident in the DMTA results are related to changes in impact performance with temperature. The beta transition is found to fall in the transition region between high impact performance at low temperatures and lower impact performance at ambient temperatures.     

Mechanical properties of injection molded long fiber polypropylene composites,Part 2: Impact and fracture toughness

This study describes the effect of fiber length and compatibilizer content on notched izod impact and fracture toughness properties. Long fiber polypropylene (LFPP) pellets of different sizes were prepared by extrusion process using a new radial impregnation die, and subsequently, pellets were injection molded as described in previous publication 1 . The content of glass fiber reinforcement was maintained same for all compositions. Maleic‐anhydride grafted polypropylene (MA‐g‐PP) was chosen as a compatibilizer to increase the adhesion between glass fiber and PP matrix and its content was maintained at 2 wt%. Notched izod impact property was studied for LFPP composites prepared with and without compatibilizer for different pellet sizes. Failure mechanism due to sudden impact was analyzed with scanning electron micrographs and was correlated with impact property of LFPP composites. Fracture and failure behavior of injection molded LFPP composite were studied and relationship between fracture toughness and microstructure of LFPP composite was analyzed. The microstructure of the composites was characterized by the dimensionless reinforcing effectiveness parameter, which accounts for the influence of fiber layer structure, fiber alignment, fiber volume fraction, fiber length distribution, and aspect ratio. Matrix stress condition factor and energy absorption ratio were determined for LFPP composites prepared with and without compatibilizer. Failure mechanism of both the matrix and fiber, revealed with SEM images, were discussed. POLYM. COMPOS., 2008. © 2008 Society of Plastics Engineers     

Some factors influencing cooling rates of rotationally molded parts

Recently, rotational molding engineers, concerned with warpage and uneven cooling in parts, have been “pre-cooling” the mold in forced draft air after removal from the oven and prior to water quenching to removal temperature. In this paper, we analyze some of the factors that influence the rate of heat removal from an amorphous plastic in a metal mold. We find that mold thickness and thermal diffusivity, convection heat transfer coefficient of the cooling fluid, the thermal properties of the plastic and the initial, final and “freezing” temperatures of the plastic influence this cooling rate and the corresponding rate of volumetric shrinkage. We illustrate our analysis with several examples and discuss some guidelines in detail.     

The effect of cooling rate on the impact performance and dynamic mechanical properties of rotationally molded metallocene catalyzed linear low density polyethylene

This article examines changes to the morphology of rotationally molded metallocene catalyzed linear low density polyethylene brought about by varying the cooling rate during processing. These changes in morphology lead to variations in the impact performance, which is reflected in the dynamic mechanical characteristics of the materials. Various analytical techniques are used in an attempt to explain the differences in impact behavior. Slow cooling is shown to result in high crystallinity, and in the formation of large spherulites, which in turn is detrimental to the impact performance of the material, particularly at low temperatures. The high crystallinity corresponds with a shift in the β transition of the material to a higher temperature, and is shown to result in a higher brittle–ductile transition. A case study was also carried out on samples from a finished part provided by an industrial molder, one section of which failed in a brittle manner when impact tested while the other failed in a ductile manner. Microscopy results showed that the brittle material had large spherulites at the inside surface, while the ductile material showed incipient degradation at this surface, which has previously been shown to be of benefit to impact strength in rotationally molded parts. Dynamic mechanical studies again showed a β transition at a higher temperature in the brittle samples. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 101: 1963–1971, 2006     

Weld line morphology of injection molded polypropylene

The weakness of plastics at weld lines provides serious difficulties for the design and long term durability of injection molded parts. The goal of this work was to identify the cause of weld line weakness in polypropylene (PP) systems. The morphology of weld lines in a high molecular weight PP has been studied. It was found that the PP contains a hindered phenolic antioxidant additive that is not soluble in the polymer at the standard processing conditions. Transmission electron microscopy (TEM) pictures reveal the additive existing as a dispersed phase in the bulk polymer. Even though very small concentrations of this additive are normally used, (0.1–0.5%) large quantities were found at weld lines in a band approximately 100 nm wide and penetrating about 10 μm into the surface of the part, hindering strength development at the weld line. X-ray photoelectron spectroscopy (XPS) results confirm enhanced concentrations of antioxidant on the flow front and mold wall surface of short shot samples. The mechanical properties (Izod impact, tensile strength) are measured for samples molded at various processing conditions, varying amounts of antioxidant additive and with and without weld lines. The results are consistent with the presence of the additive playing a key role in strength development at PP weld lines.     

Residual stresses and aging in injection molded polypropylene

The residual stresses in injection molded bars of polypropylene have been examined using a stress relaxation method and by the layer removal technique. A positive value for the internal stress parameter was obtained with newly molded specimens and was found to be retained by specimens stored at liquid nitrogen temperature. The stress relaxation parameter reduced to zero both for specimens aged at room temperature and also for those aged at ?40°C. Nevertheless the relaxation behavior of specimens aged at all three temperatures was quite distinct. The layer removal technique showed that the stresses near to the surface were compressive and those in the interior tensile, in apparent contradiction to the interpretation of Kubat and Rigdahl for the meaning of a positive internal stress parameter. A marked reduction in stress levels on aging at room temperature was confirmed, however. The relevance of the relaxation spectrum of polypropylene to these observations is discussed.     

Heterogeneity and anisotropy of injection‐molded discs of polypropylene and polypropylene composites

The anisotropy and heterogeneity of injection‐molded discs of polypropylene, talc‐filled polypropylene composites, and silane‐treated talc‐filled polypropylene composites are studied by means of dynamic mechanical analysis and thermomechanical analysis. The aims of this work are to discover the relationships between the structure of the composites, their anisotropic properties, and the heterogeneity of the molded discs. The experimental results show that although the discs are almost homogeneous, they present a high degree of anisotropy. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 77: 1275–1283, 2000     

Crystalline and amorphous orientations in injection molded polyethylene

The techniques of density, birefringence, and wide X-ray diffraction were employed to characterize the microstructure of injection molded polyethylene parts. Generally, maximum crystallinity (density) occurs at the center of the molding, while the minimum crystallinity occurs near the surface. Higher densities are observed near the gate. Raising the injection temperature tends to cause a marginal increase in the crystallinity throughout the molding. Birefringence measurements suggest that the maximum orientation occurs near the surface and that the relative orientation distribution is independent of the injection temperature. X-ray diffraction indicates that the crystallographic a-axis tends to orient in the flow direction while the b and c axes vary symmetrically about that direction. Increasing the injection temperature creates c-axis orientation near the surface, while towards the core region a-axis orientation is observed. Generally, near the surface it is the amorphous phase that makes the major contribution to the total orientation as measured by birefringence. Increasing the injection temperature tends to decrease the amorphous phase orientation near the surface. The crystalline phase contribution to the total orientation increases as distance from the surface increases, regardless of injection temperature.     

Adhesion to polyethylene and polypropylene

Adhesion to polyethylene and polypropylene is a complex subject requiring understanding of (a) the poor adhesive characteristics of these polymers; (b) the superior performance following certain pretreatments and (c) the nature of the changes brought about by these pretreatments and the mechanisms involved. This review discusses work on these topics and examines the impact of recent data resulting from the application of surface analytical techniques. The roles of ‘weak boundary layers’, surface energy and wettability and specific interactions are discussed in some detail.