Cure and properties of thermosetting systems

A generalised time-temperature-transformation cure diagram for thermosetting systems is discussed from the point of view of understanding relationships between cure, properties, and thermal degradation.     

Cure kinetics of a thermosetting liquid dicyanate ester monomer/high-Tg polycyanurate material

The cure of a liquid dicyanate ester monomer, which reacts to form a high-T_g (≈200°C) polycyanurate network, has been investigated using differential scanning calorimetry (DSC), Fourier transform infrared spectroscopy (FTIR), and a dynamic mechanical technique, torsional braid analysis (TBA). The monomer is cured with and without catalyst. The same one-to-one relationship between fractional conversion and the dimensionless glass transition temperature is found from DSC data for both the uncatalyzed and catalyzed systems, independent of cure temperature, signifying that the same polymeric structure is produced. T_g is the parameter used to monitor the curing reactions since it is uniquely related to conversion, is sensitive, is accurately determined, and is also directly related to the solidification process. The rate of uncatalyzed reaction is found to be much slower than that of the catalyzed reaction. The apparent overall activation energy for the uncatalyzed reaction is found to be greater than that of the catalyzed reaction (22 and 13 kcal/mol, respectively) from time–temperature superposition of experimental isothermal T_g vs. In time data to form kinetically-controlled master curves for the two systems. Although the time–temperature superposition analysis does not necessitate knowledge of the rate expression, it has limitations, because if the curing process consists of parallel reactions with different activation energies, as is considered to be the case from analysis of the FTIR data, there should not be a kinetically-controlled master curve. Consequently, a kinetic model, which can be satisfactorily extrapolated, is developed from FTIR isothermal cure studies of the uncatalyzed reaction. The FTIR data for the uncatalyzed system at high cure temperatures, where the material is in the liquid or rubbery states throughout cure, 190 to 220°C, are fitted by a model of two parallel reactions, which are second-order and second-order autocatalytic (with activation energies of 11 and 29 kcal/mol), respectively. Using the model parameters determined from the FTIR studies and the relationship between T_g and conversion from DSC studies, T_g, vs. time curves are calculated for the uncatalyzed system and found to agree with DSC experimental results for isothermal cure temperatures from 120 to 200°C to even beyond vitrification. The DSC data for the catalyzed system are also described by the same kinetic model after incorporating changes in the pre-exponential frequency factors (due to the higher concentration of catalyst) and after incorporating diffusion-control, which occurs prior to vitrification in the catalyzed system (but well after vitrification in the uncatalyzed system). Time–temperature-transformation (TTT) isothermal cure diagrams for both systems are calculated from the kinetic model and compared to experimental TBA data. Experimental gelation is found to occur at a conversion of approximately 64% in the catalyzed system by comparison of experimental macroscopic gelation at the various curing temperatures and iso-T_g (iso-conversion) curves calculated from the kinetic model. © 1993 John Wiley & Sons, Inc.     

Pyrolysis–molecular weight chromatography–vapor-phase infrared spectrophotometry: An on-line system for analysis of polymers. IV. Influence of cis/trans ratio on the thermal degradation of 1,4-polybutadienes

The influence of the cis/trans ratio of 1,4-polybutadienes on the volatile products formed during temperature-programmed thermal degradation to 15% weight loss has been investigated using a mass chromatograph (a gas chromatograph which directly provides mass numbers of resolved components of a mixture) and an “on the fly” vapor-phase infrared spectrophotometer. In order of amounts, major volatile products were 4-vinyl-1-cyclohexene (dimer), 1,3-butadiene (monomer), cyclopentene, and 1,3-cyclohexadiene. With increasing trans content, the relative quantities of 4-vinyl-1-cyclohexene decreased strongly, cyclopentene increased strongly, 1,3-butadiene decreased moderately, and 1,3-cyclohexadiene increased moderately. For a high-trans polybutadiene, increasing the heating rate produced relatively more monomer and dimer but less cyclopentene. Mass chromatograms from 1,4-polybutadienes which had been heated to 15% weight loss in their prehistory were similar to those obtained from 1,2-polybutadiene, indicating that 1,4-polybutadiene undergoes isomerization prior to degradation. Mechanisms for the formation of the main volatile products of decomposition are discussed.     

Effect of dispersity on the Tll (>Tg) transition in polystyrene

The presence of a high temperature (>T_g) relaxation in amorphous polystyrene has been investigated further. In the previous work,¹ the techniques of differential thermal analysis (DTA) and torsional braid analysis (TBA) were employed to study polystyrene as a function of “monodisperse” molecular weight. The occurrence of the T_ll transition appeared to be associated with the attainment of a critical viscosity level with also corresponded with a free volume level. An entanglement network developed at a critical value of molecular weight, M_c, giving a break in the T_ll-versus-M plots. The present work deals with the influence of dispersity on the T_ll transition, below and above M_c. A series of binary blends of “monodisperse” anionically polymerized polystyrenes with systematic changes in M?_n and heterogeneity index (M?_w/M?_n) was tested by TBA. The results show that when both components have molecular weights below M_c, single and average values of T_g and T_ll are observed which are linearly related to M?_n^?1, as predicted by free volume arguments. Although a single T_g is observed when one component has a molecular weight above and the other has a molecular weight below M_c, the components appear to undergo the T_ll relaxation independently. The results indicate that both the glass transition and the T_ll transition are basically governed by the same type of molecular motion but at different length ranges.     

Effect of physical annealing on the dynamic mechanical properties of a high-Tg amine-cured epoxy system

Physical annealing of a fully cured amine/epoxy system has been investigated using the freely oscillating TBA torsion pendulum technique. The material densifies spontaneously during annealing in an attempt to reach equilibrium, thereby changing material behavior. The dynamic mechanical behavior of a film specimen (T_g = 174°C, 0.3 Hz) and of a glass braid composite specimen (T_g = 182°C, 0.9 Hz) was monitored during isothermal annealing at sub-T_g temperatures (ranging to 230°C below T_g); after annealing, the behavior was measured vs. temperature and compared with that of the unannealed state. Isothermally, the storage modulus (G′) of the film specimen and the relative rigidity (1/P²) of the composite specimen increased almost linearly with log time, whereas the logarithmic decrement (Δ) decreased with time. The isothermal rates of annealing were determined from the rates of changes in G′ and in 1/P² for the film and composite specimens, respectively. In a wide temperature range between T_g and the secondary transition temperature, T_sec (≈ ?30°C, 2.3 Hz by TBA), the isothermal rates of annealing at the same annealing time appeared to be the same. Thermomechanical spectra of the isothermally annealed material revealed a maximum deviation in thermomechanical behavior from the unannealed material in the vicinity of the annealing temperature. The effects of physical aging were the same for the film and composite specimens. Effects of sequential annealing at two isothermal temperatures on the thermomechanical behavior were also investigated; when the second temperature was higher than the first, the effect of only the high-temperature annealing was evident, whereas the effect of annealing at both temperatures was revealed when the second temperature was lower than the first. Results suggest that physical annealing at different temperatures involves different length scales of chain segment relaxation and that the effects of isothermal aging can be eliminated by heating to below T_g.     

Anomalous behavior of thermosetting systems after cure vs. chemical conversion: A normalized conversion–temperature–property diagram

Isothermal properties of thermosetting materials after cure, such as density and modulus, pass through maximum and minimum values with increasing chemical conversion. In this report observed decreases in modulus and density at isothermal temperatures below the glass-transition temperature, T_g, are termed “anomalous.” Four diepoxide (diglycidyl ether of bisphenol A) and tetrafunctional diamine (trimethylene glycol di-p-aminobenzoate) high T_g thermosetting systems with different ratios of amine to epoxy were investigated for the purpose of analyzing the evolution of the isothermal properties with increasing conversion. The density, T_g, and modulus of the materials with increasing conversion were measured by a combination of dilatometric, differential scanning calorimetry, and torsional braid analysis techniques. The results are presented in the form of conversion–temperature–property (T_gTP) diagrams with modulus and density as the properties. T_g is used as a direct measure of conversion based on the one-to-one relationship between T_g and conversion. The property-conversion behavior of the systems with different ratios of amine to epoxy show similar behavior if T_g is used as the measure of conversion and the data are normalized with respect to T_g at a conversion corresponding to the lower limit of the conversion range at which a maximum in the isothermal modulus occurs. The conversion corresponding to molecular gelation, _gelT_g, correlates with the lower limit of the conversion range at which the maximum in isothermal modulus occurs; _gelT_g also marks a change in the behavior of the sub-T_g mechanical relaxations vs. conversion. The conversion corresponding to the maximum in isothermal modulus vs. conversion correlates with the conversion corresponding to the maximum in isothermal density vs. conversion. © 1995 John Wiley & Sons, Inc.     

Time–temperature–transformation (TTT) cure diagram: Modeling the cure behavior of thermosets

The times to gelation and to vitrification for the isothermal cure of an amine-cured epoxy (Epon 828/PACM-20) have been measured on macroscopic and molecular levels by dynamic mechanical spectrometry (torsional braid analysis and Rheometrics dynamic spectrometer), infrared spectroscopy, and gel fraction experiments. The relationships between the extents of conversion at gelation and at vitrification and the isothermal cure temperature form the basis of a theoretical model of the time–temperature–transformation (TTT) cure diagram, in which the times to gelation and to vitrification during isothermal cure versus temperature are predicted. The model demonstrates that the “S” shape of the vitrification curve depends on the reaction kinetics, as well as on the physical parameters of the system, i.e., the glass transition temperatures of the uncured resin (T_g0), the fully cured resin (T_g∞), and the gel (_gelT_g). The bulk viscosity of a reactive system prior to gelation and/or vitrification is also described.     

Application of the Theory of Critical Distances to predict the effect of induced and process inherent defects for SLM Ti-6Al-4V in high cycle fatigue

Additive manufacturing techniques such as selective laser melting enable the production of customised components with high geometrical freedom. However, SLM results in a material condition with different properties to their conventionally manufactured counterparts. The presence of process-inherent defects can significantly impact the degradation of part performance. Hereby, a novel approach to assessing notched SLM Ti-6Al-4V material via a critical distance theory is presented. Geometrical notches of varying size are evaluated. Results show that the Theory of Critical Distances is appropriately applicable to fatigue prediction of SLM Ti-6Al-4V in its as-built state.     

Pyrolysis–molecular weight chromatography–vapor-phase infrared spectrophotometry: An on-line system for analysis of polymers. III. Thermal decomposition of polysulfones and polystyrene

The thermal decomposition of poly(butene-1 sulfone), poly(pentene-1 sulfone), poly(hexene-1 sulfone), poly(styrene sulfone), and polystyrene was investigated in helium at a heating rate of 20°C/min using an experimental system which consists of a programmable pyrolyzer, a thermal conductivity detector, a mass chromatograph, and a vapor-phase infrared spectrophotometer. Poly(butene-1 sulfone), poly(penetene-1 sulfone), and poly(hexene-1 sulfone) displayed two-step decomposition; the primary products of decomposition at both steps were the comonomers (olefin and SO₂). For poly(styrene sulfone), in addition to styrene and SO₂, products with molecular weights corresponding to dimers of styrene were observed. Decomposition of this polymer was compared with that of polystyrene, which formed mostly monomer.