WACHEMO UNIVERSITY
College of Engineering and Technology
Department of Electro-Mechanical Engineering
Material Science and Engineering
Compiled by Dagim Asegid ([Link]. MEng.), Dec. 2023
Chapter Six
Organic Polymer Materials
Chapter Six
6.1. Introduction to Polymer
Polymer is a compound consisting of long-chain molecules, each molecule made up of
repeating units called monomers.
There may be thousands, even millions of monomer units in a single polymer molecule.
Polymers are primarily organic compounds, however few polymers are made of inorganic
compounds.
Chapter Six
6.1. Introduction to Polymer
Chapter Six
6.1. Introduction to Polymer
Reasons Why Polymers are Important:
Plastics can be formed by molding into intricate part shapes, usually with no further
processing required.
Cost competitive with metals.
Generally require less energy to produce than metals.
Certain plastics are translucent and/or transparent, which makes them competitive with glass
in some applications.
Chapter Six
6.1. Introduction to Polymer
Advantages of Polymers
High resistance to corrosion and chemicals.
Low electrical and thermal conductivity,
However nowadays, advanced conducting polymers are emerging.
Low density relative to metals and ceramics.
Chapter Six
6.1. Introduction to Polymer
Advantages of Polymers
Ease of manufacturing and complexity of design possibilities
Wide choice of colors and transparencies
Relatively low cost
Good strength-to-weight ratios for certain (but not all) polymers
Chapter Six
6.1. Introduction to Polymer
Drawbacks
Low strength relative to metals and ceramics
Comparatively low dimensional stability.
Low modulus of elasticity (stiffness)
High performance plastics have very high cost
Chapter Six
6.1. Introduction to Polymer
Drawbacks
They are softer than metals and are more susceptible to deformation under load
Brittle at low temperature and are flammable.
Some polymers degrade when subjected to sunlight and other forms of radiation
Chapter Six
6.2. Classification and Chemistry of Polymers
As engineering materials, polymers are grouped into the following three categories:
Thermoplastic
Thermosetting polymers
Elastomers
where (1) and (2) are plastics and (3) are rubbers
Chapter Six
6.2. Classification and Chemistry of Polymers
1. Thermoplastic Polymers (TP)
Solid materials at room temperature but viscous liquids when heated to temperatures of only a
few hundred degrees.
It has linear or branched like structure.
This characteristic allows them to be easily and economically shaped into products.
They can be subjected to heating and cooling cycles repeatedly without significant degradation
Chapter Six
6.2. Classification and Chemistry of Polymers
1. Thermoplastic Polymers (TP)
Chemical structure remains unchanged during heating and shaping.
Represents 70% of the tonnage of all synthetic polymers produced.
Chapter Six
6.2. Classification and Chemistry of Polymers
Common Thermoplastic Polymers
PET: Polyethylene Terphalate (Beverage Containers)
HDPE: High Density Polyethylene (Milk bottles, detergent bottles)
PVC: Polyvinyl Chloride (Food wrap, vegetable oil bottles)
LDPE: Low Density Polyethylene (Shrink wrap, plastic bottles)
Chapter Six
6.2. Classification and Chemistry of Polymers
Common Thermoplastic Polymers
PP: Polypropylene (Margerine and yogurt containers)
PS: Polystyrene (Egg cartons, fast food trays)
Thermoplastic products include molded and extruded items, fibers, films and sheets,
packaging materials, and paints and varnishes.
Chapter Six
6.2. Classification and Chemistry of Polymers
2. Thermosetting Polymers (TS)
Cannot tolerate repeated heating cycles as thermoplastics can. Once cured, they cannot be
remelted instead they degrade or burn.
Curing is an irreversible chemical reaction known as crosslinking, which usually occurs
under heat.
Capable of higher service temperatures than TP, but at elevated temperature it consist of 3-D
network structures based on strong covalent bonds to form rigid solids.
Chapter Six
6.2. Classification and Chemistry of Polymers
2. Thermosetting Polymers (TS)
However, for some thermosetting materials, curing is initiated or completed at room
temperature.
Modulus of elasticity of thermosets is two to three times greater than thermoplastics.
It is brittle, virtually no ductility.
Less soluble than thermoplastics in common solvents.
Chapter Six
6.2. Classification and Chemistry of Polymers
2. Thermosetting Polymers (TS)
Some of the common thermosetting polymers are;
Epoxies,
Amino resins,
some polyester resins, etc.
Chapter Six
6.2. Classification and Chemistry of Polymers
2. Thermosetting Polymers (TS)
These common thermosetting polymers are used to produce;
automotive engine parts,
electrical outlet parts,
handles on pots and pans,
ash trays, etc.
Chapter Six
6.2. Classification and Chemistry of Polymers
3. Elastomers
Elastomers are plastics with wide netlike crosslinking between the molecules.
Usually, they cannot be melted without degradation of the molecule structure.
Above the glass temperature Tg, as the state of application, elastomers are soft elastic.
Some elastomers can be extended 500% or more and still return to their original shape.
Chapter Six
6.2. Classification and Chemistry of Polymers
3. Elastomers
Below Tg they are hard elastic to brittle.
The value of the glass temperature increases with increasing number of crosslinks.
Characterized by low modulus / rigidity / strength, but high toughness.
Chapter Six
6.3. Fabrication of Plastics
Plastics Processing – in a simple layman's language – can be defined as the process of
converting the plastic raw materials into semi-finished or finished products.
In a more technocrats way we may say “Get the Shape and set the Shape”.
Technique to get the shape and set the shape varies depending on process and material
employed.
Chapter Six
6.3. Fabrication of Plastics
Effect of Polymer Properties on Processing Technique
When processing thermoplastic melts the following factors should be taken into account in
order to process efficiently and obtain quality products.
Water absorption of raw materials,
Physical form of raw material,
Thermal stability of polymer,
Flow properties,
Compressibility and shrinkage,
Chapter Six
6.3. Fabrication of Plastics
a. Processability
Processability means generally the ease or difficulty with which a plastic can be handled
during its fabrication into film, molded products, pipe, etc.
The main characteristics or properties which determine a plastic's processability are
molecular weight, uniformity, additive type and content, and plastic feed rates.
Chapter Six
6.3. Fabrication of Plastics
b. Processing Methods:
The type of process to be used depends on a variety of factors such as:
Product shape and size
plastic type
Quantity to be produced
Quantity to be produced, quality and accuracy (Tolerances) required
Design load performance and cost limitation
Chapter Six
6.3. Fabrication of Plastics
c. Classification of Plastic Processing Methods
Primary Processing Methods: Injection, Extrusion, Blow moulding, Compression and
Transfer Moulding.
Secondary Processing Methods: Roto, Thermoforming, Coating, Casting, Calendaring, etc.
Tertiary Processing Methods: Cutting, Drilling, Welding and Bending, etc.
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
i. Injection Moulding
Thermoplastic or Thermoset plastic products are made at control temperature inside the screw
pump (a combination of screw & barrel), then forced under pressure through a nozzle into
sprue, runners, gates and cavities of mould.
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
i. Injection Moulding
Types of Injection moulding machine:
Hand injection moulding:
Semi-auto (Plunger type) Injection moulding:
Fully-auto (Screw type) Injection moulding:
Advanced injection moulding
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
a. Hand Injection Moulding
It is a vertical machine consists of barrel, plunger, band heaters along with energy regulator,
rack & pinion system for injecting the material by the plunger, a torpedo and nozzle.
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
b. Semi Auto Injection Moulding (Plunger Type)
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
c. Fully Auto Injection Moulding: (Screw Type)
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
d. Advanced Injection Moulding
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
ii. Blow Moulding
An extruded parison tube of heated thermoplastics is positioned between two halves of an
open split mould and inflated against the sides of the closed mould using air pressure.
Bottles, Containers, Air Ducts, Panels, Portable Toilets, Arm rests, tanks, gas tanks are some
of the typical products in blow moulding process.
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
ii. Blow Moulding
Types of Blow moulding machine:
Extrusion Blow moulding
Injection Blow moulding
Stretch Blow moulding
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
a. Extrusion Blow moulding
In extrusion blow molding (EBM), plastic is melted and extruded into a hollow tube (a
parison).
This parison is then captured by closing it into a cooled metal mold.
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
a. Extrusion Blow moulding
Air is then blown into the parison, inflating it into the shape of the hollow bottle, container or
part.
After the plastic has cooled sufficiently, the mold is opened and the part is ejected.
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
a. Extrusion Blow moulding
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
b. Injection Blow Moulding
The process of injection blow molding (IBM) is used for the production of hollow glass and
plastic objects in large quantities.
The blow molding process begins with melting down the plastic and forming it into a parison.
The parison is a tube-like piece of plastic with a hole in one end through which compressed
air can pass.
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
b. Injection Blow Moulding
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
c. Stretch Blow Molding
In the stretch blow molding (SBM) process, the plastic is first molded into a "preform" using
the injection molding process.
The preforms are heated (typically using infrared heaters) above their glass transition
temperature, then blown using high pressure air into bottles using metal blow molds.
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
c. Stretch Blow Molding
The preform is always stretched with a core rod as part of the process.
In the single-stage process both preform manufacture and bottle blowing are performed in the
same machine.
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
c. Stretch Blow Molding
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
iii. Extrusion Process
Thermoplastic moulding compound is fed from a hopper to a screw pump where it is heated
to plasticate then pumped out through the shaping orifice (die) to achieve desired cross
section.
Carried out as a continuous process; extrudate is then cut into desired lengths.
Widely used for continuous production of film, sheet, tube, hose, structural shapes, and
coated electrical wire.
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
iii. Extrusion Process
Hollow profiles require mandrel to form the shape.
Mandrel often includes an air channel through which air is blown to maintain hollow form of
extrudate during hardening.
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
iii. Extrusion Process
Low tool cost, numerous complex profile shapes possible, very rapid production rates, can
apply coatings or jacketing to core materials (Such as wire).
Limitations: Usually limited to sections of uniform cross section.
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
iii. Extrusion Process
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
iii. Extrusion Process
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
iv. Compression Molding
Thermoset compound is positioned in a heated mould cavity; the mould is closed (heat and
pressure are applied) and the material flows and fills the mould cavity.
Heat completes polymerization and the part is ejected.
Molding compound available in several forms: powders or pellets, liquid, or preform.
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
iv. Compression Molding
The process is sometimes used for thermoplastics, e.g. Vinyl phonograph records. Also used
for rubber tires and polymer matrix composite parts.
Little material waste is attainable; large, bulky parts can be moulded; process is adaptable to
rapid automation.
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
iv. Compression Molding
Typical compression-molded products: Electric plugs, sockets, pot handles, and dinnerware
plates, Engine Casing switches.
Limitations: Extremely intricate parts containing undercuts, side draws, small holes, delicate
inserts, etc.; very close tolerances are difficult to produce and it is a time consuming process.
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
iv. Compression Molding
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
v. Transfer Moulding
Thermoset moulding charge is loaded into a chamber immediately ahead of mold cavity,
where it is heated; pressure is then applied to force soft polymer to flow into heated mold
where it cures.
Transfer molding is capable of molding more intricate part shapes than compression molding
but not as intricate as injection molding.
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
v. Transfer Moulding
Types of Products: Plugs, Sockets, Handles, Engine Casing Switches, Storage tanks, etc.
Pot transfer molding - charge is injected from a "pot" through a vertical sprue channel into
cavity.
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
v. Transfer Moulding
Figure: (a) Pot transfer molding: (1) charge is loaded into pot, (2) softened polymer is pressed into mold cavity and cured, and
(3) part is ejected.
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
v. Transfer Moulding
Plunger transfer molding – plunger injects charge from a heated well through channels into
cavity.
Figure: (b) plunger transfer molding: (1) charge is loaded into pot, (2) softened polymer is pressed into mold cavity and cured,
and (3) part is ejected.
Chapter Six
6.3. Fabrication of Plastics
6.3.1. Primary Processing Methods
v. Transfer Moulding
Chapter Six
6.3. Fabrication of Plastics
6.3.2. Secondary Processing Methods
Group Assignment
Explain briefly the following secondary processing techniques of plastics
Rotation Moulding
Thermoforming Moulding
Vacuum Thermoforming
Calendering
Coating
Casting
Chapter Five
End Of Chapter Five
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