TOPIC 6

PLASTIC
PREPARED BY:
AZMARINI BINTI AHMAD NAZRI
PENSYARAH POLITEKNIK UNGKU OMAR

6.1 THE IMPORTANT USES

OF PLASTIC
6.1.1 THE POLYMERIC STRUCTURE
Polymer is a substance (natural or synthetic),
molecules of which consist of numerous small
repeated chemical units (monomers) linked to each
other in a regular pattern. Polymers usually combine
crystalline and amorphous structures (semicrystalline).
Degree of polymerization is an average number of
monomers (mers) in a polymer molecule. Polymer
molecules may combine up to million of monomers
(mers) forming a one-dimensional structure (chain),
two-dimensional structure (planar molecules) or

6.1 THE IMPORTANT USES

OF PLASTIC
6.1.1 THE POLYMERIC STRUCTURE (CONTINUE)
Atoms of a polymer molecule are held by covalent
bonding. Neighboring chains may form secondary
bonds between them (cross-links) which are less
strong than covalent bonding between the atoms
within the molecules. Cross-links provide elasticity to
the polymer, preventing sliding of the neighboring
chains when the material is stretched. Branched
polymer consists of molecules having side chains
(branches) attached to the main chain.
Copolymer is a polymer molecule of which contains
more than one kind of monomers. Nylon is a

6.1 THE IMPORTANT USES

OF PLASTIC
6.1.2 DIFFERENTIATE THERMOSETTING PLASTIC
AND THERMO-PLASTIC
THERMOPLASTIC
Thermoplastics are polymers, which soften (becomes
pliable and plastic) and melt when heated. In the
melted conditions thermoplastics may be formed
by various methods (injection molding, extrusion,
Thermoforming). No new cross-links form
(no chemical curing) when a thermoplastic cools and
harden.
Thermoplastics may be reprocessed (re-melt) many
times. Molecules of most of thermoplastics
combine long polymer chains alternating with

6.1 THE IMPORTANT USES

OF PLASTIC
6.1.2 DIFFERENTIATE THERMOSETTING PLASTIC
AND THERMO-PLASTIC
THERMOSETTING PLASTIC
Thermosets are Polymers which do not melt when heated.
Thermosets molecules are cross-linked by strong
covalent intermolecular bonds, forming one giant
molecule. Cross-linking is irreversible therefore
thermosets can not be reprocessed (re-melt).
Thermosets are stronger and stiffer than Thermoplastics.
Stiffness of thermosets is even higher than some
metals (aluminum). Thermosets also have higher
thermal, chemical and creep resistance than
thermoplastics. Thermoset materials may contain filler
materials in form of powder or fibers, providing

Property
Density
Modulus of elasticity

0.92 *10
0.29

Thermoplastic
Low Density Polyethylene (LDPE)
Value in metric unit
kg/m
57.4
GPa
42

Value in US unit
lb/ft
ksi

Tensile strength

17

MPa

2500

psi

Elongation
Flexural strength

500
14

%
MPa

500
2000

%
psi

Thermal expansion (20 16*10-5

C)

9*10-5

in/(in* F)

Thermal conductivity

0.33

W/(m*K)

2.29

BTU*in/(hr*ft*F)

Melting point
Maximum work
temperature

120
90

C
C

248
194

F
F

Electric resistivity

1013-1016

Ohm*m

1015-1018

Ohm*cm

Dielectric constant

2.3

2.3

6.1 THE IMPORTANT USES

OF PLASTIC
6.1.3 APPLICATION AND MECHANICAL
PROPERTIES OF THERMOPLASTIC.
A. POLYETHYLENE
i.

Low Density Polyethylene (LDPE)

Good impact strength;

Good chemical resistance;
Good flexibility;
Poor UV resistance;
Good hot formability.

Applications: packaging films (general purpose, shrink,

lamination), containers, cable insulation,

6.1 THE IMPORTANT USES

OF PLASTIC
6.1.3 APPLICATION AND MECHANICAL
PROPERTIES OF THERMOPLASTIC.
A. POLYETHYLENE
i.

High Density Polyethylene (HDPE)

Good strength;
Good impact strength;
Good chemical resistance;
Good stiffness;
Poor UV resistance.

Applications: packaging films, heavy duty shrink film,

pipes, containers, bags, blown bottles.

Property
Density
Modulus of
elasticity
Tensile strength

Thermoplastic
High Density Polyethylene (HDPE)
Value in metric unit
0.95 *10
kg/m
59.3
1.86
GPa
270
31

Value in US unit
lb/ft
ksi

MPa

4500

psi

Elongation
100
Flexural strength 40

%
MPa

100
5800

%
psi

Thermal
expansion (20 C)
Thermal
conductivity
Melting point
Maximum work
temperature

12.6*10-5

7*10-5

in/(in* F)

0.48

W/(m*K)

3.33

130
120

C
C

266
248

BTU*in/
(hr*ft*F)
F
F

Electric
resistivity
Dielectric
constant

1013-1016

Ohm*m

1015-1018

Ohm*cm

2.4

2.4

6.1 THE IMPORTANT USES

OF PLASTIC
6.1.3 APPLICATION AND MECHANICAL
PROPERTIES OF THERMOPLASTIC.
B. POLYPROPYLENE

Good chemical resistance;

Good fatigue resistance;
Good heat resistance.

Applications: packaging, ventilators, boxes of TV and

radio sets, toys, furniture components, bumpers.

Thermoplastic
Polypropylene (PP)
Value in metric unit
0.91 *10
kg/m
56.8
1.36
GPa
195

Property
Density
Modulus of
elasticity
Tensile strength 37
Elongation
350
Flexural strength 49
Thermal
expansion (20 C)
Thermal
conductivity
Glass transition
temperature
Maximum work
temperature
Electric resistivity
Dielectric
constant

Value in US unit
lb/ft
ksi

MPa
%
MPa

5300
350
7000

psi
%
psi

90*10-6

50*10-6

in/(in* F)

0.16

W/(m*K)

1.11

-10

14

BTU*in/
(hr*ft*F)
F

150

302

107 -109

Ohm*m

109 -1011

Ohm*cm

2.4

2.4

6.1 THE IMPORTANT USES

OF PLASTIC
6.1.3 APPLICATION AND MECHANICAL
PROPERTIES OF THERMOPLASTIC.
C. POLYSTYRENE

Rigid;
transparent thermoplastic, which is present in solid
or glassy state at normal temperature;
Pure polystyrene polymer is colorless and hard
with limited flexibility

Applications: Shell forms for containers, model boats

and model cars

6.1 THE IMPORTANT USES

OF PLASTIC
6.1.3 APPLICATION AND MECHANICAL
PROPERTIES OF THERMOPLASTIC.
D. POLYVINYL CHLORIDE (PVC)

May be rigid or flexible (depending on

formulation);
High density;
Environmentally durable;
May release chlorine and hydrochloric acid when
heated.

Applications: drainage pipes, water service pipes,

bottles, window frames, wire and cable insulation,
resilient floors, automotive interiors, stationary,

Property
Density
Modulus of
elasticity
Tensile strength
Elongation
Flexural strength
Thermal
expansion (20 C)
Thermal
conductivity
Glass transition
temperature
Maximum work
temperature
Electric resistivity

Thermoplastic
Polyvinyl Chloride (PVC)
Value in metric unit
1.44 *10
kg/m
89.9
3.32
GPa
475

Value in US unit
lb/ft
ksi

47
60
91

MPa
%
MPa

6700
60
13000

psi
%
psi

75*10-6

42*10-6

in/(in* F)

0.18

W/(m*K)

1.25

BTU*in/(hr*ft*F)

87

189

80

176

106

Ohm*m

108

Ohm*cm

Dielectric constant 4

6.1 THE IMPORTANT USES

OF PLASTIC
6.1.3 APPLICATION AND MECHANICAL
PROPERTIES OF THERMOPLASTIC.
E. POLYMETIL METHACRYLATE (PMMA)

Good weather resistance;

High strength;
Transparent.

Applications: automobile lights, swimming pools,

lenses.

Property
Density
Modulus of
elasticity
Tensile strength
Elongation
Flexural strength

Thermoplastic
Polymethylmethacrylate (PMMA)
Value in metric unit
1.19 *10
kg/m
74.3
2.77
GPa
400

Value in US unit
lb/ft
ksi

61
4
103

MPa
%
MPa

9000
4
15000

psi
%
psi

Thermal
expansion (20 C)

65*10-6

36*10-6

in/(in* F)

Thermal
conductivity
Glass transition
temperature
Maximum work
temperature
Electric resistivity

0.21

W/(m*K)

1.46

BTU*in/(hr*ft*F)

100

212

100

212

106-108

Ohm*m

108-1010

Ohm*cm

2.7

Dielectric constant 2.7

6.1 THE IMPORTANT USES

OF PLASTIC
6.1.3 APPLICATION AND MECHANICAL
PROPERTIES OF THERMOPLASTIC.
F. POLYAMIDE (NYLON 6)

Very high toughness;

Good chemical resistance;
Good thermal resistance;

Applications: bushings, electrical plugs and sockets,

gears, fibers for textiles, food packaging film,
bearings, carpets.

Thermoplastic
Polyamide (Nylon 6)
Value in metric unit
1.13 *10
kg/m
70.5
2.95
GPa
420

Property
Density
Modulus of
elasticity
Tensile strength 100
Elongation
60
Flexural strength 91

Value in US unit
lb/ft
ksi

MPa
%
MPa

14500
60
13000

psi
%
psi

Thermal
66*10-6
expansion (20 C)

37*10-6

in/(in* F)

Thermal
conductivity
Glass transition
temperature
Maximum work
temperature
Electric resistivity

0.25

W/(m*K)

1.73

50

122

BTU*in/
(hr*ft*F)
F

110

230

104 -107

Ohm*m

106 -109

Ohm*cm

Dielectric
constant

4.5

4.5

6.1 THE IMPORTANT USES

OF PLASTIC
6.1.4 THE PLASTIC POLYMERISATION PROCESS.
Polymerisation is the process of joining together a large
number of small molecules to make a smaller
number of very large molecules. The reactants (i.e.
the small molecules from which the polymer is
constructed) are called Monomers and products of
the polymerisation process are called Polymers.
There are significant differences between the chemical
and physical properties of polymers and those of
the monomers from which they are made. This
polymerisation process can occur by two different
mechanisms : by addition polymerisation and

6.1 THE IMPORTANT USES

OF PLASTIC
6.1.5 APPLICATION AND MECHANICAL
PROPERTIES OF THERMOSETTING PLASTIC.
A. PHENOL FORMALDEHYDE

High hardness;
Brittle;
Excellent thermal stability;
Resistance to heat, water, electricity and chemical.

Applications: wiring devices, lamps holders,

switchboards, bottle caps, automotive parts, plugs
and switches, handles on kitchen utensils (filled
with mineral fibers), motor housings, welding
tongs, ashtrays.

Property
Density
Modulus of
elasticity
(flexural)

Thermoset
Phenolics (PF)
Value in metric unit
1.40 *10
kg/m
8.3
GPa

Tensile strength 50
Elongation
1
Flexural
69
strength
Thermal
expansion (20
C)

40*10-6

Maximum work 120

temperature

87.4
1200

Value in US unit
lb/ft
ksi

MPa
%
MPa

7000
1
10000

psi
%
psi

22*10-6

in/(in* F)

250

6.1 THE IMPORTANT USES

OF PLASTIC
6.1.5 APPLICATION AND MECHANICAL
PROPERTIES OF THERMOSETTING PLASTIC.
B. EPOXIDE(EP)
High strength;
Excellent corrosion resistance;
Excellent dimension stability;
Excellent toughness;
Good dielectrical properties;
Low shrinkage;
Good adhesion.
Applications: electrical molding, electrical circuits
(reinforced with glass fiber), protective coating,
pipe fittings, adhesive, rocket motors components

Property
Density
Modulus of
elasticity
Tensile strength
Elongation
Flexural yield
strength
Compressive
strength
Thermal expansion
(20 C)
Thermal
conductivity
Specific heat
capacity
Maximum work
temperature

Thermoset
Epoxy (EP)
Value in metric unit
1.15 *10
kg/m
2.5
GPa

71.8
360

60
4
120

MPa
%
MPa

8700
4
17400

psi
%
psi

140

MPa

20300

psi

50*10-6

28*10-6

in/(in* F)

0.17

W/(m*K)

1.18

BTU*in/(hr*ft*F)

1100

J/(kg*K)

0.26

BTU/(lb*F)

180

356

Value in US unit
lb/ft
ksi

6.1 THE IMPORTANT USES

OF PLASTIC
6.1.5 APPLICATION AND MECHANICAL
PROPERTIES OF THERMOSETTING PLASTIC.
C. POLYESTER

Excellent rigidity;
High strength;
High creep strength;
Good chemical resistance;

Applications: fiberglass boats, building panels, fans,

fences, helmets, compressor housing, auto body
components, bathroom accessories.

Property
Density
Modulus of
elasticity

Thermoset
Polyester
Value in metric unit
1.12 *10
kg/m
3.4
GPa

Tensile strength 60
Elongation
2
Flexural yield 113
strength

70.0
493

Value in US unit
lb/ft
ksi

MPa
%
MPa

8700
2
16400

psi
%
psi

Thermal
expansion (20
C)

31*10-6

17*10-6

in/(in* F)

Thermal
conductivity

0.17

W/(m*K)

1.18

BTU*in/
(hr*ft*F)

325

Maximum work 170

temperature

6.1 THE IMPORTANT USES

OF PLASTIC
6.1.5 APPLICATION AND MECHANICAL
PROPERTIES OF THERMOSETTING PLASTIC.
D. UREA FORMALDEHYDE

High hardness;
Brittle;
High toughness;
Scratch resistant;

Applications: dinnerware, protective coatings,

adhesives, lighting fixtures, heavy duty electrical
equipment, decorative laminates.

Property
Density
Modulus of
elasticity

Thermoset
Urea Formaldehyde (UF)
Value in metric unit
1.55 *10
kg/m
96.8
9
GPa
1300

Tensile strength 65
Elongation
0.8
Flexural yield 100
strength

Value in US unit
lb/ft
ksi

MPa
%
MPa

9500
0.8
14000

psi
%
psi

Compressive
strength

240

MPa

35000

psi

Thermal
expansion (20
C)

29*10-6

16*10-6

in/(in* F)

170

Maximum work 80
temperature

6.1 THE IMPORTANT USES

OF PLASTIC
6.1.5 APPLICATION AND MECHANICAL
PROPERTIES OF THERMOSETTING PLASTIC.
E. MELAMINE FORMALDEHYDE

High hardness;
Brittle;
High toughness;
Scratch resistant;

Applications: dinnerware, protective coatings,

adhesives, lighting fixtures, heavy duty electrical
equipment, decorative laminates.

Property
Density
Modulus of
elasticity

Thermoset
Melamine Formaldehyde (MF)
Value in metric unit
1.55 *10
kg/m
96.8
12
GPa
1800

Tensile strength 65
Elongation
0.6
Flexural yield 140
strength

Value in US unit
lb/ft
ksi

MPa
%
MPa

9500
0.6
20000

psi
%
psi

Compressive
strength

240

MPa

35000

psi

Thermal
expansion (20
C)

29*10-6

16*10-6

in/(in* F)

300

Maximum work 150

temperature

6.1 THE IMPORTANT USES

OF PLASTIC
6.1.6 ADVANTAGES AND DISADVANTAGES OF
PLASTICS APPLICATION IN THE ENGINEERING
FIELD.
Advantages of plastic:

Advantages of plastic are light in weight.

Can be easily moulded and have excellent
finishing.
Very good strength and toughness
Good corrosion resistant and chemically inert.
Low thermal expansion
Good thermal and electrical insulating property.
Very good water resistant and possess good

6.1 THE IMPORTANT USES

OF PLASTIC
6.1.6 ADVANTAGES AND DISADVANTAGES OF
PLASTICS APPLICATION IN THE ENGINEERING
FIELD.
Disadvantages of plastic:

Plastic is softer than metal.

Low melting temperature.
Low strength than metal
Plastics are brittle at low temperature.
Deformation under load.
low heat resistant and poor ductility.

6.1 THE IMPORTANT USES

6.1.7
PLASTIC PRODUCTS PROCESSES.
OF PLASTIC

A. INJECTION MOULDING
Injection Molding is a process in which molten
polymer is forced under high pressure into a mold
cavity through an opening (sprue).

6.1.7 PLASTIC PRODUCTS PROCESSES.

A. INJECTION MOULDING

Polymer material in form of pellets is fed into an Injection

Molding machine through a hopper.

The material is then conveyed forward by a feeding screw

and forced into a split mold, filling its cavity through a
feeding system with sprue gate and runners. Screw of
injection molding machine is called reciprocating screw since
it not only rotates but also moves forward and backward
according to the steps of the molding cycle.

It acts as a ram in the filling step when the molten polymer is

injected into the mold and then it retracts backward in the
molding step. Heating elements, placed over the barrel,
soften and melt the polymer.

The mold is equipped with a cooling system providing

controlled cooling and solidification of the material. The
polymer is held in the mold until solidification and then the
mold opens and the part is removed from the mold by ejector
pins.

6.1.7 PLASTIC PRODUCTS PROCESSES.

A. INJECTION MOULDING
Injection Molding is highly productive method providing
high accuracy and control of shape of the
manufactured parts. The method is profitable in
mass production of large number of identical parts.
Thermoplastics commonly used in Injection Molding are as follows:

Polypropylene (PP)

Polycarbonate (PC)

Nylon 6 (N6)
Injection Molding is used for manufacturing DVDs, pipe fittings, battery
casings, toothbrush bases, bottle lids, disposable razors, automobile
bumpers and dash boards, power-tool housing, television cabinets,
electrical switches, telephone handsets, automotive power brake,
automotive fascias, transmission, and electrical parts, mirror
housings, steam irons, washer pumps, spoilers, butter tubs, and
etc.

6.1 THE IMPORTANT USES

6.1.7
PLASTIC PRODUCTS PROCESSES.
OF PLASTIC

B. EXTRUSION MOULDING
Extrusion is a process of manufacturing long products
of constant cross-section (rods, sheets, pipes,
films, wire insulation coating) forcing soften
polymer through a die with an opening

6.1.7 PLASTIC PRODUCTS PROCESSES.

B. EXTRUSION MOULDING

Polymer material in form of pellets is fed into an

extruder through a hopper. The material is then
conveyed forward by a feeding screw and forced
through a die, converting to continuous polymer
product.

Heating elements, placed over the barrel, soften

and melt the polymer. The temperature of the
material is controlled by thermocouples. The
product going out of the die is cooled by blown air
or in water bath.

Extrusion produces items such as pipe/tubing,

weather stripping, fence, deck railing, window
frames, adhesive tape and wire insulation.

6.1 THE IMPORTANT USES

OF PLASTIC
PLASTIC
6.1.7
PRODUCTS PROCESSES.
C. COMPRESSION MOULDING

Compression Molding is a process in which a molding polymer is

squeezed into a preheated mold taking a shape of the mold
cavity and performing curing due to heat and pressure
applied to the material. The method is used mostly for
molding thermosetting resins (thermosets), but some
thermoplastic parts may also be produced by Compression
Molding. The method uses a split mold mounted in a
hydraulic press

6.1.7 PLASTIC PRODUCTS PROCESSES.

C. COMPRESSION MOULDING

A pre-weighed amount of a polymer mixed with additives and

fillers (charge) is placed into the lower half of the mold.
The charge may be in form of powders, pellets, putty-like
masses or pre-formed blanks.
The charge is usually preheated prior to placement into the
mold. Preheated polymer becomes softer resulting in
shortening the molding cycle time.
The upper half of the mold moves downwards, pressing on
the polymer charge and forcing it to fill the mold cavity.
The mold, equipped with a heating system, provides curing
(cross-linking) of the polymer (if thermoset is processed).
The mold is opened and the part is removed from it by
means of the ejector pin.
If thermosetting resin is molded, the mold may be open in
hot state cured thermosets maintain their shape and
dimensions even in hot state.
If thermoplastic is molded, the mold and the molded part are
cooled down before opening.

6.1.7 PLASTIC PRODUCTS PROCESSES.

C. COMPRESSION MOULDING
The method is suitable for molding large flat or moderately curved
parts.
Materials commonly processed by Compression Molding are:

Epoxies (EP)
Urea Formaldehyde (UF)
Melamine Formaldehyde (MF)
Phenolics (PF)

Compression Molding is used for manufacturing electrical wall

receptacles, brush and mirror handles, meter cases, trays,
circuit breakers, cookware knobs, clothes dryer blower fan
blade, electronic and cooking utensils, milling machine
adjustment wheel, automotive parts, water testing
equipment buttons, television cabinets, dinnerware,
appliance housings, radio cases, aircraft main power terminal
housing, hoods, pot handles, spoilers, electric plugs and

6.17 PLASTIC PRODUCTS

PROCESSES.
D.
BLOW MOULDING

Blow Molding is a process in which a heated hollow thermoplastic

tube (parison) is inflated into a closed mold conforming the
shape of the mold cavity.

6.1.7 PLASTIC PRODUCTS PROCESSES.

D. BLOW MOULDING
The production cycle consists of the following steps:

The parison is extruded vertically in downward

direction between two mold halves.
When the parison reaches the required length the
two mold halves close resulting in pinching the top
of parison end and sealing the blow pin in the
bottom of the parison end.
Parison is inflated by air blown through the blow
pin, taking a shape conforming that of the mold
cavity. The parison is then cut on the top.
The mold cools down, its halves open, and the final
part is removed

6.1.7 PLASTIC PRODUCTS PROCESSES.

D. BLOW MOULDING
The most widely used materials for Blow Molding are:

Low Density Polyethylene (LDPE), High Density Polyethylene

(HDPE)

Polypropylene (PP)

Polyvinyl Chloride (PVC)

Polyethylene Terephtalate (PET)

Disposable containers of various sizes and shapes, drums,
recyclable bottles, automotive fuel tanks, storage tanks,
globe light fixtures, toys, tubs, small boats are produced by
Blow Molding method.