What are Plastics?

Plastics is a general term that describes materials

composed of very large molecules called polymers that
are synthetically made or modified from small
components called monomers.

Plastics are solids that in some stage

have been shaped by flow or molding in the
liquid, molten or softened form.

Plastics are those materials which are

considered to be plastics by common
acceptance.
 General characteristics of plastics materials
Versatility Design Flexibility
Low specific gravity Transparency
Colorability Low energy requirements
Chemical resistance Range of mechanical properties
Electrical insulation Thermal insulation
Re-usability Flammability
Poor weather resistance Thermal expansion
Polymers and Plastics
Although the words polymers and plastics are often used
interchangeably, there is a distinction between the two. Polymer is the
pure material which is the main end product of polymerisation. Pure
polymers are seldom used on their own and it is when additives are
present that the term plastic is applied.

PLASTIC = POLYMER + ADDITIVES

 Classification of plastics
P L A S T IC S

T h e r m o p la s tic s T h e rm o s e ts
u n d e rg o o n ly a p h y s ic a l u n d e rg o a p h y s ic a l a s w e ll a s
c h a n g e d u rin g p ro c e s s in g c h e m ic a l c h a n g e d u rin g p ro c e s s in g
w h ic h is ir r e v e rs ib le

C r y s t a llin e A m o rp h o u s P F, U F, M F

E p o x id e s
P P ,P E P S , A B S , P P O
P U R
N y lo n s A c ry lic
P o ly e s te rs
P o ly a c e ta ls P o ly c a rb o n a te

P E T, P B T P V C

P TFE P E S
Thermoplastics vs Thermosets

Thermoplastics
•Processing is reversible change --> Recyclable
•Lower total part cost
•Greater design freedom due to higher ductility
•Stable Electrical Properties

Thermosets
•Processing is irreversible change --> Not Recyclable
•Lower Material Cost
•High Heat/Creep resistance
•High arc resistance
 Plastics - categories
Commodity plastics
Mainly used as a replacement for conventional packaging materials
like glass, wood and paper. They are characterised by their low cost,
easy processibility and average properties.

Engineering plastics
An engineering plastic is expected to support loads more or less
indefinitely. They are characterised by their ability to sustain loads at
higher working temperatures.

Specialty plastics
These polymers offer high temperature performance which is far
superior to anything available so far. Service temperatures in excess
of 200O C for unfilled grades and over 300O C for fiber filled grades
are possible.
 T H E R M O P L A S T IC S

C o m m o d it y t h e r m o p la s t ic s E n g in e e r in g th e r m o p la s tic s S p e c ia lit y p la s t ic s

P o ly o le fin s P o l y a m id e s P o ly e t h e r s
LDPE, HDPE, PP N y l o n - 6 , N y lo n - 6 6 PES,PEK,PEEK

S t y r e n ic s P o ly a c e t a ls P o ly i m id e s
P S , H IP S , A B S , S A N H o m o p o ly m e r s , c o p o l y m e r s P E I, P I, P A I

V in y l c h l o r i d e s P o l y p h e n y le n e s F lu o r o p o ly m e r s
PVC,PVDC PPE,PPS PTFE, FEP

E t h y le n e c o p o ly m e r s P o ly c a r b o n a t e
EVA

O th e rs T h e r m o p la s t i c P o l y e s t e r s
P M M A , C e ll u lo s i c s PET, PBT
 Atoms which comprises plastics
Atom Symbol Valence Atomic Weight
Carbon C -C- 12.011
Hydrogen H H- 1.008
Oxygen O -O- 15.999
Nitrogen N -N- 14.007
Chlorine Cl Cl - 35.453
Fluorine F F- 18.998
Sulfur S -S- 32.064
-S-
Polymerization

Monomer Polymer
polymerization

Repeating
unit
H H H H H H H H H H
C=C polymerization C C C C C C C C
H H H H H H H H H H…n
Ethylene Polyethylene
Monomer A long chain of
polyethylene
molecule
Structure of some polymers

H H H H H H
C C C C C C
H CH3 H C6H5 H Cl

n n n
Polypropylene Polystyrene Polyvinyl Chloride

H H H
C C C O
H COOCH3 H

n n
Acrylic Acetal(homopolymer)
Bonding forces in Polymers
Primary bonds
These are covalent bonds connecting the atoms of the
molecule. They have a dissociation energy of 83 Kcal/mole.
Primary bonds are responsible for intermolecular forces.

Secondary bonds
These are the intermolecular forces which keep the molecules
of the mass of a polymer together. Their dissociation energy
is only 2 to 5 Kcal/mole and much weaker compared to
primary bonds. During processing the intermolecular forces
separate due to thermal agitation and the molecules slip past
each other causing flow.
Molecular weight
Molecular weight is the sum of atomic weights of all atoms
forming a molecule

As molecular weight increases ….

MFI decreases and processability becomes difficult
Crystallinity decreases
Density decreases
Mechanical properties improve
Thermal stability improves
Crystalline and Amorphous polymers

In crystalline polymers clusters

of polymer chains aggregate into
a regular structure
eg., Nylon, Acetal, HDPE

In amorphous polymers the

molecules do not arrange
themselves in any order.
eg., PC, PMMA, PS
 Differences between amorphous and crystalline plastics
PROPERTY CRYSTALLINE AMORPHOUS
Melting point Sharp melting point Softens over a range
of temperatures
Transparency Usually opaque/translucent Usually transparent
Shrinkage High Low
Chemical resistance High Low
Permeability Low High
Heat content High Low
Fatigue & wear resistance High Low
Tensile strength High Low

Process conditions which promote Crystallinity

Higher mould/melt temperatures
Slow cooling
 Glass Transition Temperature (Tg)

The temperature at which a rigid, hard amorphous plastic

changes into a soft rubbery state is called glass transition
temperature
The glass transition is associated with amorphous polymers
and amorphous regions of crystalline polymers

Below their Tg , polymers are glassy and rigid; above their Tg

polymers are rubbery and flexible.

Material: PC POM PA(66) PMMA PS PVC PP PE

Tg (OC) :: 150 -85 56 105 100 80 -10 -120
Key properties for material selection

Mechanical properties - strength, stiffness, fatigue and

toughness and the influence of high or low temperature on
properties
Corrosion susceptibility and degradation
Wear resistance and frictional properties
Thermal properties
Electrical properties
Optical properties
Weather resistance
Material Selection Hints

Focus First on Polymer Classes :

AMORPHOUS SEMICRYSTALLINE

BLENDS
 Material Selection Hints

AMORPHOUS

Strengths Limitations
• Good Impact Performance • Chemical Resistance
• Dimensional Stability • Flow
• Low Creep • Fatigue Resistance
• No Warpage
• Low and Uniform Shrinkage
• Transparency possible
 Material Selection Hints

SEMICRYSTALLINE

Strengths Limitations

• Broad Chemical Resistance • High Shrinkage

• High Flow • Creep
• Fatique Resistance • Warpage
• Lubricity
 Material Selection Hints

AMORPHOUS BLENDS SEMICRYSTALLINE

Better balance
• chemical resistance
• dimensional stability
 Application requirements Checklist

Are there any regulations and safety issues ?

•Flammability
•Fire resistance and smoke generation
•Food contact
•Water contact
•Toys
•Medical criteria
•Automotive specifications
•Electrical specifications
•Others
Application requirements Checklist

What is the service environment ?

•Chemicals, solvents, lubricants

•Water, humidity, steam
•Operating temperatures : high and low limits
•Duration at maximum service temperature
•Thermal expansion acceptable limits
•Indoor/Outdoor : UV irradiation
Application requirements Checklist

What are the structural requirements ?

•Continuous vs intermittent load

•Stiffness requirement
•Creep resistance requirement
•Strength requirement
•Impact strength requirement
•Fatigue resistance requirement
Application requirements Checklist

Are there other considerations ?

•Electrical properties (dissipation, conductivity ....)

•Antistatic requirements
•Tolerances
•Aesthetics (colours, gloss, transparency...)
•Wear and friction
•Barrier properties
•Paint adhesion, foam adhesion, printability ...
Application requirements Checklist

Fabrication and secondary operations ?

•Assembly : glueing, welding ...

•Finishing : painting, printing ...
•Others