MSE 201-Polymers 1. General Overview of Polymers (Unit 1 5a)
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1 MSE 201-Polymers 1 General Overview of Polymers (Unit 1 5a) Instructor: Joshua U. Otaigbe Iowa State University Goals for the Unit Goals for the Unit Introduction Definition General Classes ow are polymers made? Review important commercial polymers Polymers versus plastics?
2 MSE 201-Polymers 2 Learning Objectives Contd. Learning Objectives Contd. Why design with plastics? Unique & differentiating features Plastics categories, properties & applications? Chemical formulae & Nomenclature Illustrate historical devmt What is a Polymer? What is a Polymer? From the Greek polus (many), and meros (parts) Contain C O Cl N S - Natural & Synthetic About 80 commercial SYNTETIC polymers (cf: inorganic polymers) 180 including alloys, blends including different grades (polymers and compounds) Illustrate over
3 MSE 201-Polymers 3 Monomer Units in Some Polymers Mer unit Mer unit F F F F F F C C C C C C F F F F F F PTFE C C C C C C C 3 C 3 C 3 PP Mer unit C C C C C C Cl Cl Cl PVC Chemical Formulae & Nomenclature C C n PE C C C3 n PP C C n PS
4 MSE 201-Polymers 4 Chemical Formulae & Nomenclature C C Cl n PVC C C CN x C C C C ABS y C C z Chemical Formulae & Nomenclature O F F C C F F n C 3 C C 3 O PTFE C 3 O n C 3 O C n PC PPO
5 MSE 201-Polymers 5 Chemical Formulae & Nomenclature N(C 2 ) 5 CO n PA 6 N(C 2 ) 6 NCO(C 2 ) 4 CO n PA 6/6 N(C 2 ) 11 CO n PA 12 N(C 2 ) 6 NCO(C2 ) 8 CO PA 6/10 n Global Output of Polymers? 70 BILLION Pounds of plastics produced annually world wide!! = 1 mile 2 X 40 feet deep = 0.002" FILM to cover TE STATE of TEXAS!
6 MSE 201-Polymers 6 General Classes of Polymers Thermoplastics Thermosets Elastomers Linear Branched Crosslinked Network POLYMERS & TEIR COMMON USES TERMOPLASTICS Acrylic Optical lenses, automotive taillights, decorative nameplates, medical devices Polycarbonate Coffee makers, food blenders, automobile lenses, safety helmets, etc. Polyesters Auto louvres, under the hood electricals,mechanical parts, etc.
7 MSE 201-Polymers 7 POLYMERS & TEIR USES POLYMERS & TEIR USES TERMOPLASTICS (cont d) Polyethylene** Bottles, buckets, trash bags, boxes, laminated coatings, etc. Polyetherimide Printed circuit boards, heater housings, electrical components, etc. Polystyrene** Tinted glasses, low cost blender jars, etc.) POLYMERS & TEIR USES POLYMERS & TEIR USES TERMOPLASTICS (cont d) Fluoroplastics Bearings, valves, pumps, human implants, etc.) PEEK Wire and cable for aerospace, military hardware, nuclear plants, oil wells, etc. PVC** Pipes, siding and window profiles, low cost disposable products, etc Expandable PS Packaging of fragile products, etc.
8 MSE 201-Polymers 8 POLYMERS & TEIR USES POLYMERS & TEIR USES TERMOSETS AMINOS (e.g.melamines) Dinnerware, buttons, counter tops (Formica), toilet seats, wall switchplates EPOXY** Circuit boards, tooling surfaces for metals, composites (FIBERGLASS) POLYESTER GFRP for boats, automobiles, aircraft parts, microwave dinnerware, FRPs POLYMERS & TEIR USES POLYMERS & TEIR USES TERMOSETS (cont d) PENOLICS Electrical appliances, brake linings (w/fibers), black or brown handles for cookware POLYURETANE Skateboard wheels, solid tires, automotive bumpers, upholstery, etc
9 MSE 201-Polymers 9 POLYMERS & TEIR USES POLYMERS & TEIR USES ELASTOMERS Silicones flexible molds for casting, human implants, printing, etc. Natural rubber Tires w/carbon Polybutadiene Impact modifier for glassy polymers OW ARE POLYMERS MADE? OW ARE POLYMERS MADE? Polymerization of monomers: Addition (or chain) Step Growth (or condensation) Copolymerization**
10 MSE 201-Polymers 1 0 = white C = red N = blue O = yellow Example of Step-Growth Reaction (Nylon 66) addition & copolymerization (TBD) UNIQUE PROPERTIES of Polymers Molecules and their arrangement can be CANGED!! (cf. metals) Molecular Engineering (chain length, MWD, etc)
11 MSE 201-Polymers 1 1 UNIQUE PROPERTIES of Polymers PE LLDPE MDPE DPE UMWPE* (* difficult to process, machinable) Room Temperature Mechanical Properties Material polypropylene acrylic phenolic steel brass oak wood Modulus (MPa) 1, , , ,000 11,200
12 MSE 201-Polymers 1 2 Thermal Expansivities Thermal Expansivities Material polypropylene acrylic phenolic steel brass oak wood Thermal exp. 9.7 x 10 5 m/m C 10.1 x 10 5 m/m C 1.48 x 10 5 m/m C 1.17 x 10 5 m/m C 2.12 x 10 5 m/m C 0.49 x 10 5 m/m C What is the difference b/w polymer and plastic? Polymer denotes virgin material Plastic denotes polymer + additives*
13 MSE 201-Polymers 1 3 Common Additives in Plastics Antistatics (alkyl sulphonics) Coupling agents Fillers and extenders (CaCO 3, silica, & clay) Lubricants (wax or soaps) Flame retardants (Cl, Br, P, 2 O) Common Additives in Plastics Plasticizers Reinforcements Stabilizers antioxidants (hindered phenols) heat (organotin mercapto acid esters) UV (hindered amines)
14 MSE 201-Polymers 1 4 Why design with plastics? Why design with plastics? Lightweight*, resilient, corrosion resistant Transparent, color fastness, ease of processing Favorable balance of properties COMMERCIAL PLASTIC CATEGORIES Engineering Plastics» PA, acetal, PC, modified PPO, thermoplastic PET» Polysulfone, PPS» Polyethersulfone (PES), PEEK, polyamide imide (PAI)** (relatively NEW) Thermosets (relatively heat insensitive)»» Urea, melamine, unsaturated PET, epoxies
15 MSE 201-Polymers 1 5 Commercial plastics & their uses P l a s t i c L D P E L L D P E D P E P P P A P T F E P E T ( P B T ) P E E K A C E T A L C o m m o n U s e s p a c k a g in g, e le c t r ic a l in s u la t o r, b o t t le s, c o ld w a t e r t a n k s L D P E r e p la c e m e n t d is t b in s, b o t t le c r a t e s, p ip e s g e n e r a l p u rp o s e f lu id c o n t a in e r s C r a t e s, c a r c o m p o n e n t s ( f a s c ia s, f a n s ), T V c a b in e t s, c a r p e t b a c k in g g e a r s, p o w e r t o o l h o u s in g s, f ib e r s, b e a r in g s, s p o c k e t s, e t c. n o n s t ic k c o a t in g s ( C o r e lle ), b e a r in g s, g a s k e t s, e t c. p o p c a n s, g e a r s, b e a r in g s, b u m p e r b a c k u p e x t e n s io n s, e t c. h ig h t e m p t a p p lic a t io n s, w ir e c o a t in g s, e le c t r ic a l, f ib e r s, e t c. h o t w a t e r p lu m b in g, e le c t r ic k e t t le b o d ie s, e t c. (after Crawford, 1994) Composites D e fin e M a t e r ia l F le x M o d u lu s ( P S I ) T e n s ile S t r e n g t h ( P S I ) D T, F N y lo n 6 / , , % G F / N y lo n 6 /6 1,3 0 0, , % C F / N y lo n 6 /6 2,5 0 0, , P o ly p r o p y le n e 1 8 0, , % G F /P P 7 3 0, % T a lc /P P 3 8 0, , % C a C O , ,
16 MSE 201-Polymers 1 6 Composites Aerospace & automobile industries largest consumers (10% of total or 10,000 tonnes) Thermoset matrix (SMC) and thermoplastic matrix (Azdel, ICI s APC)** Composites Glass fibers preferred reinforcement cos of good strength, stiffness, and price OFFERS MANY DESIGN FLEXIBILITY (to be discussed further later)*
17 MSE 201-Polymers 1 7 Structural Foams (lightweight) Structural Foams (lightweight) Blowing agents + plastic melt yields rigid cellular foam core with tough skin PC, PP, modified PPO are popular choices» Overhead 5 Structural Foams (lightweight) Structural Foams (lightweight) Optionally contains short fibers for improved stiffness and strength Casings for business equipment and domestic appliances, vehicle body panels, furniture, etc.
18 MSE 201-Polymers 1 8 Elastomers (rubber vs. vulcanizate) General properties» resilient, resistant to oils, greases & ozone» low tempts, resistant to many acids.» molding & vulcanization are energy intensive. Elastomers (rubber vs. vulcanizate) Thermoplastic elastomers (TPE) to address above limitations» combines processability of plastics and rubber properties (plastics grafted onto rubber moles).» PU, styrenics, polyesters, rubber toughened PP, PA.
19 MSE 201-Polymers 1 9 Schematic of TPE Schematic of TPE Thermoplastic (PP) Rubber particles Polymer alloys (or polyblends) Practical motivation» cost considerations» (cf. cost of new polymers) Component selection factors» properties, cost, processability
20 MSE 201-Polymers 2 0 Polymer alloys (or polyblends) Examples PC or ABS or PU for improved impact) PPO or PBT or polysulfone for improved heat resistance EVA for improved barrier properties* Liquid Crystal Polymers Liquid Crystal Polymers e.g., Amoco s Xydar, oechst Celanese s Vectra Explain unique structure/flow properties**
21 MSE 201-Polymers 2 1 Liquid Crystal Polymers Liquid Crystal Polymers In situ (or self reinforced) composites application limited by high costs promising for electronics/telecom Goal: PROCESSING Find OPTIMUM Combination of Materials, Design, and Process Combinations Relative ease of processing Thermoplastics vs. thermosets** cf. metals/ceramics
22 MSE 201-Polymers 2 2 PROCESSING Two major routes Semi finished articles followed by post fabrication Fabrication of complex shape in ONE operation (e.g., telephone casing, etc) eat/shape/cool Principles of heat/mass transfer PROCESSING METODS (many) EXTRUSION Pipes, sheets, films, insulated wires, granules INJECTION MOLDING Complex shapes & parts TERMOFORMING Body panels of automobiles, chairs, etc.
23 MSE 201-Polymers 2 3 PROCESSING METODS (many) BLOW MOLDING Pop" bottles COMPRESSION & TRANSFER MOLDING Sheets, etc Details in MatE 454 PROCESS SELECTION PROCESS SELECTION COICE BASED ON: part shape & economics thermoplastics vs. thermosets Details in MatE 454
24 MSE 201-Polymers 2 4 Major Market Outlets Major Market Outlets A pp lic a tio n Pa cka g ing B uild ing /Co n stru ctio n T ran spo rtatio n Ele ctrical ou sew a re s Ap p lia n ces Fu rnitu re T oys C o ns u m p tio n ( B illio ns lbs End of Lecture, Unit 1 4a End of Lecture, Unit 1 4a READ»Class notes and Callister 2000, pp , , Optional Reading»Shackelford 2000, Chap. 13»
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