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GROUP 5: PLASTICS Chain length controls many of the properties of a plastic.

In increasing
the chain length, it tends to also increase its toughness, creep
Non-metallic materials: Plastics, Elastomers, Ceramics, and Composites resistance, melting temperature, melt viscosity, and difficulty in
Examples of non-metallic materials: processing.
Wood Stone Copolymers are a special category of polymer where two different
Leather Rock types of mers are combined into the same addition chain.
Clay Terpolymers further extend the possibilities by combining three
The family in nonmetallic materials has expanded from the natural materials different monomers.
and now includes an extensive list of plastics (polymers), elastomers, ceramics, Condensation polymerization occurs when reactive molecules
and composites. combine with one another to produce a polymer plus small, by-product
molecules, such as water. Heat, pressure, and catalysts are often
Plastics required to drive the reaction.
Plastics it is applied to engineering materials characterized by large molecules
that are built up by the joining of smaller molecules. On a practical level, these Thermosetting and Thermoplastic Materials
materials are natural or synthetic resins, or their compounds, that can be The terms thermosetting and thermoplastic refer to the material's
molded, extruded, cast, or used as thin films or coatings. response to elevated temperature.
They offer: For these materials, the intermolecular forces strongly influence the
1. Low density mechanical and physical properties. In general, the linear polymers
2. Low tooling costs tend to be flexible and tough. When the material is cooled, it becomes
3. Good resistance to corrosion and chemicals harder and stronger.
4. Cost reduction Because thermoplastic materials contain molecules of different lengths,
5. Design versatility they do not have a definite melting temperature but, instead, soften
Plastics are used to save lives in application such as artificial organs, shatter- over a range of temperatures.
proof glass, and bullet-proof vests. Many thermoplastics can partially crystallize when cooled below the
melting temperature. When the polymers "crystallize", the chains
Molecular Structure of Plastics closely align over appreciable distances, with a companion increase in
Paraffin-type hydrocarbons in which carbon and hydrogen combine density. In addition, the polymer becomes stiffer, harder, less ductile,
in the relationship CnH2n+2.Theoretically, the atoms can link together and more resistant to solvents and heat.
indefinitely to form very large molecules, extending the series.
Carbon and hydrogen can also form molecules where the carbon atoms Properties and Applications
are held together (Example: ethylene and acetylene) 1. Light weight
Isomers are same kind and number of atoms that unite in different 2. Corrosion resistance. Many plastics perform well in hostile, corrosive,
structural arrangements and these ultimately behaved as different or chemical environments. Some are notably resistance to acid
compounds with different engineering properties. They can be corrosion.
considered analogous to allotropism or polymorphism in crystalline 3. Electrical resistance. Plastics are widely used as insulating materials.
materials, where the same material possesses different properties 4. Low thermal conductivity. Plastics are relatively good thermal
because of different crystal structures. insulators.
Polymerization process, or linking of molecules occurs by either an 5. Variety of optical properties. Many plastics have an almost unlimited
addition or condensation mechanism. In polymerization by addition, a color range, and the color goes throughout, not just on the surface.
number of basic units (monomers) link together to form a large Both transparent and opaque materials are available.
molecule (polymer) in which there is a repeated unit (mer). Activators 6. Formability or ease of fabrication. Objects can frequently be produced
or catalysts, such as benzoyl peroxide, initiate and terminate the chain. from plastics in a single operation. Raw material can be converted to
The average number of mers in the polymer, known as the degree of final shape through processes such as casting, extrusion, and molding.
polymerization, ranges from 75 to 750 for most commercial plastics. Relatively low temperatures are required for forming of plastics.
7. Surface finish. The same processes that produce the shape also c. Lubricants such as waxes, stearates, and soaps can be added to
produce excellent surface finish. Additional surface finishing may not improve the moldability of plastics and to facilitate removal of parts
be required. from the mold.
8. Comparatively low cost. The low cost of plastics generally applies to d. Coloring agents may be either dyes, which are soluble in the resins, or
both the material itself and the manufacturing process. Plastics insoluble pigments, which impart color simply by their presence.
frequently offer reduced tool costs and high rates of production. e. Stabilizers retard degradation due to heat or light.
9. Low energy content f. Antioxidants retard degradation due to oxidation.
g. Flame retardants can be added when nonflammability is important.
Common types or families of plastics
Thermoplastics Oriented Plastics
1. ABS Additive Agents in Plastics and Their Purpose
2. Acrylics Type Purpose
3. Cellulose acetate Fillers Enhance mechanical properties, reduce shrinkage, reduce
4. Cellulose acetate butyrate weight, or provide bulk
5. Ethyl cellulose Plasticizer Increase flexibility, improve flow during molding, and
6. Fluorocarbons reduce elastic modulus
7. Nylon (polyamides) Lubricant Improve moldability and extraction from molds
8. Polycarbonates Coloring agents Impart color
9. Polyethylenes Stabilizers Retard degradation due to heat or light
10. PMMA (polymethyl methacrylate) Antioxidants Retard degradation due to oxidation
11. Polypropylene Flame retardants Reduce flammability
12. Polystyrenes
13. Polyvinyl chloride (PVC) Viscoelastic memory a phenomenon where oriented plastics tend to deform
14. Vinyls back from their original shape when reheated
Thermosets
1. Epoxies Engineering Plastics
2. Melamines A group of plastics have been developed with:
3. Phenolics 1. Improved thermal properties
4. Polyesters 2. Enhanced impact and stress resistance
5. Silicones 3. High rigidity
6. Urea-formaldehyde 4. Superior electrical characteristics
5. Excellent processing properties
Additive Agents in Plastics 6. Little dimensional change with varying temperature and humidity
Additional materials are incorporated into plastics to: These true engineering plastics include:
1. Impart or improve properties Polyamides (PA) Polybutylene Terephtalates
2. Reduce cost Polyacetals Polyketones
3. Improve moldability Polyacrylates Polysulfones
4. Impart color Polycarbonates (PC) Polyetherimides (PEI)
Additive constituents are classified as: Modified Polyphenylene Oxides Liquid crystal polymers
a. Fillers and reinforcements The engineering plastics offer a more balanced set of properties. They are
b. Plasticizers can be added in small amounts to reduce viscosity and usually produced in small quantities, however, and are often quite expensive.
improve the flow of the plastic during molding or to increase the
flexibility of thermoplastic products by reducing the intermolecular
contact and strength of the secondary bonds between polymer chains.
Plastics as Adhesives Processes
Adhesive Bonding occurs when a third substance bonds a plastic to another Injection molding is the most widely used process for the high-volume
plastic or to metal, rubber, ceramic, glass, or wood. production of relatively complex thermoplastic parts
Polymeric adhesives are synthetic bonding substances made from polymers The process is quite similar to the die casting of molten metal, and the
and are considered to be stronger, more flexible and have greater impact result is usually a finished product needing no further work before
resistance than other forms of adhesives and are used in many industrial assembly or use.
applications. Some injection molding machines incorporate a hot-runner distribution
Examples can be found from the: system to transfer the material from the injection nozzle to the mold
1. Thermoplastics (hot melt glues) cavities.
2. Thermosets (two-part epoxies) Injection molding can also be applied to the thermosetting materials,
3. Elastomer (silicone adhesives) but the process must be modified to provide the temperature,
The 7 most common structural adhesives: pressure, and time required for curing.
1. Epoxies Reaction injection molding process in which two or more liquid reactants are
2. Urethanes metered into a unit where they are intimately mixed by the impingement of
3. Cyanoacrylates liquid streams that have been pressurized to a value between 13 and 20 MPa
4. Acrylics (2000 and 3000 psi).
5. Anaerobics At present, the dominant materials for reaction injection molding are
6. Hot melts polyurethanes, polyamides, and composites containing short fibers or
7. Silicones flakes.
Selection usually involves consideration of the manufacturing conditions, the From a manufacturing perspective, reaction injection molding has a
substance to be bonded, the end-use environment, and cost. number of attractive features.
Extrusion where long plastic products with uniform cross sections can be
Plastics Versus Other Materials readily produced
Features of plastics: The process is continuous and provides a cheap and rapid method of
The ability to be fabricated with lower tooling costs molding.
The ability to be molded at the same rate as product assembly, thereby Common production shapes include a wide variety of constant cross-
reducing inventory section profiles, such as window and trim molding, as well as tubes,
A possible reduction in assembly operations and easier assembly pipes, and even coated wires and cables. Thermoplastic foam shapes
through snap fits, friction welds, or the use of self-tapping fasteners can also be produced.
The ability to reuse manufacturing scrap If an emerging tube is expanded by air pressure, allowed to cool, and
Reduced finishing costs then rolled, the product can be a double layer of sheet or film.
Calendering this process is used to convert thermoplastic materials into
Plastics for Tooling continuous sheets, films, and for applying plastic coatings to textiles, paper, or
Tooling (also known as machine tooling) is the process of acquiring the other supporting material.
manufacturing components and machines needed for production. Calendering is an alternative to extrusion with the usual film at three or
Polymers can also provide inexpensive tooling for applications where pressures, more mils (75 microns) thick.
temperatures, and wear requirements are not extreme. Because of their wide Calendering converts plastic into a melt and then passes the paste like
range of properties, their ease of conversion into desired shapes, and their melt through roll nips of series of heated and corotating speed-
excellent properties when loaded in compression, plastics have been widely controlled rolls into webs of specific thickness and width.
used in applications such as jigs, fixtures, and a wide variety of forming-die The purpose for the calendar is to provide sufficient energy to convert
components. mass of plastic into film or sheet form without supplying so much heat
as to cause degradation.

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