Processing–mechanical property relationships in injection moldings of polybutylene

Two unfilled nonpigmented extrusion grades of polybutylene have been injection-molded into a tensile bar mold under a wide range of barrel and mold temperatures. The overall structure of the moldings has been determined and correlated with processing conditions. The short term tensile mechanical properties of the moldings have been ascertained and correlated with molding structure. For low mold temperatures, the Young's modulus and tensile strength of injection moldings of polybutylene are controlled by the extent of and structure within the highly oriented skin. Low barrel temperatures can give rise to highly crystalline thick skins that treble the Young's modulus and fracture stress, when compared to high barrel temperature moldings. Increasing the mold temperature introduces a brittle response in polybutylene injection moldings. Modulus is controlled, at the high mold temperatures, by the skin thickness and by the crystallinity of the material comprising the core of the molding.     

Dependence of crack trajectories on stress distributions in the surfaces of injection moldings produced under high packing pressure

The curved trajectories of solvent-induced cracks in the surfaces of polycarbonate injection moldings produced under high packing pressures have been rationalized in terms of the residual body stresses that exist largely in a thin surface layer. The analysis indicates that the residual tensile stress in the skin of the molded plaque can reach values as large as 5 MPa and the tangential tensile stress values as large as 12 MPa, depending on location in the plaque and on molding conditions. The inward penetration of the crack is stopped eventually by the interior compressive stresses that counterbalance the tensile stresses in the “skin.” The crack tends to turn sideways and grow further in Mode II as a result of the intense interlayer shear stress set up at the crack tip by the difference between the skin tension and core compression. The most important practical conclusion from this analysis is that in the absence of externally applied stress, these so-called edge cracks are unlikely to penetrate the molding's interior since the tensile stress in the surface layer is necessarily counterbalanced by the subsurface compression.     

Flexural properties of moldings of rigid polyurethane made by reaction injection molding

Flexural properties of moldings made by Reaction Injection Molding (RIM), which are structural foams consisting of high density skin and low density core, were investigated by three-point bending tests. Two failure modes were observed in bending tests of the moldings made by RIM, and they are classified as follows according to the density ratio of skin layer to core layer: the opposite side of the skin layer to which load was subjected failed by tensile stress: and the same side of the skin layer to which load was subjected failed by compressive stress, causing wrinkling or buckling. Then the conventional composite beam theory was applied to the former failure mode and Hoff s buckling theory to the latter, and equations were derived to predict the flexural properties of the structural foams, which involved buckling from the flexural properties of solid construction. In addition, it has been shown that there exists a density distribution that maximizes the flexural strength of the moldings made by RIM with a given overall density. The results obtained here should be useful to the optimum structural design of moldings made by RIM.     

Frozen-in birefringence and anisotropic shrinkage in optical moldings: II. Comparison of simulations with experiments on light-guide plates

The thermally-, flow-induced and total birefringence components and anisotropic shrinkages in LGP moldings were simulated by using a combination of a CV/FEM/FDM technique nonlinear viscoelastic and photoviscoelastic constitutive equations and orientation functions, as described in Part I of this study. The simulated results were compared with measurements on LGP moldings of a polystyrene (PS) and two optical grade polycarbonates (PCs) OQ1030 and OQ3820 having low and high molecular weights. The thermally-induced birefringence was simulated by a combination of constrained and free cooling during molding. In LGP moldings of PS, the simulated thermally-induced birefringence indicated a minor variation with location in the mold plane, a parabolic shape in the core region and an increase towards the wall. Compared to the flow-induced birefringence, the thermal birefringence provided a minor contribution to the total transverse birefringence Δn₁₂. In LGP moldings of PCs, the simulated thermally-induced birefringence showed a significant variation with location in the mold plane, nearly constant value in the core region and high value in the wall region. In LGP moldings of both PCs, the contributions of the thermally- and flow-induced birefringence to the total transverse birefringence Δn₁₂ were significant. The effect of processing conditions on the development of the normal birefringence in LGP moldings of PCs was ranked from most to least: the packing pressure, mold temperature, melt temperature, injection speed and packing time. However, in LGP moldings of PS the packing time effect was significant due to a longer gate freezing time. Simulated and measured normal birefringence along the flow direction was in fair agreement, but simulations were unable to describe the observed birefringence maximum arising near the gate. The averaged luminance of LGP moldings exhibited some correlation with the averaged normal birefringence. LGP moldings of PC OQ1030 indicated a pronounced maximum in the simulated transverse flow birefringence in the core but a low value near the wall. In contrast, the LGP molding of PC OQ3820 showed a high simulated birefringence near the wall and a low value of maximum in the core. The simulated and measured total transverse birefringence in LGP moldings was in fair agreement. LGP molding of both PCs showed similar tendency in shrinkage variation with processing conditions. However, the thickness shrinkage was higher in LGP moldings of PC OQ3820. The effect of processing conditions on the development of shrinkage in LGP moldings of both PCs was ranked from most to least: the packing pressure, melt temperature, mold temperature, injection speed and packing time. In LGP moldings of PS, the thickness shrinkage slightly increased with increasing melt temperature and significantly increased with reducing packing time. A good agreement between the simulated and measured anisotropic shrinkages in LGP moldings at various processing conditions was observed.     

Resistance of a polyetherimide to environmental stress crazing and cracking

The environmental stress crazing and cracking (ESC) behavior of an aromatic polyetherimide (PEI) has been characterized in a wide spectrum of organic liquids and compared to the behavior of several other glassy thermoplastics. PEI's response is qualitatively similar to that of the other resins for each of which ESC resistance reaches a minimum in solvents having solubility parameters close to that of the resin. Taken as a whole, the ESC resistance of PEI is found to be quantitatively superior to that of any other glassy resin for which similar data are available for comparison.     

Construction of three-dimensional dynamic growth TGO (thermally grown oxide) model and stress simulation of 8YSZ thermal barrier coating

A three-dimensional cylindrical numerical simulation physical and geometric model of TBCs sinusoidal surface was established based on the ultrasonic C-scan results of 8YSZ coating after thermal cycling. The stress distribution and evolution law of the TGO/BC interface and sample center and edge affected by TGO growth were simulated by the finite-element method. The results show that the stress at the TGO/BC interfaces changes from compressive stress to tensile stress with the increase of the number of thermal cycles. The center of the interface is distributed with large radial, circumferential and axial tensile stresses, while the edge of the sample is affected by thermal mismatch, which shows that shear stresses are alternately distributed in the XZ direction. The tensile stress at the center and the shear stress at the edge are the main reasons for the failure of the core and edge flakes of the thermal barrier coating. The linear elasticity, creep effect, fatigue effect and stress accumulation effect of each layer of TBCs in each thermal cycle period are fully considered by the model, which reveals the reason why the core and edges of the thermal barrier coating are most likely to form cracks.     

Impact properties and microhardness of double‐gated glass‐reinforced polypropylene injection moldings

Injection moldings with weld lines were produced in glass reinforced polypropylene grades differing in filler content using a two‐gated hot runner injection mold. The skin‐core microstructure developed during injection molding was qualitatively analyzed by means of optical and scanning electronic microscopy techniques. The load bearing capacity of the moldings was assessed by uniaxial tensile‐impact and biaxial instrumented falling dart impact tests. Microhardness was also used to ascertain the possibility of using it as a simple nondestructive technique for characterizing glass fiber‐reinforced injection moldings. The properties were monitored at various points to evaluate their variation at the bulk and the knit region. The biaxial impact test highlights the 10‐fold reduction of the impact strength caused by the weld line. POLYM. ENG. SCI., 2009. © 2009 Society of Plastics Engineers     

Environmental stress cracking of poly(acrylonitrile-butadiene-styrene)

The environmental stress cracking (ESC) of acrylonitrile-butadiene-styrene (ABS) copolymer caused by a non-ionic surfactant (poly-oxyethylene alkylether) was studied by constant-load tensile creep tests and edge crack tension (ECT) tests. The fracture surfaces were investigated by a scanning electron microscope (SEM) and the morphology of the crack tip was investigated by a transmission electron microscope (TEM). It was found that the results of the creep tests performed in the non-ionic surfactant were very different from those performed in air. SEM images of the fracture surfaces showed that there were three different mechanisms of fracture and that specimens had a tendency to rupture by ESC when the stress was small. The results of the ECT tests and the TEM images showed that the change in the mechanism of the fracture was attributable to the change of morphology at the crack tip.     

The influence of branch length on the deformation and microstructure of polyethylene

The length and number of side chain branches have a profound influence on the microstructure and physical properties of polyethylene (PE). For a series of linear PE copolymers: environmental stress cracking resistance (ESCR), melting points, creep resistance and modulus, and equilibrium spherulite size were all found to increase with increasing branch length (methyl to hexyl) at a given density and molecular weight. It is proposed that (at a fixed molecular weight) branch length and branch concentration determine spherulite size and, consequently, spherulitic boundary areas, in which the dry crazing/voiding occurs during the incubation period of environmental stress cracking (ESC). At a fixed density, decreased spherulite size contributes to greater spherulite boundary slip and increased creep at low (less than 2 MPa) stresses.     

Prediction of process-induced warpage in injection molded thermoplastics

The main cause of warpage in injection moldings is the imbalance of the thermal residual stresses that are caused by a non-uniform temperature distribution through the thickness of the moldings resulting from variation in cross sections, part geometries, and temperature difference between the mold surfaces. As the hot plastic melt is injected into the relatively cooler mold, a temperature gradient develops between the core of the molding and its surfaces, determining the magnitude of the residual stresses and warpage deflection. The relationship between the temperature difference of the two halves of the mold and warpage for a flat plate was measured and predicted by use of a finite element software package. The development of warpage in a 3D component (L-shaped bracket) was also measured, and the results were compared with computer predictions.     

Internal stress,molecular orientation,and distortion in injection moldings: Polypropylene and glass-fiber filled polypropylene

Residual stress measurements and distortion analyses have been conducted on injection molded plaques made from polypropylene (PP) and a short glass-fiber filled polypropylene (GFPP). The residual stress analyses include measurements both parallel and perpendicular to the direction of flow during mold filling. Residual stresses are very anisotropic in GFPP, but not in PP. The residual stress levels in PP fall on aging at room temperature, whereas in GFPP the proportion of stress relaxation is smaller, and significant stresses remain even after heating to elevated temperatures. A significant contribution to distortion has been linked to the ejection process, and the long- and short-term distortion of moldings is discussed within the framework of the properties of the materials measured here.     

The thermomechanical environment and the mechanical properties of injection moldings

Axisymmetric specimens were injection molded in a propylene copolymer with systematic variations of the melt and mold temperatures and the injection flow rate, in a total of 15 different processing conditions. From computer simulations of the mold filling stage using commercially available software packages, two thermomechanical indices were calculated. They aim at evaluating the level of orientation of the skin and the degree of crystallinity of the core layers. Assuming that these morphological features determine the mechanical response of the moldings, the thermomechanical indices were weighted by the relative thickness of the skin and core layers. The tensile behavior of the moldings was assessed at two velocities of 3.3 × 10^?5 (2 mm/min) and 3 m/s. The mechanical properties studied were the initial modulus, the yield stress and the strain at break. The relationships between the weighted thermomechanical indices and these mechanical properties were analyzed from 3D response surfaces obtained by polynomial fittings. Globally, a marked effect of the strain rate on the mechanical response along with a distinct sensitivity on the weighted thermomechanical indices was found. At high strain rates the microstructural differences were enhanced. The dependence of the yield stress on the thermomechanical indices was not significantly affected by the strain‐rate. However, the strain‐rate dependence of the other mechanical properties was strongly influenced by the initial microstructural state. Furthermore, the maximization of different mechanical properties could not be made simultaneously due to their distinct microstructural dependences. The concept of the thermomechanical indices is evidenced as a simple, valid and valuable tool to establish straightforward relationships between the processing and the mechanical behavior. Polym. Eng. Sci. 44:1522–1533, 2004. © 2004 Society of Plastics Engineers.     

Residual thermal stresses in injection moldings of thermoplastics: A theoretical and experimental study

Internal stresses in injection molded components, a principal cause of shrinkage and warpage, are predicted using a three‐dimensional numerical simulation of the residual stress development in moldings of polystyrene and high‐density polyethylene. These residual stresses are mainly frozen‐in thermal stresses due to inhomogeneous cooling, when surface layers stiffen sooner than the core region as in free quenching. Additional factors in injection molding are the effects of melt pressure history and mechanical restraints of the mold. Transient temperature and pressure fields from simulation of the injection molding cycle are used for calculating the developing normal stress distributions. Theoretical predictions are compared with measurements performed on injection molded flat plates using the layer removal method on rectangular specimens. The thermal stress development in the thinwalled moldings is analyzed using models that assume linear thermo‐elastic and linear thermo‐viscoelastic compressible behavior of the polymeric materials. Polymer crystallization effects on stresses are examined. Stresses are obtained implicitly using displacement formulations, and the governing equations are solved numerically using a finite element method. Results show that residual stress behavior can be represented reasonably well for both the amorphous and the semicrystalline polymer. Similarities in behavior between theory and experiment indicate that both material models provide satisfactory results, but the best predictions of large stresses developed at the wall surface are obtained with the thermo‐viscoelastic analysis.     

Deformation Mechanisms in Polycrystalline Graphite

The microstructure of SGBF graphite was observed under tensile and compressive stresses. Increasing stress generated extensive cracking parallel to the layering direction in the particles. Such cracking, however, was not necessarily directly attributable to the low strength of the graphite crystallites in the c direction but rather to flaws or weak regions which tended to occur between the layer planes. For tensile stress, the cracks were perpendicular to the direction of the applied stress, whereas in compression, the cracking was parallel to the applied stress. Analysis of the stress-strain relations for SGBF graphite in tension indicates a discrepancy with the previously proposed plastic deformation model. The discrepancy is attributed to the effect of the observed cracking on the internal stress distribution. An alternative explanation is proposed on the basis of internal stresses, localized cracking, and interlayer slip.     

Effects of environment on the mechanical properties of plastics under high pressure

Polystyrene (PS), high-impact polystyrene (HIPS), and polyethylene (PE) have been investigated studying the pressure dependence of stress-elongation behavior in tension over the range from atmospheric pressure to four kilobars at room temperature. The effect of strain rate was also observed for PS specimens. Tensile deformation of PS and HIPS has shown that the pressure-transmitting fluid (silicon oil) acts as a stress crazing and cracking agent. Non-sealed specimens of PS showed a brittle-to-ductile transition at 2.95 kbar while specimens sealed from the environment showed the same transition at only 0.35 kbar. Scales HIPS and PE specimens exhibited ductile behavior at all pressures. The extent of plastic deformation for PE was affected when specimens where exposed to the silicon oil environment. Surprisingly, HIPS exposed to the oil exhibited two transitions as the applied hydrostatic pressure was raised: a ductile-to-brittle followed by a brittle-to-ductile transition. Analysis of the stress-elongation curves for sealed PS and HIPS specimens indicated that the pressure dependency of craze-initiation stress differs from that of shear band initiation stress. The brittle-to-ductile transition occurred when the initiation stresses of both processes became equal. The principal stress for craze initiation showed almost no pressure dependency, suggesting that crazes initiate when the principal stress level of the tensile specimen reaches a critical value irrespective of the applied hydrostatic pressure.     

Bi‐axial self‐reinforcement of high‐density polyethylene induced by high‐molecular weight polyethylene through dynamic packing injection molding

Previously, bi‐axial self‐reinforcement of high‐density polyethylene (HDPE) was achieved through a uni‐axial shear stress field introduced by dynamic packing injection molding technology. Here, further improvement of tensile strength along the flow direction (MD) was achieved by blending a small amount of high‐molecular‐weight polyethylene (HMWPE) with HDPE, while the tensile strength along the transverse direction (TD) still substantially exceeded that of conventional moldings. Tensile strengths in both flow and transverse directions were considerably enhanced, with improvements from 23 MPa to 76 MPa in MD and from 23 MPa to 31 MPa in TD. The effect of HMWPE content and molding parameters on tensile properties was also investigated. The tensile strength along MD was highly dependent on HMWPE content, oscillating cycle, mold temperature, melt temperature and packing pressure, while that along TD was insensitive to composition and processing parameters within the selected design space. According to the stress–strain curves, samples with HMWPE produced by dynamic packing injection molding had a special tensile failure mode in MD, different from both typical plastic and brittle failure modes. There were no yielding and necking phenomena, which are characteristic during tensile testing of plastic materials, but there was still a considerably higher elongation compared to those of brittle materials. However, in TD, all dynamic injection molding samples exhibited plastic failure as did typical conventional injection molding samples. Copyright © 2006 Society of Chemical Industry     

Crystallization of polyamide 11 during injection molding

The semicrystalline morphology of injection moldings of polyamide 11 (PA 11) prepared using mold temperatures of 25, 50, and 80°C was investigated. Regardless of the mold temperature, position‐resolved X‐ray diffraction (XRD) and polarized‐light optical microscopy (POM) revealed presence of poor/imperfect α‐crystals with an almost hexagonal arrangement of molecular stems in a nonspherulitic superstructure in the skin, and formation of α‐crystals and spherulites in the core. With increasing mold temperature, the thickness of the skin layer decreased, and the perfection of α‐crystals and the spherulite size in the core increased. The experimental observations are discussed in terms of predicted crystallization temperatures, with the prediction based on cooling‐rate simulations for the various parts of the injection moldings using Moldflow^® and analysis of crystallization of the relaxed melt using fast scanning chip calorimetry, XRD, and POM. It is shown that the structure gradient in PA 11 injection moldings can be forecast without considering the effects of shear for this particular polymer. POLYM. ENG. SCI., 58:1053–1061, 2018. © 2017 Society of Plastics Engineers     

Environmental stress cracking resistance of blow moded poly(ethylene terephthalate) containers

A method is developed for determining the environmental stress cracking resistance (ESCR) of blow molded poly(ethylene terephthalate) (PET) containers. By this method, the internal chamber of a container is presurized in 68.9 kPa (10 psi) increments while the outside of the base is being exposed to an environmental stress cracking (ESC) agent. The base of the container is examined after each 68.9 kPa of pressurization if crazing has occurred. The process is continued until a threshold value of craze initiation pressure (CIP) can be determined. Low CIP for the type of containers tested generally corresponds to a high rate of field failures. The method does not only gage the susceptibility of different types of one-piece PET containers to ESC but also provides helpful information to improve the container designs.     

注塑工艺对聚碳酸酯制品环境应力开裂行为的影响

研究了不同注塑工艺下成型的聚碳酸酯（PC）平板制品的环境应力开裂行为。结果表明：在四氯化碳浸渍下,在制品侧壁位置出现分层开裂;熔体温度升高可以提升PC制品的耐环境应力开裂性;保压压力较大时,制品开裂现象较为明显。在分析分子取向和残余应力与制品环境应力开裂行为关系的基础上,探讨了注射成型工艺对PC注塑制品环境应力开裂行为的影响机理。     

The effect of a temperature gradient on residual stresses and distortion in injection moldings

Distortion of bars injection-molded from polystyrene, polypropylene, and glass-fiber-filled polypropylene and subsequently placed in a temperature gradient has been examined. Residual stress distributions have been measured both for the as-molded state and after annealing in a temperature gradient. In the as-molded state all moldings showed the usual residual stress distribution with compressive stresses near the surface and tensile stresses in the interior. In all three materials it was found that tensile stresses could be developed near to the warmer surface on gradient annealing and that tensile stresses still remained at this surface when the bar was cooled and permitted to bend to restore internal equilibrium. It is shown therefore that in addition to the dimensional changes which occur and which may render the molding unserviceable after temperature gradient annealing, another undesirable change takes place, leaving the molding much more susceptible to fracture from a surface flaw. Uniform annealing is found to be much less likely to cause stress reversal and the stresses remain balanced so that distortion is minimal.