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Astm D2663 - 2014
Astm D2663 - 2014
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1. Scope TEST METHOD A—VISUAL INSPECTION
1.1 These test methods cover the degree of dispersion of 3. Scope
carbon black in rubber. Four test methods are described as 3.1 Test Method A is a qualitative visual test method.
follows: Ratings are made against a set of standard photographs (Fig.
Sections 1),3 and the results are expressed on a numerical scale. This test
Test Method A—Visual Inspection 3 – 11
Test Method B—Agglomerate Count 12 – 22 method cannot be used for compounds that contain fillers other
Test Method C—Microroughness Measurement than carbon black.
with Profilometer 23 – 33
Test Method D—Microroughness Measurement with IFM 34 – 42 4. Summary of Test Method
1.2 The values stated in SI units are to be regarded as 4.1 The compound rubber is torn or cut to expose a fresh
standard. No other units of measurement are included in this surface for examination by the eye, aided preferably by a hand
standard. lens or a low-power binocular microscope. The dispersion
1.3 This standard does not purport to address all of the level of the carbon black is compared against a series of five
safety concerns, if any, associated with its use. It is the photographic standards and then rated numerically from 1
responsibility of the user of this standard to establish appro- (very low) to 5 (high) (see Fig. 1).
priate safety and health practices and determine the applica- 5. Significance and Use
bility of regulatory limitations prior to use.
5.1 Visual dispersion ratings correlate with certain impor-
tant physical properties of the compound. A rating of 5
2. Referenced Documents
indicates a state of dispersion developing near maximum
2.1 ASTM Standards:2 properties, while a rating of 1 would indicate a state of
D3182 Practice for Rubber—Materials, Equipment, and Pro- dispersion developing considerably depressed properties.
cedures for Mixing Standard Compounds and Preparing Normally, the visual dispersion ratings indicate the following
Standard Vulcanized Sheets levels of compound quality:
D4483 Practice for Evaluating Precision for Test Method Visual Dispersion Rating Classification
Standards in the Rubber and Carbon Black Manufacturing
Industries 4 to 5 High
3 to 4 Intermediate
2.2 ASTM Adjuncts: 2 to 3 Low
1 to 2 Very low
Carbon Black Dispersion Standards3
Carbon Black Dispersion Chart4 6. Apparatus
6.1 Sharp Knife or Razor Blade.
6.2 Hand Lens (10×) or binocular microscope (10 to 20×).
1
These test methods are under the jurisdiction of ASTM Committee D24 on
Carbon Black and are the direct responsibility of Subcommittee D24.71 on Carbon
6.3 Illuminator, microscopical-type.
Black Testing in Rubber. 6.4 Knife Heater.
Current edition approved Jan. 1, 2014. Published February 2014. Originally
approved in 1967. Last previous edition approved in 2008 as D2663 – 08. DOI: 6.5 Series of Photographic Standards, rating 1 to 5. These
10.1520/D2663-14. standards give the following percent dispersion ratings by the
2
For referenced ASTM standards, visit the ASTM website, www.astm.org, or Agglomerate Count Method:
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Standards volume information, refer to the standard’s Document Summary page on Visual Rating Black Dispersed, %
the ASTM website. 1 70
3
Available from ASTM International Headquarters. Order Adjunct No. 2 80
ADJD266302. Original adjunct produced in 1967. 3 91
4
Available from ASTM International Headquarters. Order Adjunct No. 4 96
ADJD266301. Original adjunct produced in 1967. 5 99
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
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7. Test Specimen thickness. Mill and cure in accordance with Practice D3182.
7.1 Vulcanized Compounds—Use a slab of rubber about Then proceed as in 7.1.
2 mm in thickness. Tear it so that a fresh surface is exposed. 7.2.2 If the specimen contains no curatives, add the appro-
The tear may be initiated by a small cut. The most nearly flat priate materials with a minimum of mixing. Then cure and
part of the tear is used for rating. proceed as above.
7.2 Unvulcanized Compounds—Unvulcanized rubber may 7.2.3 If the specimen contains no curatives and a dispersion
be examined as follows: evaluation with no further mixing is required, the compound
7.2.1 If the specimen contains curing agents, sheet it out and must first be compressed to remove most of the air holes. To
cure in a press to form a vulcanized slab about 2 mm in accomplish this, press the rubber into a slab between thin
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FIG. 2 Rotary Microtome with Cryogenic Attachment for Sectioning Rubber Specimens
5
16. Reagents and Materials
Example, Leica RM2265.
6
Example, Leica LN22. 16.1 Liquid Nitrogen.
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FIG. 3 Light Microscope Equipped with Digital Camera and Computer System
16.2 Organic Solvents—Appropriate organic liquid to aid in pressed out to eliminate most of the air holes. Cure in
flattening section onto the glass microscope slides. Examples accordance with Practice D3182.
include xylenes, toluene, and methanol.
18. Test Specimen
17. Sampling
18.1 Cut out a specimen approximately 1 cm long, 1 cm
17.1 Vulcanizates—Specimens may be cut from standard wide, and approximately 2-mm deep.
test sheets (about 2-mm thick) or from pieces of actual cured
articles. Vulcanized samples must be employed because of the 18.2 Cut the square block into a trapezoidal shape that will
solvent used to uncurl the thin sections. If pieces other than fit the sample chuck on the rotary microtome.
2-mm sheets are used, they should first be cut down to a 18.3 Prepare one specimen block for each different com-
thickness of about 2 to 3 mm. pound to be examined.
17.2 Unvulcanized Compounds—For rubbers of high un-
saturation (for example, OE-SBR, NR, and BR), dust small bits 19. Procedure
(enough subsequently to form buttons about 10 mm in diameter 19.1 Microtome Preparation—Turn on the rotary
and about 2 to 3-mm deep) thoroughly with dicumyl peroxide. microtome, insert the knife into the microtome and adjust to
Cure in a button mold7 under high pressure at about 155°C. the correct cutting angle (see microtome manufacturer instruc-
OE-SBR rubbers require about 30 to 60-min cure. BR requires tions). Fill the liquid nitrogen dewar and attach to the cryo-
about 10 to 15-min cure. After cure, scrape off the excess genic chamber on the microtome. Cool the microtome chamber
peroxide from the sample surface and proceed with sectioning and knife holder.
in the standard manner, taking care not to pare down below the
cured surface layer. 19.2 Sample Preparation—Insert the prepared specimen
17.2.1 For IIR, satisfactory surface cures can be obtained block into the microtome chuck and insert the chuck into the
with a mixture of 1 part tetramethylthiuram disulfide (TMTD), microtome such that the long axis of the specimen is parallel to
1 part mercaptobenzothiazole (MBT), 1 part sulfur, and 5 parts the cutting direction. Cool the sample to approximately 50°C
zinc oxide, with a cure of 1 h at 155°C. Other alternative below the elastomer glass transition temperature.
approaches for curing high unsaturation polymers without 19.3 Microtome Operation—Manually advance the speci-
actually mixing in curatives are (1) high-energy radiation and men so that the cutting face almost reaches the knife. At this
(2) chemical treatment with sulfur monochloride. However, point, with the advance set in increments of 5 to 10 µm, start
before using either of these latter methods, the stock should be microtoming until the specimen is faced level and full-size
sections are being cut.
7
A special mold containing several circular cavities that are approximately 19.4 Cutting Thin Sections—After facing is complete, set
10 mm in diameter and 3 mm deep. the microtome control to the appropriate thickness depending
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second sable brush, add a few drops of the organic liquid to the
section. With careful manipulation of the solvent wet brush, to lose micrograph information) file format.
unroll and spread the section out flat on the slide. An additional 19.10 Micrograph Analysis—In an appropriate image analy-
brush or small pointed stick may be helpful to roll out the sis software package, open the first micrograph. To analyze the
section. Continue brushing gently to remove all wrinkles. images, the first step is to threshold the image such that the
Small amounts of additional solvent may be added as needed. carbon black aggregates are isolated from the background
19.6 Repeat steps 19.4 and 19.5 until a sufficient number of (usually brown in color). Care should be taken to minimize the
sections have been brushed out. Then cover the sections with number of defects (knife marks, folds, etc.) that are included in
cover glasses or another glass microscope slide, and seal with the area selected by the threshold operation. Once the threshold
tape, or a bit of cement at each corner. is complete, a binary image will be generated (Fig. 4). Using
the appropriate software tool, the agglomerates greater than 5
19.7 Preparing for Counting—Inspect the sections for qual- µm in size should be counted and a total area fraction of these
ity under the light microscope, and select one that is relatively agglomerates calculated. Repeat this analysis for each image
free of wrinkles, holes, and knife marks. Also avoid sections and average the ten area fraction values together to obtain the
that are very thin as some of the clumps of carbon black may overall agglomerate area fraction.
be brushed out. If the sections are too thick or have too many
wrinkles, holes or knife marks, adjust the microtome accord- 20. Calculation and Interpretation of Results
ingly and produce additional sections.
20.1 Percent Dispersion—Calculate the percent dispersion,
19.8 Once good sections are obtained, remove the specimen representing the percentage of carbon black that has been
from the microtome and measure the length and width of the dispersed below the 5-µm agglomerate size, as follows:
faced block where the sections were obtained. The product of
Dispersion, % 5 100 2 SU/L
these dimensions is the area before swelling. Also, measure the
length and width of a few of the sections mounted on the glass where:
slides. Average these dimensions and their product is the U = agglomerate area fraction. (This represents an average
section area after swelling. Record this value along with the of the ten area fraction measurements on the sections.
sample area before swelling. See Note 1.)
19.9 Micrograph Acquisition—Place the slides in the light NOTE 1—Most agglomerates are not composed entirely of carbon black.
They may contain substantial amounts of polymer or extender oil. In
microscope in transmission mode and select the magnification. extreme cases, where U is very large, negative dispersion ratings are
Magnification should be in the range from 75 to 100× but the therefore possible. Such stocks are extremely poor and may simply be
exact figure is left to the discretion of the individual operator, classified at a “0” or “no dispersion” rating. It must also be assumed that
FIG. 4 Left: Light micrograph showing the carbon black agglomerates (dark regions) in a rubber sample. Right: The binary image pro-
duced from the micrograph after thresholding to isolate the carbon black agglomerates
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FIG. 5 Components of Profilometer Dispersion Analyzer System
28. Test Specimen 29.1.2 Set the length of the trace at about 10 cm by
28.1 Using a scissors, cut out a rectangular specimen that is positioning the steps on the side of the drive unit.
approximately 3.5-cm long, 2-cm wide, and 0.2-cm deep. The 29.1.3 Press the high-speed (2.5 mm/s) switch and then
longest dimension of the specimen should be cut along the activate the RUN switch on the control console. This will start
direction in which the rubber slab was sheeted out. the stylus tracking in an alternating in and out direction above
28.2 Store unvulcanized specimens at about −5°C for a the horizontal reference surface.
minimum of 30 min prior to testing. 29.1.4 Lower the stylus by turning the control knob on top
of the probe in a clockwise direction. Continue until the stylus
29. Calibration makes contact with the reference surface. The position of the
29.1 The dispersion analyzer drive unit must be leveled so stylus is indicated as HIGH or LOW by an indicator LED on
that the stylus moves in a horizontal plane. Position the drive the right side of the vertical display on the control console. The
unit on the vibration isolator slab prior to this procedure. HIGH and LOW designations refer to the pressure of the stylus
29.1.1 Position the stylus to trace over a known flat surface on the surface.
which provides a suitable horizontal reference plane. A sheet of 29.1.5 Observe whether the stylus is HIGH or LOW during
plate glass on the surface of the vibration isolator is suitable for the trace and stop the drive unit at the extreme point by
this purpose. activating the HALT switch on the control console.
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about 0.5 cm in from the end.
(intercept), for the dispersion index calculation. These con-
stants are specific to individual formulations. If the constants 30.15 Set the tracking speed of the stylus for normal
are not available for the rubber formulation that is to be operation (0.25 mm/s).
analyzed, see Section 31. 30.16 Bring the stylus into contact with the surface of the
30.5 Set the roughness width cutoff at 0.80. specimen by adjusting the height control switch until the
30.6 Enter the constant, C, for minimum roughness peak indicator bar is midway between the HIGH and LOW ex-
height. This constant eliminates high frequency electronic or tremes. This setting will remain constant for subsequent
vibrational noise which may be dependent on the location of specimens which can simply be mounted in place by gently
the instrument. A value of C = 0.7 µm is typically used when lifting the stylus with a finger.
the drive unit is mounted on a vibration isolation slab. Lower 30.17 Activate the single cycle switch on the control con-
or higher values for C may be used at the discretion of the sole. The stylus will move outward 2.0 cm at a speed of
operator. This selection may depend on the type of rubber 2.5 mm/s, pause briefly, and then start the trace of the specimen
formulation or the size range of agglomerates that are pertinent in an inward direction.
to specific aspects of product performance.
30.18 When the trace has been completed (80 s), record the
30.7 Set the drive unit for a trace length of 2.0 cm. measured values for dispersion index (DI), number of rough-
30.8 Insert the rubber specimen into the specimen holder ness peaks/cm, F, average roughness peak height, H, and
clamp. The longest dimension of the specimen should be roughness factor, F2H.
parallel to the top edge of the clamp with about 8 to 10 mm of 30.19 Displace the mounted specimen laterally by about
the specimen protruding above the clamp. 0.2 mm and make a second roughness trace. Record the
30.9 Mount the specimen holder over the alignment pins on measurements and average the values for the first and second
the specimen cutting device. In the cutting position the clamp traces. These average values represent a single test result.
handle should be facing upright. 30.20 Repeat 30.8 through 30.19 for additional specimens
of the same rubber formulation.
TABLE 1 Type 1—Method C Precision Results (Measured
Dispersion Index)
31. Calculation
Dispersion Index
Sr r (r) SR R (R)
(average) 31.1 The dispersion index (0 to 100 scale) and roughness
35.4 3.52 9.96 28.1 7.59 21.5 60.7 measurements for each sample are printed on the recorder
85.3 1.09 3.08 3.61 2.03 5.74 6.73 chart, and DI, F, and H may also be viewed directly on the
92.0 1.31 3.70 4.02 1.35 3.82 4.15
98.5 0.88 2.49 2.53 0.77 2.18 2.21 control console. If the A and B constants for the DI calculation
Sr = repeatability standard deviation (in measurement units), are unknown, however, they must be derived using a series of
r = repeatability (in measurement units), standard mixes which have been analyzed by Test Method B.
(r) = repeatability (in relative percent),
SR = reproducibility standard deviation (in measurement units), 31.2 Preparation of Standards—Prepare a series of four
R = reproducibility (in measurement units), and
(R) = reproducibility (in relative percent)
different carbon black dispersion levels for the rubber formu-
lation of interest by varying the total mixing energy or time.
37.2 Vibration Isolation Table, about 43 by 53 cm and 2 cm 40.5 Leave the SPIP software running and start the Imag-
deep is recommended for mounting the microscope head. eStudio Software.
37.3 Scissors. 40.6 Within ImageStudio, start the Dispersion index mod-
37.4 Razor Blades,9 single edge (coated) stainless steel ule.
type, required for the specimen cutting device. 40.7 Within the “Microscope Control” window verify the
37.5 Hand Lens (10×). following parameter values:
40.7.1 “Mode” is set to “Texture”.
37.6 Freezer—A standard refrigerator freezer unit (–5°C)
40.7.2 “Pixels” is set to “480 × 480”.
is required for unvulcanized compounds.
40.7.3 “Magnification” is set to “×10.0”.
38. Sampling 40.8 Insert the rubber specimen into the specimen holder
38.1 Vulcanizates—Specimens may be cut from standard clamp. The longest dimension of the specimen should be
test sheets (about 2 mm thick) or from actual rubber products parallel to the top edge of the clamp with about 5 to 7 mm of
which can be cross-sectioned to a uniform thickness of about 2 the specimen protruding above the clamp.
to 3 mm. 40.9 Position the specimen holder into the specimen cutting
38.2 Unvulcanized Compounds—Specimens may be pre- device. In the cutting position the clamp screw should be
pared from rubber slabs sheeted out to a uniform thickness of facing upright.
2 to 3 mm. 40.10 Insert a new razor blade into the specimen cutter with
the cutting lever in the upright position.
39. Test Specimen
40.11 Lower the cutting lever in a slow, smooth stroke until
39.1 Using scissors, cut out a rectangular specimen that is the razor blade has passed through the specimen. Remove the
approximately 3-cm long, 1-cm wide, and 0.2-cm deep. The specimen holder from the cutter, and discard the used blade and
longest dimension of the specimen should be cut along the the excess piece of rubber cut from the specimen.
direction in which the rubber slab was sheeted out.
40.12 Inspect the cut rubber surface on the specimen in the
39.2 Store unvulcanized specimens at about 5°C for a holder using a 10× hand lens. If the surface is uneven or
minimum of 30 min prior to cutting.
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40.1 Turn on the power to the computer and motor control- 40.13 Insert the specimen holder into the mounting bracket
ler. on the microscope stage such that the cut surface is on top and
toward the back of the stage.
40.2 Start the Scanned Probe Image Processing (SPIP)
software. 40.14 Click on the “Move Sample In” button to move the
sample under the microscope objective. If necessary, adjust the
40.3 Start the batch processor module within the SPIP position of the specimen holder and stage to bring the cut
software. surface beneath the light spot from the microscope. The light
40.4 Open a file saved during a previous run and allow the spot should be centered front to back and approximately 5 mm
batch processor software to process this file. from the right hand side of the specimen.
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