NATURE OF CHEMICAL ATTACKS ON PLASTIC AND RUBBERS
Corrosion of polymers
Corrosion on polymers, both plastics and rubber materials, is in many
cases similar to metals but in other cases it looks very different. Corrosion
attacks on polymers are often hard to discover, the material may look
normal but can in fact be embrittled and have lost it´s mechanical strength.
Mechanical stressed polymers applied in chemical environments may
initiate cracks on the surfaces. These cracks can thereafter propagate
through the material either as a result of the mechanical stresses or in
combination with continuing chemical attack. Corrosion of polymers can be
divided into either chemical reaction or physical interaction.
Cover made of glassfiber reinforced polycarbonate. High temperature
under load in water give cracks that cause leakage.
Chemical reaction
Polymers consist of a network with molecular chains mainly consisting of
carbon, hydrogen and oxygen. Corrosion by chemical reaction changes the
configuration of the polymer chains. Listed below are some of the
environments that causes chemical reactions in polymers.
Heat: Chain scission will occur when polymers are exposed to heat above
a specified temperature limit, which is unique for each type of polymer.
UV- radiation: In the presence of oxygen, UV-radiation can cause a
breakdown of the polymer chains.
Ozone: Attacks from ozone on unsaturated polymers (e.g. natural rubber)
under stress, causes characteristic cracks.
Water: Absorption of water at elevated temperatures causes hydrolysis of
certain groups in a polymer chain (e.g. urethane and ester groups).
Hydrolysis weakens the polymer since the backbone structure is altered.
Chemicals: It is important to distinguish chemical deterioration caused by
chemicals from effect caused by swelling/dissolving which do not alter the
chemical structure of the polymer chains. Chemical resistance is highly
dependent on the molecule structure of a polymer as for thermoplastics,
whether they are amorphous (e.g. PC, PVC, PS, PMMA) or partially
crystalline (e.g. PE, PA, PP, POM). Partially crystalline are more resistant
to organic substances and solvents than amorphous polymers.
Thermosetting resins (e.g. PUR, EP, UP) can, due to their cross-linked
structure not be dissolved, but can be subjected to swelling or chemical
reaction (e.g. hydrolysis).
Physical interaction
Physical effects on polymers are caused by interaction with the
environment. This may lead to swelling, dissolving or leakage of additives.
The interaction is dependent on diffusion of substances into the polymer,
and the process is in some cases reversible.
Organic substances usually affect polymers through physical interaction,
while substances like strong acids or bases normally result in an
irreversible breakdown of polymers.
COMPOSITION, FABRICATION AND USES OF RUBBER
THERMOPLASTICS AND THERMOSETTING PLASTICS.
RUBBER THERMOPLASTICS
Thermoplastic rubber is a relatively new class of polymer. It has the
solubility and thermoplasticity of polystyrene, while at ambient
temperatures it has the toughness and resilience of vulcanized natural
rubber or polybutadiene. These rubbers are actually block copolymers. The
simplest form consists of a rubbery mid-block with two plastic end blocks
(A-B-A), as shown in the fig below Examples of commercial products are
Kraton and Solprene. These materials are often compounded with
plasticizers to decrease hardness and modulus, eliminate drawing,
enhance pressure-sensitive tack, improve low-temperature flexibility,
reduce melt andsolution viscosity, decrease cohesive strength or increase
plasticity if desired, and substantially lower material costs. Low levels of
thermoplastic rubbers are sometimes added to other rubber adhesives.
These materials are used as components in the following applications:
PSAs, hot-melt adhesives, heat-activated assembly adhesives, contact
adhesives, reactive contact adhesives, building construction adhesives,
sealants, and binders. Two common varieties of thermoplastic rubber
adhesives are styrene-butadiene-styrene (S-B-S) and styrene-isoprene-
styrene (S-I-S)
THERMOSETTING PLASTICS
Thermosetting Plastics, also known as thermosetting resins, are rigid
polymeric materials that are resistant to higher temperatures than ordinary
thermoplastics. They are petrochemical materials that irreversibly cure. The
cure may be brought on by heat, generally above 392°F (200°C), chemical
reaction or suitable irradiation. It is used as adhesives as well as in
semiconductors and integrated circuits. The International Union of Pure
and Applied Chemistry (IUPAC) defines a thermosetting plastics as
petrochemicals in an indulgent solid or viscous state that changes
irreversibly into an infusible, insoluble polymer network by curing.
Thermosetting plastics are normally made up of lines of polymers which are
highly cross-linked. The heavily cross-linked structure produced by
chemical bonds in thermoset materials is directly responsible for the high
mechanical and physical strength compared with thermoplastics or
elastomers. However, it provides poor elasticity or elongation of the
material—once hardened, a thermoset resin cannot be reheated and
melted to be shaped differently. The cross-linking process eliminates the
risk of the product remelting when heat is applied, making thermosets ideal
for high-heat applications such as electronics and appliances. Since their
shape is permanent, they tend not to be recyclable as a source for newly
made plastic.
Common thermosetting plastics or resins include:
Polyester resin
Vinyl ester resin
Epoxy
Phenolic
Urethane
As a result of crosslinking, thermoset plastics generally have better
strength and stiffness than thermoplastics, which do not contain crosslinks,
and this has made them attractive as the matrix resin in conventional fibre-
reinforced plastic composites, such as fibreglass and carbon
fibre composites. While natural fibres are inferior to high
performance fibres, such as carbon fibres, they have a specific modulus
which is similar to, or better than, that of glass fibres. This makes natural
fibre thermoset matrix composites attractive as an alternative to fibreglass
(glass fibre-reinforced thermoset matrix composites).
USE OF REINFORCEMENT TO PRODUCE COMPOSITE MATERIALS
Reinforcements for the composites
can be fibers, fabrics particles or whiskers. Fibers are essentially
characterized by one very long axis with other two axes either often circular
or near circular. Particles have no preferred orientation and so does their
shape. Whiskers have a preferred shape but are small both in diameter and
length as compared to fibers.
Reinforcing constituents in composites provide the strength that makes the
composite what it is. But they also serve certain additional purposes of heat
resistance or conduction, resistance to corrosion and provide rigidity.
Reinforcement can be made to perform all or one of these functions as per
the requirements. A reinforcement that embellishes the matrix strength
must be stronger and stiffer than the matrix and capable of changing failure
mechanism to the advantage of the composite. This means that the ductility
should be minimal or even nil the composite must behave as brittle as
possible.
It provides strength and stiffness to the composite material in one
direction as reinforcement carries the load along the length of the
fiber.
It increases the mechanical properties of the composite.
It also increases the cho-efficient of thermal expansion and the
conductivity.
ADVANTAGES OF USING POLYMERIC MATERIALS FOR COATING
METAL
1. Adhesion - binds together dissimilar surfaces
2. Wettability - is the ability of a liquid to maintain contact with a solid
surface
3. Corrosion resistance - some metals are more resistant to corrosion
(the conversion of refined metal to a chemically-stable form), than others.
You can protect metals from oxidation (corrosion) by applying polymer
paints or coatings.
4. Wear resistance - wear rate varies depending on its stage (early, middle,
or old). The fundamental cause of wear resistance is chemical reactions
between the worn material and the corroding medium.
1. Polymers are more resistant to chemicals than their metal
counterparts.
2. Polymer parts do not require post-treatment finishing efforts,
unlike metal.
3. Polymer and composite materials are up to ten times lighter than
typical metals.
4. Polymer materials handle far better than metals in chemically
harsh environments. This increases the lifespan of the aircraft
and avoids costly repairs brought about by corroding metal
components
5. Polymers are naturally radar absorbent as well as thermally and
electrically insulating.
6. In medical Facilities polymer and composite materials are easier
to clean and sterilize than metal.
7. Polymer materials allow the oil and gas industry to explore
deeper depths than ever before by offering tool weight reduction
without a loss of strength as well as materials which offer
superior sealing.