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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

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. HARPER

EDWARD 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

Plastics Materials and Processes: A Concise Encyclopedia, by Charles A. Harper and Edward M. PetrieISBN 0-471-45603-9 Copyright © 2003 John Wiley & Sons, Inc.

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

Table IN.4 Film Selection Chart

Thermal Dielectric Dissipation Electric Water FoldingFilm Cost Stability Constant Factor Strength Strength Absorption Endurance

Cellulose Low Low Medium Medium High Medium High LowFEP fluorocarbon High High Low Low Low High Very low MediumPolyamide Medium Medium Medium Medium High Low High Very highPTFE polytetra-

fluoroethylene High High Low Low Low Low Very low MediumAcrylic Medium Low Medium Medium Medium Low Medium MediumPolyethylene Low Low Low Low Low Low Low HighPolypropylene Low Medium Low Low Low Medium Low HighPolyvinyl fluoride High High High High High Medium Low HighPolyester Medium Medium Medium Low High High Low Very highPolytrifluoro-

chloroethylene High High Low Low Medium Medium Very low MediumPolycarbonate Medium Medium Medium Medium Medium Low Medium LowPolyimide Very high High Medium Low High High High Medium

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

Table IN.5 Descriptions and Guidelines for Plastic Processing Methods (Ref: Hauck, J. E., “Engineer’s Guide to Plastics’’, MaterialsEngineering, February 1967)

Process Description Key advantages Notable limitations Cost factor**

Blow molding An extruded tube (parison) of heated thermoplastic Low tool and die costs; rapid Limited to hollow or tubular 1.5–5,is placed between two halves of an open split production rates; ability to parts; wall thickness and 2–3mold and expanded against the sides of the mold relatively complex tolerances often hard toclosed mold by air pressure. The mold is hollow shapes in one piece controlopen, and the part is ejected

Calendering Doughlike thermoplastic mass is worked into a Low cost; sheet materials are Limited to sheet materials; 1.5–3,sheet of uniform thickness by passing it through virtually free of molded-in very thin films not possible 2–5.5and over a series of heated or cooled rolls. stresses; i.e., they areCalenders also are used to apply plastic covering isotropicto the back of other materials

Casting Liquid plastic (usually thermoset except for Low mold cost; ability to Limited to relatively simple 1.5–3,acrylics) is poured into a mold (without pressure), produce large parts with shapes; except for cast films, 2–2.5cured, and removed from the mold. Cast thick cross sections; good becomes uneconomical atthermoplastic films are made by depositing the surface finish; suitable to high-volume production material, either in solution or in hot-melt form, low-volume production most thermoplastics against a highly polished supporting levels; not suitablesurface

Compression A thermoplastic or partially polymerized Little waste of material and Extremely intricate parts 2–10,molding thermo-setting resin compound, usually preform- low finishing costs; large, involving undercuts, side 1.5–3

ed, is placed in a heated mold cavity; the mold is bulky parts are possible draws, small holes, delicateclosed, heat and pressure are applied, and inserts, etc., not practical;the material flows and fills the mold cavity. very close tolerancesHeat completes polymerization, and the difficult to producemold is opened to remove the part. The process is sometimes used for thermoplas-tics, e.g., vinyl phonograph records

xxii



Cold forming Similar to compression molding in that material is Ability to form heavy or Limited to relatively simple charged into split mold; it differs in that it uses tough-to-mold materials; shapes; few materials can beno heat—only pressure. Parts are cured in a simple; inexpensive; often processed in this mannerseparate operation. Some thermoplastic has rapid production ratesheet material and billets are cold-formed in process similar to drop hammer-die forming of metals. Shotgun shells are made in this manner from polyethylene billets

Extrusion Thermoplastic or thermoset molding compound is Low tool cost; great many Limited to sections of uniform 2–5, fed from a hopper to a screw and barrel where complex profile shapes cross section 3–4it is heated to plasticity and then forwarded, possible; very rapid pro-usually by a rotating screw, through a nozzle duction rates; can applyhaving the desired cross-section configuration coatings or jacketing to

core materials, such as wireFilament Continuous filaments, usually glass, in form of High-strength fiber Limited to shapes of positive 5–10,

winding rovings are saturated with resin and machine- reinforcements are oriented curvature; openings and 6–8wound onto mandrels having shape of desir- precisely in direction where holes reduce strengthed finished part. Once winding is completed, strength is needed; excep-part and mandrel are placed in oven for tional strength/weight ratio;curing. Mandrel is then removed through good uniformity of resinporthole at end of wound part distribution in finished part

xxiii

Injection Thermoplastic or thermoset molding compound is Extremely rapid production High initial tool and die costs; 1.5–5,molding heated to plasticity in cylinder at controlled rates, hence low cost per not practical for small runs 2–3

temperature; then forced under pressure part; little finishingthrough a nozzle into sprues, runners, gates, required; good dimensionaland cavities of mold. The resin solidifies accuracy; ability to producerapidly, the mold is opened and the relatively large, complexpart(s) ejected. In modified version shapes; very goodof process —-runnerless molding—the surface finishrunners are part of mold cavity

Laminating, Material, usually in form of reinforcing cloth, Excellent dimensional stability High tool and die costs; 2-5,high pressure paper, foil, etc., preimpregnated or coated with of finished product; very limited to simple shapes 3-4

thermoset resin (sometimes a thermoplastic), is economical in large and cross-section profilesmolded under pressure greater than 1,000 lb/in2 production of partsinto sheet, rod, tube, or other simple shape

Matched- A variation of conventional compression molding, Rapid production rates; good High mold and equipment 2–5,die molding this process uses two metal molds having a quality and reproducibility costs; parts often require 3–4

close-fitting, telescoping area to seal in the plastic of parts extensive surface finishing,compound being molded and to trim the e.g., sandingreinforcement. The reinforcement usually mator preform, is positioned in the mold,and the mold is closed and heated (pressuresgenerally vary between 150 and 400 lb/in2).Mold is then opened and part lifted out

xxiv



Rotational A predetermined amount of powdered or liquid Low mold cost; large hollow Limited to hollow parts; in 1.5–5,molding thermoplastic or thermoset material is poured parts in one piece can be general, production 2–3

into mold. Mold is closed, heated, and rotated produced; molded parts are rates are slowin the axis of two planes unitl contents have essentially isotropicfused to inner walls of mold. The mold is in natureopened and part removed

Slush molding Powdered or liquid thermoplastic material is Very low mold costs; very Limited to hollow parts; 1.5–4,poured into a mold to capacity. Mold is closed economical for small production rates are very 2–3and heated for a predetermined time to achieve -production runs slow; limited choice of a specified buildup of partially cured materials that can be material on mold walls Mold is opened, processedand unpolymerized material is poured

out. Semifused part is removed from moldand fully polymerized in oven

Thermoforming Heat-softened thermoplastic sheet is placed over Tooling costs generally are In general, limited to parts 2–10,male or female mold. Air is evacuated from low; produces large parts of simple configuration; 3–5between sheet and mold, causing sheet to with thin sections; often limited number ofconform to contour of mold. There are economical for limited materials to choose many variations, including vacuum production of parts from; high scrapsnapback, plug assist, drapeforming, etc.

xxv

Transfer Thermoset molding compound is fed from hopper Good dimensional accuracy; Molds are expensive; high 1.5–5,molding into a transfer chamber where it is heated rapid production rate; very material loss in sprues 2–3

to plasticity. It is then fed by means of intricate parts can be and runners; size of partsa plunger through sprues, runners, and produced is somewhat limitedgates of closed mold into mold cavity.Mold is opened and the part ejected

Wet lay-up Number of layers, consisting of a mixture of Very low cost; large parts Not economical for large- 1.5–4,or contact reinforcement (usually glass cloth) can be produced; suitable volume production; 2–3molding and resin (thermosetting), are placed for low-volume uniformity of resin

in mold and contoured by roller to mold’s production of parts distribution veryshape. Assembly is allowed to cure difficult to control; mainly (usually in an oven) without application limited to simple shapesof pressure. In modification of process,called spray molding, resin systemsand chopped fibers are sprayedsimultaneously from spraygun against mold surface; rollerassist also is used. Wet lay-up partssometimes are cured underpressure, using vacuumbag, pressure bag, or auto-clave

*Material cost � factor � purchase price of a part: top figure is overall range, bottom is probable average cost.

xxvi

Table IN.6 Guidelines on Part Design for Plastic Processing Methods

Reinforced plastic molding

Wet lay-upBlow Compression Injection (contact Matched die Filament Rotational Thermo- Transfer

Design rules molding Casting molding Extrusion molding molding) molding winding molding forming molding

Major shape charac- Hollow Simple con- Moldable in Constant Few limita- Mold- Mold- Structure Hollow Mold- Simple con-teristics bodies figurations one plane cross-section tations able able with bodies able figurations

profile in one in one surfaces in oneplane plane of revo- plane

lutionLimiting size factor M M ME M ME MS ME WE M M MEMin inside radius, in 0.125 0.01–0.125 0.125 0.01–0.125 0.01–0.125 0.25 0.06 0.125 0.01–0.125 0.125 0.01–0.125Undercuts Yes Yesa NRb Yes Yesa Yes NR NR Yesc Yesa NRMin draft, degrees 0 0–1 >1 NAb <1 0 1 2–3 1 1Min thickness, in 0.01 0.01–0.125 0.01–0.125 0.001 0.015 0.06 0.03 0.015 0.02 0.002 0.01–0.125Max thickness, in >0.25 None 0.5 6 1 0.5 1 3 0.5 3 1Max thickness buildup, in NA 2–1 2–1 NA 2–1 2–1 2–1d NR NA NA 2–1Inserts Yes Yes Yes Yes Yes Yes Yes Yes Yes NR YesBuilt-up cores Yes Yes No Yes Yes Yes Yes Yes Yes Yes YesMolded-in holes Yes Yes Yes Yese Yes Yes Yes Yes Yes No YesBosses Yes Yes Yes Yes Yes Yes Yes No Yes Yes YesFins or ribs Yes Yes Yes Yes Yes Yes Nof Nog Yes Yes YesMolded-in designs and nos. Yes Yes Yes No Yes Yes Yes No Yes Yes YesOverall dimensional

tolerance, in./in. �0.01 �0.001 �0.001 �0.005 �0.001 �0.02 �0.005 �0.005 �0.01 �0.01 �0.001Surface finishh 1–2 2 1–2 1–2 1 4–5 4–5 5 2–3 1–3 1–2Threads Yes Yes Yes No Yes No No No Yes No Yes

M � material. ME � molding equipment. MS � mold size. WE � winding equipment.aSpecial molds required.bNR—not recommended; NA—not applicable.cOnly with flexible materials.dUsing premix: as desired.eOnly in direction of extrusion.fUsing premix: yes.gPossible using special techniques.hRated 1 to 5:1 � very smooth, 5 � rough.

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

INTRODUCTION xxix

Table IN.7 Widely Used ASTM Tests for Plastics

Performance testsD1693, environmental stress crackingG23 (formerly E42), accelerated weatheringPipe tests (Commercial Standard CS 255-63)D794, permanent effect of heatD1435, outdoor weatheringWeight loss on heating (D706, specification for cellulose acetate molding compounds)D570, water absorption

Chemical testsC619, chemical resistance of asbestos-fiber-reinforced thermosetting resinsC581, chemical resistance of thermosetting resins of color in CIE 1931 system

Mechanical testsD790, flexural propertiesD1822, tensile impactD747, stiffness in flexureD256, Izod impactD638, tensile propertiesD785, Rockwell hardnessD621, deformation under loadD695, compressive properties of rigid plasticsD732, shear strength

Thermal testsD648, deflection temperatureD635, flammability (for self-supporting materials)D1238, flow rate (melt index) by extrusion plastometerD569, flow propertiesD1525, Vicat softening pointD746, brittleness temperature

Analytical testsD792, specific gravity and densityD1505, density by density-gradient technique

Optical testsE308, spectrophotometry and descriptionD1003, haze

Electrical testsD618, conditioning proceduresD495, arc resistanceD149, dielectric strengthD150, dielectric constant and dissipation factorD257, tests for electrical resistance, insulation resistance, volume resistivity, volume

resistance

xxx PLASTICS MATERIALS AND PROCESSES

Table IN.8 Cross-Referenced ASTM and Federal Tests

FederalStandardMethod

Test method No. ASTM No.

Abrasion wear (loss in weight) 1091Accelerated service tests (temperature and humidity extremes) 6011 D 756-56Acetone extraction test for degree of cure of phenolics 7021 D 494-46Arc resistance 4011 D 495-61Bearing strength 1051 D 953-54,

Method ABonding strength 1111 D 229-63T,

pars 40-43Brittleness temperature of plastics by impact 2051 D 746-64TCompressive properties of rigid plastics 1021 D 695-63TConstant-strain flexural fatigue strength 1061Constant-stress flexural fatigue strength 1062Deflection temperature under load 2011 D 648-56,

Procedure 6(a)Deformation under load 1101 D 621-64,

Method ADielectric breakdown voltage and dielectric strength 4031 D 149-64Dissipation factor and dielectric constant 4021 D 150-64TDrying test (for weight loss) 7041Effect of hot hydrocarbons on surface stability 6062Electrical insulation resistance of plastic films and sheets 4052Electrical resistance (insulation, volume, surface) 4041 D 257-61Falling-ball impact 1074Flame resistance 2023Flammability of plastics 0.050 in. and under in thickness 2022 D 568-61Flammability of plastics over 0.050 in. in thickness 2021 D 635-63Flexural properties of plastics 1031 D 790-63Indentation hardness of rigid plastics by means of a

durometer 1083 D 1706-61Interlaminar and secondary bond shear strength of

structural plastic laminates 1042Internal stress in plastic sheets 6052Izod impact strength 1071 D 256-56,

Method ALinear thermal expansion (fused-quartz tube method) 2031 D 696-44Machinability 5041Mar resistance 1093 D 673-44Mildew resistance of plastics, mixed culture method,

agar medium 6091Porosity 5021Punching quality of phenolic laminated sheets 5031 D 617-44

Rating of Plastics by Property Comparisons

The Appendices of this book contain data on plastics as a function of the mostimportant variables. It is frequently useful to compare or rate plastics for a givenproperty or characteristic. Any such data must be considered approximate, of course,because of the many possible variables involved. Some such comparative data arepresented in the Appendices and the main section of this book.

ELASTOMERS

ASTM D1566 defines elastomers as “macromolecular materials that return rapidlyto approximately the initial dimensions and shape after substantial deformation by aweak stress and release of the stress.” It also defines rubber as “material that is capa-ble of recovering from large deformation quickly and forcibly, and can be, or alreadyis, modified to a state in which it is essentially insoluble (but can swell) in solvent,such as benzene, methyl ethyl ketone, and ethanol toluene azeotrope.”

A rubber in its modified state, free of diluents, retracts within 1 min to less than1.5 times its original length after being stretched at room temperature to twice itslength and held for 1 min before release. More specifically, an elastomer is a

INTRODUCTION xxxi


FederalStandardMethod

Test method No. ASTM No.

Resistance of plastics to artificial weathering usingfluorescent sunlamp and fog chamber 6024 D 1501-57T

Resistance of plastics to chemical reagents 7011 D 543-60TRockwell indentation hardness test 1081 D 785-62,

Method ASalt-spray test 6071Shear strength (double shear) 1041Shockproofness 1072Specific gravity by displacement of water 5011Specific gravity from weight and volume measurements 5012Surface abrasion 1092 D 1044-56Tear resistance of film and sheeting 1121 D 1004-61Tensile properties of plastics 1011 D 638-64TTensile properties of thin plastic sheets and films 1013 D 882-64TTensile strength of molded electrical insulating materials 1012 D 651-48Tensile time—-fracture and creep 1063Thermal-expansion test (strip method) 2032Warpage of sheet plastics 6054 D 1181-56Water absorption of plastics 7031 D 570-63

rubberlike material that can be or already is modified to a state exhibiting little plas-tic flow and quick and nearly complete recovery from an extending force. Suchmaterial before modification is called, in most instances, a raw or crude rubber or abasic high polymer and by appropriate processes may be converted into a finishedproduct.

When the base high polymer is converted (without the addition of plasticizers orother diluents) by appropriate means to an essentially nonplastic state, it must meetthe following requirements when tested at room temperature:

1. It is capable of being stretched 100%.

2. After being stretched 100%, held for 5 min, and then released, it is capable ofretracting to within 10% of its original length within 5 min after release.

The rubber definition with its swelling test certainly limits it to only the natural latextree sources, whereas the elastomer definition is more in line with modern newsynthetics.

Elastomers, when compared with other engineering materials, are characterizedby large deformability, lack of rigidity, large energy storage capacity, nonlinearstress-strain curves, high hysteresis, large variations in the stiffness, temperature,and rate of loading, and compressibility of the same order of magnitude as mostliquids. Certain of the elastomeric materials possess additional useful characteristicsto a relative degree, such as corrosive chemical resistance, oil resistance, ozone resis-tance, temperature resistance, and resistance to other environmental conditions.

The nomenclature for elastomers, common names, ASTM designations, relativecosts, and general characteristics are summarized in Appendix C. Further discussionof these commercially available elastomers can be found in the following sectionsunder their specific names.

The proper selection and application of elastomers are difficult for designengineers in many instances because engineering terms in conventional usage havedifferent meanings when applied to rubber properties. Elastomers are organic mate-rials and react in a completely different manner from metals. For this reason someof the more common definitions are presented in the following section.

xxxii PLASTICS MATERIALS AND PROCESSES

APPENDICES


615

LISTING OF APPENDICES

Appendix A Some Common Abbreviations Used in the Plastics Industry

Appendix B Important Properties of Plastics and Listing of Plastics Suppliers

Appendix C Important Properties of ElastomersC.1 Rubber—Molded, ExtrudedC.2 Thermoplastic Elastomers

Appendix D Important Information Regarding CoatingsD.1 Organic CoatingsD.2 Organic Coatings—Solvent BaseD.3 Application Methods for CoatingsD.4 Specific Test Methods for CoatingsD.5 NEMA Standard for Magnet Wire Insulation

Appendix E Important Properties of LaminatesE.1 Description of NEMA Laminate GradesE.2 Properties of NEMA Laminate Grades

Appendix F Composite Ply Orientation—Symmetry and Balance

Appendix G Important Information Regarding Processing of PlasticsG.1 Plastics and Rubber Fabrication ProcessesG.2 Guidelines on Part Design for Plastics Processing MethodsG.3 Approximate Part Size Ranges for Principal ProcessesG.4 Plastics Available for Processes

Appendix H Recommended Materials for Specific Properties


616 PLASTICS MATERIALS AND PROCESSES

Appendix I Important Information Regarding Machining of PlasticsI.1 Machining Guidelines for Common PlasticsI.2 Geometries for Cutting and Drilling ToolsI.3 Suggested Drill Sizes and Speeds for Various Plastic Materials

Appendix J Sources of Specifications and Standards for Plastics and Composites

Appendix K Important Information Regarding Assembly of Plastics and Adhesives.

K.1 Assembly Methods for PlasticsK.2 Description of Various Methods to Bond and Weld PlasticsK.3 Adhesives Classified by Chemical CompositionK.4 Thermosetting AdhesivesK.5 Thermoplastic AdhesivesK.6 Elastomeric AdhesivesK.7 Alloy AdhesivesK.8 Common ASTM Adhesive Test StandardsK.9 Common Adhesive Joint Designs

Appendix L Important Information Regarding Liquid ResinsL.1 General Comparisons of Properties of Liquid ResinsL.2 Properties of Various Liquid ResinsL.3 Characteristics Influencing Choice of Resins in Electrical

ApplicationsL.4 Characteristics Influencing Choice of Resins in Nonelectrical

Applications

Appendix M Important Information Regarding Fillers, Modifiers,Reinforcements

M.1 Types of Filler for PlasticsM.2 Filler/Reinforcement ApplicationsM.3 Additive/Modifier ApplicationsM.4 Glass Fiber Reinforcement FormsM.5 Electrical-Grade Glass FabricsM.6 Mechanical-Grade Glass FabricsM.7 Marine-Grade Glass FabricsM.8 Scrim-Grade Glass FabricsM.9 Properties of Glass FibersM.10 Fibers—OrganicM.11 Fibers—Inorganic

Appendix N Trade Name Directory

Appendix O Conversion Units

617

APPENDIX A

Some Common Abbreviations Usedin the Plastics Industry*

AAGR average annual growth rateAS atomic absorption spectroscopyABA acrylonitrile-butadiene-acrylateABS acrylonitrile-butadiene-styrene copolymerACM acrylic acid ester rubberACS acrylonitrile-chlorinated PE-styreneAES acrylonitrile-ethylene-propylene-styreneAMMA acrylonitrile-methyl methacrylateAN acrylonitrileAO antioxidantAPET amorphous polyethylene terephthalateAPP atactic polypropyleneASA acrylic-styrene-acrylonitrileASTM American Society for Testing and MaterialsATH aluminum trihydrateAZ(O) azodicarbonamideBATF Bureau of Alcohol, Tobacco, and FirearmsBM blow moldingBMC bulk molding compounds

*Reprinted with permission from Modern Plastics Encyclopedia ,98, William A. Kaplan (Ed.),

Modern Plastics is a Division of Chemical Week Associates, New York, NY, 1998.



BMI bismaleimideBO biaxially-oriented (film)BOPP biaxially-oriented polypropyleneBR butadiene rubberBS butadiene styrene rubberCA cellulose acetateCAB cellulose acetate butyrateCAD computer aided designCAE computer aided engineeringCAM computer aided manufacturingCAP cellulose acetate propionateCAP controlled atmosphere packagingCBA chemical blowing agentCF cresol formaldehydeCFA chemical foaming agentCFC chlorofluorocarbonsCFR Code of Federal RegulationsCHDM cyclohexanedimethanolCIM computer integrated manufacturingCN cellulose nitrateCOP copolyesterCOPA copolyamideCOPE copolyesterCP cellulose propionateCPE chlorinated polyethyleneCPET crystalline polyethylene terephthalateCPP cast polypropyleneCPVC chlorinated polyvinyl chlorideCR chloroprene rubberCS caseinCSD carbonated soft drinkCTA cellulose triacetateCVD chemical vapor depositionDABCO diazobicyclooctaneDAM days after manufactureDAM diallyl maleateDAP diallyl phthalateDCPD dicyclopentadieneDE diotamaceous earthDEA dielectric analysisDETDA diethyltoluenediamineDMA dynamic mechanical analysisDSC differential scanning analysisDMT dimethyl ester of terephthalateDWV drain, waste, vent (pipe grade)

SOME COMMON ABBREVIATIONS USED IN THE PLASTICS INDUSTRY 619

EAA ethylene acrylic acidEB electron beamEBA ethylene butyl acrylateEC ethyl celluloseECTFE ethylene-chlorotrifluoroethylene copolymerEEA ethylene-ethyl acrylateEG ethylene glycolEMA ethylene-methyl acrylateEMAA ethylene methacrylic acidEMAC ethylene-methyl acrylate copolymerEMC electromagnetic compatibilityEMI electromagnetic interferenceEMPP elastomer modified polypropyleneEnBA ethylene normal butyl acrylateEP epoxy resin, also ethylene-propyleneEPA Environmental Protection AgencyEPDM ethylene-propylene terpolymer rubberEPM ethylene-propylene rubberEPS expandable polystyreneESCR environmental stress crack resistanceESI ethylene-styrene copolymersETE engineering thermoplastic elastomersETFE ethylene-tetrafluoroethylene copolymerETP engineering thermoplasticsEVA(C) polyethylene-vinyl acetateEVOH polyethylene-vinyl alcohol copolymersFDA Food and Drug AdministrationFEP fluorinated ethylene propylene copolymerFPVC flexible polyvinyl chlorideFR flame retardantFRP fiber reinforced plasticGIM gas injection moldingGIT gas injection techniqueGMT(P) glass mat reinforced thermoplasticsGPC gel permeation chromotographyGPPS general purpose polystyreneGRP glass fiber reinforced plasticsGTP group transfer polymerizationHALS hindered amine light stabilizerHAS hindered amine stabilizersHB Brinell hardness numberHCFC hydrochlorofluorocarbonsHCR heat-cured rubberHDI hexamethylene diisocyanateHDPE high-density polyethylene


HDT heat deflection temperatureHFC hydrofluorocarbonsHIPS high-impact polystyreneHMDI diisocyanato dicyclohexylmethaneHMW high molecular weightHNP high nitrile polymerIIR butyl rubberIM injection moldingIMC in-mold coatingIMD in-mold decorationIPI isophorone diisocyanateIV intrinsic viscosityLCP liquid crystal polymersLIM liquid injection moldingLDPE low-density polyethyleneLLDPE linear low-density polyethyleneLP low-profile resinMAP modified atmosphere packagingMbOCA 3,3�-dichloro-4,4-diamino-diphenylmethaneMBS methacrylate-butadiene-styreneMC methyl celluloseMDI methylene diphenylene diisocyanateMEKP methyl ethyl ketone peroxideMF melamine formaldehydeMFI melt flow indexMIS management information systemsMMA methyl methacrylateMPE metallocene polyethylenesMPF melamine-phenol-formaldehydeMPR melt-processable rubberMRP manufacturing requirement planningMWD molecular weight distributionNBR nitrile rubberNDI naphthalene diisocyanateNDT nondestructive testingNR natural rubberODP ozone depleting potentialOFS organofunctional silanesOPET oriented polyethylene terephthalateOPP oriented polypropyleneO-TPV olefinic thermoplastic vulcanizateOEM original equipment manufacturerOSA olefin-modified styrene-acrylonitrilePA polyamidePAEK polyaryletherketone


PAI polyamide imidePAN polyacrylonitrilePB polybutylenePBA physical blowing agentPBAN polybutadiene-acrylonitrilePBI polybenzimidazolePBN polybutylene naphthalatePBS polybutadiene styrenePBT polybutylene terephthalatePC polycarbonatePCC precipitated calcium carbonatePCD polycarbodiimidePCR post-consumer recyclatePCT polycyclohexylenedimethylene terephthalatePCTA copolyester of CHDM and PTAPCTFE polychlorotrifluoroethylenePCTG glycol-modified PCT copolymerPE polyethylenePEBA polyether block polyamidePEC chlorinated polyethylenePEDT 3,4 polyethylene dioxithiophenePEEK polyetheretherketonePEI polyether imidePEK polyetherketonePEL permissible exposure levelPEKEKK polyetherketoneetherketoneketonePEN polyethylene naphthalatePES polyether sulfonePET polyethylene terephthalatePETG PET modified with CHDMPF phenol formaldehydePFA perfluoroalkoxy resinPI polyimidePID proportional, integral, derivativePIBI butyl rubber (also IIR)PIM powder injection moldingPLC programmable logic controllerPMDI polymeric methylene diphenylene diisocyanatePMMA polymethyl methacrylatePMP polymethylpentenePO polyolefinsPOM polyacetalPP polypropylenePPA polyphthalamidePPC chlorinated polypropylene


PPE polyphenylene ether, modifiedppm parts per millionPPO polyphenylene oxidePPS polyphenylene sulfidePPSU polyphenylene sulfonePS polystyrenePSU polysulfonePTA purified terephthalic acidPTFE polytetrafluoroethylenePU polyurethanePUR polyurethanePVC polyvinyl chloridePVCA polyvinyl chloride acetatePVDA polyvinylidene acetatePVDC polyvinylidene chloridePVDF polyvinylidene fluoridePVF polyvinyl fluoridePVOH polyvinyl alcoholQMC quick mold changeRFI radio frequency interferenceRHDPE recycled high density polyethyleneRIM reaction injection moldingRPET recycled polyethylene terephthalateRTD resistance temperature detectorRTM resin transfer moldingRTV room temperature vulcanizingSI silicone plasticSAN styrene acrylonitrile copolymerSB styrene butadiene copolymerSBC styrene block copolymerSBR styrene butadiene rubberSMA styrene maleic anhydrideSMC sheet molding compoundSMC-C SMC-continuous fibersSMC-D SMC-directionally orientedSMC-R SMC-randomly orientedSPC statistical process controlSQC statistical quality controlSRIM structural reaction injection moldingTA terephthalic acidTDI toluene diisocyanateTEO thermoplastic elastomeric olefinTGA thermogravimetric analysisTLCP thermoplastic liquid crystal polymerTMA thermomechanical analysis


TMC thick molding compoundT/N terephthalate/naphthalateTPA terephthalic acidTP thermoplasticTPE thermoplastic elastomerTPO thermoplastic olefinsTPU thermoplastic polyurethaneTPV thermoplastic vulcanizateTS thermosetTWA time-weighted averageUF urea formaldehydeUHMW ultrahigh molecular weightULDPE ultralow-density polyethyleneUP unsaturated polyester resinUR urethaneUV ultravioletVA(C) vinyl acetateVC vinyl chlorideVDC vinylidene chlorideVLDPE very low-density polyethyleneVOC volatile organic compoundsZNC Ziegler-Natta catalyst

APPENDIX G

Important Information RegardingProcessing of Plastics

803


804

APPENDIX G.1a

Formp The Process Advantages Limitations.

PLASTICS

Injection Molding Similar to die casting of metals. A thermoplastic molding compound is Extremely rapid production rate and hence High tool and die costs; highheated to plasticity in a cylinder at a controlled temperature and forced low cost per part; little finishing required; scrap loss; limited to under pressure through sprues, runners and gates into a mold; the resin excellent surface finish; good dimensional relatively small parts; notsolidifies rapidly, the mold is opened, and the parts ejected; with certain accuracy; ability to produce variety of practical for small runs.modifications, thermosetting materials can be used for small parts. relatively complex and intricate shapes.

Extrusion Thermoplastic molding powder is fed through a hopper to a chamber Very low tool cost; material can be Close tolerances difficult towhere it is heated to plasticity and driven, usually by a rotating screw, placed where needed; great variety achieve; openings must bethrough a die having the desired cross section; extruded lengths are either of complex shapes possible; rapid indirection of extrusion; used as-is or cut into sections; with modifications, production rate. limited to shapes of uniformthermosetting materials can be used. cross section (along length).

Sheet Molding VACUUM FORMING—Heat-softened sheet is placed over a male or Simple procedure; inexpensive; good Limited to parts of low profile.(Thermoforming) female mold; air is evacuated form between sheet and mold, causing dimensional accuracy; ability to produce

sheet to conform to contour of mold. Modifications include vacuum large parts with thin sections.snapback forming, plus assist, drape forming, etc.

BLOW OR PRESSURE FORMING—The reverse of vacuum forming Ability to produce deep drawn parts; Relatively expensive; moldsin that positive air pressure rather than vacuum is applied to ability to use sheet too thick for vacuum must be highly polished.form sheet to mold contour. forming; good dimensional accuracy;

rapid production rate.MECHANICAL FORMING—Sheet metal equipment (presses, benders, Ability to form heavy and/or tough Limited to relatively simple

rollers, creasers, etc.) forms heated sheet by mechanical means. materials; simple; inexpensive; shapes.Localized heating is used to bend angles; where several bends are rapid production rate.required, heating elements are arranged in series.

Blow Molding An extruded tube (parison) of heated plastics is placed within the two Low tool and die cost; rapid production Limited to hollow or tubularhalves of a female mold and expanded against the sides of the mold by rate; ability to produce relatively complex parts; wall thickness air pressure; the most common method uses injection molding hollow shapes in one piece. difficult to control.equipment with a special mold.

G.1 Plastics and Rubber Fabrication Processes

805

Slush, Rotational, Powder (polyethylene) or liquid material (usually vinyl plastisol or Low cost molds; relatively high degree of Relatively slow productionDip Molding organosol) is poured into a closed mold, the mold is heated to fuse a complexity; little shrinkage. rate; choice of materials

specified thickness of material adjacent to mold surface, excess material limited.is poured out, and the semifused part placed in an oven for final curing.A variation, rotational molding, provides completely enclosed hollow parts.

Compression Material to be molded is placed in a matched-metal-die mold cavity Rapid production rates, little waste of Not suitable for intricate parts,Molding and the mold closed. The part is formed by compressing the material material, low finishing costs, large parts undercuts, or delicate

under heat and pressure until the resin is cured or sufficiently cool to possible. High reinforcement content inserts. Close tolerances allow removal. Suitable for sheet (SMC) or bulk molding compounds yields high-strength parts. High volume difficult to achieve. High (BMC), preforms, wet resin applied to reinforcement in the mold process equipment costs.(wet system molding) or reinforced thermoplastic sheet (hot stamping).

Transfer Molding A change of material, often preheated, is placed in a chamber (pot) Thin sections and delicate inserts are Molds are more elaborate thanconnected to the closed cavity of a heated matched-metal-die mold. easily molded; flow of material is more compressionmolds, andThe material is hydraulically forced into the mold by a plunger through a easily controlled than in compression more expensive; loss ofseries of runners/gates. Part removed after resin cures. molding; good dimensional accuracy; material in of cull and

rapid production rate. sprue; size parts limited.Liquid Resin Resin and catalyst held separately, are rapidly metered, mixed and Capable of forming large parts with fast Class A surfaces difficult to

Molding delivered into a closed mold cabvity, filling the cavity before reaction is cycle times at low capital equipment and obtain. Considered ancomplete. Often combined with precut-or preformed-fiber reinforcement energy costs. Low volatile emissions intermediate volume placed in the mold first, yielding a composite part as the mixture compared to open-mold processes. process.impregnates the reinforcement. Variations known as resin transfermolding (RTM), and reaction injection molding (RIM).

Hand Lay-Up The lay-up, which consists of a mixture of reinforcement (usually glass Los cost; no limitations on size or Parts are sometimes erratic incloth or fibers) and resin (usually thermosetting), is placed in mold by shape of part. performance and hand, rolled to improve consolidation, and allowed appearance; limited toto harden without heat or pressure. polyesters, epoxies and

some phenolics.Spray-Up Resin system and chopped fibers are sprayed simultaneously from two Low cost; relatively high production rate; Requires skilled workers;

guns against a mold; after spraying, layer is rolled flat with a hand roller. high degree of complexity possible. lack of reproducibility.Either room temperature or oven cure.

Source: Reprinted with permission from 1994 Materials Selector Issue, Machine Design, Penton Publishing, Cleveland, Ohio, 1993.

806 APPENDIX G.1b

Form p The Process Advantages Limitations

PLASTICS

Vacuum Bag Similar to hand lay-up except a flexible film is placed over lay-up and a Greater densification allows higher glass Limited to polyesters, expoxiesMolding vacuum drawn between film and mold (about 12 psi). contents resulting in higher strengths. and some phenolics.

Autoclave After hand lay-up, winding, or other fabrication technique, mold and High pressures provide increased Equipment and operatingMolding composite part are placed in an autoclave. Heat and pressure are applied laminate consolidation and improved expenses are high. Parts

via steam, consolidating and curing part. Usually combined with a removal of volatiles, for high-strength limited to cavity size of vacuum-bag bleeder and release cloth. Hydroclave uses water as the parts. autoclave.pressure media. Thermoclave process uses powdered silicone rubberwhich acts as a fluid under heat/pressure.

Pultrusion Reinforcing filaments saturated with thermosetting resin are pulled Capable of producing complex profiles in Limited to constant cross-through an orifice in a heated die. Polymerization of the resin occurs as unlimited length. High fiber content up to section profiles. Can’t make the wet bundle passes through the die, forming a continuous, rigid 75% yields high-strength a curved product.profile corresponding to the orifice shape. structural parts. Low labor content.

Pulforming Variation of pultrusion producing continuously reinforced products other Unlike pultrusion, curved shapes (leaf Complex tooling arrangements.than profiles. By pulling fibers through a rotation wagon-wheel-type die, springs) and non-constant cross section Dies are expensive.curved shapes are formed. Recirculating molds which clamp around the parts (hammer handles) can be formedwet fiber package allow continuous forming of various shapes. continuously.

Tape Placement Thermoset or thermoplastic, fiber-reinforced unidirectional tape is laid Lay-down rates substantially higher than . High cost of equipment.automatically by a programmed dispensing machine to form a desired hand lay up, with improved placement Intrinsically stiff tapes limitshape. A gantry system provides the necessary lay-down motions accuracy and reduced human error. the complexity of finished of the tape head, producing either flat or contoured surfaces. parts.

Fiber Placement Similar to automated tape placement using resin-impregnated fiber Fiber roving flexibility allows Unlike filament winding,rovings. Rovings are automatically placed on a complex mold surface more-complex shapes than tape rovings are placed and notwhich can include both positive and negative surfaces. Can also be placement. Negative surfaces can wound under tension,applied to surfaces of rotation like filament winding. be formed. diminishing consolidation

and structural properties such as tensile strength.

Filament Winding Glass filaments, usually in the form of rovings, are saturated with resin Provides precisely oriented reinforcing Limited to shapes of positiveand machine wound onto mandrels having the shape of desired finished filaments; excellent strength-to-weight curvature; drilling or cuttingpart; finished part is cured at either room temperature or in an oven, ratio; good uniformity. reduces strength.depending on resin used and size of part.

807

Casting Plastic material (usually thermosetting except for the acrylics) is heated Low mold cost; ability to produce large Limited to relatively simpleto a fluid mass, poured into mold (without pressure), cured, and parts with thick sections; little finishing shapesremoved from mold required; good surface finish

Cold Molding Method is similar to compression molding in that material is charged Because of special materials used, parts Poor surface finish; poorinto a split, or open, mold; it differs in that it uses no heat—only pressure. have excellent electrical insulating dimensional accuracy; moldsAfter the part is removed from mold, it is placed in an oven to properties and resistance to moisture wear rapidly; relativelycure to final state and heat; low cost; rapid expensive finishing;

materials must be mixed and used immediately

RUBBER

Compression An excess amount of uncured compound is placed in mold cavity; mold is Good surface finish; parts can be made in Close tolerances difficult toMolding closed and heat and pressure applied, forcing compound to fill mold almost any hardness, shape and size; achieve; flash has to be

cavity; heat cures (vulcanizes) compound and mold is opened relatively low cost; little waste; most removed; extreme intricacyto remove hardened parts compounds suitable. difficult; slow

production rate.Transfer, Injection Similar to compression molding except that mold is closed empty and Very good dimensional accuracy; no flash High mold costs; not all rubber

Molding rubber compound is forced into it through sprues, runners and gates. removal; ability to produce extremely compounds can be used; highintricate parts; good finish and scrap loss due to sprues,uniformity; rapid production rate. runners, etc.

Extrusion Similar to plastic extrusion in that heated material is forced through a die Very low cost operation; great variety of Close tolerances difficult tohaving desired cross section. However, vulcanizatin does not take place complex shapes possible; achieve; limited to parts ofin mold cavity; extruded lengths are cured n a steam vulcanizer and either rapid production rate. uniform cross section (alongused as-is or cut into sections. length); openings must be in

direction of extrusion.Die Cut Parts are stamped or cut from vulcanized sheet or slab with inexpensive Practically any rubber material can be cut Thickness of part is limited;

steel dies. in almost any size; low cost; economical limited to flat parts.for small quantities.

Source: Reprinted with permission from 1994 Materials Selector Issue, Machine Design, Penton Publishing, Cleveland, Ohio, 1993.

808

G.2 Guidelines on Part Design for Plastics Processing Methods

Reinforced plastic molding

Wet Lay-up MatchedBlow Compression Injection (Contact –die Filament Rotational Thermo- Transfer

Design rules Molding Casting Molding Extrusion Molding Molding) Molding winding Molding Forming Molding

Major shape Hollow Simple con- Moldable in Constant Few limita- Mold- Mold- Structure Hollow Mold- Simple con-characteristics bodies figurations one plane cross-section tions able able with bodies able figurations

profile in one in one surfaces in oneplane plane of revo- plane

lutionLimiting size factor M M ME M ME MS ME WE M M MEMin inside radius, in 0.125 0.01–0.125 0.125 0.01–0.125 0.01–0.125 0.25 0.06 0.125 0.01–0.125 0.125 0.01–0.125Undercuts Yes Yesa NRb Yes Yesa Yes NR NR Yesc Yesa NRMin draft, degrees 0 0–1 >1 NAb <1 0 1 2–3 1 1Min thickness, in 0.01 0.01–0.125 0.01–0.125 0.001 0.015 0.06 0.03 0.015 0.02 0.002 0.01–0.125Max thickness, in >0.25 None 0.5 6 1 0.5 1 3 0.5 3 1Max thickness buildup, in NA 2–1 2–1 NA 2–1 2–1 2–1d NR NA NA 2–1Inserts Yes Yes Yes Yes Yes Yes Yes Yes Yes NR YesBuilt-up cores Yes Yes No Yes Yes Yes Yes Yes Yes Yes YesMolded-in holes Yes Yes Yes Yese Yes Yes Yes Yes Yes No YesBosses Yes Yes Yes Yes Yes Yes Yes No Yes Yes YesFins or ribs Yes Yes Yes Yes Yes Yes No f Nog Yes Yes YesMolded-in designs and nos Yes Yes Yes No Yes Yes Yes No Yes Yes Yes

809

Overall dimensional tolerance, in./in. �0.01 �0.001 �0.001 �0.005 �0.001 �0.02 �0.005 �0.005 �0.01 �0.01 �0.001

Surface finishh 1–2 2 1–2 1–2 1 4–5 4–5 5 2–3 1–3 1–2Threads Yes Yes Yes No Yes No No No Yes No Yes

M � material. ME � molding equipment. MS � mold size. WE � winding equipment.aSpecial molds required.bNR—not recommended; NA—not applicable.cOnly with flexible materials.dUsing premix: as desired.eOnly in direction of extrusion.fUsing premix: yes.gPossible using special techniques.hRated 1 to 5:1 � very smooth, 5 � rough.

Source: Meier, J. F., “Fundamentals of Plastics and Elastomers’’, Handbook of Plastics, Elastomers, and Composites, 3rd ed., McGraw-Hill, New York, 1998.

810 G.3 Approximate Part Size Ranges for Principal Processes

APPENDIX G.3

Process Smallest Known Largest Commercial Largest Known

Blow molding 3�8 in deep � 11�4in long 9 1�2 ft long � 1 ft deep � 4 in thick, 1320-gallon tank28 in deep � 44 in long

Casting No limit Limited only by physical ability to Limited only by physicalhandle molds and moldments ability to handle molds

and moldmentsCoinjection molding 1�4 �

1�4 �1�4 in 2 � 5 � 5 ft 2 1�2 � 4 � 10 ft

Cold molding 11�2 � 11�2 ft 10 � 10 � 1 1�2 ft 14-ft boat hullCompression molding 1�4 �

1�4 �1�16 in 4 � 5 � 8 ft 1 1�2 � 4 1�2 � 14 ft

Extrusion No limit 12 � 12 in 42 in deepFilament winding 4 ft deep � 8 in long 13 ft deep � 60 ft long 10-ft high � 82 1�2 ft deepInjection molding 0.008 � 0.020 � 0.020 in 2 1/2 deep � 3 ft 4 ft � 4 ft 6 in � 7 ftLay-up and spray-up 1�4 � 6 � 6 in 150-ft minesweeper Continuous roadwayMachining No limit 10 ft wide or 15 in deep Limited by size of stock

availablePultrusion 1�16 in deep 12 � 12 in 15 � 100 inReaction injection molding 4 � 12 in 3 � 4 � 10 ft 10 � 10 ftResin transfer molding 1 in � 3 in � 2 ft 16 in � 4 ft � 8 ft 4 ft � 8 ft � 28 inRotational molding 1�2-in -diam sphere 6 ft deep � 18 ft long 12 ft deep � 30 ft longStructural foam molding 1�4 �

1�4 �1�4 in 2 1/2 � 6 1�2 � 6 1�2 ft 2 1�2 � 4 � 10 ft

Transfer molding 1�8 �1�8 �

1�16 in 2 � 1 �1�2 ft 2 1�2 � 1 ft � 9 in

Thermoforming: thin gauge 1�4 � 1 � 1 in 3 � 3 � 3 ft 3 � 3 � 3 ftThermoforming: heavy gauge 6 � 6 � 6 in 3 � 10 � 12 FT 2 � 6 � 20 ftTwin-sheet thermoforming 6 � 6 � 6 in 6 in � 3 ft � 6 ft 6 in � 3 ft � 6 ft

Source: Rotheiser, J. I., “The Bigger Picture”, Plastics Engineering Magazine, January, 1997.

IMPORTANT INFORMATION REGARDING PROCESSING OF PLASTICS 811

G.4 Plastics Available for Certain Processes

APPENDIX G.4

Process Materials

Blow molding ABS, acrylic, cellulosics, nylon, polycarbonate, polyester (thermoplastic), polyethylene polypropylene,

polystyrene, polysulfone, PVC, SANCasting Acrylic (thermoset), alkyd, epoxy, nylon, phenolic,

polyester (thermoset), polyurethane (thermoset), silicone

Cold molding Epoxy, phenolic, polyester (thermoset), polyurethane(thermoset)

Compression molding Alkyd, allyl, amino, epoxy, fluorocarbons, phenolic,(including BMC and SMC) polyester (thermoset), polyurethane (thermoset),

siliconeExtrusion ABS, acetal, acrylic, cellulosics, liquid crystal polymer,

nylon, polycarbonate, polyester (thermoplastic),polyethylene, polyphenylene oxide polypropylene,polystyrene, polysulfone, polyurethane(thermoplastic), PVC, SAN

Filament winding Epoxy, polyester (thermoset)Gas-assisted ABS, acetal, acrylic, cellulosics, nylon, polycarbonate,

injection molding polyester (thermoplastic), polyethylene, polyphenylene oxide, polypropylene, polystyrene, PVC, SAN

Injection molding ABS, acetal, acrylic, alkyd,* allyl,* amino,* cellulosics,epoxy,* fluorocarbons,* liquid crystal polymer, nylon,phenolic,* polycarbonate, polyester (thermoplastic),polyester (thermoset),* polyethylene, polyphenyleneoxide, polypropylene, polystytrene, polysulfone,polyurethane (thermoplastic), PVC, SAN

Lay-up and spray-up Epoxy, polyester (thermoset)Pultrusion Epoxy, polyester (thermoset), siliconeReaction injection molding Nylon, polyurethane (thermoset), epoxy, polyesterResin transfer molding Epoxy, polyester (thermoset), siliconeRotational molding Acetal, acrylic, cellulosics, fluorocarbons, nylon,

polyester (thermoplastic), polyethylene, polypropylene,polystyrene, polyurethane (thermoplastic), PVC

Structural foam molding ABS, acetal, nylon, polycarbonate, polyethylene,polyphenylene oxide, polypropylene, polystyrene,polysulfone, SAN

Thermoforming ABS, acrylic, cellulosics, polycarbonate, polyethylene,polypropylene, polystyrene, polysulfone, PVC, SAN

Transfer molding Alkyd, allyl, amino, fluorocarbons, phenolic, polyester(thermoset), polyurethane (thermoset), silicone

*Special equipment required.

Source: Rotheiser, J. I., “Design of Plastics Products’’, Modern Plastics Handbook, C. A. Harper, ed.,McGraw-Hill, New York, 2000.

APPENDIX H

Recommended Materials for SpecificProperties*

813

Property Recommendation

Abrasion, resistance to (high) NylonCost:weight (low) Urea, phenolics, polystyrene, polyethylene,

polypropylene, PVCCompressive strength Polyphthalamide, phenolic (glass), epoxy, melamine,

nylon, thermoplastic polyester (glass), polyimide

Cost:volume (low) Polystyrene, polyethylene, urea, phenolics,polypropylene, PVC

Dielectric constant (high) Phenolic, PVC, fluorocarbon, melamine, alkyd, nylon,polyphthalamide, epoxy

Dielectric strength (high) PVC, fluorocarbon, polypropylene, polyphenyleneether, phenolic, TP polyester, nylon (glass), polyolefin, polyethylene

Dissipation factor (high) PVC, fluorocarbon, phenolic, TP polyester, nylon,epoxy, diallyl phthalate, polyurethane

Distortion, resistance Thermosetting laminatesto under load (high)

Elastic modulus (high) Melamine, urea, phenolicsElastic modulus (low) Polyethylene, polycarbonate, fluorocarbons

*Source: Rotheiser, J. I., “Design of Plastic Products’’, Modern Plastics Handbook, C. A. Harper, ed.,McGraw-Hill, New York, 2000.




Electrical resistivity (high) Polystyrene, fluorocarbons, polypropyleneElongation at break (high) Polyethylene, polypropylene, silicone, ethylene vinyl

acetateElongation at break (low) Polyether sulfone, polycarbonate (glass), nylon (glass),

polypropylene (glass), thermoplastic polyester,polyetherimide, vinyl ester, polyetheretherketone,

epoxy, polyimideFlexural modulus (stiffness) Polyphenylene sulfide, epoxy, phenolic (glass), nylon

(glass) polyimide, diallyl phthalate, polyphthalamide, TP polyester

Flexural strength (yield) Polyurethane (glass), epoxy, nylon (carbon fiber)(glass), polyphenylene, sulfide, polyphthalamide,polyetherimide, polyetheretherketone, polycarbonate(carbon fiber)

Friction, coefficient of (low) Fluorocarbons, nylon, acetalHardness (high) Melamine, phenolic (glass) (cellulose), polyimide,

epoxyImpact strength (high) Phenolics, epoxies, polycarbonate, ABSMoisture resistance (high) Polyethylene, polypropylene, fluorocarbon,

polyphenylene sulfide, polyolefin, thermoplastic polyester, polyphenyleneether, polystyrene, polycarbonate (glass or carbon fiber)

Softness Polyethylene, silicone, PVC, thermoplastic elastomer,polyurethane, ethylene vinyl acetate

Tensile strength, break (high) Epoxy, nylon (glass or carbon fiber), polyurethane,thermoplastic polyester (glass), polyphthalamide,polyetheretherketone, polycarbonate (carbon filter),polyetherimide, polyether-sulfone

Tensile strength, yield (high) Nylon (glass or carbon fiber), polyurethane,thermoplastic polyester (glass),polyetheretherketone, polyetherimide, polyphthalamide, polyphenylene sulfide(glass or carbon fiber)

Temperature, heat deflection Phenolic, epoxies, polysulfone, thermoset polyesters,polyether sulfone, polyimide (glass)

Temperature (maximum use) Fluorocarbons, phenolic (glass), polyphthalamide,polyimide thermoplastic polyester (glass),melamine, epoxy, nylon (glass or carbon fiber)polyetheretherketone, polysulfone, polyphenylene sulfide

Thermal conductivity (low) Polypropylene, PVC, ABS, polyphenylene oxide,polybutylene, acrylic, polycarbonate, thermoplasticpolyester, nylon


Thermal expansion, Polycarbonate (carbon fiber or glass), phenolic (glass),coefficient of (low) nylon (carbon fiber or glass), thermoplastic polyester

(glass), polyphenylene sulfide (glass or carbon fiber),polyetherimide, polyetheretherketone,polyphthalamide, alkyd, melamine

Transparency, permanent Acrylic, polycarbonate(high)

Weight (low) Polypropylene, polyethylene, polybutylene, ethylenevinyl acetate, ethylene methyl acrylate

Whiteness retention (high) Melamine, urea

RECOMMENDED MATERIALS FOR SPECIFIC PROPERTIES 815

A-Stage, 1Abhesive, 1Ablative plastic, 1–2Abrasion, 2–3, 543, 596Abrasion resistance, 2–3Abrasive, 3, 241Abrasive finishing, 3, 493–494Absolute viscosity, 4Absorption, 4Accelerator, 4–5, 166Accumulator, 5Acetal: polyacetal, polyoxymethylene

(POM), 5–6Acetone, 302Acetylene, 27Acid anhydride, 164Acid index, 6–7Acoustic emission test, 575Acrylate monomer adhesive, 34Acrylic fiber, 7Acrylic styrene acrylonitrile (ASA)

terpolymer, 9–10Acrylic: polymethyl methacrylate

(PMMA), 7–9, 274Coating, 97Fiber, 7, 413Thermosetting, 9

Acrylic-PVC, 9Acrylonitrile, 10Acrylonitrile butadiene styrene (ABS),

10–12, 274Acrylonitrile butadiene, 10Acrylonitrile-chlorinated polyethylene-styrene

terpolymer (ACS), 12Activation, 12Addition polymer, 12–13, 107Addition polymerization, 13, 35, 473Additive, 13–14Adherend, 14, 18, 436Adhesion, 14

Adhesion promoter, 15Adhesion theory, 16Adhesive, 17–18, 436

Anaerobic, 34Bonding 18–19, 296–300Contact, 109Cyanoacrylate, 123Failure, 19Heat sealing, 255 Hot melt, 267 Joint, 19Joint design, 297–300Pressure sensitive, 143, 461–462 Stress, 20Structural, 534 Tape and film, 197 Tape, 546 Tests, 20–23

Adhesive bonding, 18–19, 296–300Plastic parts, 296–297

Adhesive failure, 19Adhesive joint, 19Adhesive stress, 20Adhesive tests, 20–23Adipates, 23Adipic acid, 23Admixture, 23, 28Adsorption, 23–24Advanced composite, 24, 103Afterbake, 36Afterflame, 24Afterglow, 24Aggregate, 24Aging, 24–25

Accelerated, 24Artificial, 24, 44–45

Air assist forming, 25Air atomized spray coating, 527Air blasting, 25Air gap, 25

951

INDEX


Air lock, 25–26Air ring, 25Air slip forming, 26Air vent, 26Airless spraying, 25, 527Alcohol, 27Aldehyde, 27Algicide, 37Aliphatic, 27Aliphatic amine, 164Aliphatic ester, 407–408Aliphatic hydrocarbon, 27, 269Alkaline cleaning, 94Alkane, 27, 391Alkene, 27Alkyd, 27–28Alkyl, 28Alloy, 28, 58Allyl diglycol carbonate (ADCO), 29Allyl, 28–29Allylic ester

Casting resin, 82 Paint, 391

Alternating copolymer, 29Alternating stress, 29–30Alumina trihydrate (ATH), 30Aluminosilicate, 93Aluminum filler, 30Aluminum trichloride, 316Aluminum trihydrate (ATH), 199, 513Amide, 30Amido-amine, 30–31Amine adduct, 31Amine, 31Amino resin, 31–34, 166Aminoplast, 31Amorphous phase, 34Amorphous polymer, 34, 120Amyl acetate, 167Anaerobic adhesive, 34Anchorage, 34Anelastic deformation, 34–35Angle press, 35Anhydrous, 35Aniline formaldehyde, 35Aniline, 34–35, 414Anionic polymerization, 35, 326–327Anisotropic, 35–36Anneal, 7, 36Antiaging additive, 36Antiblocking agent, 36–37, 58–59Antifogging agent, 37Antimicrobial, 36–37, 55, 132Antimony, 200

Antimony oxide, 38Antimony trioxide, 37Antioxidant, 38–40, 36, 343Antislip, 198Antistatic agent, 39, 40–42, 133, 157Apparent density, 42Apparent viscosity, 592Aragonite, 73Aramid, 42, 373Aramid composite, 42Aramid fiber, 42–43, 182, 303–304Arc and track resistant plastic, 43Arc resistance, 43Arching, 565Aromatic, 43Aromatic amine, 39, 43–44, 164Aromatic copolyester, 325–326Aromatic hydrocarbon, 269Aromatic polyamide, 44Aryl dicyanate, 122Arylamine, 39Asbestos, 45, 562, 543Ash content, 45–46Ash test, 515Ashing, 3, 45–46, 68, 513Atactic, 46, 544Attenuated total reflectance Fourier

transformation infrared spectroscopy(ATR-FTIR), 538

Attenuation, 46Auger electron spectroscopy (AES), 538Auto-acceleration, 46Autoclave molding, 46, 551Autoclave, 46Autodeposition coating, 47Automatic mold, 47Autophoretic coating, 47Axial vibration welding, 588Axial winding, 48Azo compound, 216, 383Azodicarbonamide (ABFA), 60

B-stage, 49, 189, 460Back pressure relief port, 50Back pressure, 49–50Backing plate, 49Bactericide, 54Bag molding, 50Bagging, 50Bakelite, 50, 398Balanced construction, 50Balanced mold, 492Balanced runner, 50

952 INDEX

Balancing sheet, 127Ball hardness, 247Ball mill, 51Balsam, 379Banbury mixer, 51Barbender Plasticorder, 209Barcol hardness, 52Barium sulfate (barites), 52Barrier coat, 52Barrier properties, 52Barrier resin, 52–53Barytes, 52Base, 53Basket weave, 53, 601Beading, 53Bentonite, 562Benzene, 53Benzoate, 321, 408Benzophenone, 54, 321, 579Benzoquinone, 282Benzotriazole, 15, 321, 579Benzoyl peroxide, 9, 381–383, 423–426Benzyl dimethylamine (BDMA), 166, 363Beryllium copper, 54Beta gauge, 54Biaxial orientation, 54Biaxial stress, 54Bicomponent injection, 54Bifunctional monomer, 54Bi-injection molding, 54Binder, 55

Preform, 459Biocide, 37, 55Biodegradable plastic, 55–56Biodegradation, 129–130Biotite, 588Biphenol derivative, 56–57Bismaleimide (BMI), 57

Composite, 103Laminating resin, 313

Bisphenol A, 161–163Bisphenol F, 162Bituminous plastic, 57Black marking, 57Blanking (die cutting), 57Blanking, 122, 134Blasting, 241–243Bleeder, 583Bleeding, 58Bleedout, 58Blend, 58Blenders, 58Blister, 58Block copolymer, 58, 535

Blocking, 58–59, 176Bloom, 59Blow molding, 61–62

Bottom blow, 65 Die line, 139 Die swell, 139 False neck, 183

Blow molding (types) Coextrusion, 99 Continuous tube process, 110 Hollow part processes, 261 Injection, 283 Neck ring process, 365 Needle blow, 365 Orientation (stretch), 386 Pinch tube, 404 Platform, 409–410 Trapped air process, 568

Blow pin, 63Blow pressure and blow rate, 63 Blow rate, 63Blowing agent, 59–61, 216Blown film and tubing, 62–63, 194Blow-up ratio, 63Blueing, 63Bond, 63–64Bonded fabrics, 368Boron compounds, 64Boron fiber, 64Boron nitride, 64, 260Boron trifluoride (BF3), 316

Boron trifluoride complex, 166Borosilicate, 151Boss, 64Bottom blow, 65Bottom plate, 65Brabender Plasticorder, 65Braiding, weaving, knitting, stitching, 65–66Branched polymer, 65Breakdown voltage, 66Breaker plate, 66Breather cloth, 588Breathing (film), 67Breathing, 66–67Brittle failure, 67Brittleness temperature, 67Bromine, 200Brookfield viscometer, 67Bubble viscometer, 68Bubbler, 68Bubbler mold cooling, 68Buckling, 68Bucky ball, 223Buffing, 4, 68, 513

INDEX 953

Bulk compression, 68Modulus, 251

Bulk density, 68–69Bulk factor, 68Bulk molding compound (BMC), 68–69, 609Bulk polymerization, 437–438Bulk rope molding compound, 69–70Buna N, 366Burn (burn mark), 70Burning rate, 70Burring, 70Burrs, 189–190Bursting strength, 70Butadiene acrylonitrile, 71Butadiene rubber (BR), 71Butadiene styrene, 71Butadiene, 70–71Butt fusion, 71Butyl acetate, 167Butyl glycidyl ether, 166–167Butyl rubber (IIR), 72, 132Butylated hydroxytoluene (BHT), 39Butylene (butene) plastic, 71–72

C-scan, 73C-stage, 73Calcite, 73Calcium carbonate, 73, 192, 562Calcium metasilicate, 74, 604Calcium stearate, 74Calcium sulfate, 74–76Calender, 76–77, 157, 195, 223Capacitance, 77Capacitor, 77–78Capillary rheometer, 78Caprolactam, 78Carbon 60, 223Carbon black, 79, 107, 192–193, 321, 384,

578–579Carbon fiber, 79, 108. 238–259Carbon mat, 107 Carbonate, 78–79Carbonyl, 79Carborane plastic, 64Carbowax, 238Carboxyl, 79Carpet plot, 79 Carrier, 80, 144Casein, 80CASING, 405 Cast film, 81, 176Casting, 80–81, 159Casting resin, 81–82Catalyst, 83

Caul plate, 83Cavity, 83Cell, 83Cellophane, 83–84Cellosolve, 238Cellular plastic, 84Celluloid, 86Cellulose, 84–85Cellulose acetate (CA), 86

Foam, 219Cellulose acetate butyrate (CAB), 86Cellulose acetate propionate (CAP), 86Cellulose nitrate, 86, 307Cellulosic plastic, 85–97 Center gated mold, 87Centipoise, 87Centrifugal casting, 81, 87–88Centrifugal coating, 88Ceramic fiber, 88Ceramic matrix, 24Cermoplastic, 231Chain extender, 88–89Chain length, 89Chain reaction polymerization, 473Chalk, 73Chalking, 89Charge, 89Charpy impact test, 89Chase, 89Chelating agent, 36, 89, 343Chemical etch, 405Chemical resistance, 89–90Chemical stripper, 533Chill roll, 90Chlorinated hydrocarbon / plastic /

rubber, 90–91Chlorinated paraffin, 200, 392Chlorinated polyether, 91Chlorinated polyethylene, 91–92, 275Chlorinated polyvinyl chloride (CPVC), 453Chloroprene, 92Chlorostyrene, 425Chlorosulfonated polyethylene (CSM), 92Chlorotrifluoroethylene (CTFE), 213–214Chopped strand, 232Chromatography - gas, liquid, paper,

column, thin layer, 92Chrome complex, 15Circuit board, 92, 463Circumferential winding, 92–93Citrate, 408Clamping plate, 93Clamping pressure, 93Clarifying agent, 93

954 INDEX

Clay filler, 93–94Clay, calcinated, 94Cleaning, 94–95Clicking, 134Closed cell cellular plastics, 95Coal tar, 53Coat hanger die, 95Coated fabrics, 95Coaters, 525–527Coating

Air-atomized, 627Airless, 527 Autodeposition, 47Autophoretic, 47Barrier, 52Conformal, 109Curtain, 121–122Die blades, 134 Die gap, 134 Dip, 141–142Dispersion, 142–143 Double roll processes, 489 Electro-, 154–155 Electrostatic, 157, 526Extrusion, 459Flow, 121, 207–208Fluidized bed powder, 209–210, 457Gravure, 160, 240, 376, 464 Kiss roll, 304, Knife, 304–305 Multicomponent, 527 Powder, 209–210, 527 Roll, 489 Single roll processes, 489 Spray, 525

Coating cure, 95–96Coating process, 96Coating resin, 96–97Coating weight, 98 Cobalt compound, 15Cobalt naphthalene, 4Cobalt salt, 465Co-curing, 98Coefficient of friction, 98, 222, 511Coefficient of thermal expansion, 98Coextrusion blow molding, 99Coextrusion, 99 Cohesion, 99Cohesive failure, 99Coin test, 100Coinjection, 54Coinjection molding, 99, 495, 533Cold drawing, 437Cold flow, 99, 118

Cold forming, 105Cold molding, 99–101Cold runner molding, 101

Mold, 392Cold slug, 101Cold stretch, 101Colophony, 101Color, 101Color measurement and control, 102Colorant, 101–102Colorimeter, 102Combustion, 102, 513, 565Compatibilizer, 102Compliance, 102Composite, 103–104Composite

Advanced, 24, 103Aramid, 42Compounder, 104Film stacked, 197Undirectional, 35–36

Compounding, 104Compression mold, 502Compression molding, 104–106Compression ratio, 106Compression set, 106, 503Compressive strength, 107Condensation polymer, 107Condensation polymerization, 107Conditioning, 107Conductive filler, 39Conductive filler and reinforcement, 107–109Conductive plastic, 107Conductivity, 505Cone calorimeter, 204Conformal coating, 109Consistency, 109Contact angle, 539–540, 595–596Contact cement or adhesive, 109Contact layup, 245Contact pressure, 109Contact pressure laminate, 110Continuous chain injection molding, 109Continuous filament, 232, 491Continuous laminate, 110Continuous phase, 541Continuous tube process, 110Continuous use temperature, 110Convergent die, 111Cooling channel, 111Cooling fixtures, 111Copolyester elastomer, 111–112Copolymer, 112–113, 435, 474–475Copolymerization, 437

INDEX 955

Copper clad laminate, 113Core drill, 113Core, 113, 261, 494Corona, 113Corona resistance, 113–115Corona surface preparation, 115–116, 405Corrosivity index, 116Cotton, 84, 325

Linen, 116Coumarone-indine resin, 215Coupling agent, 15, 76, 116–118, 511, 609Crack growth, 118Cratering, 118Craze, 161Crazing, 118, 532. 551Creep, 118–119, 396–397Crimp, 186Critical stress intensity factor, 222Crosslinked polyethylene, 431Crosslinking, 119Crowfoot mark or crowsfeet, 119Crowfoot weave, 598Cryogenic temperature, 119Crysotile, 45Crystalline, 119–120Crystallinity, 530Crystallite, 120, 521Cull, 121Cumene hydroperoxide, 383, 426Cup flow test, 121, 208Cup viscosity test, 121Cure, 121Curing agent, 83, 121, 246Curtain coating, 121–122Cut edge, 354Cutting, 122, 496Cutting (knife), 305Cyanate ester, 122–123

Composite, 103Cyanoacrylate adhesive, 123Cyclic compound, 123Cyclic thermoplastic, 123Cyclized rubber, 124Cycloaliphatic epoxy, 162Cyclohexanone, 124Cyclo-olefin, 124

Dacron, 125Damping, 125, 564Daylight opening, 125Debond, 125Decabromodiphenyl oxide, 200Deckle rod, 126Decomposer, 579

Decorating, 126–127Decorating and coating, in-mold, 264–265Decorative laminate, 127Deflashing, 4, 127–128, 568–569Deflection temperature, 129, 250Defoamers, 129 Degassing, 66, 129Degradability agent, 129–130Degradation, 130Degree of polymerization, 130, 358Delamination, 130Dendrimer, 130–131Dendrites, 155Denier, 131, 186Density, 131–132, 521

Apparent, 42Bulk, 68–69

Deodorant, 132, 375Depolymerized rubber, 132Desicator, 133Desiccant, 133Desktop manufacturing, 475Destaticization, 133Detergents, 133Dextrin, 133Diallyl isophthalate (DAIP), 28–29, 560 Diallyl orthophthalate, 28–29Diallyl phthalate (DAP), 133, 425, 560Diaminodiphenyl sulfone (DDS), 31Diaphragm gate, 133Diatomaceous earth, 562Dibutoxy ethyl adipate, 23Dibutyl phthalate, 401Dibutyl tin dilaurate (DBTDL), 133–134, 490Dicumyl peroxide, 381–383Dicyandiamide, 166Dicyclohexyl phthalate, 401Die, 134Die cutting, 57, 134Die line, 139Die swell and die swell ratio, 1391,2-dieketone, 15Dielectric, 134Dielectric breakdown, 134Dielectric constant, 134, 136Dielectric curing or heating, 135Dielectric heat sealing/welding, 135–136Dielectric heating, 136Dielectric loss, 136–137Dielectric monitoring, 136Dielectric properties, 136–139Dielectric spectroscopy, 136Dielectric strength, 134, 138, 139Dielectrometry, 136

956 INDEX

Diethyl phthalate, 401Diethylaniline, 465Diethylene triamine (DETA), 31, 164Differential scanning calorimetry (DSC), 139,

249, 254, 387–388, 502, 550Differential thermal analysis (DTA), 140, 249,

387–388Diffusion, 4, 140Diffusion coefficient, 52, 397Diffusivity, 140Digylcidyl ether of bisphenol A, 161–162Dihexyl phthalate, 401Diluent, 140, 166–167Dimensional stability, 140–141Dimer, 141Dimethoxy ethyl phthalate, 401Dimethyl aniline, 9, 465Dimethyl phthalate, 401Dimethyl silicone polymer, 141Dimethyl polysiloxane, 508Dinitropentamethylene tetramine, 60Dinking, 134Dioctyl phthalate, 401, 408Dioxazine pigment, 384–385Dip coating, 141–142Dip molding, 142Diphenyl phthalate, 401Direct gate, 142Disbond, 125Discoloration, 101Dishing, 142–143Disk flow test, 208Dispersant, 142Dispersed phase, 541Dispersion, 142Dispersion coating, 142–143Displacement mold, 143Dissipation factor, 137, 143di-tert-butyl peroxide, 426Divinyl benzene, 425Doctor roll, doctor blade, doctor bar, 143Dolomite, 73Domain, 143Dome, doming, 142–143Double backed tape, 143–144Double gate, 144Double shot molding, 144Draft, 144Drape, 144, 186Drape assist frame, 144Drape forming, 144Draw ratio, 145Drawing, 144, 437Drilling, 145

Drop impact test, 145Dry abrasion, 3Dry blend, 145Dry coloring, 145Dry spinning, 522Dry spot, 148, 483Dry strength, 148, 531Dry winding, 148Drying, 148, 258Drying agent, 133Ductility, 148–149Duplicate cavity plate, 149Durometer hardness, 149, 505Dwell, 149Dye, 101Dying (fibers), 149Dynamic mechanical analysis (DMA),

149–150, 550, 564Dynamic mechanical spectrophotometer

(DMS), 150Dynamic testing, 150

E-glass, 151Ebonite, 151Eight-harness satin weave, 152, 598Ejector assembly mold hardware, 152Elastic deformation, 152, 407Elastic limit, 152, 466Elastic memory, 152Elasticity, 152Elastomer, 152–154Electric discharge machining, 154Electric insulation, 154Electrical laminate, 154Electrocoating, 154–155Electroformed mold, 155Electroless and electrolytic plated plastics,

155, 344–347Electromagnetic interference, 108, 155Electromagnetic shielding, 155Electromigration, 155Electron beam radiation, 471Electron spectroscopy for chemical analysis

(ESCA), 538Electronic plastic, 155–157Electrostatic discharge (ESD), 157Electrostatic powder coating, 157Electrostatic printing, 465Electrostatic spray, 457, 526Elmendorf test, 547–548Elongation, 157, 548Embossing, 157Emulsifier, 158Emulsion polymerization, 158, 437–438

INDEX 957

Enamel, 158, 391Encapsulation, 159Endothermic reaction, 159Engineering plastic, 5, 159–160Engraved roll coating, 160Environmental stress cracking, 161Epichlorohydrin (ECH, ECO), 161Epoxy, 161–164

Brominated 163 Casting resin, 82 Coating, 97 Composite, 103 Cycloaliphatic, 162 Epoxy ester, 408Foam, 220 Laminating resin, 313Molding compound, 561

Epoxy - glass, 161Epoxy resin, 161–164

Curing agent, 164–166Modifier, 166–167

Equivalent weight, 167Erucamide, 512Ester polymer, 133Ester, 167Etching, 167Ethanol, 168Ether, 168Ethyl acetate, 167Ethyl alcohol, 27, 168Ethyl cellulose, 86, 168Ethylene acrylic acid copolymer (EAA), 168Ethylene ethyl acrylate copolymer (EEA),

168–169Ethylene methyl acrylate copolymer (EMA), 169Ethylene n-butyl acrylate copolymer

(EBA), 169–170Ethylene oxide, 388Ethylene plastic, 170Ethylene propylene copolymer (EPM) and

ethylene propylene diene terpolymer(EPDM), 170

Ethylene propylene diene monomer(EPDM), 275

Ethylene propylene liquid polymer, 170–171Ethylene tetrafluoroethylene copolymer

(ETFE), 171Ethylene vinyl acetate copolymer (EVA),

171–172, 275Ethylene vinyl alcohol (EVOH), 172Ethylene-chlorotrifluoroethylene copolymer

(ECTFE), 213Ethylene-tetrafluoroethylene copolymer

(ETFE), 213

Ethyleneurea, 34Exotherm, 172Expanded plastic, 172Expanded polystyrene foam, 445Expanding monomer, 173Extender, 13, 173, 190–192

Plasticizer, 499Extensometer, 173Extruder screw, 74, 106Extruder, multiple screw, 361Extrusion, 174–177

Barrel, 177 Die, 177 Blow molding, 177 Blown film, 176 Breaker plate, 66, 177 Cast film, 176 Coat hanger die, 95 Coating die, 126 Coating, 176 Coextrusion, 177 Covering, 176 Die block, 134 Die bushing, 134, Die line, 139 Die swell, 139 Drive motor, 178 Feed hopper, 178, Feed throat and feed port, 178 Lead, 173 Melt spinning, 342–343 Multiple-screw, 175 Pitch, 173, Screen pack, 179 Screw, 174, Screwless, 175 Single-screw extruder, 174, Twin screw, 570Vertical, 175

Extrusion barrel, 177Extrusion blow molding, 61, 177Extrusion breaker plate, 177Extrusion coating, 459Extrusion die, 177–178Extrusion drive motor, 178Extrusion feed hopper, 178Extrusion feed throat and feed port, 178Extrusion plastometer (rheometer),

178–179Extrusion screen pack, 179

Fabric, 181–182Fabrication, 182Fadometer, 183False neck, 183

958 INDEX

Family mold, 183Fan gate, 183Fatigue, 30, 183–184Fatigue endurance, 184Fatty acid ester, 356Fatty alcohol, 331Fatty amide, 331Feather edge, 184Feed, 184Feldspar, 184–185Felt, 185Fiber show, 187Fiber washout, 187Fiber, 185–187, 436–437

Acrylic, 7Aramid, 42–43, 182, 303–304Carbon, 79, 108, 238–259Ceramic, 88Dying, 149Graphite, 238–259Metallic, 344Milled, 250Monofilament, 359Multifilament, 359PBO, 395Pitch, 404Polyethylene, 431–432Polymer, 436–437

Fiberglass, 187Fiber-reinforced plastic (FRP), 187Filament, 185–186Filament winding, 48, 187–189

Axial, 48Circumferential, 92 Dwell, 149 Helical pattern, 258 Hollow part processes, 261Wet winding, 148

Filing, grinding, and sanding, 128, 189–190Fill, 190, 401Fill and wipe, 190Fill fibers, 601Filler, 190–193Fillet, 193Fill-in painting, 392Film, 193–197. See also by chemical name

Adhesive, 197Cast, 81, 176Packaging, 389–391Stacked Composite, 197

Fin, 198, 387Finish insert, 198Finish, 198Fish eye, 199

Fish paper, 199Flame polishing, 199, 514Flame retardant, 30, 199–200Flame retardant resin, 200–202Flame spraying, 203Flame treatment, 203Flammability (in-plant safety), 203Flammability of plastics, 24, 204, 262, 273,

278, 324, 471, 499, 502Flash, 50, 127–129, 204–205Flash ignition, 273Flash mold, 206Flash point, 203, 206Flash ring, 588Flatting agent (matting agent), 36, 206Flex cracking, 206Flexibilizer, 206Flexible circuit, 206, 463Flexible mold, 206–207Flexographic printing, 464Flexural modulus, 351Flexural properties, 207Flow coating, 121, 207–208Flow drilling, 208Flow line, 602Flow molding, 208Flow tests, 208–209Fluidized bed powder coating, 209–210, 457Fluorinated ethylenepropylene (FEP), 213Fluorocarbon / fluoropolymer / fluoroplastic,

211–215, 332, 356Fluorocarbons, etching, 167Fluoroelastomer (FKM), 215Fluorophosphazene rubber, 400Fluorosilicone, 215Flux, 215Foam molding, 220Foam, see also by chemical name

Closed cell, 83 Open cell, 83Microcellular, 349Structural, 534Syntactic, 216, 220, 235, 541–542

Foamed plastic, 215–220Foaming agent, 59, 220Fogging, 220–221Foil, 193Foil decorating, 221Fokker bond test, 575Folding endurance, 221Force plate, 221Force plug, 221Forging, 221Formaldehyde, 27, 221, 392

INDEX 959

Four-harness satin, 221Fracture, 221–222Free radical, 13, 38, 222Free radical polymerization, 8, 13, 222, 549Free volume, 222Friction, 2, 222Friction calendering, 223Friction welding, 223Frog skin, 25Frost line, 223Frothing, 223Fuller’s earth, 223Fullerine, 223Functionality, 223Fungicide / fungistat, 54, 223, 224Fungus resistance, 224Furane resin, 224Furfural, 224Fuse, 224Fusion point, 224Fusion welding, 250

Gang mold, 225Gardner color scale, 225Gas counterpressue molding, 533Gas trap, 227Gasket material, 225–227Gate, 227–230Gel, 230Gel coat, 230, 245–246Gel content, 230Gel permeation chromatography (GPC),

230–231Gel point (gel time), 231General purpose polystyrene (GPPS), 445Glass bonded mica, 231Glass fabric, 231–232Glass fiber, 232–234Glass finish, 235Glass mat, 232, 235Glass sphere, 192, 235Glass transition temperature, Tg, 236–237Glass transition, 235–236Glazing material, 237Gloss, 237Glossmeter, 237Glue, 237Glue line, 237Glycol, 238Government rubber, 243Graft polymer and copolymer, 238Graft polymer, 11Grafting, 404Granular structure, 238

Granulating machine, 238Granulators, 478Graphite fiber, 238–240Gravure coating, 160Gravure printing, 240, 376, 464Green strength, 240, 544Grignard process, 240Grinding, 3, 190, 241Grit blasting, 25, 241–243GR-rubber, 243Guanamine, 34Guide pin, 243Gum, 243Gutta-percha, 243

Hammer milling, 350Hand, 186, 245Hand lay-up, 46, 245–246Hand mold, 246Hard rubber, 248Hardener, 83, 121, 246–247Hardness, 2, 247–248

Ball, 247Barcol, 52Durometer, 149 Rockwell, 485 Shore, 505

Haze, 237, 248–249, 566Head, 249Heat aging, 249Heat capacity, 249Heat cleaning, 249Heat deflection temperature (heat distortion

point), 249–250Heat of fusion, 254, 502Heat sealing, 255Heat stabilizers, 255–256Heat transfer, 265Heat treating, 256Heat welding (direct), 256–257Heat welding (indirect), 257Heated-manifold mold, 250Heated-tool welding, 250–253Heaters, 253–254Heating chamber, 254Heat-shrinkable tubing and film, 255 Heel, 257Helical pattern, 258Heteropolymerization, 437Hevea rubber, 364, 491High density polyethylene (HDPE), 430High performance plastic, 160High pressure laminate, 110High thermal conductivity plastic, 259–260

960 INDEX

High voltage resistant plastic, 260High voltage, 260High-flow resin, 258High-frequency heating, 258High-impact polystyrene (HIPS), 445High-performance plastic, 258High-pressure laminate, 258–259High-pressure liquid chromatograph, 259High-resistivity plastic, 259Hindered amine light stabilizer, 260, 321, 579Hindered phenolic, 39HMC, 260, 504, 607Hobbing, 89, 261Hollow part processes, 261Holographic analysis, 368Holography, 537Homopolymer, 261Honeycomb, 261–262, 494Honing, water, 128Hooke’s law, 262, 466Hookean elasticity, 152, 486Hoop stress, 262Hopper, 262Horizontal / vertical burning, 262Hot decorating, 126, 262–265Hot forming, 265Hot melt adhesive, 267–268Hot runner mold, 269Hot staking, 269Hot stamping, 263, 269Hot-gas welding, 265–267Hybrid, 269Hydrocarbon, 269Hydrolysis (hydrolytic stability), 90,

269–271, 595Hydrophilic, 271Hydrophobic, 271Hydroquinone, 425Hydroxyl group, 271Hygroscopic, 271Hygrothermal, 271Hysterisis, 271

IBM spiral mold, 525IEEE thermal rating, 273Ignition temperature, 206, 273–274Immersion ultrasonic testing, 574Impact

Charpy test , 89, 277 Drop test, 145 Dynamic testing, 150 Falling dart test, 277, Falling weight (tup), 570 Izod test, 277

Modifiers, 274–276 Pendulum test, 277Resistance, 276–277 Tensile test, 277,

Impact modifiers, 274–276Impact resistance, 276–277 Impregnating resin, 277–278Impregnation, 278Impulse sealing, 278Incandescent contact, 278Inclusion, 278Index of refraction, 278Induction welding, 279–280Induction, 282Infrared analysis, 280–282Infrared radiation, 471Infrared welding, 282Inherent viscosity, 592Inhibitor, 282, 425Initiation, 222, 283, 465Initiator, 283Injection blow molding, 61, 283Injection mold resin flow, 286–287Injection molding, 283–285

Bubbler mold cooling, 68 Coinjection, 495, 534 Cold runner, 101 Diaphragm gate, 133 Jet molding, 285 Jetting, 295 Reaction, 449 Reactive (RIM), 481 Screw-injection, 284 Vacuum, 585

Injection molding machine, 285–286Injection molds, 287–289Ink jet printing, 465Insert, 289–290, 338In-situ joint, 290Instron tester, 290Insulating materials, electrical, 290Insulating materials, thermal, 291 Insulation resistance, 138, 291, 484Insulators, 291Integral skin molding, 291Interface, 291Interference fit, 291, 499International system of units (SI), 506Interpenetrating polymer network (IPN), 291Interphase, 291–292Intrinsic viscosity, 292Intumescent coating, 292Ion exchange resin, 292–293Ion scattering spectroscopy (ISS), 538

INDEX 961

Ionomer, 293, 370Iridescence, 293Iron dithiocarbamate, 56, 130Irradiated film, 293–294Irradiated polyalkene, 431Irradiated polyolefin, 431Isoindolinone pigment, 385Isoprene, 294, 364Isostatic pressing, 294Isotactic, 294, 544Isotropic, 294Izod impact test, 294

Jacket, 295Jet molding, 295Jet spinning, 295Jetting, 295Jig, 296Joining (of plastic parts), 296–297Joint design (adhesive bonding), 297–300Jute, 300

K-factor, 301, 551Kaolin clay, 301Kaolinite, 93Kel-F, 301–302Ketone based peroxide, 302Ketone based polymers (PAEK, PEEK, PEK),

302–303Ketone peroxide, 381–383Ketone, 123, 302Kevlar, 42, 44, 303–304, 373Kick over, 304Kirksite, 304Kiss role coating, 304Knife coating, 304–305Knife cutting, 122, 305Knit line, 144, 305, 387, 602Knockout, 305–306Knurl, 306Kraft paper, 306

L / D ratio, 307, 497Lacquer, 307, 391Lactone stabilizer, 39Ladder polymer, 43, 307–308Lagging, 308Lamella, 308Laminae, 308Laminar flow, 308Laminate design factors, 311–312Laminate, 308–311

Contact pressure, 110Copper clad, 113

Decorative, 127 Design factors, 311 Electrical, 151, 154 Fish paper, 199 High pressure, 258–259 Low pressure, 328 Multilayer, 197 NEMA, 365–366Resin, 312–314 Thermoplastic, 311, 314Unidirectional, 581

Laminating resin, 312–314Land, 314Landed plunger mold, 314–315Lapping, 315Laser cutting, 496Laser jet printing, 465Laser welding, 315–316Latent catalyst, 64Latent curing agent, 166, 316Latent solvent, 316Latex, 142, 316–317Latex paint, 317Lay flat film and tubing, 62,176, 317–318Lay-up, 318–319Leaching, 319Lead trimming and forming, 319Leader pin, 243Leakage current, 319Leno weave, 319, 598Let-down ratio, 319Lettering, 319Letterpress printing, 376, 464Lewis acid, 316Lewis base, 363Lexographic printing, 376Light stabilizer, 320–323, 578Light transmission and color, 324Lignin, 324Limestone, 73Limiting oxygen index, 324, 388Linear low density polyethylene (LLDPE), 430Linear polymer, 324–325Linear vibration welding, 588Linters, 325Liquid crystal polymer (LCP), 325–326,

421–423Liquid injection molding, 326Liquid silicone rubber (LSR), 509Liquid transfer molding, 326Litharge, 326Living polymer, 35, 326–327Loading shoe mold, 327, 532Loading tray, 327

962 INDEX

Loading well, 327Locating ring, 327London dispersion forces, 327Loop strength, 327Loss factor, 137, 327Loss tangent (loss angle), 143, 328Low density polyethylene (LDPE), 430Low loss plastic, 328Low pressure laminate, 328Low profile additive, 328Low profile resin, 328–329Low shrink resin, 328–329Low-temperature properties, 329–330Lubricant, 198, 330–332Lubricant bloom, 330Lubrication, 511Luminance, 237Luminescent plastic, 332Luster, 237

Macerate, 333Machine shot capacity, 333Machining of plastics, 128, 333–335Macromolecule, 335Magnesium carbonate, 513Magnesium hydroxide, 199, 513Magnesium oxide, 562Magnesium silicate, 544Magnet wire coating, 335Magnetic fillers, 335Maleic acid, 335–336Mandrel, 336Manifold, 336Marble, 73Mass spectrometer, 336Massicot, 326Mat, 336Matched metal molding, 336–337Matrix, 337Mechanical fasteners, 337–339Mechanical fastening, 296–297Mechanical joining of plastics, 339–341MEK peroxide, 302, 383Melamine, 560Melamine formaldehyde (MF), melamine

phenol formaldehyde (MPF), 31–33, 341Laminating resin, 313 Molding compound, 561

Melt, 341Melt extractor, 341Melt flow, 341Melt fracture, 341Melt index (melt flow index), 341Melt processable rubber (MPR), 342

Melt spinning, 342–343, 522Melting point, 120Melting temperature, Tm, 342Mer, 130, 435Mercaptan, 343Mesa flow mold, 208, 525Metal deactivator, 36, 343Metal filler, 108Metal hydrate, 199Metal inlay, 343–344Metal matrix, 24Metal oxide, 88Metallic filament, 344Metallic pigment, 344Metallic soap, 331Metallic stearate, 466Metallization of plastics, 344–347Metallized filler, 108Metallizing, 585Metallocene catalysts, 170, 347–348, 389Metaphenylene diamine (MPDA), 31, 43, 164Metering screw, 348Methacrylate butadiene styrene (MBS), 274Methyl acetate, 167Methyl alcohol, 27Methyl cellulose, 238, 348Methyl chloride, 348Methyl ethyl ketone peroxide, 426Methyl isobutyl ketone, 302Methyl methacrylate acrylonitrile butadiene

styrene (MABS), 348Methyl methacrylate, 348Methylene dianiline (MDA), 43, 164Methylene dichloride, 533Methylpentene, 348Mica, 348–349, 396, 588Microballoon, 235Microcellular foam, 349Microcrack, 349Microdispensing, 349, 482Microphotography, 537Microsphere, 235, 349, 541Microwave susceptor, 135Migration, 349–350Mildewcide, 54Mill, bar, 51Milled fiber, 350Milling, turning, and routing, 350, 570Mineral rubber, 594Mixer

Muller, 360–361 Banbury, 51, 412

Mock leno weave, 350, 598Modifier, 13, 351

INDEX 963

Modulus of elasticity (elastic modulus,stiffness), 351, 548, 608

Moisture absorption, 352Moisture content, 352Moisture in plastics, 352Moisture vapor transmission, 352Mold cavity, 83Mold cooling, 353Mold parts

Bottom plate, 65 Chase ring, 89 Chase, 89 Cold slug well, 101 Core pin, 113 Duplicate cavity plate, 149 Ejector assembly, 152 Fan gate, 183 Finish insert, 198 Force plate, 221 Force plug, 221 Gate, 227–230 Guide pins, 243 Heaters, 253–254 Hob blank, 89 Knockout parts, 305–306 Land, 314 Loading tray, 327 Loading well, 225, 327 Locating ring, 327 Neck insert, 198 Restricted gate, 486 Retainer plate, 83 Return pin, 486 Side coring, 506 Spider, 521 Split cavity block, 89 Sprue bushing, 528 Sprue orifice, 101 Submarine gate, 536, 570 Tap gate, 543 Thread plug, 363 Tie bars, 564 Vertical flash ring, 588

Mold shrinkage, 357Mold steel, 357–358Mold types

Automatic, 47Balanced, 492 Center-gated, 87 Cold runner, 492 Combination, 183 Compression, 105 Displacement, 143Electroformed, 155

Family, 183 Flash, 206, 225, 314Flexible, 206–207 Gang, 225, Hand, 246 Hot runner, 269 Injection, 289 Landed plunger, 314 Landing shoe, 327 Multicavity, 353 Multiple gate, 353 Porous, 455 Positive, 455 Removable plate, 482, Removable plunger, 482 Runnerless, 492 Sandwich, 529 Semipositive, 502 Single cavity, 509 Split wedge, 525Sprayed metal, 527 Spring box, 528 Stacked, 529 Stripper plate, 532 Subcavity, 225 Subcavity gang, 536Three plate, 563 Two-level, 571 V-bar, 583 Wedge, 601

Mold, 352–353Molded circuit, 463Molded edge, 354Molding compound processing, 354–355Molding compound, 354, 515, 560

Bulk molding compound (BMC), 68–69 HMC, 260, 607–608 Processing, 354 Sheet molding compound, 504 (SMC), Solid polyester, 515 Thick molding compound (TMC), 562 XMC, 607–608 ZMC, 609

Molding cycle, 355–356Mold-release agent, 356Molecular weight, 130, 358Molecular weight, average, 47–48Molybdenum disulfide, 332Monofil, 359Monofilament, 359Monomer, 112, 141, 359–360Monosil process, 360Mooney scorch, 497Morphology, 360

964 INDEX

Motionless (static) mixer, 360, 483Mucilage, 360Muffle furnace, 45, 360, 515Muller type mixer, 360–361Multicomponent spray coating, 527Multifilament, 359Multifilament yarn, 361Multiple head machine, 361Multiple screw extruder, 361Muscovite, 348Muscovy glass, 348Mylar, 361

Nadic methyl anhydride, 164, 363Nanophase material, 363–364Natural gum, 243Natural resin, 364Natural rubber latex, 317Natural rubber, 151, 364–365Near-field welding, 365Neck ring process, 365Neck-in, 365Necking, 365Needle blow, 365NEMA, 365–366Neoprene, 366, 420Nepheline syenite, 185Nest plate, 366Newtonian behavior, 366Newtonian liquid, 592Nickel organic complex, 321Nickel quencher, 579Nip, 366Nitrates, 86Nitrile rubber (NBR), 10, 366–367Nitrobenzene, 367Nitrocellulose, 84NOL ring, 368Nomex, 44, 373Nondestructive testing, 368, 551–552, 573,

607Acoustic emission test, 575Beta gauge, 54Coin test, 100Fokker bond test, 575Holography, 368, 537Immersion ultrasonics, 574Radiography, 607Through transmission testing, 368, 573Ultrasonic, 368, 573–575

Non-Newtonian, 366Nonwoven fabric, 368–369Notch factor, 369Notch sensitivity, 369

Novolac, 369Nozzle, 369–370Nuclear magnetic resonance, 370Nucleating agent, 370Nutshell flour, 371Nylon, 78, 371–373

Fabric, 182 Fiber, 373 Yarn, 373

Odorant, 132, 375Offset molding, 376Offset printing, 376Oil resistance (heat and oil resistance), 376–377Oleamide, 512Olefin, 27Olefin and TPO elastomers, 377–378Olefinics, 378–379Oleoresin, 379Oligomer, 379One shot molding, 381Opacity, 566–568Open cell foam, 380Optical properties, 380Orange peel, 380Orbital vibration welding, 588Organic filler, 381Organic peroxide, 8, 381–383Organic pigment, 383–385Organic, 380–381Organometallic, 132

Salt, 450Organosilicone, 74Organosol, 142, 385–386, 408, 454Organotin catalyst, 450Orientation, 386Orientation (stretch) blow molding, 386Orifice, 387Orifice flow test, 208Ortho-nitrobiphenyl, 56Orthotropic, 387Orthotropic composite, 103Out gassing, 387Overcoating, 387Overflow groove, 387Overinjection, 54Overlap gate, 543Overlay mat (surfacing mat), 387Oxidation, 90, 387, 468–469, 551Oxidative coupling, 440Oxidative induction time, 387–388Oxirane, 388Oxygen index, 388Oxymethylene, 440

INDEX 965

Packaging, 389–391Pad transfer printing, 376, 464Painting plastics, 126, 391–392

Fill and wipe, 190Paraffin, 27, 392, 356

Chlorinated, 200, 392Paraformaldehyde, 392Parallels, 392Para-xylylene, 393–394Parison, 139, 392–393, 541Partial discharge, 113Parting agent, 393Parting line, 53, 393Parylene, 393–394Paste, 394–395Paste resin, 385–386, 395PBO fiber, 395Pearl essence, 395–396Pearlescent pigment, 395–396Peel ply, 396Peel, 396Pellet, 396Perfluoroalkoxy resin (PFA), 214–215Perfluoroalkoxy teflon (PFA), 396Permanent set, 152, 396–397Permeability coefficient, 52Permeability, 397Permitivity, 134, 397Peroxide, 397Peroxide catalyst, 418, 423–426Peroxide decomposer, 36Peroxyester, 423Phenol formaldehyde, see PhenolicPhenol resorcinol-formaldehyde, 486Phenol-furfural, 224Phenolic (phenol formaldehyde, PF), 398–399,

485Casting resin, 82 Foam, 220 Laminating resin, 312–313 Molding compound, 560

Phenolic triazine, 103–104Phenoplast resin, 166, 398Phenoxy, 399–400Phenylsilane resin, 400Phillips catalyst, 430Phlogopite, 348Phosphate ester, 200Phosphate trimester, 408Phosphazene polymer, 400Phosphorescent, 332Phosphorylated polyethylene, 400Photoconductivity, 400Photodegradation, 56, 129–130

Photoelasticity, 400Photoinitiators, 571Photopolymer, 400, 475Phthalate ester, 401, 407Phthalic anhydride, 164Phthalocyanine, 385Pick count, 401Piezoelectric polymer, 401Pigment, 101, 401–403Pinch tube process, 404Pitch fiber, 404Plain weave, 404, 598Plasma surface preparation, 404–407Plastic

Ablative, 1–2Arc and track resistant, 43Biodegradable, 55–56Bituminous, 57Carborane, 64Cellular, 84Cellulosic, 85–97Closed cell, 96Conductive, 107Engineering, 5, 159–160Expanded, 172Fiber reinforced, 187Foamed, 215–220High performance, 160, 258High resistivity, 259High thermal conductivity, 259–260High voltage resistant, 260Joining of parts, 296–297Low loss, 328Luminescent, 332Machining of, 128, 333–335Mechanical joining of, 339–341Metalization of, 344–347Moisture in, 352Reinforced, 479–481Reprocessed, 482Reworked, 486Rigid, 486–487

Plastic deformation, 407Plastic memory, 152, 255, 408Plasticating, 285, 497Plasticizer, 407–408, 541Plastigel, 385–386Plastisol, 224, 385–386, 395, 408–409, 454Plastometer, 409Plate dispersion plug, 409Platen, 409Plate-out, 409Platform blowing, 409–410Plating, 126, 410

966 INDEX

Platinum catalysts (silicone), 490Plexiglas, 7Plug forming, 411Plunger molding, 411, 565Ply orientation, 411Ply, 411Poise, 412Poison’s ratio, 412Polishing, 3, 513–514Poly(p-phenylene-2-6-benxobisoxazole)

(PBO), 395Polyacrylate acrylic rubber (ACM), 412Polyacrylonitrile, 412–413Polyalcohol, 439Polyallomers, 413–414Polyamide thermoplastic elastomer, 414Polyamide TPE, 559Polyamide, 164, 370, 414

Fabric, 182Polyamide-imide, 414Polyaniline, 135, 414Polyaryl ether (PAE), 415–416, 426Polyaryl sulfone (PAS), 416Polyarylate (PAR), 415Polyarylketone (PAEK), 302–303Polybenzimidazole (PBI), 416–417Polybutadiene (PBD), 417–418Polybutylene (BP), 71, 418–419Polybutylene terephthalate (PBT), 421–423Polycarbonate (PC), 419–420Polycarbonic acid, 60Polychloroprene (CR), 420–421Polycyclohexylene dimethylene terephthalate

(PCT), 421–423Poly-dichloroparaxylene, 394Polydispersity index, 48Polyester resin, 27

Casting resin, 82 Coating, 97 Composite, 103 Laminating resin, 313 Molding compound, 515, 561

Polyester (thermoplastic), 421–423Polyester (thermosetting), 423–426Polyester amide, 414Polyester polyurethane, 448Polyester-glass, 421Polyether block amide, 414Polyether ether ketone (PEEK), 302–303,

434–435Polyether ether ketone ketone (PEEKK),

434–435Polyether ketone (PEK), 302–303, 434–435Polyether polyurethane, 448

Polyether sulfone (PES), 427–428Polyether, 426, 432

Chlorinated, 91Polyetherester amide, 414Polyetherimide (PEI), 427Polyether-imide carbonate, 427Polyether-imide silicone, 427Polyethylene (PE), 428–431

Chlorinated, 91–92, 275Crosslinked, 431Fabric, 182 Foam, 218Phosphorylated, 400

Polyethylene copolymer, 431Polyethylene fiber, 431–432Polyethylene glycol, 432, 439Polyethylene naphthalene (PEN), 389Polyethylene terephthalate (PET), 421–423

Film, 361Polyglycol, 238, 426, 432Polyhydroxybutyrate-valerate (PHBV), 56Polyimidazopyrrolone, 468Polyimide (PI) and polyamide-imide (PAI),

432–434Composite, 103 Laminating resin, 313

Polyimide-glass, 432Polyisoprene, 132Polyisoprene rubber (IR), 434Polyketones, 434–435Polyliner, 435Polymer, 435–436Polymer blend, 436Polymer fiber, 436–437Polymerization, 437

Anionic, 35, 326–327Bulk, 437–438Chain reaction, 473Condensation, 107Copolymerization, 437Degree of, 130, 358Free radical, 8, 13, 222, 549Suspension, 8, 437–438Vinyl, 13

Polymerization system, 437–438Polymethyl methacrylate (PMMA), 439Polymethylpentene (PMP), 439Poly-monochloroparaxylene, 394Poly-m-xylene adipamide, 44Polyol, 439, 448, 460Polyolefin, 428, 439Polyolefin copolymer, 413Polyoxyethylene (polyethylene oxide),

439–440

INDEX 967

Polyoxymethylene (POM), 5, 440Polyphenyl sulfone (PPSU), 442Polyphenylene ether (PPE), 440Polyphenylene oxide (PPO), 440–441Polyphenylene sulfide (PPS), 441–442Polyphthalamide (PPA), 442–443Polypropylene (PP), 443–444Poly-p-xylene, 444Polysaccharide, 56Polysiloxane, 444Polystyrene (PS), 444–446

Foam, 219Polysulfide, 343Polysulfide rubber (PTR), 446Polysulfone (PSU), 416, 427, 442, 447–448Polyterpene resin, 448Polytetrafluoroethylene, 211–213Polyurethane (PUR), 432, 448–449, 481

Casting resin, 82 Coating, 97–98 Foam, 217–219, 494

Polyurethane catalyst, 449–450Polyurethane foam catalyst, 450Polyvinyl acetal, 450–451Polyvinyl acetate (PVAc), 451Polyvinyl alcohol (PVA), 451–452Polyvinyl butyral, 23, 450–451Polyvinyl carbazole, 452Polyvinyl chloride (PVC), 452–154

Chlorinated (CPVC), 453Coating, 98 Foam, 218

Polyvinyl chloride acetate, 454Polyvinyl fluoride (PVF), 214Polyvinyl formal, 450–451Polyvinylidene chloride (PVDC),

454–455Polyvinylidene fluoride (PVF), 214, 301–302,

308Porous mold, 455Positive mold, 455Postcure, 455Postforming, 456Pot life, 456Potting, 456Potting resin, 456–457Powder blend, 145Powder coating, 209–210, 457–458Powder molding, 459Power factor, 138, 459p-quinone dioxime, 170Precure, 459Predrying, 459Preform, 459, 473

Preforming, 64, 105Preheat roll, 459Preheating, 459, 473–474Preimpregnation, 460Premix, 460,Premix molding compound, 504Prepolymer, 460Prepreg, 49, 189, 460Preservative, 55Press fit, 499Pressure bag molding, 46, 461, 584Pressure forming, 461Pressure pad, 461Pressure roll, 461Pressure sensitive adhesive, 461–462Primary amine, 31Primer, 462–463Printed circuit board, 463Printing on plastics, 126, 463–465, 529Processing aid, 465Promoter, 4, 425, 465Proof pressure, 465Propagation, 222, 465Proportional limit, 466Propylene glycol, 432Propylene-ethylene polyallomer, 413p-tertbutylcatechol, 425Pulforming, 467Pulp molding, 466Pulse echo, 573–574Pultrusion, 466–467

Die line, 139 Hollow part processes, 261

Punching, 122Puncture strength, electrical, 467Purging, 467Push-on fastener, 339PV limit, 596Pyrolysis, 1, 467–468, 551Pyroxylin, 367Pyrrone, 468

Qualified products list (QPL), 469Quality control, 469Quality factor (Q-factor), 143Quartz, 469–470Quasi-isotropic laminate, 470Quaternary ammonium salt, 39Quench, 470Quench rolls, 470Quench tank extrusion, 470Quencher, 320–323Quinacridone pigment, 385Quinophthalone pigment, 385

968 INDEX

Radiant panel test, 471Radiation curing, 471Radiation resistance, 472–473Radical, 473Radical, free, 473Radio frequency preheating, 473–474Radio frequency welding, 474Radiography, 607Ram, 474Ram extrusion, 474Random copolymer, 474–475Rapid prototyping, 475Rapid tooling, 475Rayon, 475–476Reaction injection molding (RIM), 449,

476–477, 481Reactive diluent, 477Reaming, 70, 350, 477Reciprocating screw machine, 477Recycled plastics, 477–478Reflow, 96Refractive index, 478Regenerated cellulose, 478Regrind, 478–479Reinforced plastics, 479–481Reinforcement, 481Relative humidity (RH), 481Relative temperature index (maximum

continuous use temperature), 481Relative viscosity, 592Relaxation, 481–482Release agent, 245, 482Release film, 482, 503Release paper, 482Release sheet, 583Removable plate mold, 482, 532Rennet, 80Reprocessed plastic, 482Resiliency, 482Resin dispensing, 482Resin mixer, 483Resin pocket, 483Resin transfer molding, 483Resin, 482Resistance (electrical), 484Resistance wire welding, 484Resistivity, 485, 593Resistor, 485Resol, 485Resorcinol, 485Resorcinol-formaldehyde, 485–486Restricted gate, 486Retarder, 486Return pin, 486

Reversion, moisture, 269Reworked plastic, 486R-factor, 301, 551Rheology, 486Rigid plastic, 486–487Rigidsol, 408Rise time, 487Rivet, 339Rockwell hardness, 247, 487Roll coating, 488–489Roll mill, 489Room temperature vulcanizing (RTV), 490, 508Rosin, 490Rotating spreader, 406Rotational molding, 261, 459, 490–491Rotoforming, 490Rotogravure, 160, 240Rotomolding, 490Roving, 187, 491Roving cloth, 606RTP, 491Rubber, 152–153, 491. See also elastomer,

142–154Cyclized, 124Government, 243Hard, 248Hevea, 364, 491Mineral, 594 Natural, 151, 364–365Latex, 317 Synthetic, 542. See also by chemical name

Runnerless mold, 492Runners, 491–492

S-glass, 493Salicylate, 321Salt spray test, 493Sandblasting, 25, 493–494Sanding, 3, 68, 128, 189, 241Sandwich construction, 262, 494Sandwich foam molding, 495Sandwich heating, 494Sandwich molding, 494–495

Mold, 529Saran, 397, 454, 495Saturated compound, 496Sawing, cutting, shearing, 122, 496Scale, 496Scavenger, 579Scorch (scorching), 70, 496–497Scotch-Brite, 3Scrap, 497Screw, 338–339Screw length, 497

INDEX 969

Screw plasticating injection molding, 497Screw speed, 497–498Scrim, 498SCRIMP process, 483Sealant, 498Secant modulus, 498–499Secondary crystallization, 499Secondary ion mass spectrometry (SIMS), 538Secondary plasticizer, 499Self-extinguishing, 70, 499Self-fastening, 499–502Self-ignition, 502Self-ignition temperature, 273Semi-automatic molding machine, 502Semi-crystalline polymer, 502Semi-positive mold, 502Semi-rigid plastic, 502Separator ply, 503Sequential blow molding, 62Sequential coextrusion, 62Set, 503Shape factor, 503Shark skin, 503Shear, 503Shear compliance, 102Shear modulus, 351Shear ply, 504Shear strength, 503Shearing, 122, 496Sheet forming, 512Sheet molding compound (SMC), 504Shelf life, 504Shielding compound, 505Shore hardness, 247, 505Short shot, 50, 510Short, 505Shot, 505Shrink film, 255, 506Shrink fixture, 111Shrink mark, 506Shrink wrapping, 506Shrinkage, 505, 510Shuttle press, 506SI, 506Side corings, 506Side draw pin, 506Side-ram press, 35Silane, 15, 76, 116–117, 198Silane coupling agent, 506Silica, 506–507

Fumed, 562, 563Silicone, 129, 332, 356, 490

Foam, 219 Laminating resin, 313

Molding compound, 561Silicone resin (rigid), 507–508Silicone rubber, 508–509Silk screen printing, 464, 509Single cavity mold, 509Single screw extruder, 510Sink mark, 510–511Siopas process, 360Sizing, 511Skins, 262Skiving, 195, 511Slat fog test, 493Slip, 176, 511Slip agent, 36, 511–512Slip forming, 512Slitting, 122Slot extrusion, 512Slush molding, 459, 512–513Smoke / toxic gas generation, 513Smoke suppressants, 30, 513Smoothing, 3, 513–514S-N diagram, 184Snap back forming, 514Snap fit, 499–501Sodium aluminum silicate, 514Sodium benzoate, 370Sodium bicarbonate, 60Sodium borohydride, 60Sodium-naphthalene, 167Softening point, vicat, 590Softening temperature range, 514Sol fraction, 230Solid polyester molding compound, 515Solid-phase forming, 221Solids content, 515Solubility, 397Solubility coefficient, 52Solution, 541Solution casting, 515Solution polymerization, 437–438Solvation, 515Solvent, 515–516Solvent cementing (welding), 7, 296–297,

516–520, 602Solvent cleaning, 94Solvent molding, 520Solvent resistance, 520–521Spear, gate valve, 586Specific gravity, 131, 521Specific heat, 249, 521Specific modulus, 521Specific strength, 521Spectra, 431–432Spectrophotometer, 102

970 INDEX

Infrared, 280–281Spherulite, 521Spider, 521Spin welding, 522–525Spinneret, 186–187, 343, 522Spinning, 522Spiral flow test, 208, 525Spiral mold cooling, 525Spiro-orthocarbonate, 173Split wedge or split center mold, 525Spontaneous ignition, 502Spray coating, 525–527Sprayed metal mold, 527Spray-up, 246, 527Spreader, 527–528Spring box mold, 528Sprue, 142, 528Sprue bushing, 528Sprue plug, 492Spun roving, 491, 528Stabilizer, 528Stable fiber, 232Stacked mold, 529Stamp printing, 376, 464, 529Stampable thermoplastic, 529Stamping, 106Standard dimension ratio (SDR), 529Standards, 529–530Stannous octoate, 450Staple, 186, 530Starch, 133Starved area, 530Static electricity, 530Static mixer, 483Stationary platen, 530Steam molding, 530Stearate, 76, 331, 356Stearic acid, 74Stechkin apparatus, 273Steiner tunnel test, 513, 569Step cure, 530Stereospecific (stereoregular) plastics, 530Stiffness, 351, 531Stitching, 531Stops, 31Storage life, 531Strain, 531Strain gauge, 173Strands, 491Strength, dry and wet, 531Stress, 531Stress crack, 531–532Stress crazing, 94Stress relaxation, 481, 532

Stress-rupture strength, 119Stress-strain curve, 548Stress-strain diagram, 532Stretch blow molding, 386Stretch forming, 532Stripper, 533Stripper plate mold, 532–533Stripping agent, 533Structural adhesive, 534Structural foam molding, 534Styrene, 534Styrene acrylonitrile copolymer (SAN), 413,

534–535Styrene block copolymers, 558Styrene butadiene polymer, 535–536Styrene butadiene rubber (SBR), 71, 535Subcavity gang mold, 536Submarine gate, 536, 570Substrate, 14, 536–537Sulfone resin, 537Sulfonyl hydrazide, 60Sulfonyl semicarbazide, 60Surbitol, 370Surface active agent, 537, 540Surface analysis, 537–539Surface energy, 539–540Surface mat, 586Surface modifying agent, 539Surface resistivity, 138, 484, 485, 539Surface tension, 539Surface tension depressant, 129Surface tension, critical, 16Surface treatment, 539–40Surfacing mat, 540Surfactant, 540–541Surging, 541Suspension, 541Suspension polymerization, 8, 437–438Sweating, 541Syndiotactic, 541, 544Syntactic foam, 216, 220, 235, 541–542Synthetic rubber, 542

Tab gate, 543Taber abrasion, 543Tack, 543–544Tack primer, 544Tacticity, 544Talc, 192, 544–546Tangent delta (tan delta), 143, 546Tapes, 546Tapping and thread cutting, 546–547T-die, 547Tear ply, 396, 547

INDEX 971

Tear resistance, 547–548Telomer, 548Tenacity, 186, 548Tenacity (loop), 327Tensile modulus, 351Tensile strength, 548–549Tensile-shear, 503Terephthalate, 549Termination, 222, 549Terminators (free radical), 320–323Terpolymer, 549Tertiary amine, 31, 166, 363, 450Tetrabromo-bisphenol A, 200Tg, glass transition temperature, 549Thermal analysis, 550

Thermomechanical analysis (TMA), 98,550, 551, 556

Thermogravimetric analysis (TGA), 550,556

Dynamic mechanical analysis (DMA),149–150, 550, 564

Differential scanning calorimetry (DSC),139, 219, 254, 387–388, 502, 550

Differential thermal analysis (DTA), 140,249, 387–388

Thermal conductivity, 156–157, 301, 550–551Thermal degradation, 551Thermal expansion coefficient, 551Thermal expansion molding, 551Thermal stress cracking, 551Thermal surface impedance testing, 552Thermal transmission inspection, 551–554Thermal welding, 296–297, 554Thermally stable plastic, 551Thermoforming, 554–555

Air-Assist, 25 Air-slip, 26 Plug forming, 411 Pressure forming, 461 Twin sheet, 261, 571 Vacuum forming, 584

Thermogravimetric analysis (TGA), 550, 556Thermogravimetry, 556Thermomechanical analysis (TMA), 98, 550,

551, 556Thermoplastic, 556–557Thermoplastic copolyester elastomer, (TPE)

559Thermoplastic elastic olefins (TEO), 111Thermoplastic elastomer, 170, 535, 557–559Thermoplastic etherester elastomers (TEEE),

111Thermoplastic olefin copolymer (TPO), 123,

558–559

Thermoplastic polyurethane elastomer (TPU),449, 559

Thermoplastic vulcanizate (TPV), 111, 559Thermoset, 559–560Thermoset injection molding, 560Thermoset molding compound, 560–562Thermosetting polyurethane, 449Thick molding compound (TMC), 562Thickening agent, 562Thinner, 563Thiobisphenolic, 39Thioester, 39Thixotrope, 562, 563Thixotropic, 366, 563Thixotropy, 67Thread count, 563Thread cutting, 546Thread plug, 563Three plate mold, 563Through transmission testing, 368, 573Tie bars, 564Tin catalyst, 450Tin octoate, 490Titanate, 15, 74, 117–118Titanate coupling agent, 564Top blow, 564Torpedo, 285, 341, 406, 564Torsion pendulum test, 564Torsion, 564Toughness, 564Tow, 187, 564Toxicity, 564–565Track, 565Track resistance, 565Tracking, 138–139Transfer molding, 105, 159, 565–566

Cull, 121 Diaphragm gate, 133

Transmittance, 566Transparency, translucency, and opacity,

566–568Transparent polymers, 380Transverse isotropy, 568Transverse properties, 568Trapped air process, 568Trees, 155Triallyl cyanurate, 425Triazine ring, 122Triethylenediamine (TEDA), 450Triethylenetetramine (TETA), 31Trimellitate, 408Trimer, 141Tris (dimethylaminomethyl)-phenol (DMP-30),

363

972 INDEX

Tris-nonylphenyl phosphite (TNPP), 39Trommadorff effect, 46Trouser tear method, 548Tumbling, 128, 568–569Tunnel fire test, 569–570Tunnel gate, 570Tunnel oven process, 466Tup impact test, 570Turning and milling, 570Twill weave, 570, 598Twin screw extrusion, 570Twin sheet thermoforming, 555, 571Twist, 571Two level mold, 571Two-shot molding, 54

Ultimate strength, 573Ultimate tensile strength, 521Ultra high molecular weight polyethylene

(UHMWPE), 430Ultrasonic inspection, 573–575Ultrasonic testing, 368Ultrasonic washing, 95Ultrasonic welding, 575–576Ultraviolet (UV), 576Ultraviolet degradation, 576–578Ultraviolet radiation, 471Ultraviolet resistance (or light resistance),

578Ultraviolet stabilizer, 578–579Unbond, 579–580Undercure, 580Undercut, 580Undercuts, 525Underfill compound, 580Underwriters’ Laboratories, 481,

580–581Uniaxially oriented film, 581Unicellular, 581Unidirectional composite, 35–36Unidirectional laminate, 581Unipol process, 428Unsaturated compound, 581Unsaturated polyester, 581Urea formaldehyde resin, 31–33, 582

Foam, 220 Molding compound, 561

Urea, 581Urethane, 582Urethane foam catalyst, 582UV absorber, 320–323, 579UV quencher, 579UV screener, 321, 578UV stabilizer, 260, 320–323

V bar mold, 583Vacuum bag molding, 46, 583–584Vacuum forming, 584–585Vacuum hot pressing, 585Vacuum impregnating, 585Vacuum injection molding, 585Vacuum metallizing, 344–347, 585–586Valve gating, 586Van der Waals forces, 14, 16, 99, 516, 586Vapor curing, 96, 586Vapor degreasing, 94Vapor honing, 596Varnish, 586Vat pigment, 385Vehicle, 586Veil, 387, 586Vent, 587–588Vent cloth, 588Venting, 588Venturi dispersion plug, 588Vermiculite, 588Versamid, 166Vertical flash ring, 588Very low density polyethylene (VLDPE),

429–430Vibration welding, 588–590Vicat softening point, 590Vinyl acetate, 590Vinyl chloride, 590Vinyl chloride copolymers, 453–454Vinyl ester, 590–591Vinyl phenolic, 591–592Vinyl polymerization, 13Vinyl resin, 592Vinyl toluene, 425Vinylidene chloride, 591Vinylidene fluoride, 591Virgin material, 592Viscoelastic, 486, 592Viscose process, 475Viscosity, 592–593

Absolute, 4Barbender Plasticorder, 209 Brookfield, 67Bubble, 68 Capillary rheometer, 78 Centipoise, 87 Consistency, 109 Cup, 121 Depressant, 593 Dynamic, 4Extrusion plastometer, 178–179Inherent, 592 Plastometer, 409

INDEX 973

Relative, 592 Zahn, 609

Viscosity depressant, 593Viscous flow, 486Volatile matter, 593Volume resistivity, 138, 484, 485, 593Vulcanization, 153, 593Vulcanized fiber, 84, 594Vulcanized oils, 594

Wallastonite, 348Warp, 595Water absorption, 352, 595Water break, 595–596Water extended polyester, 596Water honing, 596Water jet cutting, 496, 596Water repellency, 198Water-based paint, 391Wax, 331–332, 356Weak boundary layer, 540, 596Wear, 2, 596–597Weather resistance, 597–598Weathering, artificial, 45, 89Weatherometer, 597Weave, 181, 598–601Web, 601Wedge mold, 601Wedges, 525Weft, 601Weld mark, 305Welding

Axial vibration, 588Friction, 223 Fusion, 250 Heat (direct), 256–257 Heated-tool, 250–253, 278 Hot gas, 265–267 Hot plate, 278 Induction, 279 Infrared, 282 Laser, 315 Plastic, 601–602Radio frequency, 474 Spin, 523–525 Thermal, 554

Ultrasonic, 575–576 Vibration, 588–590

Welding (plastic), 601–602Wet abrasion, 3Wet abrasive blasting, 602Wet lay-up, 603Wet molding, 426Wet spinning, 522Wet strength, 148, 531, 603Wetting, 16, 603, 605Wetting agent, 129, 603Whiskers, 603–604White metal blast, 494Wicking, 4Wipe-in painting, 392Wollastonite, 74, 604–605Woof, 605Woof fiber, 601Working life, 456, 605Woven fabric, 606Woven roving, 235, 606

X-ray inspection, 607X-y axis, 607Xylenol, 608XMC, HMC, 504, 607–608X-Ray emission spectroscopy (XES), 538

Yarn, 608Yellowness index, 101Yield value, 608Yoke forming, 608Young’s modulus, 102, 351, 521, 608

Z-axis, 608–609Zahn viscosity cup, 609Ziegler, Karl, 544Ziegler-Natta catalyst, 34, 348, 418, 430,

609Zinc borate, 200Zinc compound, 579Zinc oxide, 321Zirconate, 118, 609Zirconate propionate, 15Zirconium propionate, 609ZMC, 609

974 INDEX

PLASTICS MATERIALS AND PROCESSES - TU Delft · PDF filePlastics Materials and Processes: A...

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