Approach Failure Analysis Polymer Materials CF 18nov10

Spoormaker Consultancy in Reliability & Liability of Plastic Products
Approaches to Failure analysis of polymeric materials

Jan Spoormaker
Spoormaker
Spoo a e Co
Consultancy
su a cy / Delft
e U University
es yo of Technology
ec o ogy
If you don't know the fords,
don't step
p in the water!
VeMet
Spoormaker Consultancy in reliability and liability of plastic products
Contents
Co te ts
Polymers
Typical failure mechanisms of plastics: failure might occur.
Failure causes of plastic products: failure has occurred .
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Polymerisation
y of ethylene
y C2H4 oPE
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Polyethelyne
y y C 2H 4
length
unbranched
branching
branched
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Verdeling Molecuulmassa
Molecular masso
Chain lengtho
IO-2040-20091130
Chain lengte
g of PE (C
( nH2n+2)
paraffin (500 g/mol ) glue container(105 g/mol) UHMW-PE (5.106 g/mol)

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Amorphous and semi-crystalline
low binding energy high binding energy tie-molecule
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Bending strength and impact strength as a function of Mn
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Viscosity
y as a function of molecular mass
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Injection
j moulding
g of thermoplastics
p
All you need is speed !!!
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Failure
a u e mechanisms
ec a s s aand
d causes
Failure Mechanisms Failure Causes
UV-degradation
UV degradation faulty ribbing
creep & stress relaxation difference in stiffnesses
environmental stress cracking high stiffness of mating parts
dimensional stability grade and polymer selection
static fatigue
dynamic fatigue stress concentrations
wear
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Fatigue
at gue
UV-degradation faulty ribbing

static fatigue
wear
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Fatigue
Disentanglement in
polymers can occur
occur,
resulting in stable crack
extension.
This is also referred to as
static fatigue.
g
Dynamic fatigue is a
similar mechanism.
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Dynamic
y crack g
growth Paris law
Crack growth per cycle

Constant for dynamic loads
St
Stress iintensity
t it diff
difference
exponent
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Crack extension
crack Stable crack unstable
initiation extension crack
extension
Threshhold
of initiation
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Static fatigue
g
Crack growth rate
Crack
C ac ggrowth
o t rate
ate
Constant
Stress intensity
exponent
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Static fatigue
g crack growth
g
unstable
crack
extension
wrh rate
Stable crack
Crrack groww
extension
crack
initiation
Polycarbonate
o yca bo ate sp
spring
g
UV-degradation
static fatigue
wear
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PC--spring in service position

PC
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Photo of PC spring in service position
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Spring in unlocked position
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Photo of Spring
p g in unlocked position
p
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Crack extension
Polycarbonate (PC)
has relativelyy smooth
molecular chains and
has a low resistance to
stable crack extension.
It has, however, a
l
large resistance
i t to
t
crack initiation.
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Impact & notch sensitivity
ECEFA -IV
Failed springs
p g
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SEM of fracture surface ((static fatigue)

g )
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SEM of fracture surface ((dynamic

y fatigue)
g )
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Melt Flow Rate (MFR)
MFR - the mass of polymer, in grams, flowing in 10

minutes through a capillary of a specific diameter
and length by a pressure applied via prescribed
weights for prescribed temperatures.
ECEFA -IV
Molecular mass (Mn) -MFR
Relationship between the Molecular Weight and the

MFR for PC (Calibre 300 of DOW Plastics)
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R l ti MFR
Relation MFR-Impact
I t strength
t th
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Kid-Sit
dSt
UV-degradation
static fatigue
wear
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.
Kid-Sit
dSt
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Kid-Sit stiffness differences
Extreme high
stiffness differences
between swivel plate
(steel) and the board
adjacent to the swivel
plate (polymer)
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.
Kid-Sit - cracking
g
cracks
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Fatigue
g
Semi-crystalline
(final material
selection PA6 with
30 % glass fibres
Amorphous
p
(initial material
selection)
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S-N curve of PA66-30GF ((flow direction))
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. Spoormaker Consultancy in Reliability & Liability of Plastic Products
Kid-Sit
Kid Sit
Extreme high
g stiffness
differences between swivel
wheel plate (steel) and the
board adjacent to the swivel
plate (polymer)
Bending stiffnesss Dsw Es I na 82 Nm 2
swp
Dsw \Db = 31
Bending
g stiffness b Db E p Ib 2.9 Nm2
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Impact
p factor \
Fim pact 2h
\ 1 k tot 1
F static mg
ECEFA -IV
Impact
p factor \
Fim pact 2h
\ 1 k tot 1
F static mg
h 0.1
0 1 m
2 0.1
m 18 kg \ 1 22000 1 6.1
g 9.8 m/s2 18 9.8
ktot = 22000 N/m2
<o6
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.
Kid-Sit FEM calculation I
Very
y high
g secondary y stresses in the
region near the stiffness difference
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.
FEM ca
calculation
cu at o ((filliting)
t g)
Still very high secondary stresses in the region near

the stiffness difference. Filleting does not help
ECEFA -IV
UV-degradation
g
UV-degradation
static fatigue
wear
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Weathering
ECEFA -IV
Weathering
1. Definition
2. Sunlight and spectral sensitivity
3. Effect of UV on polymers
4. Attack of bonds
5. Change in mechanical properties
ECEFA -IV
Definition of weathering
g
Weathering is the adverse response of a material or

product
d t to
t climate,
li t often
ft causing
i unwantedt d and
d
premature product failures.
Primary Factors of Weathering:
solar radiation (light energy)

temperature
water (moisture/dew)
ECEFA -IV
Weathering
1. Definition
4. Attack of bonds
ECEFA -IV
Solar radiation spectrum

p
ECEFA -IV
Weathering
1. Definition
4. Attack of bonds
ECEFA -IV
UV- induced reactions

UV
Loss of H-atom
H atom
Reaction with O2
Reaction with a molecule
Reaction with O2
ECEFA -IV
Hydrogen
yd oge peroxide
pe o de & hydroperoxide
yd ope o de
ECEFA -IV
Degradation
g reactions
ECEFA -IV
Weathering
1. Definition
4. Attack of bonds
ECEFA -IV
Attack on bonds
ECEFA -IV
PE
Chain scission
branched/side group
ECEFA -IV
Pattack on bonds
ECEFA -IV
Transferring
g of energy
gy
ECEFA -IV
Weathering
1. Definition
4. Attack of bonds
ECEFA -IV
Scission and cross

cross-linking
linking
ECEFA -IV
Chain scission and cross linking

g
ECEFA -IV
UV - embrittlement
60
.
Polypropene (PP)
{ degraded specimens
x notched specimens
ECEFA -IV
Ultra violet stabilisation (Tinuvin)
62
ECEFA -IV
Keysaver
eysa e
UV-degradation
static fatigue
wear improper mould design
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Construction of KEYSAVER
Detail of
click boss Keysaver in
bobber with spool t
transparant
t ABS
Click
disk Parts of Keysaver with
boss
y to be saved
keys
sponge
ROSMOULD 2006
Floating device
ANTEC2008
Functioning and non functioning KEYSAVERS

Critical p
points
Dimensions
Diameter of snap-fit disk
Height of bosses
Material selection
Snap-fit disk (PA6)
Inner housing ABS
Processing and gating

Lay-out
Lay out of KEYSAVER
Critical dimensions
Dd diameter of disk
Db diameter of boss circle
Force to unclick is depends on:
Dd - Db
Macro photo of boss

Equilibrium
q of water absorption
p in air
3 % water uptake!!
Deformation of inner house ((ABS)) ((bw))

Deformation of ABS test bars

Critical dimensions
Dd diameter of disk
Db diameter of boss circle
Force to unclick is depends on:
Dd - Db
Stiffness
Effect of stiffness on scatter
15
Force (N)
10
0
0.0 0.5 1.0 1.5 2.0
displacement (mm)
Failure
a u e mechanisms
ec a s s aand
d causes
UV-degradation
static fatigue
dynamic fatigue (temperature) stress concentrations
wear (heat, hardness) improper mould design
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Adhesive wear
ECEFA -IV
Abrasive wear
ECEFA -IV
Pitting
g as a result of fatigue
g
Fatigue cracks Pitting
ECEFA -IV
.
Wear
ECEFA -IV
.
Wear ((NX-UHMWPE))
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.
Conclusions
1. Basic understanding of structure related properties.
2. Typical failure mechanisms and causes.
3. Material and grade selection.
4. Do not rely on injection moulders
5 More education in designing in plastics is necessary
5.
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Literature list
Polymers
McCrum, N.G. et al., Principles of Polymer Engineering, Oxford University Press.

Oberbach, K, Kunststoff Kernwerte fr Konstrukteure, Carl Hanser Verlag, Mnchen
1980.
Spoormaker, J.L., Ten Essential Pictures for Understanding the Mechanical Behavior
of Plastics, Proceedings of ANTEC 2002.
Peter C. Powell & A.J. Ingen Housz Engineering with Polymers
Failure of Plastics
M. Ezrin, Plastics Failure Guide Cause and Prevention, Hanser, Cincinnati, OH

(1996).
M. Ezrin et al., The Role Of Analytical and Physical Methods in Plastics Failure
Analysis, SPE-ANTEC Tech. Papers, 53, 2762 (2007).
P.R. Lewis, Reynolds K., Gagg Forensic Materials Engineering, CRC Press, London
2004.
Bohme, E., Failure Analysis using microscopic techniques. DuPont.
http://plastics.dupont.com/plastics/pdflit/europe/ design/failureanalysise.pdf
Brostow, W. and R.D. Cornelissen, Failure of Plastics, Hanser Publishers, New York
(1986).

Approach Failure Analysis Polymer Materials CF 18nov10

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Approach Failure Analysis Polymer Materials CF 18nov10

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Spoormaker Consultancy in Reliability & Liability of Plastic Products

Approaches to Failure analysis of polymeric materials

paraffin (500 g/mol ) glue container(105 g/mol) UHMW-PE (5.106 g/mol)

Amorphous and semi-crystalline

low binding energy high binding energy tie-molecule

Bending strength and impact strength as a function of Mn

All you need is speed !!!

UV-degradation faulty ribbing

Crack growth per cycle

Crack growth rate

PC--spring in service position

Photo of PC spring in service position

Spring in unlocked position

Impact & notch sensitivity

SEM of fracture surface ((static fatigue)

SEM of fracture surface ((dynamic

Melt Flow Rate (MFR)

MFR - the mass of polymer, in grams, flowing in 10

Molecular mass (Mn) -MFR

Relationship between the Molecular Weight and the

Kid-Sit stiffness differences

S-N curve of PA66-30GF ((flow direction))

Bending stiffnesss Dsw Es I na 82 Nm 2

Kid-Sit FEM calculation I

Still very high secondary stresses in the region near

Weathering is the adverse response of a material or

Primary Factors of Weathering:

solar radiation (light energy)

Solar radiation spectrum

UV- induced reactions

Reaction with a molecule

Scission and cross

Chain scission and cross linking

Ultra violet stabilisation (Tinuvin)

Functioning and non functioning KEYSAVERS

Processing and gating

Force to unclick is depends on:

Macro photo of boss

Deformation of inner house ((ABS)) ((bw))

Deformation of ABS test bars

Force to unclick is depends on:

Effect of stiffness on scatter

Fatigue cracks Pitting

McCrum, N.G. et al., Principles of Polymer Engineering, Oxford University Press.

M. Ezrin, Plastics Failure Guide Cause and Prevention, Hanser, Cincinnati, OH

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