Lab: Characterization of Materials-2

Experiment: Melt Flow Index (MFI)

Submitted To: Dr. Syed Mujtaba ul Hassan

Submitted By:
Group Number 1
Name (Serial No)
1. M. Daniyal Shahid (22)
2. M. Ahtisham Aziz (21)
3. Fahad Uddin (07)
4. Abdul Ahad Naeem (01)
5. M. Kaleem Qureshi (27)

Date: 08/03/2023

Abstract Format Discussion Results

Department of Metallurgy and Materials Engineering

Batch: 2021-2025
Abstract:
The melt flow index (MFI) experiment is a standard method used to measure the flowability of
thermoplastic materials under specific processing conditions. In this experiment, a polymer
sample was subjected to a specific temperature and pressure, and the amount of material that
flowed through a small orifice within a specified time was measured. The MFI test is an essential
tool for evaluating the rheological properties of polymers and determining their suitability for
various manufacturing processes.
 TABLE OF CONTENTS

1.0 Introduction……………………………………………………………………… 1
1.1 Melt Flow Index…………………………………………………………... 1
1.2 Melt Flow Indexer………………………………………………………… 2
1.3 Viscosity…………………………………………………………………... 2
1.4 Relation between Viscosity and MFI……………………………………... 3
1.5 Relation between DPE and MFI…………………………………………... 3

2.0 Experiment……………………………………………………………………….. 3
2.1 Apparatus………………………………………………………………….. 3
2.2 Procedure………………………………………………………………….. 4

3.0 Observations and Calculations………………………………………………….. 5

4.0 Discussion…………………………………………………………………………. 6

5.0 Conclusion………………………………………………………………………… 6

6.0 References…………………………………………………………………………. 7
1.0 Introduction:
The melt flow rate method is widely used in the polymer industry and is likely to remain as a
dominant tool for quality control and assurance. It is globally used for materials specification. The
melt flow rate method, or melt flow index as it was historically known, has been in existence for
several decades. It fulfils a requirement for rapid materials characterization, specifically for
checking the quality of the material and for assessing its processability, both of these in terms of
the material’s ease of flow. However, the melt flow rate also has its critics.
The melt flow rate method, put simply, is a measure of the quantity of material (pre-heated in a
barrel) that is extruded through a die of a given length and diameter in a given time when a
specified load is applied to the piston. The current standard ISO 1133 [1] covers two principal
procedures, specifically the melt mass flow rate (MFR) and the melt volume flow rate (MVR). The
difference between these two measures is that in the former the mass of material extruded in a
given time is measured, and in the latter the volume of material extruded in a given time is
measured. Thus, a single value is obtained, for either MFR or MVR, that characterizes the flow
behavior of the material. MFR is expressed in g/10 minutes and MVR in cm3 /10 minutes.

1.1 Melt Flow Index:

The melt flow index (MFI) is a measure of the ease of flow of the melt of a thermoplastic
polymer. It is defined as the mass of polymer, in grams, flowing in ten minutes through a capillary
of a specific diameter and length by a pressure applied via prescribed alternative gravimetric
weights for alternative prescribed temperatures. Polymer processors usually correlate the value of
MFI with the polymer grade that they have to choose for different processes, and most often this
value is not accompanied by the units, because it is taken for granted to be g/10min. Similarly, the
test load conditions of MFI measurement are normally expressed in kilograms rather than any
other units. The method is described in the similar standards ASTM D1238 and ISO 1133.
Melt flow rate is an indirect measure of molecular weight, with high melt flow rate corresponding
to low molecular weight. At the same time, melt flow rate is a measure of the ability of the
material's melt to flow under pressure. Melt flow rate is inversely proportional to viscosity of the
melt at the conditions of the test, though it should be borne in mind that the viscosity for any such
material depends on the applied force. Ratios between two melt flow rate values for one material
at different gravimetric weights are often used as a measure for the broadness of the molecular
weight distribution.
Melt flow rate is very commonly used for polyolefins, polyethylene being measured at 190 °C and
polypropylene at 230 °C. The plastics engineer should choose a material with a melt index high
enough that the molten polymer can be easily formed into the article intended, but low enough that
the mechanical strength of the final article will be sufficient for its use.

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1.2 Melt Flow Indexer:
Melt flow index of the LLDPE foam mixer has been checked with dynisco melt flow indexer
as per ASTM D 1238. Melt Flow Index is the output rate (flow) in grams that occurs in 10 minutes
through a standard die of 2.0955 ± 0.0051 mm diameter and 8.000 ± 0.025mm in length when a
fixed pressure is applied to the melt via a piston and a load of total mass of 2.16 kg at a temperature
of 190°C. Melt flow index is an assessment of average molecular mass and is an inverse measure
of the melt viscosity; in other words, the higher a MFI, the more polymer flows under test
conditions. Knowing the MFI of a polymer is vital for anticipating and controlling its processing.

Melt flow indexer

1.3 Viscosity:
Viscosity is the measure of the internal friction of a fluid. This friction becomes apparent when
a layer of fluid is made to move in relation to another layer. The greater the friction, the greater
the amount of force required to cause this movement, which is called shear. Shearing occurs
whenever the fluid is physically moved or distributed, as in pouring, spreading, spraying, mixing,
etc. Highly viscous fluids, therefore, require more force to move than less viscous materials.
Viscosity is the most important flow property. It represents the resistance to flow. Strictly
speaking, it is the resistance to shearing, i.e., flow of imaginary slices of a fluid like the motion of

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a deck of cards. We can define viscosity as the ratio of the imposed shear stress (force F, applied
tangentially, divided by the area A), and the shear rate (different velocities V1 and V2, divided by
distance dx).

1.4 Relation between Viscosity and MFI:

The MFI value is inversely proportional to the viscosity of a polymer, meaning that as MFI
increases, viscosity decreases. This is because a higher MFI value indicates that the polymer flows
more easily, and therefore has a lower resistance to flow, while a lower MFI value indicates that
the polymer has a higher viscosity and flows more slowly.
This relationship between MFI and viscosity can be used to predict the flow behavior of a polymer
under different processing conditions. For example, if the MFI of a polymer is known, it may be
possible to estimate the viscosity of the material under different shear rates and temperatures,
which can be useful in selecting the appropriate processing conditions for a particular application.
It is important to note, however, that the relationship between MFI and viscosity is not linear and
varies depending on the specific polymer and testing conditions. Therefore, it is necessary to use
caution when interpreting MFI values and to consider additional factors, such as molecular weight
and shear rate, when assessing the flow properties of a polymer.

1.5 Relation between DPE and MFI:

MFI is a measure of the flow properties of a polymer under specific conditions, and HDPE is a
type of polyethylene with a high density and high crystallinity. HDPE typically has a lower MFI
value compared to other types of polyethylene, such as low-density polyethylene (LDPE). This is
because HDPE has a higher molecular weight and more tightly packed molecular structure, which
leads to a higher viscosity and lower flow rate.
The MFI value of HDPE can be affected by various factors, including the molecular weight
distribution, degree of branching, and processing conditions. In general, a higher MFI value
indicates that the HDPE has a lower viscosity and flows more easily, while a lower MFI value
indicates that the HDPE has a higher viscosity and flows more slowly.
Therefore, there is an inverse relationship between MFI and HDPE viscosity, with lower MFI
values corresponding to higher viscosities and vice versa. However, it is important to note that this
relationship is not linear and can be influenced by various factors, such as processing conditions
and polymer structure.

2.0 Experiment:
2.1 Apparatus:
 Melt Flow Indexer
 Piston
 Mass balance
 Weight
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 Schematic of a melt flow rate instrument

2.2 Procedure:
 Start by selecting a material sample that you want to analyze.
 Cut the sample into small pieces and dry it in an oven at a temperature and time specified
by the manufacturer or the testing standard to remove any moisture.
 Turn on the Melt Flow Indexer and allow it to warm up for the specified time period.
 Set the testing temperature, typically ranging from 190°C to 330°C, and the load weight
for the specific material and testing standard.
 Attach the nozzle die to the Melt Flow Indexer.
 Weigh the sample accurately using a balance and load it into the cylinder of the Melt
Flow Indexer.
 Use a plunger to push the sample into the cylinder while taking care not to damage the
sample or create any air pockets. Note the mass of the loaded sample.
 Start the Melt Flow Indexer test by turning on the motor that pushes the piston to apply
the specified load to the sample.
 The sample is melted by heating element in the cylinder and extruded through the nozzle
die at a constant rate over a specified time period, usually ranging from 5 to 15 minutes.
 The extruded polymer is collected and weighed to determine the MFI value.
 Calculate the Melt Flow Index (MFI) value (g/10min) by dividing the mass of the
extruded polymer by the time taken for the polymer to pass through the nozzle die.
 The MFI value can be used to characterize the flow properties of the polymer under
specific conditions.

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3.0 Observations & Calculations:
Sample: PolyOlefins
Load Applied: 2.16 kg
Melting Point: 175 ⁰C
Melting Time: 7 minutes
Number of cuts: 3
Cut interval: 60 seconds

Weighted sample after cuts = 4.5972 g/min

(Converting to g/10min for MFI)
Melt Flow Index = (4.5972 g/min) x 10/10
Melt Flow Index = 45.972 g/10min

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4.0 Discussion:

MFI is a measure of the flowability of a thermoplastic polymer. The MFI value of

different kinds of materials is different. It is dependent on several factors, including the
molecular weight distribution, polymer structure, and processing conditions. The
molecular weight distribution of a polymer is a major factor that affects its MFI.
Generally, high molecular weight polymers have lower MFI values, whereas low
molecular weight polymers have higher MFI values. This is because high molecular
weight polymers have more entanglements between polymer chains, which hinder the
flow of the material.

There is also a relationship between MFI and melting point of a polymer, but it can vary
depending on the specific polymer being considered. In general, higher melting point
polymers tend to have lower MFI values, while lower melting point polymers tend to
have higher MFI values.

This is because the melting point of a polymer is related to the strength of the
intermolecular forces holding the polymer chains together. Polymers with strong
intermolecular forces will have higher melting points and tend to be more rigid, which
can restrict their flow and result in lower MFI values and vice versa. However, it's
important to note that this relationship is not always consistent, and there can be
exceptions. For example, some polymers may have high melting points but still exhibit
high MFI values due to their unique molecular structure or processing conditions.

Viscosity and MFI are also related. The MFI value is inversely proportional to the
viscosity of a polymer, meaning that as MFI increases, viscosity decreases. This is
because a higher MFI value indicates that the polymer flows more easily, and therefore
has a lower resistance to flow, while a lower MFI value indicates that the polymer has a
higher viscosity and flows more slowly.

5.0 Conclusion:
In conclusion, the melt flow index (MFI) experiment was performed to determine the
flowability of the polymer sample under specific processing conditions. The MFI value
obtained for the sample was 45.972 g/10min, which indicates that the polymer has
moderate flowability. This value can be used to evaluate the suitability of the polymer for
various manufacturing processes. The results obtained were reliable and consistent.

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6.0 References:
[1] NPL Report “Melt Flow Index”, (Online)

https://eprintspublications.npl.co.uk/3980/1/MAT3.pdf

[2] Science Direct, “Melt Flow Index”, (Online)

https://www.sciencedirect.com/topics/chemistry/melt-flow-index

[3] SGS Polymer Solutions, “Melt Flow Index Testing”, (Online)

https://www.polymersolutions.com/blog/melt-flow-index-testing

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