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polypropylene
A. Dasari, S. J. Duncan, and R. D. K. Misra
Atomic force microscopy (AFM) in tapping mode has been used to characterise surface damage on deformed
polypropylenes induced during a scratch test. Atomic force micrographs revealed differences in microstructures that
could be used to predict the deformation resistance of two different types of polypropylene. The undeformed surface
of the two types of polypropylene (identi ed as polypropylene-L and polypropylene-R) was characterised by
differences in arrangement (regular or irregular) of brils depending on their melt ow conditions. Polypropylene-L
is a polymer with longer chains and with restricted ow, whereas polypropylene-R has shorter chains obtained by
controlled rheology. The micro brils in undeformed polypropylene-L bend, forming raised surface features of height
in the region of 10 50 nm. In comparison to polypropylene-L, the micro brils in undeformed polypropylene-R
exhibited surface features of relatively lower height (10 20 nm). 30630 nm scan AFM images provided details
of micro brils containing chains of molecules of ~ 0.5 nm wide. Surface deformation induced by the scratch resulted
in the formation of scratch tracks characterised by regions of quasi-periodic (consecutive) cracking. This type
of deformation is attributed to higher applied loads or to higher contact strains. This is particularly important
in semicrystalline polymers, where there is partial reorganisation of microstructure on the application of
surface stresses because of their viscoelastic properties. Atomic force micrographs of mechanically deformed
polypropylene-L and polypropylene-R at a scan size of 161 l m indicated a lesser amount of reorganisation of
microstructure in polypropylene-L as compared with polypropylene-R. Surface pro les and section analysis of the
AFM micrographs suggested that polypropylene-R is more scratch resistant in comparison to polypropylene-L
under identical scratch test conditions, consistent with Raman spectroscopy observations of tensile deformed
polypropylene.
MST/5253
Mr Dasari and Professor Misra (dmisra@louisiana.edu) are in the Department of Chemical Engineering, University of
Louisiana at Lafayette, PO Box 44130, Lafayette, LA 70504 4130, USA and Dr Duncan is with Basell Polyole ns, Bramley
Road, Mount Farm, Bletchley, Milton Keynes, MK1 1LZ, UK. Manuscript received 8 October 2001; accepted 8 January 2002.
# 2002 IoM Communications Ltd. Published by Maney for the Institute of Materials, Minerals and Mining.
Introduction
Polymers are substituting for traditional engineering
materials in automotive applications, while metals are continuing to advance, but at a far slower rate than polymers. 1
The growth of polymers is driven by a deliberate effort to
meet human requirements by engineering design, reduced
cost, and increase in recyclability.
Thermoplastic ole ns (TPO), polypropylene (PP) and
polyethylene (PE) are emerging as primary materials in
automotive systems because of relatively low cost and ready
availability. However, it is important that they are manufactured with durable, low gloss rst surfaces, and are
pleasing aesthetically.2 6 To maintain a good appearance,
it is desirable that polymeric materials exhibit minimal
susceptibility for mechanically induced surface damage (e.g.
good scratch resistance) and do not stress whiten to any
signi cant extent when scratched. Stress whitening of polymers is aesthetically undesirable because the white marks
are in prominent contrast to the colour of the article. This
characteristic is also important for tribological applications. Surface damage induced by scratching or mechanical
deformation processes detracts the user from the subjective
perception of quality of the product and limits the applicability of polymeric material. Additionally, mechanically
induced surface damage undermines the longevity of polymeric components and restricts the usage of polymers for
automotive applications, such as for instrument panels.4 6
Scratches may also induce stress raisers and can reduce the
mechanical strength of materials.
Since the introduction of thermoplastic ole ns in the
automotive industry in the early 1990 s, a scratch test was
introduced to evaluate the scratch resistance of automotive
DOI 10.1179/026708302225005945
Gloss level
Scratch Visibility
Experimental procedure
Two polypropylene samples conforming to ISO R527
geometry were cast by the injection moulding process
with the longitudinal axis of tensile specimen corresponding to the direction of extrusion; the rst designated as
polypropylene-L and the second, polypropylene-R. The
mechanical and physical properties are summarised in
Table 1. In polypropylene-L the ow was restricted and
polypropylene-R is controlled rheology ( see Table 2 for
melt ow rates).
The scratch test machine was a conventional lever type
machine with a conical indenter attached to the lever arm.
The samples were xed on a levelling platform that was
attached to a displacement stage. The stage provided scratch
velocities in the range of 0 .001 40 mm s 1 . The indenter
holder was connected to a piezoelectric force transducer
to record the scratch (frictional) force. Normal load was
applied by placing dead weights upon the indenter holder.
Figure 1 shows a schematic of the scratch test. The two
polypropylene samples identi ed as L and R were scratched
using a load of 7 N.
Table 1 Mechanical
and
physical
properties
polypropylene-L and polypropylene-R
of
Polypropylene-L Polypropylene-R
Melting point
obtained using DSC
Tensile modulus
at displacement
rate of 1 mm min 1
Tensile yield stress
at displacement
rate of 50 mm min 1
Tensile yield strain
at displacement
rate of 50 mm min 1
Charpy notch impact strength
Izod notch impact strength
163C
163C
1500 MPa
1500 MPa
34 MPa
34 MPa
9%
18%
1.5 kJ m 2
1.3 kJ m 2
1.5 kJ m 2
1.3 kJ m 2
Melt ow rate
at 230/2. 16
Melt volume
rate at 230/2.16
of
polypropylene-L
Polypropylene-L
Polypropylene-R
6 g/10 min
23 g/10 min
8 cm /10 min
and
c
a scan size 464 mm; b scan size 161 mm; c scan size 306
30 nm
of the more pronounced viscoelastic properties of semicrystalline polymers such as polypropylene. This type of
deformation can be attributed to the higher applied loads
(7 N in the present study) or due to highly localised strains
produced during the scratch deformation process. If the
applied normal load is less, or at lower contact strains, a
different kind of deformation process, namely, viscoelastic
ploughing, can be expected within the scratch because of a
signi cant viscoelastic recovery at the rear of the contact.
This may occur without any evidence of discrete failure
and the formation of well de ned edges on the sides of the
scratch grooves.2 Quantitatively, the depth of the scratch
track and the density of scratch tracks per unit area should
be indicative of the resistance of a material to mechanical
deformation.
The surface pro le and section analysis plots for
polypropylene-L and polypropylene-R are presented in
Figs. 7 and 8, respectively. Figure 7 a shows that the average
c
a scan size 464 mm; b scan size 161 mm; c scan size 306
30 nm
b
a polypropylene-L; b polypropylene-R
b
a polypropylene-L; b polypropylene-R
11
10
12
13
Conclusion s
1. Atomic force microscopy (AFM) operated in tapping mode revealed differences in microstructure (up to the
microlevel) of the surface damage induced during the
scratch test in two different grades of polypropylene with
different melt ow rates. The mechanically induced surface
damage could be predicted by comparing with AFM images
of undeformed polypropylene. However, at the molecular
level, no signi cant differences in the microstructure of the
surface damaged polypropylenes was observed by the AFM
technique.
2. The microtopography of the two types of undeformed
polypropylene is characterised by differences in arrangement (regular or irregular) of brils depending on their
melt ow conditions. The micro brils in undeformed
polypropylene-L bend upwards forming raised surface
features of height in the region of 10 50 nm. In comparison to polypropylene-L, the micro brils in undeformed
polypropylene-R are characterised by surface features of
lesser height (10 20 nm). AFM molecular scale images
at a 30 630 nm scan size provided details of micro brils
containing chains of molecules ~ 0.5 nm wide.
3. Surface deformation induced by the scratch test on the
two polypropylenes involved the formation of scratch
tracks that exhibited regions of quasi-periodic (consecutive)
cracking.
4. From the surface pro le and section analysis of AFM
micrographs of mechanically deformed polypropylene-L
and polypropylene-R, the average surface height and the
peak to valley height (considered to be a measure of the
depth of induced scratch) were 65 and 442 nm; and 28 and
187 nm, respectively, implying that polypropylene-L is less
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