Materials Science of Polymers for Engineers

by Osswald, Tim A.; Menges, Georg

• ISBN13: 9781569903483
• ISBN10: 1569903484
• Edition: 2nd
• Format: Hardcover
• Copyright: 2003-06-01
• Publisher: Hanser Pub Inc

Table of Contents

Part I Basic Principles	1	(182)
1 Introduction to Polymers	3	(12)
1.1 General Properties	3	(7)
1.2 Identification of Polymers	10	(3)
Problems	13	(1)
References	13	(2)
2. Historical Background	15	(28)
2.1 From Natural to Synthetic Rubber	15	(6)
2.2 Cellulose and the $10,000 Idea	21	(3)
2.3 Galalith-The Milk Stone	24	(1)
2.4 Leo Baekeland and the Plastic Industry	25	(2)
2.5 Herman Mark and the American Polymer Education	27	(4)
2.6 Wallace Hume Carothers and Synthetic Polymers	31	(3)
2.7 Polyethylene-A Product of Brain and Brawn	34	(3)
2.8 The Super Fiber and the Woman who Invented it	37	(1)
2.9 One last Word-Plastics	38	(5)
3 Structure of Polymers	43	(54)
3.1 Macromolecular Structure of Polymers	43	(2)
3.2 Molecular Bonds and Inter-Molecular Attraction	45	(1)
3.3 Molecular Weight	45	(6)
3.4 Conformation and configuration of Polymer Molecules	51	(4)
3.5 Arrangement of Polymer Molecules	55	(13)
3.5.1 Thermoplastic Polymers	55	(1)
3.5.2 Amorphous Thermoplastics	56	(2)
3.5.3 Semi-Crystalline Thermoplastics	58	(9)
3.5.4 Thermosets and Cross-Linked Flastorners	67	(1)
3.6 Copolymers and Polymer Blends	68	(3)
3.7 Polymer Additives	71	(5)
3.7.1 Flame Retardants	71	(2)
3.7.2 Stabilizers	73	(1)
3.7.3 Antistatic Agents	74	(1)
3.7.4 Fillers	74	(1)
3.7.5 Blowing Agents	75	(1)
3.8 Viscoelastic Behavior of Polymers	76	(12)
3.8.1 Stress Relaxation Test	76	(2)
3.8.2 Time-Temperature Superposition (WLF-Equational)	78	(2)
3.8.3 The Boltzmann Superposition Principle	80	(1)
3.8.4 Applying Linear Viscoelasticity to Describe the behavior of Polymers	81	(7)
Examples	88	(3)
Problems	91	(3)
References	94	(3)
4 Thermal Properties of Polymers	97	(32)
4.1 Material Properties	100	(16)
4.1.1 Thermal Conductivity	100	(7)
4.1.2 Specific Heat	107	(2)
4.1.3 Density	109	(3)
4.1.4 Thermal Diffusivity	112	(1)
4.1.5 Linear Coefficient of Thermal Expansion	113	(2)
4.1.6 Thermal Penetration	115	(1)
4.1.7 Glass Transition Temperature	115	(1)
4.1.8 Melting Temperature	116	(1)
4.2 Measuring Thermal Data	116	(7)
4.2.1 Differential Thermal Analysis (DTA)	117	(1)
4.2.2 Differential Scanning Calorimeter (DSC)	118	(2)
4.2.3 Thermomechanical Analysis (TMA)	120	(1)
4.2.4 Thermogravimetry (TGA)	121	(1)
4.2.5 Density Measurements	122	(1)
Examples	123	(1)
Problems	124	(4)
References	128	(1)
5 Rheology of Polymer Melts	129	(54)
5.1 Introduction	129	(8)
5.1.1 Continuum Mechanics	129	(2)
5.1.2 The Generalized Newtonian Fluid	131	(2)
5.1.3 Normal Stresses in Shear Flow	133	(1)
5.1.4 Deborah Number	134	(3)
5.2 Viscous Flow Models	137	(10)
5.2.1 The Power Law Model	137	(2)
5.2.2 The Bird-Carreau-Yasuda Model	139	(1)
5.2.3 The Bingham Fluid	140	(1)
5.2.4 Elongational Viscosity	140	(2)
5.2.5 Rheology of Curing Thermosets	142	(4)
5.2.6 Suspension Rheology	146	(1)
5.3 Simplified Flow Models Common in Polymer Processing	147	(4)
5.3.1 Simple Shear Flow	148	(1)
5 3 2 Pressure Flow Through a Slit	148	(1)
5.3.3 Pressure Flow Through a Tube-Hagen-Poiseuille Flow	149	(1)
5.3.4 Couette Flow	150	(1)
5.4 Viscoelastic Flow Models	151	(8)
5.4.1 Differential Viscoelastic Models	151	(3)
5.4.2 Integral Viscoelastic Models	154	(5)
5.5 Rheometry	159	(11)
5.5.1 The Melt Flow Indexer	159	(1)
5.5.2 The Capillary Viscometer	159	(3)
5.5.3 Computing Viscosity Using the Bagley and Weissenberg-Rabinowitsch Equations	162	(1)
5.5.4 Viscosity Approximation Using the Representative Viscosity Method	163	(1)
5.5.5 The Cone-Plate Rheometer	164	(2)
5.5.6 The Couette Rheometer	166	(1)
5.5.7 Extensional Rheometry	167	(3)
5.6 Surface Tension	170	(4)
Examples	174	(5)
Problems	179	(1)
References	180	(3)
Part II Influence of Processing on Properties	183	(186)
6 Introduction to Processing	185	(98)
6.1 Extrusion	185	(17)
6.1.1 The Plasticating Extruder	188	(11)
6.1.1.1 The Solids Conveying Zone	191	(4)
6.1.1.2 The Melting Zone	195	(2)
6.1.1.3 The Metering Zone	197	(2)
6.1.2 Extrusion Dies	199	(3)
6.1.2.1 Sheeting Dies	199	(2)
6.1.2.2 Tubular Dies	201	(1)
6.2 Mixing Processes	202	(31)
6.2.1 Distributive Mixing	204	(4)
6.2.1.1 Effect of Orientation	205	(3)
6.2.2 Dispersive Mixing	208	(6)
6.2.2.1 Break-Up of Particulate Agglomerates	208	(3)
6.2.2.2 Break-Up of Fluid Droplets	211	(3)
6.2.3 Mixing Devices	214	(10)
6.2.3.1 Static Mixers	215	(1)
6.2.3.2 Banbury Mixer	216	(2)
6.2.3.3 Mixing in Single Screw Extruders	218	(2)
6.2.3.4 Cokneader	220	(1)
6.2.3.5 Twin Screw Extruders	221	(3)
6.2.4 Energy Consumption During Mixing	224	(1)
6.2.5 Mixing Quality and Efficiency	225	(2)
6.2.6 Plasticization	227	(6)
6.3 Injection Molding	233	(12)
6.3.1 The Injection Molding Cycle	234	(4)
6.3.2 The Injection Molding Machine	238	(5)
6.3.2.1 The Plasticating and Injection Unit	238	(1)
6.3.2.2 The Clamping Unit	239	(2)
6.3.2.3 The Mold Cavity	241	(2)
6.3.3 Related Injection Molding Processes	243	(2)
6.4 Secondary Shaping	245	(10)
6.4.1 Fiber Spinning	245	(1)
6.4.2 Film Production	246	(3)
6.4.2.1 Cast Film Extrusion	246	(1)
6.4.2.2 Film Blowing	247	(2)
6.4.3 Blow Molding	249	(34)
6.4.3.1 Extrusion Blow Molding	249	(2)
6.4.3.2 Injection Blow Molding	251	(2)
6.4.3.3 Thermoforming	253	(2)
6.5 Calendering	255	(2)
6.6 Coating	257	(3)
6.7 Compression Molding	260	(2)
6.8 Foaming	262	(2)
6.9 Rotational Molding	264	(2)
Examples	266	(9)
Problems	275	(4)
References	279	(4)
7 Anisotropy Development During Processing	283	(38)
7.1 Orientation in the Final Part	283	(14)
7.1.1 Processing Thermoplastic Polymers	283	(9)
7.1.2 Processing Thermoset Polymers	292	(5)
7.2 Predicting Orientation in the Final Part	297	(15)
7.2.1 Planar Orientation Distribution Function	298	(2)
7.2.2 Single Particle Motion	300	(2)
7.2.3 Jeffery's Model	302	(1)
7.2.4 Folgar-Tucker Model	303	(1)
7.2.5 Tensor Representation of Fiber Orientation	304	(17)
7.2.5.1 Predicting Orientation in Complex Parts Using Computer Simulation	306	(6)
7.3 Fiber Damage	312	(2)
Examples	314	(2)
Problems	316	(2)
References	318	(3)
8 Solidification of Polymers	321	(48)
8.1 Solidification of Thermoplastics	321	(13)
8.1.1 Thermodynamics During Cooling	321	(4)
8.1.2 Morphological Structure	325	(1)
8.1.3 Crystallization	326	(3)
8.1.4 Heat Transfer During Solidification	329	(5)
8.2 Solidification of Thermosets	334	(9)
8.2.1 Curing Reaction	334	(2)
8.2.2 Cure Kinetics	336	(4)
8.2.3 Heat Transfer During Cure	340	(3)
8.3 Residual Stresses and Warpage of Polymeric Parts	343	(19)
8.3.1 Residual Stress Models	346	(7)
8.3.1.1 Residual Stress Model Without Phase Change Effects	349	(1)
8.3.1.2 Model to Predict Residual Stresses with Phase Change Effects	350	(3)
8.3.2 Other Simple Models to Predict Residual Stresses and Warpage	353	(5)
8.3.2.1 Uneven Mold Temperature	354	(1)
8.3.2.2 Residual Stress in a Thin Thermoset Part	355	(2)
8.3.2.3 Anisotropy Induced Curvature Change	357	(1)
8.3.3 Predicting Warpage in Actual Parts	358	(4)
Examples	362	(2)
Problems	364	(2)
References	366	(3)
Part III Engineering Design Properties	369	(222)
9 Mechanical Behavior of Polymers	371	(76)
9.1 Basic Concepts of Stress and Strain	371	(2)
9.1.1 Plane Stress	372	(1)
9.1.2 Plane Strain,	373	(1)
9.2 The Short-Term Tensile Test	373	(15)
9.2.1 Rubber Elasticity	373	(6)
9.2.2 The Tensile Test and Thermoplastic Polymers	379	(9)
9.3 Long-Term Tests	388	(5)
9.3.1 Isochronous and Isometric Creep Plots	391	(2)
9.4 Dynamic Mechanical Tests	393	(5)
9.4.1 Torsion Pendulum	393	(4)
9.4.2 Sinusoidal Oscillatory Test	397	(1)
9.5 Viscoelastic Behavior of Polymers	398	(9)
9.5.1 Kelvin Model,	399	(2)
9.5.1.1 Kelvin Model Creep Response	400	(1)
9.5.1.2 Kelvin Model Stress Relaxation	400	(1)
9.5.1.3 Kelvin Model Strain Recovery	401	(1)
9.5.1.4 Kelvin Model Dynamic Response	401	(1)
9.5.2 Jeffrey Model	401	(2)
9.5.2.1 Jeffrey Model Creep Response	402	(1)
9.5.2.2 Jeffrey Model Stress Relaxation	403	(1)
9.5.2.3 Jeffrey Model Strain Recovery	403	(1)
9.5.3 Standard Linear Solid Model	403	(2)
9.5.3.1 Standard Linear Solid Model Creep Response	404	(1)
9.5.3.2 Standard Linear Solid Model Stress Relaxation	405	(1)
9.5.4 Maxwell-Wiechert Model	405	(2)
9.5.4.1 Maxwell-Wiechert Model Stress Relaxation	406	(1)
9.5.4.2 Maxwell-Wiechert Model Dynamic Response	407	(1)
9.6 Effects of Structure and Composition on Mechanical Properties	407	(13)
9.6.1 Amorphous Thermoplastics	409	(1)
9.6.2 Semi-Crystalline Thermoplastics	410	(2)
9.6.3 Oriented Thermoplastics	412	(6)
9.6.4 Cross-Linked Polymers	418	(2)
9.7 Mechanical Behavior of Filled and Reinforced Polymers	420	(9)
9.7.1 Anisotropic Strain-Stress Relation	422	(1)
9.7.2 Aligned Fiber Reinforced Composite Laminates	423	(3)
9.7.3 Transformation of Fiber Reinforced Composite Laminate Properties	426	(3)
9.7.4 Reinforced Composite Laminates with a Fiber Orientation Distribution Function	429	(1)
9.8 Strength Stability Under Heat	429	(2)
Examples	431	(9)
Problems	440	(4)
References	444	(3)
10 Failure and Damage of Polymers	447	(74)
10.1 Fracture Mechanics	447	(8)
10.1.1 Fracture Predictions Based on the Stress Intensity Factor	448	(2)
10.1.2 Fracture Predictions Based on an Energy Balance	450	(3)
10.1.3 Linear Viscoelastic Fracture Predictions Based on J-Integrals	453	(2)
10.2 Short-Term Tensile Strength	455	(12)
10.2.1 Brittle Failure	456	(3)
10.2.2 Ductile Failure	459	(5)
10.2.3 Failure of Highly Filled Systems or Composites	464	(3)
10.3 Impact Strength	467	(16)
10.3.1 Impact Test Methods	473	(5)
10.3.2 Fracture Mechanics Analysis of Impact Failure	478	(5)
10.4 Creep Rupture	483	(5)
10.4.1 Creep Rupture Tests	484	(3)
10.4.2 Fracture Mechanics Analysis of Creep Rupture	487	(1)
10.5 Fatigue	488	(11)
10.5.1 Fatigue Test Methods	488	(10)
10.5.2 Fracture Mechanics Analysis of Fatigue Failure	498	(1)
10.6 Friction and Wear	499	(4)
10.7 Stability of Polymer Structures	503	(2)
10.8 Environmental Effects on Polymer Failure	505	(10)
10.8.1 Weathering	505	(6)
10.8.2 Chemical Degradation	511	(2)
10.8.3 Thermal Degradation of Polymers	513	(2)
Examples	515	(2)
Problems	517	(1)
References	518	(3)
11 Electrical Properties of Polymers	521	(24)
11.1 Dielectric Behavior	521	(11)
11.1.1 Dielectric Coefficient	521	(3)
11.1.2 Mechanisms of Dielectrical Polarization	524	(4)
11.1.3 Dielectric Dissipation Factor	528	(4)
11.1.4 Implications of Electrical and Thermal Loss in a Dielectric	532	(1)
11.2 Electric Conductivity	532	(5)
11.2.1 Electric Resistance	532	(2)
11.2.2 Physical Causes of Volume Conductivity	534	(3)
11.3 Application Problems	537	(6)
11.3.1 Electric Breakdown	537	(3)
11.3.2 Electrostatic Charge	540	(2)
11.3.3 Electrets	542	(1)
11.3.4 Electromagnetic Interference Shielding (EMI Shielding)	542	(1)
11.4 Magnetic Properties	543	(1)
11.4.1 Magnetizability	543	(1)
11.4.2 Magnetic Resonance	543	(1)
References	544	(1)
12 Optical Properties of Polymers	545	(26)
12.1 Index of Refraction	545	(3)
12.2 Photoelasticity and Birefringence	548	(5)
12.3 Transparency, Reflection, Absorption, and Transmittance	553	(6)
12.4 Gloss	559	(1)
12.5 Color	560	(3)
12.6 Infrared Spectroscopy	563	(2)
12.7 Infrared Pyrometry	565	(2)
12.8 Heating with Infrared Radiation	567	(2)
References	569	(2)
13 Permeability Properties of Polymers	571	(14)
13.1 Sorption	571	(2)
13.2 Diffusion and Permeation	573	(6)
13.3 Measuring S, D and P	579	(1)
13.4 Corrosion of Polymers and Cracking	580	(3)
13.5 Diffusion of Polymer Molecules and Self-Diffusion	583	(1)
References	584	(1)
14 Acoustic Properties of Polymers	585	(6)
14.1 Speed of Sound	585	(2)
14.2 Sound Reflection	587	(2)
14.3 Sound Absorption	589	(1)
References	590	(1)
Appendix	591	(20)
Subject Index	611	(7)
Author Index	618