BDA 2042/20402

MATERIALS SELECTION

POLYMERIC
MATERIALS
Polymer Structure
Raw Materials
Polymer Matrices

Polymer

Thermoset Thermoplastics Rubbers

Non-crystalline Crystalline
Polymer Matrices
Thermoplastics Polymer

Amorphous/ Semi-
Non-Crystalline Crystalline
Polymer Polymer
Thermoset Polymer
Thermoplastics Matrices
z Can be fabricated into required component
z Can be repeatedly heated, fabricated and cooled
Properties Acrylic Nylon Polycarbonate Polypropylen
(PMMA) (6.6) e
Density (g/cm3) 1.2 1.1 1.1-1.2 0.9

Young’s Modulus (GPa) 3.0 1.4-2.8 2.2-2.4 1.9-1.4

Tensile Strength (MPa) 60-70 45-70 25-38

Ductility (%) 30-100 90-110 100-600

Fracture Toughness 1.5

KIC (MPa m1/2)
Thermal Expansion 50-90 90
(10-6 K—1)
Glass Trans. Temp (°C) 90-105 150

Melting point (°C) 261 175

Polymer Matrices
Comparison of typical ranges of property values for thermosets
and thermoplastics (Matthew & Rawlings, 1999)
Properties Thermosets Themoplastics
Young’s modulus 1.3-6.0 1.0-4.8
(GPa)
Tensile Strength 20-180 40-190
(MPa)
Fracture toughness
KIC (MPa m1/2) 0.5-1.0 1.5-6.0
GIC (kJ/m2) 0.02-0.2 0.7-6.5
Maximum service
temperature (°C) 50-450 25-230
Thermoset Matrices
Advantages
z The stiffness increased due to the cross-link
z Can be used at higher temperature

z Better creep properties

Disadvantages
z Thermosetting polymers or thermosets – resin readily cross-
link during curing*
z Thermoset cannot be reshaped by reheating – cross-links
z Only degrade on reheating or in the some cases may burn but
do not soften sufficiently

*curing-involves the application of heat and pressure or

the addition of a catalyst/curing agent/hardener
 Thermoset Matrices(Matthew & Rawlings,
1999)
Properties Epoxy Polyester Phenolics Polyimides

Density (g/cm3) 1.1-1.4 1.1-1.5 1.3 1.2-1.9

Young’s Modulus (GPa) 2.1-6.0 1.3-4.5 4.4 3-3.1

Tensile Strength (MPa) 35-90 45-85 50-60 80-190

Fracture Toughness
KIC (MPa m1/2) 0.6-1.0 0.5
GIC (kJ/m2) 0.02 0.3-0.39

Thermal Expansion 55-10 100-200 45-110 14-90

(10-6 K—1)

Glass Trans. Temp (°C) 120-190

Thermoset Matrices
Matrices Properties
Polyester -Relatively inexpensive
-Low viscosities
-Shrinkage is higher (4-8%)
Epoxy -More expensive, more viscous than Polyester
- Shrinkage is 1-5%
Phenolics -Good fire resistant
-Volatile by product are evolved during curing
Polyimides -Can withstand relatively high service temperature
 TYPES OF POLYMER

(i) ELASTOMER
 TYPES OF POLYMER

(i) THERMOPLASTIC
 TYPES OF POLYMER

(i) THERMOSET
 COMPOUNDING OF POLYMERS
¾ Pure polymers are mixed with other materials – to improve
& enhance theirPenyebatian
properties.
¾ Compounding Öprocess by which the constituents are
intimately mixed together in the molten state into as nearly
a homogeneous mass as is possible.
Pengaloian Pengadunan
¾ The general term given to ;
(1) the process of alloying or blending polymers
(2) using additives or fillers such as colorants, flame
retardants, antistatic agents, plasticizers and others.
(3) adding reinforcement – or a combination of all three
(Polymer Matrix Composites - PMC)
 Alloying and Blending
ƒ Alloys & blends – combination of polymers that are
mechanically mixed.
ƒ Do not depend on chemical bonding – require
‘stabilizers’ to keep the constituents from
segregating.
ƒ The best characteristics of each constituent is
usually retained .
ƒ Objective – to find two or more constituents whose
mixture yields synergistic improvements.
ƒ Improvements – impact strength, weather
resistance, improved low temperature performance
and flame retardation.
 Alloying and Blending
œ Alloy → has a single glass transition
temperature
→ exhibits a synergistic effect in properties.

œ Blend → multiple glass transition temperature

→ with properties that are the average of
the contributions of the individual
constituent polymers.
→ need a stabilizer
Additives and Fillers

Ö Compounded with plastics to change and improve their

physical, mechanical and processing properties.
Ö There are 9 types additives and fillers
Ö The types of additives and fillers and their effects ;

1. Fillers
- may be inorganic, organic, mineral, natural or synthetic
- commonly used with thermosetting resins
- help reducing the cost of the plastic
- e.g. wood flour, silica, calcium carbonate and clay
Additives and Fillers
2. Plasticizers
- to enhance flexibility, resiliency and melt flow
- acts like an internal lubricants by reducing the van der
Waals forces
- e.g. phthalates, epoxies, phosphates etc.

3. Heat stabilizers
- prevent the degradation of resins during processing
when subjected to high temperature
- extend the life of end products
- e.g. barium, organotin and zinc liquids
 Additives and Fillers
4. Antioxidants
- protect materials from deterioration through
oxidation
brought on by heat, light or chemically
mechanism.
- 3 main preventive mechanisms :
(i) absorbing or screening ultraviolet light
(ii) deactivating metal ions
(iii) decomposing hydro-peroxides to nonradical
products.
Additives and Fillers
5. UV light absorbers
- stabilize the color and lengthen the life of the product
- e.g. carbon black, black paint, benzophenones etc.

6. Antistatic agents
- to reduce the buildup of electrostatic charges on the
surface of the plastics due to their inherent poor
electrical conduction.
- e.g. amines, phosphate esters and polyethylene glycol
esters.
Additives and Fillers
7. Blowing agents
- used singly or in combination with other substances to
produce cellular structure (foam) in a plastic
- e.g. ammonium or sodium bicarbonate

8. Lubricants
- to enhance the processability and the appearance of the
final products.
- must be compatible with the resins
- e.g. metallic stearates, fatty acids, hydrocarbon waxes
etc.
 Additives and Fillers
9. Colorants
- provide colorfastness when exposed to light,
temperature, humidity, chemical and so on – without
reducing other desirable properties.
- e.g. pigments and dyes.