The effect of orientation on the mechanical properties of injection molded polystyrene

The deformation and fracture behavior of injection molded plaques have been determined, and the results interpreted in terms of the effect of molecular orientation on the crazing and shear yielding behavior. The molecular orientation was characterized by optical birefringence. A range of injection molding conditions and two mold thicknesses were Used and this resulted in a large variation in the molecular orientation, particularly through the sheet thickness. Tensile tests were made on samples cut at different angles to the injection molding direction. The moldings are considered to consist of a composite of layers of material with different orientation, and the properties of the samples cut from the molding are analyzed in terms of the properties of each layer. Results from material oriented unidirectionally by hot drawing have been used to predict the composite properties, and good agreement has been obtained.     

The effect of annealing on the thermal properties of reaction injection molded urethane elastomers

Reaction injection molded (RIM) polyurethanes, especially reinforced RIM polyurethanes, are promising candidates to replace metal exterior body panels on automobiles. One of the most important performance properties which these RIM parts must possess is thermal dimensional stability. Thermal dimensional stability is defined as the ability of a part to withstand distortion or change in size during thermal cycles. This property is important for two reasons. First, during paint operations parts are exposed to high paint bake temperatures. Second, parts may be exposed to relatively high temperatures in use. Thermal dimensional stability is mostly controlled by formulation and post-treatment. Formulation can change the structure of the polymer leading to different thermal properties. Posttreatment such as annealing can change (a) the degree of hard segment phase order, (b) the degree of phase separation and (c) the relative continuity of the phases. Experimental evidence is given to support all these factors.     

The morphology and mechanical properties of dynamic packing injection molded PP/PS blends

As a part of long-term project aimed at super polyolefin blends, in this work, we report the mechanical reinforcement and phase morphology of the immiscible blends of polypropylene (PP) and polystyrene (PS) achieved by dynamic packing injection molding (DPIM). The shear stress (achieved by DPIM) and interfacial interaction (obtained by using styrene-butadiene-styrene (SBS) as a compatibilizer) have a great effect on phase morphology thus mechanical properties. The shear-induced morphology with core in the center and oriented zone surrounding the core was observed in the cross-section areas of the samples. The phase inversion was also found to shift towards lower PS content under shear stress, at 70 wt% in the core and 30 wt% in the oriented zone, compared with 80 wt% for static samples (without shear). The tensile strength, tensile modules and impact strength were found largely increase by means of either shear stress or compatibilizer. The PS particle size is greatly reduced with adding of SBS, and the reduced particle size results in greater resistance to deformation, which causes the co-continuous structure at oriented zone change into droplet morphology. The morphology resulting from blending and processing was discussed based on effect of interfacial tension, shear rate, phase viscosity ratio and composition. The observed change of mechanical properties was explained based on the combined effect of phase morphology (droplet-matrix or co-continuous phase) and molecular orientation under shear stress.     

Morphology and mechanical properties of direct injection molded polypropylene/thermotropic copolyester blends

Blends of two grades of polypropylene (PP) with thermotropic copolyester (Rodrun) contents of up to 40% were obtained by direct injection molding at different processing temperatures. In the skin of the molded specimens rather long fibers were seen in blends with low‐viscosity PP, whereas sheets were found when the high‐viscosity PP was the matrix. In the core, the viscosity of the matrix played a more relevant role than the viscosity ratio on the orientation level of the dispersed Rodrun phase. The better mechanical properties of the blends with the low viscosity PP are attributed to the morphology change of the dispersed phase from sheets to fibers when the viscosity of the matrix decreased.     

The effect of annealing on tensile properties of injection molded biopolyesters based on 2,5-furandicarboxylic acid

In this study, we investigate four polyesters based on 2,5-furandicarboxylic acid and different diols including 1,2-ethylene glycol, 1,3-propylene glycol, 1,4-butylene glycol, and 1,6-hexylene glycol. Poly(ethylene 2,5-furanoate), poly(propylene 2,5-furanoate), poly(butylene 2,5-furanoate), and poly(hexylene 2,5-furanoate) (PHF) were characterized by thermogravimetric analysis, X-ray diffraction, differential scanning calorimeter, and tensile tests. In addition, the influence of annealing polyesters on their thermal and mechanical properties was investigated. For these reasons samples for the tensile test were prepared by injection molding. The tensile properties of injection molded samples were compared with samples that were additionally annealed after injection molding. All studied polyesters after heating treatment showed multiple melting behavior. The increase in the degree of crystallinity significantly influenced also the mechanical properties of the samples. It was found that the length of the aliphatic chain and degree of crystallinity plays a major role in the final properties of furan-based polyesters.     

Thermal and mechanical properties of injection molded liquid crystalline polymer/amorphous polymer blends

Injection molded samples of binary blends of Vectra (LCP) and the three amorphous polymers polyethersulfone (PES), polycarbonate (PC), and aromatic poly(ester carbonate) (APEC) have been subjected to morphological and rheological characterization, and coefficients of linear thermal expansion and Young's moduli have been determined. The Young's modulus of the PES/LCP blends exhibited a near lower-bound behavior that could be predicted by the one-adjustable-parameter equations of Halpin-Tsai (ζ = 0.18) and Takayanaga (b = 0.23), whereas the coefficients of linear thermal expansion followed the Takayanaga equation with a value of b = 0.50. The chain orientation of the LCP component was essentially constant in all PES/LCP blends with a Herman's orientation parameter of 0.39 ± 0.03. Transesterification reactions led to randomization of the constituents of the PC/LCP and APEC/LCP blends. The effect was more pronounced in the PC/LCP blends. The introduction of the LCP into the PC/LCP blends led to no reduction in melt viscosity and no self-reinforcement. APEC/LCP exhibited self-reinforcement in blends with a content greater than 27 vol% LCP, and especially the blend with 67 vol% LCP. The self-reinforcement was caused by the presence of an oriented LCP phase, confirmed by X-ray diffraction, and by improved interfacial bonding, presumably resulting from the transesterification reactions occurring at the phase boundaries.     

Weld lines and mechanical properties of injection molded polyethylene/polystyrene/copolymer blends

In this article, we investigate the effect of weld lines on the tensile mechanical properties of unmodified and copolymer modified high density polyethylene (HDPE) and polystyrene (PS) blends. The homopolymers were melt blended in the proportion of 20 wt% HDPE and 80 wt% PS using a twin screw extruder at a temperature of 200°C. The results show that the mechanical properties are generally lower when weld lines are present. The decrease of the mechanical properties is much more pronounced for the blends. The addition of small amounts of a commercial styrene/butadiene copolymer significantly improves the strength and the elongation at break of this blend. An optimum copolymer concentration was observed at 3 wt%. This value coincides with the interphase saturation concentration of the copolymer obtained from the analysis of the DMTA (dynamic mechanical and thermal) properties of the blends. The copolymer was also found to induce important changes in the morphology of the blend. The interdiffusion of the polymer fronts in the weld region was also improved by the presence of the copolymer. It is believed that these two aspects contribute to the enhanced properties obtained with copolymer modified blends in presence of weld lines. An important effect of the injection temperature on the tensile strength and the elongation at break of welded samples with copolymer modified blends was observed. The effect of mold temperature on these properties was less important mainly at low injection temperatures. Only a slight effect of these two parameters was observed for the tensile modulus in the range of mold and injection temperatures considered in this study.     

Effects of annealing on the hierarchical crystalline structures and mechanical properties of injection‐molded bars of high‐density polyethylene

The effect of annealing on the microstructural evolution and mechanical properties of high‐density polyethylene parts molded via gas‐assisted injection molding was investigated using scanning electron microscopy, differential scanning calorimetry, two‐dimensional wide‐angle X‐ray diffraction and tensile testing. The results indicated that a variety of annealing temperatures could induce considerable variations in the hierarchical structures, crystallinity, lamellar thickness and yield stress of the molded bars. According to these results, the annealing temperatures could be divided into three regions. In the low‐temperature region of annealing at 80 °C, the spatial variation of the superstructure developed along the thickness direction and mechanical properties of the annealed sample were mainly unchanged and similar to those of the original specimen. At 100 and 120 °C, the intermediate temperature region of annealing, the thickness of the crystals, degree of orientation and yield stress of annealed samples were greatly improved. Finally, at 127 °C, the degree of orientation decreased and yield stress slightly improved, an indication of the high‐temperature annealing region being characterized by increasing melting/recrystallization and causing relaxation of oriented molecular chains. A model is proposed to interpret the mechanism of the annealing treatment of the samples at various temperatures. © 2013 Society of Chemical Industry     

Barrier properties of injection molded blends of liquid crystalline polyesters (Vectra) and high‐density polyethylene

Blends of an extrusion‐grade high‐density polyethylene and two liquid crystalline copolyesters (LCP; Vectra A950 and Vectra RD501) were prepared by melt mixing and injection molding, and the morphologies and oxygen permeabilities of the blends were assessed. Scanning electron microscopy revealed that the LCP was present in the blends as mixed oriented bands and small spheres at low LCP contents (4–9 vol%), whereas blends with more than 18 vol% LCP showed LCP lamellae of macroscopic lateral size (mm). Scanning electron microscopy revealed a two‐dimensional continuity of the LCP domains in the disc plane due to radial shear deformation and circumferential stretching of the melt leaving the central gate of the disc‐shaped cavity. The oxygen permeability, diffusivity and solubility decreased with increasing LCP content of the blends. The decrease in permeability with respect to polyethylene was significant (46%–55%) already at 9 vol% LCP. At 27 vol% LCP, the decrease with respect to polyethylene, was 92% for the Vectra A950 blend and 98% for the Vectra RD501 blend. These blends showed a greater decrease in diffusivity (86%–92%) than in solubility (39%–76%) with respect to polyethylene, which showed the very pronounced effect of the LCP lamellae on the geometrical impedance factor. Microvoids were present in all the blends despite the use of a very high injection pressure (180 MPa) but their impact on the oxygen permeability was negligible for the Vectra RD501 blends and relatively small for the Vectra A950 blends.     

Tailoring microstructure and mechanical properties of injection molded isotactic–polypropylene via high temperature preshear

In this work, isotactic–polypropylene (iPP) specimens were prepared by a modified injection molding machine, in which high temperature preshear (HTPS) can be imposed on the molten polymer during the plasticizing stage. The effect of HTPS on the microstructure and mechanical property of iPP was investigated. It was found that spherulite size in core region of iPP part decreased steadily with the increasing HTPS duration, indicating that HTPS could substantially enhance iPP nucleation. Moreover, β ‐iPP formation correlated strongly with HTPS duration. That is, in the absence of HTPS, β ‐iPP existed only in intermediate region; with moderate HTPS duration, β ‐iPP could be unexpectedly formed in core region; however, long HTPS duration inhibited β ‐iPP formation in both intermediate region and core region. Based on the relationship between β ‐iPP formation and HTPS duration, metastable nuclei, instead of α ‐row nuclei, were proposed to be responsible for the development of β ‐iPP. Notched Izod impact test showed that moderate HTPS duration enhance the impact strength of injection molded iPP by decreasing the thickness of shear region and elevating β ‐iPP crystallinity in core region. Dynamic mechanical test indicated that with the increase of HTPS duration, the storage modulus of injection‐molded iPP improves drastically. POLYM. ENG. SCI., 55:2714–2721, 2015. © 2015 Society of Plastics Engineers     

Solid state and mechanical properties of injection molded poly(ether ether ketone)/polyarylate blends

Blends of poly(ether ether ketone) (PEEK) and bisphenol-A polyarylate (PAr) were directly prepared during the plasticization step of an injection molding machine and their solid-state and mechanical behaviors were studied. Despite the fact that PEEK-rich blends were apparently miscible by differential scanning calorimetry (DSC), from the dynamic-mechanical analysis (DMTA) results all the blends were composed of (a) a crystalline PEEK phase, (b) a practically pure amorphous PEEK phase, and (c) a PAr-rich phase richer in PEEK as the PEEK content in the blends increased. Annealed blends showed a poor mechanical performance in the PAr-rich region, but the PEEK-rich blends showed additive modulus of elasticity and tensile strength, and ductility and impact strength values similar to those of the highest of the two pure components. All the as-molded low-crystalline blends presented a synergistic behavior in the modulus of elasticity, as well as, surprisingly, in ductility and impact strength in the intermediate and slightly majority PEEK compositions. The different mechanical response of the components in fine dispersed phases and in macroscopic tensile specimens may account for the observed results.     

The effect of molding conditions on mechanical and morphological properties at the interface of film insert injection molded polypropylene‐film/polypropylene matrix

An extensive study on the peel strength between a polypropylene (PP) film and PP substrate fabricated using film insert injection molding technique was carried out through a 180° peel test. Injection molding conditions such as barrel temperature, injection speed and holding pressure were varied to gauge their effects on the mechanical and morphological properties. Morphological observations were made at the film‐substrate interfacial regions by means of transmission electron microscopy (TEM). The injection molded products, with the films still attached, were subjected to bending and impact tests to determine if there is any relationship between film‐substrate adhesion and bulk properties. Observation of the load‐displacement curves during the peel test revealed three unique and interesting curves, corresponding to different peeling and film fracture mechanisms. Increases in injection speed, barrel temperature and holding pressure lead to increased bonding between the film and substrate surfaces. The enhancement of bonding between these two polymer surfaces could be attributed to polymer‐polymer interdiffusion. Substantiating evidence from TEM, which shows the fading of the interface as the bond strengthens, further boosts the accuracy of this assumption. The hope that the films could contribute to enhancing bulk properties has been diminished since the bending properties appeared to be similar with or without the film attached. Polym. Eng. Sci. 44:2327–2334, 2004. © 2004 Society of Plastics Engineers.     

Synergism on tensile properties of injection molded polybutene-1 /polypropylene blends

Blends of polybutene- 1 (PB-1) and polypropylene (PP) have been injection and compression molded. A synergism appears in the ultimate elongation and the tensile strength for the injection moldings. The maximum point of the synergism at the composition of 25 wt% PB-1 shifts to 50 wt% PB-1 after annealing at 145° C for 1 h. A linear relation and negative deviation from the additivity rule for these two properties are observed for the compression moldings with quick cooling and slow cooling, respectively. Thermal analysis, polarized optical microscopy, and scanning electron microscopy (SEM) are used to study the occurrence of the synergism. The mutual interference between the two components on the crystal formation and the plasticization effect of PB- 1 on PP result in the synergism. An increased phase separation probably occurs during the compression molding with slow cooling. So, the blends compression-molded with slow cooling having a higher amount of PP have brittle breaks, similar to pure PP.     

The effect of pre-curing at 50° C on autoclave expansion of high magnesia cements

The effect of pre-curing at 50°C for various periods of time on the expansion of specimens subsequently subjected to the ASTM autoclave test has been examined. High magnesia cements with and without the addition of fly ash were studied. The effect of pre-curing on autoclave expansion dependend principally on the lime/silica ratio of the cement but also varied with other factors such as whether the periclase present originated in the clinker or was deliberately added. It is concluded that changes in the curing schedule of the ASTM autoclave test of the type investigated here would not improved the reliability of the test. The work has however provided useful new insights into the mechanism of the stabilisation process.     

The compatibility of linear low density polyethylene-polypropylene blends: Viscosity ratio plots

Blends of linear low density polyethylene (LLDPE) and polypropylene (PP) show diverse mechanical property behavior in the published literature. The main objectives of this work were: to investigate the effect of viscosity of the component phases on the mechanical properties of such blends and to use the results to obtain a method for compatibilizing diaper manufacturing waste. The significant result of the study was that although LLDPE/PP blends are often termed “incompatible,” when viscosity of the components was more closely matched to each other, increases of as much as 50% in tensile strength and modulus were observed over the “rule of mixtures” line. Also, scanning electron microscopy then showed a more diffuse interface between the component phases. Three dimensional views of plots of viscosity ratio of the blend components as a function of temperature and shear rate were used to demonstrate the closer matching of viscosities for the blend components of the higher performing blends. In processing diaper manufacturing waste, addition of a high molecular weight PP in a manufacturing scale single screw extruder, to provide a closer match of viscosities of the blend components, significantly improved mechanical properties.     

Effect of EPDM on the mechanical properties of blends of high and low density polyethylene

Summary We studied the effect of adding ethylene-propylene-diene rubber (EPDM) to blends of high (HDPE) and low (LDPE) density polyethylene. The extrusion torque of the blend without EPDM shows a deviation from the linear addition rule, but blends with rubber follow the addition rule. Two composition regions that are compatible with the torque behavior are present in the Young's modulus and extension at break curves. The EPDM content improves the extension at break of LDPE rich blends. This improvement extends to higher compositions of HDPE as the EPDM content is increased. Received: 4 September 1997/Revised version: 30 April 1998/Accepted: 13 May 1998     

Morphology and mechanical properties of injection molded articles with weld-lines

The effect of weld-lines on the morphology and mechanical properties of injection molded articles made of neat poly(butylene terephthalate) (PBT) and glass fiber-reinforced PBT was investigated. The weld-line was introduced to a molded article by using a rectangularly shaped insert inside a mold cavity, and tensile specimens were prepared at various positions through the entire molded article. The weld-line position was further checked by a short-shot experiment. Although the maximum tensile stress for specimens of neat PBT with a weld-line is almost the same as that without a weld-line, the maximum tensile stress and the elongation at break for fiber-reinforced PBT with a weld-line were found to be about half of those without the weld-line. This is attributed to the fact that the fibers near the weld-lines are oriented parallel to the weld-line direction (or perpendicular to the tensile force direction) due to stretching flow. Finally, we compared experimental results of flow pattern and fiber orientations with numerical simulations. We found that the predictions of flow fronts and fiber orientations are in good agreement with experimental results.     

The mechanical properties of insert‐molded bimaterial composites

Bimaterial composite samples were constructed by injecting various polymers into a mold containing a fraction of a pre‐molded specimen. The resulting series composites were tested in tension. Breaking stresses were independent of fractional length. Conversely, both elongation to break and apparent stiffness varied with Although samples broke at or near the interface, adhesion was reasonably good, as indicated by transfer of material across interfaces.     

Thermal and mechanical properties of injection molded blends of a liquid crystalline polymer and poly(butylene terephthalate)

The microstructure and the thermal and mechanical properties of injection molded samples of different blends of Vectra (LCP) and poly(butylene terephthalate) (PBT) have been studied. Differential scanning calorimetry and hot-stage polarized light microscopy showed that the crystallization of PBT was unaffected by the presence of LCP. X-ray diffraction showed that the PBT component was always unoriented in the injection molded samples. Blends with less than 28 vol% LCP exhibited the same stiffness and the same coefficient of linear thermal expansion as PBT. Blends containing more than 38 vol% LCP contained an oriented LCP phase and had a stiffness in accordance with the upper-bound composite equation. The coefficients of linear thermal expansion for these blends were close to that of pure LCP.