PLASTICS MATERIALSAND PROCESSESA Concise Encyclopedia

Charles A. HarperTechnology Seminars, Inc.

Edward M. PetrieIndustry Consultant

A JOHN WILEY & SONS, INC., PUBLICATION

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PLASTICS MATERIALSAND PROCESSESA Concise Encyclopedia

PLASTICS MATERIALSAND PROCESSESA Concise Encyclopedia

Charles A. HarperTechnology Seminars, Inc.

Edward M. PetrieIndustry Consultant

A JOHN WILEY & SONS, INC., PUBLICATION

Copyright © 2003 by John Wiley & Sons, Inc. All rights reserved.

Published by John Wiley & Sons, Inc., Hoboken, New Jersey.Published simultaneously in Canada.

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Library of Congress Cataloging-in-Publication Data:

Harper, Charles A.Plastics materials and processes : a concise encyclopedia /Charles A. Harper,

Edward M. Petrie.p. cm.

Includes index.ISBN 0-471-45603-9 (cloth)1. Plastics–Encyclopedias. I. Petrie, Edward M. II. Title.TP1110.H42 2003668.4�03–dc21

2003009475

Printed in the United States of America

10 9 8 7 6 5 4 3 2 1

http://www.copyright.com

CONTENTS

Preface vii

Acknowledgments ix

Introduction xi

Dictionary of Terms 1

Appendices 613

Index 951

v

PREFACE

Plastics Materials and Processes: A Concise Encylopedia defines the importantconcepts of the plastics industry in a single-volume encyclopedia. Materials,processes, properties, test methods, and other information that is used commonlythroughout the industry are defined without great involvement in detail and in amanner that is straightforward and efficient. This book is aimed at meeting theneeds of general managers, executives, purchasing and manufacturing personnel,supervisors, engineers, students, and all others that are working in the field of plas-tics or have interest in these important materials. It is expected that in today’s robustworking environment the time burdens on these individuals are greater than ever.When this limited time frame is coupled with the universe of exploding polymertechnology, the resulting pressures may make it difficult to maintain an overallgrasp of the information required to efficiently perform.

The selection of information provided in this book has been made with a viewtoward giving the reader an efficient, intelligent overall insight without having towade through voluminous texts or handbooks in specific areas. It is not the purposeof the book to provide an exhaustive treatise on any subject, as it is assumed thatthe reader will consult more comprehensive and detailed texts, journals, and eventhe producers of materials and processing equipment for such specific and in-depth information. However, this book should make the journey to acquire suchinformation easier and more efficient.

As the goal of this book is to provide a sourcebook of practical information forall ranges of interest, its organization is aimed primarily at reader convenience. Themain body, therefore, consists of a concise encyclopedia of knowledge useful intoday’s plastics industry. It contains an extensive array of materials information andproperty and performance data presented in an alphabetical format. In addition, itpresents all-important application guidelines, process method trade-offs, and design,finishing, and performance criteria. It also summarizes chemical, structural, andother basic polymer considerations.

This main body of information is preceded by a brief introduction to polymers andplastics that may be used to provide the reader with a “glue” to hold the individualsnippets of information together. This initial section covers the nature of polymers,and it offers an introduction to the material and process descriptions that follow.

After the encyclopedia, are several appendices containing valuable property dataand other detailed information. Here plastics and other materials commonly usedin the industry are compared to one another, and guidance is offered regardingtheir processing methods and final applications. Finally, there is a completely

vii

cross-referenced and easy-to-use index that is provided as a road map for the pre-ceding information and as a method of linking subjects and information together.

The result of this compilation is a concise, yet valuable reference to the broadamount of information required to function in the plastics industry. It will be a use-ful first-source to anyone involved in all aspects of product design, development,application, manufacturing, marketing, or other peripheral function in the plasticsindustry. The authors hope that this book will be the most worn book in the reader’sreference library as a result of being the first choice for information.

CHARLES A. HARPEREDWARD M. PETRIE

viii PREFACE

ACKNOWLEDGMENTS

This book is dedicated to my father, Edward J. Petrie, who has provided me with thematerials and processes for everything that I do and, most importantly, the will tosucceed.

—EDWARD M. PETRIE

ix

INTRODUCTION

THE NATURE OF PLASTICS

Practically stated, a plastic is an organic polymer, available in some resin form orsome form derived from the basic polymerized resin. These forms can be liquid orpastelike resins for embedding, coating, and adhesive bonding, or they can bemolded, laminated, or formed shapes, including sheet, film, or larger-mass bulkshapes.

The number of basic plastic materials is large, and the list is increasing. In addi-tion, the number of variations and modifications to these plastic materials is alsoquite large. The methods by which these materials are processed, finished, andprepared for final use is also immense. Together, the resultant quantity of materialsand processes available is just too large to be completely understood and correctlyapplied by anyone other than those whose day-to-day work puts them in directcontact with a diverse selection of materials. The practice of mixing brand names,tradenames, and chemical names of various plastics only makes the problem ofunderstanding these materials more troublesome.

Although there are numerous minor classification schemes for polymers,depending on how one wishes to categorize them, nearly all polymers can beplaced in one of two major classifications— thermosetting materials (or ther-mosets) and thermoplastic materials. Likewise, foams, adhesives, embeddingresins, elastomers, and so on, can be subdivided into thermoplastic and thermoset-ting classifications.

THERMOSETTING PLASTICS

As the name implies, thermosetting plastics or thermosets are cured, set, or hardenedinto a permanent shape. Curing is an irreversible chemical reaction known as cross-linking, which usually occurs under heat. For some thermosetting materials, curingis initiated or completed at room temperature. Even here, however, it is often the heatof the reaction or the exotherm that actually cures the plastic material. Such is thecase, for instance, with a room-temperature-curing epoxy or polyester compound.

The cross-linking that occurs in the curing reaction is brought about by the link-ing of atoms between or across two linear polymers, resulting in a three-dimensionalrigidized chemical structure. One such reaction is shown in Fig. IN.1. Although thecured thermoset part can be softened by heat, it cannot be remelted or restored to the

xi

flowable state that existed before curing. Continued heating for long times leads todegradation or decomposition.

In general, unfilled thermosetting plastics tend to be harder, more brittle, andnot as tough as thermoplastics. Thus it is common practice to add filler to ther-mosetting materials. A wide variety of fillers can be used for varying product prop-erties. For molded products, usually compression or transfer molding, mineral orcellulose fillers are often used as lower-cost, general-purpose filler and glass fiberfillers are often used or optimum strength or dimensional stability. There are alsomany product and processing trade-offs, but a general guide to the application offiller can be found in several major texts on the subject. It should be added thatfiller form and filler surface treatment could also be major variables. Thus it isimportant to consider fillers along with the thermosetting material, especially formolded products. Other product forms may be filled or unfilled, depending onrequirements.

xii PLASTICS MATERIALS AND PROCESSES

HO CH2CH2 O C CH C O

OO

CH CH2 CH2 OH

CH2CH2 O C

O

CH CH C

O

O CH2CH2 OH + 2H2OHO

CH2CH2 O C

O

CH CH

CH2

C

O

O CH2CH2

CH

CHC CH C

O

O

O

CH2CH2 O CH2CH2

H + HO H + HO

n

EthyleneGlycol

Maleic Acid EthyleneGlycol

Ethylene Glycol Maleate Polyester

Polyester polymer units react (copolymerize) with styrene monomer in presence of catalystand/or heat to yield styrene-polyester copolymer resin or, more simply, a cured polyester.(Asterisk indicates points capable of further cross-linking.)

*

*

*

Styrene

Styrene-Polyester Copolymer

*

*

Reaction B

One quantity of unsaturated acid reacts with two quantites of glycol to yield linear polyester (alkyd) polymer of n polymer units

Reaction A

*

Figure IN.1 Simplified diagrams showing how crosslinking reactions produce polyester resin (styrene-polyester copolymer resin) from basic chemicals.

Plastic materials included in the thermosetting plastic category and discu-ssed separately in the following sections of this book include alkyds, diallylphthlate, epoxies, melamines, phenolics, polyesters, silicones, and ureas. A listof typical tradenames and suppliers of the more common plastics is given inTable IN.1.

THERMOPLASTICS

Thermoplastics differ from thermosets in that they do not cure or set under heatas do thermosets. Thermoplastics merely soften or melt when heated to a flow-able state, and under pressure they can be forced or transferred from a heatedcavity into a cool mold. On cooling in a mold, thermoplastics harden and takethe shape of the mold. Because thermoplastics do not cure or set, they can beremelted and then rehardened by cooling. Thermal aging, brought about byrepeated exposure to high temperatures required for melting, causes eventual

INTRODUCTION xiii

Table IN.1 Typical Tradenames and Suppliers of Thermosetting Plastics (Note: these arebut a few, see Appendix N for an expanded listing.)

Plastic Typical trade names and suppliers

Alkyd Plaskon (Allied Chemical)Durez (Hooker Chemical)Glaskyd (American Cyanamid)

Diallyl phthalates Dapon (FMC)Diall (Allied Chemical)Durez (Hooker Chemical)

Epoxies Epon (Shell Chemical)Epi-Rez (Celanese)D.E.R. (Dow Chemical)Araldite (Ciba)ERL (Union Carbide)

Melamines Cymel (American Cyanamid)Plaskon (Allied Chemical)

Phenolics Bakelite (Union Carbide)Durez (Hooker Chemical)Genal (General Electric)

Polybutadienes Dienite (Firestone)Ricon (Colorado Chemical Specialties)

Polyesters Laminac (American Cyanamid)Paraplex (Rohm and Haas)Selectron (PPG)

Silicones DC (Dow Corning)Ureas Plaskon (Allied Chemical)

Beetle (American Cyanamid)

xiv PLASTICS MATERIALS AND PROCESSES

Table IN.2 Typical Tradenames and Suppliers of Thermoplastics (Note: these are but afew, see Appendix N for an expanded listing.)

Thermoplastic Typical trade names and suppliers

ABS Marbon Cycolac (Borg-Warner)Abson (B. F. GoodrichLustran (Monsanto)

Acetals Delrin (E. I. du Pont)Celcon (Celanese)

Acrylics Plexiglas (Rohm and Haas)Lucite (E. I. du Pont)

Aramids Nomex (E. I. du Pont)Cellulosics Tenite (Eastman Chemical)

Ethocel (Dow Chemical)Forticel (Celanese)

Ionomers Surlyn A (E. I. du Pont)Bakelite (Union Carbide)

Low-permeability thermoplastics Barex (Vistron/Sohio)NR-16 (E. I. du Pont)LPT (Imperial Chemical Industries)

Nylons (see also Aramids) Zytel (E. I. du Pont)Plaskon (Allied Chemical)Bakelite (Union Carbide)

Parylenes Parylene (Union Carbide)Polyaryl ether Arylon T (Uniroyal)Polyaryl sulfone Astrel (3M)Polycarbonates Lexan (General Electric)

Merlon (Mobay Chemical)Polyesters Valox (General Electric)

Celanex (Celanese)Celanar Film (Celanese)Mylar Film (E. I. du Pont)Tenite (Eastman Chemical)

Polyethersulfone Polyethersulphone (Imperial Chemical Industries)Polyethylenes, polypropylenes, Alathon Polyethylene (E. I. du Pont)

and polyallomers Petrothene Polyethene (U.S.I.)Hi-Fax Polyethylene (Hercules)Pro-Fax Polypropylene (Hercules)Bakelite Polyethylene and Polypropylene(Union Carbide)Tenite Polyethylene and Polypropylene (Eastman)Irradiated Polyolefin (Raychem)

Polyimides and polyamide-imides Vespel SP Polyimides (E. I. du Pont)Kapton Film (E. I. du Pont)Pyralin Laminates (E. I. du Pont)Keramid/Kinel (Rhodia)P13N (Ciba-Geigy)Torlon Polyamide-Imide (Amoco)

Polymethyl pentene TPX (Imperial Chemical Industries)

INTRODUCTION xv

degradation of the materials and so limits the number of reheat cycles. Most ofthe common thermoplastics materials are discussed in detail in the followingsection.

Specific data on a variety of thermoplastics can be found in the following sec-tions of this book. In general, thermoplastic materials tend to be tougher and lessbrittle than thermosets so that they can be applied without the use of filler.However, although some are very tough, others do tend to craze or crack easily,so each case must be considered on its individual merits. Traditionally by virtueof the basic polymer structure, thermoplastics have been much less dimensional-ly and thermally stable than thermosetting plastics. Hence, thermosets haveoffered a performance advantage, although the lower processing costs forthermoplastics have given the latter a cost advantage. However, three majortrends put both thermoplastics and thermosets on a competitive performance con-sideration basis.

1. Much has been done in the development of reinforced, fiber-filled thermo-plastics, greatly increasing stability in many areas.

2. Much has been achieved in the development of so-called engineering thermo-plastics, or high-stability, higher-performance plastics, that can also be rein-forced with fiber or fillers to increase their stability further.

3. Lower-cost processing methods for thermosetting plastics have been devel-oped, especially the screw-injection molding technology.

All of these options should be considered in optimizing the design, fabrication, andperformance of plastic parts.

A list of typical tradenames and suppliers of the more common thermoplastics isgiven in Table IN.2, and a list of so-called advanced thermoplastic materials is

Table IN.2 (Continued)

Thermoplastic Typical trade names and suppliers

Polyphenylene oxides Noryl (General Electric)Polyphenylene sulfides Ryton (Phillips Petroleum)Polystyrenes Styron (Dow Chemical)

Lustrex (Monsanto)Dylene (Koppers)Rexolite (American Enka)

Polysulfones Ucardel (Union Carbide)Vinyls Pliovic (Goodyear Chemical)

Diamond PVC (Diamond Alkali)Geon (B. F. Goodrich)Bakelite (Union Carbide)

presented in Table IN.3. Specific data and information for a variety of thermoplas-tics are given in the main body of this book.

Glass Fiber-Reinforced Thermoplastics

Basically, thermoplastic molding materials are developed and can be used withoutfiller, as opposed to thermosetting molding material, which are more commonlyused with filler incorporated into the compound. This is primarily because shrink-age, hardness, brittleness, and other important processing and use properties neces-sitate the use of filler in thermosets. Thermoplastics, on the other hand, do notsuffer from the same shortcomings as the thermosets and hence can be used asmolded products without fillers. However, thermoplastics do suffer from creep anddimensional stability problems, especially under elevated temperature and loadconditions. Because of this shortcoming, most designers find it difficult to matchthe techniques of classical stress-strain analysis with the nonlinear, time-dependent,strength modulus properties of thermoplastics. Glass fiber-reinforced thermoplas-tics (FRTPs) help to simplify these problems. For instance, 40 percent glass fiber-reinforced nylon outperforms its unreinforced version by exhibiting 2-1�2 timesgreater tensile and Izod impact strengths, 4 times greater flexural modulus and only1/5 of the tensile creep.

Thus FRTPs fill a major materials gap in providing plastic materials that can bereliably used for strength purpose and which in fact can compete with metal diecastings. Strength is increased with glass fiber reinforcement, as are stiffness anddimensional stability. The thermal expansion of FRTPs is reduced, creep is substan-tially reduced, and molding precision is much greater.

xvi PLASTICS MATERIALS AND PROCESSES

Table IN.3 Advanced Thermoplastic Materials

Matrix systems Abbreviation Trade names and suppliers

Polyphenylene sulfide PPS Ryton (Phillips Petroleum)Polysulfone PSF Udel (Union Carbide)Polyetheretherketone PEEK APC (Imperial Chemical

Industries)Polyethersulfone PES Victrex (Imperial Chemical

Industries)Polyetherimide PEI Ultem (General Electric)Polyamide-imide PAI Torlon (Amoco)Polyetherketone PEK (Imperial Chemical Industries)Polyamide PA J-2 (E. I. du Pont)Polyimide PI K-III (E. I. du Pont)Polyarylene sulfide PAS PAS-2 (Phillips Petroleum)Polyarylene ketone — HTA (Imperial Chemical Industries)Polyetherketoneketone PEKK (E. I. du Pont)

The dimensional stability of glass-reinforced polymer is invariably better thanthat of the nonreinforced materials. Mold shrinkages of only a few mils per inchare characteristic of these products. Low moisture absorption of reinforced plas-tics ensures that parts will not suffer dimensional increase under high-humidityconditions. Also, the characteristic low coefficient of thermal expansion is closeenough to metals, such as zinc, aluminum, and magnesium, that it is possible todesign composite assemblies without fear that they will warp or buckle whencycled over temperature extremes. In applications where part geometry limitsmaximum wall thickness, reinforced plastics almost always afford economies forsimilar strength or stiffness over their unreinforced equivalent. A comparison ofsome important properties for unfilled and glass-filled thermoplastics is given inthe Appendices.

Chemical resistance is essentially unchanged, except that environmental stresscrack resistance of such polymers as polycarbonate and polyethylene is markedlyincreased by glass reinforcement.

Plastic Films, Tapes, and Fibers

Films are thin sections of the same polymers described previously. Most films arethermoplastic in nature because of the great flexibility of this class of resins. Filmscan be made from most thermoplastics. Films are generally made from thermoplas-tic resins by extrusion, casting, calendering, and skiving. The films are sold in thick-nesses from 0.5 to 10 mil. Thickness in excess of 10 mil is more properly calledsheets. Tapes are films slit from film to some acceptable width and are frequentlycoated with adhesives.

Films differ from similar polymers in other forms in several key properties but areidentical in all others. The most important features of common films are summarizedin Table IN.4. Films differ from other polymers chiefly in improved electric strengthand flexibility. Both of these properties vary inversely with the film thickness.Electric strength is also related to the method of manufacture. Cast and extrudedfilms have higher electric strength than skived films. This is caused by the greaterincidence of holes in the latter films. Some films can be oriented, which improvestheir physical properties substantially. Orienting is a process of selectively stretchingthe films, thereby reducing the thickness and causing changes in the crystallinity ofthe polymer. This process is usually accomplished under conditions of elevatedtemperature, and the benefits are lost if the processing temperatures are exceededduring service.

Certain polymeric materials are also available in fiber form. These are generallythermoplastic materials. Synthetic polymeric fibers are used significantly in the gar-ment industry. They are also being used increasingly in the design and manufactureof reinforced composites. Like other forms of polymers, fibers offer properties thatcan vary significantly based on the base material, fillers and modifiers, and theprocessing methods chosen.

INTRODUCTION xvii

xviii

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POLYMER STRUCTURE

All polymers are formed by the creation of chemical linkages between relativelysmall molecules, or monomers, to form very large molecules, or polymers. As men-tioned, if the chemical linkages form a rigid, cross-linked molecular structure, a ther-mosetting plastic results. If a somewhat flexible molecular structure is formed, eitherlinear or branched, a thermoplastic results. Illustrations of these molecular structuresare presented in Fig. IN.2.

Many carbon-hydrogen chain elements tend to gather and behave in basic groups.The hydrogen in a basic group could be substituted by some other element or group toform a new group. These basic groups could then react with each other in a head-to-tailfashion to make large molecules and larger macromolecules. Also, a group can reactwith a different group to form a new larger group, which can then react with itself in ahead-to-tail fashion to produce the desired new macromolecule. These basic groups are

INTRODUCTION xix

Figure IN.2 Some possible molecular structures in polymers.

called monomers; and when they are head to tail or polymerized into long chains, theyform polymers. The reaction between different basic groups to form a new basic recur-ring group is called copolymerization. These copolymers can also recur in a head-to-tailfashion to form long-chain molecules. The basic monomers are usually gases or verylight liquids; and, as polymerization continues, the molecular weight and viscosity bothincrease until solidification and formation of the gum or solid production results.

The degree of polymerization can be controlled so that the end product has thedesired processing properties but lacks the final properties for engineering use. The longchains in this state have a great deal of mobility between them, which also varies greatlywith slight changes in temperature. Some such materials are useable as thermoplasticmaterials. These long chains can react further with themselves or with other chemicals.

The general principles relating mechanical properties of polymers to structureshave been known for many years. Rubbers, plastics, and fibers, for example, are notintrinsically different materials. Their differences are a matter of degree rather thankind. If the forces of attraction between the molecular chains are small, and thechains do not fit readily into a geometric pattern, lattice, or network, the normal ther-mal motion of the atoms tends to cause the chains to assume a random, more or lesscoiled arrangement. These conditions lead to a rubberlike character.

In practical rubbers, a few cross-links are added to prevent slippage of the mole-cular chains and permanent deformation under tension (or flow). With such poly-mers, when the stress is released, the normal thermal motion of the atoms causesthem to return to a random-coiled arrangement. If the forces between the chains arestrong and the chains fit easily into a regular geometric pattern, the material is a typ-ical fiber. In cases where the forces are moderate and the tendency to form a regularlattice is also moderate, the result is a typical plastic.

Some polymers are made and used as three different materials: rubber, plastic, andfiber. Polyethylene, for example, is used as a substitute for natural rubber in wire cover-ing, as a plastic in low-loss stand-off insulators and insulation films, and as a fiber in acid-resistant filter cloths where high fiber strength is not as important as chemical resistance.

PLASTIC PROCESSING METHODS AND DESIGN GUIDELINES

Although many users of plastics buy parts from plastic processors, they should still havesome knowledge of plastic processing, as such information can often be helpful in opti-mizing product design. Also, an increasing number of user companies are doing some in-house processing. For these reasons, some guideline information in plastic processingand some guidelines for the design of plastic parts are presented in the following section.

It should be mentioned that the information presented at this point applies broadly toall classes of plastics and types of processing. Most plastic suppliers will provide veryspecific data and guidelines for their individual production. This invaluable source ofguidance is too-often unused. It is strongly recommended that plastic suppliers be morefully utilized for product design guidance. However, the information presented at thispoint will be valuable for making initial design and process decisions.

Table IN.5 explains the major ways in which plastic materials can be formedinto parts and the advantages, limitation, and relative cost of each processing

xx PLASTICS MATERIALS AND PROCESSES

xxi

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ivel

y si

mpl

e1.

5–

3,ac

rylic

s) is

pou

red

into

a m

old

(with

out p

ress

ure)

,pr

oduc

e la

rge

part

s w

ithsh

apes

; exc

ept f

or c

ast fi

lms,

2–

2.5

cure

d, a

nd r

emov

ed f

rom

the

mol

d. C

ast

thic

k cr

oss

sect

ions

; goo

dbe

com

es u

neco

nom

ical

at

ther

mop

last

icfil

ms

are

mad

e by

dep

ositi

ng th

esu

rfac

e fin

ish;

sui

tabl

e to

hi

gh-v

olum

e pr

oduc

tion

mat

eria

l, ei

ther

in s

olut

ion

or in

hot

-mel

t for

m,

low

-vol

ume

prod

uctio

nm

ost t

herm

opla

stic

s ag

ains

t a h

ighl

y po

lishe

d su

ppor

ting

leve

ls; n

ot s

uita

ble

surf

ace

Com

pres

sion

A th

erm

opla

stic

or

part

ially

pol

ymer

ized

L

ittle

was

te o

f m

ater

ial a

nd

Ext

rem

ely

intr

icat

e pa

rts

2–

10,

mol

ding

ther

mo-

setti

ng r

esin

com

poun

d, u

sual

ly p

refo

rm-

low

fini

shin

g co

sts;

larg

e,in

volv

ing

unde

rcut

s, s

ide

1.5

–3

ed, i

s pl

aced

in a

hea

ted

mol

d ca

vity

; the

mol

d is

bulk

y pa

rts

are

poss

ible

draw

s, s

mal

l hol

es, d

elic

ate

clos

ed, h

eat a

nd p

ress

ure

are

appl

ied,

and

in

sert

s, e

tc.,

not p

ract

ical

;th

e m

ater

ial fl

ows

and

fills

the

mol

d ca

vity

.ve

ry c

lose

tole

ranc

esH

eat c

ompl

etes

pol

ymer

izat

ion,

and

the

diffi

cult

to p

rodu

cem

old

is o

pene

d to

rem

ove

the

part

. The

pr

oces

s is

som

etim

es u

sed

for

ther

mop

las-

tics,

e.g

., vi

nyl p

hono

grap

h re

cord

s

xxii

Tabl

e IN

.5(C

onti

nued

)

Proc

ess

Des

crip

tion

Key

adv

anta

ges

Not

able

lim

itatio

nsC

ost f

acto

r **

Col

d fo

rmin

gSi

mila

r to

com

pres

sion

mol

ding

in th

at m

ater

ial i

sA

bilit

y to

for

m h

eavy

or

Lim

ited

to r

elat

ivel

y si

mpl

e ch

arge

d in

to s

plit

mol

d; it

dif

fers

in th

at it

use

sto

ugh-

to-m

old

mat

eria

ls;

shap

es; f

ew m

ater

ials

can

be

no h

eat—

only

pre

ssur

e. P

arts

are

cur

ed in

asi

mpl

e; in

expe

nsiv

e; o

ften

proc

esse

d in

this

man

ner

sepa

rate

ope

ratio

n. S

ome

ther

mop

last

icha

s ra

pid

prod

uctio

n ra

tesh

eet m

ater

ial a

nd b

illet

s ar

e co

ld-f

orm

ed

in p

roce

ss s

imila

r to

dro

p ha

mm

er-d

ie f

orm

ing

of m

etal

s. S

hotg

un s

hells

are

mad

e in

this

m

anne

r fr

om p

olye

thyl

ene

bille

tsE

xtru

sion

The

rmop

last

ic o

r th

erm

oset

mol

ding

com

poun

d is

Low

tool

cos

t; gr

eat m

any

Lim

ited

to s

ectio

ns o

f uni

form

2–

5,fe

d fr

om a

hop

per

to a

scr

ew a

nd b

arre

l whe

reco

mpl

ex p

rofil

e sh

apes

cr

oss

sect

ion

3–

4it

is h

eate

d to

pla

stic

ity a

nd th

en f

orw

arde

d,po

ssib

le; v

ery

rapi

d pr

o-us

ually

by

a ro

tatin

g sc

rew

, thr

ough

a n

ozzl

edu

ctio

n ra

tes;

can

app

lyha

ving

the

desi

red

cros

s-se

ctio

n co

nfigu

ratio

nco

atin

gs o

r ja

cket

ing

to

core

mat

eria

ls, s

uch

as w

ire

Fila

men

tC

ontin

uous

fila

men

ts, u

sual

ly g

lass

, in

form

of

Hig

h-st

reng

th fi

ber

Lim

ited

to s

hape

s of

pos

itive

5–

10,

win

ding

rovi

ngs

are

satu

rate

d w

ith r

esin

and

mac

hine

-re

info

rcem

ents

are

ori

ente

dcu

rvat

ure;

ope

ning

s an

d6

–8

wou

nd o

nto

man

drel

s ha

ving

sha

pe o

f de

sir-

prec

isel

y in

dir

ectio

n w

here

hole

s re

duce

str

engt

hed

finis

hed

part

. Onc

e w

indi

ng is

com

plet

ed,

stre

ngth

is n

eede

d; e

xcep

-pa

rt a

nd m

andr

el a

re p

lace

d in

ove

n fo

r tio

nal s

tren

gth/

wei

ght r

atio

;cu

ring

. Man

drel

is th

en r

emov

ed th

roug

hgo

od u

nifo

rmity

of

resi

npo

rtho

le a

t end

of

wou

nd p

art

dist

ribu

tion

in fi

nish

ed p

art

xxiii

Inje

ctio

nT

herm

opla

stic

or

ther

mos

et m

oldi

ng c

ompo

und

isE

xtre

mel

y ra

pid

prod

uctio

n H

igh

initi

al to

ol a

nd d

ie c

osts

;1.

5–

5,m

oldi

nghe

ated

to p

last

icity

in c

ylin

der

at c

ontr

olle

dra

tes,

hen

ce lo

w c

ost p

erno

t pra

ctic

al f

or s

mal

l run

s2

–3

tem

pera

ture

; the

n fo

rced

und

er p

ress

ure

part

; litt

le fi

nish

ing

thro

ugh

a no

zzle

into

spr

ues,

run

ners

, gat

es,

requ

ired

; goo

d di

men

sion

alan

d ca

vitie

s of

mol

d. T

he r

esin

sol

idifi

esac

cura

cy; a

bilit

y to

pro

duce

rapi

dly,

the

mol

d is

ope

ned

and

the

rela

tivel

y la

rge,

com

plex

part

(s)

ejec

ted.

In

mod

ified

ver

sion

shap

es; v

ery

good

of p

roce

ss —

-run

nerl

ess

mol

ding

—th

esu

rfac

e fin

ish

runn

ers

are

part

of

mol

d ca

vity

Lam

inat

ing,

Mat

eria

l, us

ually

in f

orm

of

rein

forc

ing

clot

h,

Exc

elle

nt d

imen

sion

al s

tabi

lity

Hig

h to

ol a

nd d

ie c

osts

; 2-

5,hi

gh p

ress

ure

pape

r, fo

il, e

tc.,

prei

mpr

egna

ted

or c

oate

d w

ithof

fini

shed

pro

duct

; ver

ylim

ited

to s

impl

e sh

apes

3-4

ther

mos

et r

esin

(so

met

imes

a th

erm

opla

stic

), is

econ

omic

al in

larg

ean

d cr

oss-

sect

ion

profi

les

mol

ded

unde

r pr

essu

re g

reat

er th

an 1

,000

lb/in

2pr

oduc

tion

of p

arts

into

she

et, r

od, t

ube,

or

othe

r si

mpl

e sh

ape

Mat

ched

-A

var

iatio

n of

con

vent

iona

l com

pres

sion

mol

ding

, R

apid

pro

duct

ion

rate

s; g

ood

Hig

h m

old

and

equi

pmen

t 2

–5,

die

mol

ding

this

pro

cess

use

s tw

o m

etal

mol

ds h

avin

g a

qual

ity a

nd r

epro

duci

bilit

yco

sts;

par

ts o

ften

req

uire

3

–4

clos

e-fit

ting,

tele

scop

ing

area

to s

eal i

n th

e pl

astic

of p

arts

exte

nsiv

e su

rfac

e fin

ishi

ng,

com

poun

d be

ing

mol

ded

and

to tr

im th

ee.

g., s

andi

ngre

info

rcem

ent.

The

rei

nfor

cem

ent u

sual

ly m

ator

pre

form

, is

posi

tione

d in

the

mol

d,an

d th

e m

old

is c

lose

d an

d he

ated

(pr

essu

res

gene

rally

var

y be

twee

n 15

0 an

d 40

0 lb

/in2 )

.M

old

is th

en o

pene

d an

d pa

rt li

fted

out

xxiv

Tabl

e IN

.5(C

onti

nued

)

Proc

ess

Des

crip

tion

Key

adv

anta

ges

Not

able

lim

itatio

nsC

ost f

acto

r **

Rot

atio

nal

A p

rede

term

ined

am

ount

of

pow

dere

d or

liqu

id

Low

mol

d co

st; l

arge

hol

low

L

imite

d to

hol

low

par

ts; i

n 1.

5–

5,m

oldi

ngth

erm

opla

stic

or

ther

mos

et m

ater

ial i

s po

ured

part

s in

one

pie

ce c

an b

ege

nera

l, pr

oduc

tion

2–

3in

to m

old.

Mol

d is

clo

sed,

hea

ted,

and

rot

ated

prod

uced

; mol

ded

part

s ar

era

tes

are

slow

in th

e ax

is o

f tw

o pl

anes

uni

tl co

nten

ts h

ave

esse

ntia

lly is

otro

pic

fuse

d to

inne

r w

alls

of

mol

d. T

he m

old

isin

nat

ure

open

ed a

nd p

art r

emov

edSl

ush

mol

ding

Pow

dere

d or

liqu

id th

erm

opla

stic

mat

eria

l is

Ver

y lo

w m

old

cost

s; v

ery

Lim

ited

to h

ollo

w p

arts

; 1.

5–

4,po

ured

into

a m

old

to c

apac

ity. M

old

is c

lose

dec

onom

ical

for

sm

all

prod

uctio

n ra

tes

are

very

2

–3

and

heat

ed f

or a

pre

dete

rmin

ed ti

me

to a

chie

ve-p

rodu

ctio

n ru

nssl

ow; l

imite

d ch

oice

of

a sp

ecifi

ed b

uild

up o

f pa

rtia

lly c

ured

mat

eria

ls th

at c

an b

e m

ater

ial o

n m

old

wal

ls M

old

is o

pene

d,pr

oces

sed

and

unpo

lym

eriz

ed m

ater

ial i

s po

ured

out.

Sem

ifus

ed p

art i

s re

mov

ed f

rom

mol

dan

d fu

lly p

olym

eriz

ed in

ove

nT

herm

ofor

min

gH

eat-

soft

ened

ther

mop

last

ic s

heet

is p

lace

d ov

er

Tool

ing

cost

s ge

nera

lly a

re

In g

ener

al, l

imite

d to

par

ts

2–

10,

mal

e or

fem

ale

mol

d. A

ir is

eva

cuat

ed f

rom

low

; pro

duce

s la

rge

part

sof

sim

ple

confi

gura

tion;

3

–5

betw

een

shee

t and

mol

d, c

ausi

ng s

heet

tow

ith th

in s

ectio

ns; o

ften

limite

d nu

mbe

r of

conf

orm

to c

onto

ur o

f m

old.

The

re a

reec

onom

ical

for

lim

ited

mat

eria

ls to

cho

ose

man

y va

riat

ions

, inc

ludi

ng v

acuu

mpr

oduc

tion

of p

arts

from

; hig

h sc

rap

snap

back

, plu

g as

sist

, dra

pefo

rmin

g, e

tc.

xxv

Tra

nsfe

rT

herm

oset

mol

ding

com

poun

d is

fed

fro

m h

oppe

r G

ood

dim

ensi

onal

acc

urac

y;

Mol

ds a

re e

xpen

sive

; hig

h 1.

5–

5,m

oldi

ngin

to a

tran

sfer

cha

mbe

r w

here

it is

hea

ted

rapi

d pr

oduc

tion

rate

; ver

ym

ater

ial l

oss

in s

prue

s2

–3

to p

last

icity

. It i

s th

en f

ed b

y m

eans

of

intr

icat

e pa

rts

can

bean

d ru

nner

s; s

ize

of p

arts

a pl

unge

r th

roug

h sp

rues

, run

ners

, and

prod

uced

is s

omew

hat l

imite

dga

tes

of c

lose

d m

old

into

mol

d ca

vity

.M

old

is o

pene

d an

d th

e pa

rt e

ject

edW

et la

y-up

Num

ber

of la

yers

, con

sist

ing

of a

mix

ture

of

Ver

y lo

w c

ost;

larg

e pa

rts

Not

eco

nom

ical

for

larg

e-1.

5–

4,or

con

tact

rein

forc

emen

t (us

ually

gla

ss c

loth

)ca

n be

pro

duce

d; s

uita

ble

volu

me

prod

uctio

n;

2–

3m

oldi

ngan

d re

sin

(the

rmos

ettin

g), a

re p

lace

dfo

r lo

w-v

olum

eun

ifor

mity

of

resi

nin

mol

d an

d co

ntou

red

by r

olle

r to

mol

d’s

prod

uctio

n of

par

tsdi

stri

butio

n ve

rysh

ape.

Ass

embl

y is

allo

wed

to c

ure

diffi

cult

to c

ontr

ol; m

ainl

y (u

sual

ly in

an

oven

) w

ithou

t app

licat

ion

limite

d to

sim

ple

shap

esof

pre

ssur

e. I

n m

odifi

catio

n of

pro

cess

,ca

lled

spra

y m

oldi

ng, r

esin

sys

tem

san

d ch

oppe

d fib

ers

are

spra

yed

sim

ulta

neou

sly

from

spr

aygu

n ag

ains

t mol

d su

rfac

e; r

olle

ras

sist

als

o is

use

d. W

et la

y-up

par

tsso

met

imes

are

cur

ed u

nder

pres

sure

, usi

ng v

acuu

mba

g, p

ress

ure

bag,

or

auto

-cla

ve

*Mat

eria

l cos

t� f

acto

r �

pur

chas

e pr

ice

of a

par

t: to

p fig

ure

is o

vera

ll ra

nge,

bot

tom

is p

roba

ble

aver

age

cost

.

xxvi

Tabl

e IN

.6G

uide

lines

on

Part

Des

ign

for

Plas

tic P

roce

ssin

g M

etho

ds

Rei

nfor

ced

plas

tic m

oldi

ng

Wet

lay-

upB

low

Com

pres

sion

Inje

ctio

n(c

onta

ctM

atch

ed d

ieFi

lam

ent

Rot

atio

nal

The

rmo-

Tra

nsfe

rD

esig

n ru

les

mol

ding

Cas

ting

mol

ding

Ext

rusi

onm

oldi

ngm

oldi

ng)

mol

ding

win

ding

mol

ding

form

ing

mol

ding

Maj

or s

hape

cha

rac-

Hol

low

Si

mpl

e co

n-M

olda

ble

inC

onst

ant

Few

lim

ita-

Mol

d-M

old-

Stru

ctur

eH

ollo

wM

old-

Sim

ple

con-

teri

stic

sbo

dies

figur

atio

nson

e pl

ane

cros

s-se

ctio

nta

tions

able

able

with

bodi

esab

lefig

urat

ions

profi

lein

one

in o

nesu

rfac

esin

one

plan

epl

ane

of r

evo-

plan

elu

tion

Lim

iting

siz

e fa

ctor

MM

ME

MM

EM

SM

EW

EM

MM

EM

in in

side

rad

ius,

in0.

125

0.01

–0.

125

0.12

50.

01–

0.12

50.

01–

0.12

50.

250.

060.

125

0.01

–0.

125

0.12

50.

01–

0.12

5U

nder

cuts

Yes

Yes

aN

Rb

Yes

Yes

aY

esN

RN

RY

esc

Yes

aN

RM

in d

raft

, deg

rees

00

–1

>1

NA

b<

10

12

–3

11

Min

thic

knes

s, in

0.01

0.01

–0.

125

0.01

–0.

125

0.00

10.

015

0.06

0.03

0.01

50.

020.

002

0.01

–0.

125

Max

thic

knes

s, in

>0.

25N

one

0.5

61

0.5

13

0.5

31

Max

thic

knes

s bu

ildup

, in

NA

2–

12

–1

NA

2–

12

–1

2–

1dN

RN

AN

A2

–1

Inse

rts

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

NR

Yes

Bui

lt-up

cor

esY

esY

esN

oY

esY

esY

esY

esY

esY

esY

esY

esM

olde

d-in

hol

esY

esY

esY

esY

ese

Yes

Yes

Yes

Yes

Yes

No

Yes

Bos

ses

Yes

Yes

Yes

Yes

Yes

Yes

Yes

No

Yes

Yes

Yes

Fins

or

ribs

Yes

Yes

Yes

Yes

Yes

Yes

Nof

Nog

Yes

Yes

Yes

Mol

ded-

in d

esig

ns a

nd n

os.

Yes

Yes

Yes

No

Yes

Yes

Yes

No

Yes

Yes

Yes

Ove

rall

dim

ensi

onal

to

lera

nce,

in./i

n.�

0.01

�0.

001

�0.

001

�0.

005

�0.

001

�0.

02�

0.00

5�

0.00

5�

0.01

�0.

01�

0.00

1Su

rfac

e fin

ishh

1–

22

1–

21

–2

14

–5

4–

55

2–

31

–3

1–

2T

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method. In general, a plastic part is produced by a combination of cooling,heating, flowing, deformation, and chemical reaction. As noted previously, theprocesses differ depending on whether the material is a thermoplastic or athermoset.

The usual sequence of processing a thermoplastic is to heat the material so that itsoftens and flows, force the materials into the desired shape through a die or in amold, and chill the melt to its final shape. By comparison, a thermoset is typicallyprocessed by starting out with partially polymerized material, which is softened andactivated by heating (either in or out of a mold), forcing it into the desired shape bypressure, and holding it at the curing temperature until final polymerization reachesthe point where the part hardens and stiffens sufficiently to keep its shape whendemolded.

The cost of the finished part depends on the material and the process used. A veryrough estimate of the finished cost of a part can be obtained by multiplying the mate-rials cost by a factor ranging from 1.5 to 10.

Table IN.6 gives guidelines on part design for the various plastic processingmethods listed in Table IN.5. The design of a part frequently depends on theprocessing method selected to make the part. Also, of course, selection of the bestprocessing method frequently is a function of the part design. Major plastic pro-cessing methods and their respective design capabilities such as minimum sectionthickness and radii and overall dimensional tolerance are listed in Table IN.6. Thebasic purpose of this guide is to show the fundamental design limits of the manyplastic processing methods.

There are many plastic fabrication processes, and a wide variety of plastics canbe processed by each of the processes or method. Fabrication processes can bebroadly divided into pressure processes and pressureless or low-pressure processes.Pressureless or low-pressure processes such as potting, casting, impregnating,encapsulating, and coating are often used with thermosetting materials. Pressureprocesses are usually either thermoplastic materials processes, such as injectionmolding, extrusion, and thermoforming, or thermosetting processes, such as com-pression molding, transfer molding, and laminating. However, there are exceptionsto each.

PLASTIC FINISHING

The following sections will also provide practical information and guidance onseveral important plastic processes that occur only after the part is formed. Althoughsometimes referred to as postprocessing operations or secondary processes, thecommon operations listed below are essential to producing practical commercialproducts from plastic materials:

• Machining and finishing• Assembly• Decorating

INTRODUCTION xxvii

Fortunately, many of the processes and tools satisfactory for working with met-als, wood, and other common engineering materials also apply to plastics. Althoughthere are similarities in these processes, there are also some critical differences thatmust be considered because of the unique nature of polymeric materials. The mate-rial properties of the polymeric resins will dictate many of the processing parame-ters. There are also certain assembly and finishing opportunities that are available forthe designer because the material is a polymer. It is these unique differences thatmust occupy the designer’s early attention.

The reader should consider the individual plastic supplier as an excellent sourceof information on fabricating and finishing processes for specific types of plasticmaterials. Generally, this information is readily available because the plastic resinproducers benefit by providing the most complete and up-to-date information onhow their materials can reliably and economically produce commercial products.

Because of the tremendous number of plastic materials available, their manyforms, and the possible finishing and fabrication processes, it would be difficult toinclude in this book comprehensive information covering all product possibilitiesand all possible needs of the reader. However, this book will define the basic termsand concepts that are used in the industry, and, although additional informationis required, this will help efficiently direct and guide the reader to more completeinformation.

PLASTIC PROPERTIES

The various properties of polymeric materials are also defined in this book, as arethe methods used to test for those properties. It is important to compare propertiesof various materials and the properties that result from different processing methodsin order to select the correct material/process combination for the intended product.Information regarding how the properties of the product will change with service isalso important because all polymeric materials will generally “age” in some formbecause of their operating environment.

Much work has been done on the standardization of the measurement for proper-ties of plastics and the analysis of plastic properties. An understanding of plasticperformance as indicated by standard tests is especially important to the largepercentage of non-chemically trained users of plastic material.

Standard Tests and Their Significance

Among the most widely used test procedures are those developed by the AmericanSociety for Testing and Materials (ASTM). These test procedures, divided intocategories of performance (chemical, mechanical, thermal, analytical, optical, andelectrical) are listed in Table IN.7. A cross-reference of some important ASTM testsand Federal test methods is presented in Table IN.8.

xxviii PLASTICS MATERIALS AND PROCESSES