AutoDynamic Technologies and Solutions

Polymer Mechanical & Other Testing

By
Swapnil Ahire&
Team
Introduction
Testing of Polymeric material
Determination of technological & operational
properties of materials primarily by use of
machines & instruments.
Testing shows whether a material/part is suitable
for its intended application or not.
Purpose of testing
Purpose of
Testing

Finished
Properties of In process To Aid
Products
RM Inspection Research
Quality
Testing Standard

Test Method , Environmental conditions.

Specimen type & dimensions
Repetition of test result
ASTM-American Society for Testing of
materials
ISO-International Organization for
Standardization
DIN-Deutsches institute Fur Normung
OEM standards, Automotive standards.
Mechanical testing
Type of property to be determined
1)Tensile Properties 5) Tear Properties
I. Tensile Strength I. Tear Strength
II. Elongation
2) Flexural Properties 6) Flammability
III. Flexural Modulus
IV. Flexural Strength 7) Fogging
3) Impact Properties
I. Izod & Charpy 8) Chemical Resistance
II. Gardner
III. Multi-axial Impact 9) Sample preparation
4) Hardness
IV. Shore A & Shore D
V. IRHD
5) Thermo-Mechanical Properties
I. HDT
II. VICAT
UTM-Universal Testing machine

Universal (Versatile) can perform many standard tensile &

compression tests
Tensile properties: Compressive properties:
1) Tensile strength @ yield & 1) Load Vs deflection
break
2) Elongation @ yield & break
2) Stiffness
3) Tensile Modulus
Other properties:
4) Modulus @ different elongation
1) Adhesion Testing
Flexural properties: 2) Creep test
1)Flexural Modulus 3) Shear strength test
2)Flexural Strength 4) Tear resistance & tear strength
test
UTM-Universal Testing machine

Main Components of UTM

1. Load Frame/columns
2. Load cell
3. Cross head
4. Extensometer
5. Output device
6. Conditioning
Tensile Properties
Tensile strength: Maximum tensile stress sustained by a
test piece during tension test or ultimate strength of
material subjected to tensile loading./Measurement of the
ability of material to withstand forces that tends to pull it
apart & to what extent the material stretches before
breaking .
Tensile Test
1. Tensile strength @ yield
2. Tensile strength @ break
3. Elongation @yield
4. Elongation @ break
5. Tensile Modulus (Young's Modulus/Modulus of elasticity)
6. Resilience
7. Toughness
 Tensile Properties
Stress (load) & Strain (elongation/change in
dimension) recorded
Strain ()

Stress

% Elongation
@ yield/break *100

Tensile
Strength @ yield

Tensile
Strength @ break

Tensile
Modulus
Tensile Properties-Actual
results
Tensile Properties-Actual
results
Tensile Properties -Standards

Standard
1. ASTM D 638 : Standard Test Method for Tensile
Properties of Plastics
2. ASTM D 5083 : Standard Test Method for Tensile
Properties of Reinforced Thermosetting Plastics Using
Straight-Sided Specimens
3. ASTM D 882 : Standard Test Method for Tensile
Properties of Thin Plastic Sheeting
4. ASTM D 412 : Standard Test Methods for Vulcanized
Rubber and Thermoplastic ElastomersTension
5. ASTM D 3039/D3039 M : Standard Test Method for
Tensile Properties of Polymer Matrix Composite
Materials
Tensile properties

Significance
1.Strength of Material
2.Material Selection
3.Product designing
4.Quality control tool
5.RM inspection tool
6.Research & development- Effect of
additives
7.Data for design software
Flexural Properties

The flexural test measures the force required

to bend a beam under three point loading
conditions.
 Flexural Properties

Flexural
Flexural Strength: Strength P=Load at given point
L=Support span length
B= width of specimen
d= depth of beam
Flexural Properties
Significance
1.Strength of Material
2.Material Selection
3.Product designing
4.Research & development- Effect of additives

Standards
1. ASTM D 790 : Standard Test Methods for Flexural Properties of
Unreinforced and Reinforced Plastics and Electrical Insulating
Materials
2. ISO 178 : Plastics -- Determination of flexural properties
Flexural Properties-Actual
results
Flexural Properties-Actual
results
Poisson's Ratio
Ratio of transverse contraction strain to longitudinal extension strain in the
direction of stretching force.
Tensile deformation is considered positive and compressive deformation is
considered negative.
Materials ability to withstand tensile & compressive forces

Poisson's
ratio
Tear Strength

Force per unit thickness required to rupture, initiate, or

propagate a tear through a sheet of rubber in the form of one of
several test piece geometries
Rubber , plastic films.
A tearing strain (and stress) is applied to a test specimen by
means of a tensile testing machine operated without interruption
at a constant rate of crosshead traverse until the specimen is
completely torn.

Tear strength

Standards
1. ASTM D 624 :Standard Test Method for Tear Strength of Conventional
Vulcanized Rubber and Thermoplastic Elastomers
Tear Strength-ASTM D 624

The maximum force required to tear a test specimen is used to calculate

the tear strength of the Die A, B, and C specimens while the mean force is
 Impact Properties
Ability of a material to absorb applied energy.
Ability to resist the fracture under shock loading
or ability of materials to resist the fracture under
stress applied at high speed.
Significance -
Quick and easy quality control check to determine
if a material meets specific impact properties or to
compare materials for general toughness. Higher
the impact energy, the higher is the toughness.
Impact Test

Type of Impact Test-

1. Izod Impact Notch & Un-notched
2. Charpy Impact Notch & Un-notched
3. Multi-axial Impact Test
4. Gardner Impact Test
Izod & Charpy Impact
Difference Between Izod &
Charpy Impact
Izod Impact Charpy Impact
Sr. No. Parameters
ASTM D 256 ISO 180 ASTM D6110 ISO 179-1
Specimen
63.5 2.0 12.7 802 100.2 127 12.70 0.15 802 100.2
1 dimensions in
0.2 3 to 12.7 40.2 3 to 12.7 40.2
(mm)

Notch Type Radius of notch Base

-- 0.25 0.05 mm - 0.25 0.05 mm -

2 Type -A - (0.25 + 0.05)mm - (0.25 + 0.05)mm
Type -B - (1.00 + 0.05)mm - (1.00 + 0.05)mm
Type-C - - - (0.10+0.02)mm

5 Angle 45 1 45 1 45 1 45 1
Notch face is Notch face is
Direction of Notch face is Notch face is facing
3 positioned away positioned away from
Notch facing the striker the striker
from the striker the striker
Sample Sample placed in Sample placed in a Sample placed Sample placed
4
Position a vertical position vertical position horizontally horizontally
Hammer strike at Hammer strike at Hammer strike at Hammer strike at
6 Point Of Strike the upper tip of the upper tip of point of notch but in point of notch but in
specimen specimen opposite direction opposite direction
7 Hammer Type Farming hammer Farming hammer Ball Pin hammer Ball Pin hammer
Measurement
8 J/m J/m Or kJ/m2
Unit kJ/m2 kJ/m2
Gardner Impact

Falling dart impact is a traditional method

for evaluating the impact strength or
toughness of a plastic material.
Significance: The test is often used to
specify appropriate materials for
applications involving impact or to
evaluate the effect of secondary finishing
operations or other environmental factors
on plastic impact properties.
Gardner Impact
Test Procedure:
The test sample rests on a base plate over an opening of
specified diameter.
An "impactor" sits on top of the test sample with a nose of
specified radius in contact with the center of the test sample.
A weight is raised inside a guide tube to a predetermined
height, then released to drop onto the top of the impactor,
forcing the nose through the test sample
The drop height, drop weight, and the test result (pass / fail)
are recorded
The most common method to analyze this data is called the
"Bruceton Staircase" method.
A number of samples are used to bracket the pass/fail energy
level. Then a series of 20 impacts are conducted. If a test
sample passes, the drop height is increased by one unit. If a
test sample fails, the drop height is decreased by one unit.
The results from the 20 impacts are used to calculate the
Mean Failure Height the point at which 50% of the test
samples will fail under the impact.
Specimen size:
For optimum results using the staircase method, a minimum of 30 test samples are necessary.
Any flat specimens can be tested - the preferred test sample is a 100mm (4") disk or plaque.
Data:
Mean Failure Height in cm (inches)
Mean Failure Energy in kg-cm (in-lb)
Multiaxial Impact/High speed
Puncture Property

The High Speed Impact test is

used to determine toughness.
This test method provides a
measure of the rate sensitivity
of the material to impact.

Significance:-
This test method designed to
provide load vs deformation
response of plastic under
essentially multiaxial
deformation conditions at
impact velocities
 Test Procedure:

Clamp the Specimen between the

plates of the specimen holder,
taking care to center the specimen
for uniform gripping.
Set the speed to desired value (2.5,
25, 125, 200 & 250 m/min.)
Using the load versus
displacement trace and appropriate
scaling factors, calculate peak load
in N, deflection in mm
 Multiaxial Impact-Actual Results

PP 20 % talc filled compound

PP 20 % talc filled
compound
Multiaxial impact test-Type of
fracture

Tested at room temperature Tested at -300C

Impact Properties- Standards

Standards:

1.ASTM D 256:10e1 - Standard test methods for determining the Izod pendulum
impact resistance of plastics.
2.ASTM D 6110:10-Standard Test Method for Determining the Charpy Impact
Resistance of Notched Specimens of Plastics
3.ASTM D 1822:13 - Standard Test Method for Tensile-Impact Energy to Break
Plastics and Electrical Insulating Materials
4.ASTM D 5420: - Standard Test Method for Impact Resistance of Flat, Rigid Plastic
Specimen by Means of a Striker Impacted by a Falling Weight (Gardner Impact)
5.ASTM D 1709:16a - Standard Test Methods for Impact Resistance of Plastic Film
by the Free-Falling Dart Method
6.ASTM D 2444:10 - Standard Test Method for Determination of the Impact
Resistance of Thermoplastic Pipe and Fittings by Means of a Tup (Falling Weight)
7.ISO 180:10 - Plastics -- Determination of Izod impact strength
8.ISO 179:10 - Plastics -- Determination of Charpy impact properties -- Part 1:
Non-instrumented impact test
Hardness-Shore

Hardness: Resistance to Indentation

Shore A hardness
Shore D hardness
Hardness-IRHD
International Rubber Hardness degree
Measuring the difference between the depths of indentation of a
ball into a rubber surface under a small initial contact force
followed by a large total test force.
Four Types
Indenter Additional
Contact force Total force
Test method diameter force Application
N N
mm N
Thickness>=4
mm
N Range: 35IRHD
2,50 0,01 0,30 0,02 5,40 0,01 5,70 0,03
(normal test) - 85IRHD
or 30IRHD -
95IRHD
Thickness>=4
H
mm
(high 1,00 0,01 0,30 0,02 5,40 0,01 5,70 0,03
Range: 85IRHD
hardness)
- 100IRHD
Thickness>=6
L
mm
(low 5,00 0,01 0,30 0,02 5,40 0,01 5,70 0,03
Range: 10IRHD
hardness)
- 35IRHD
Thickness<4m
m
Hardness-IRHD
Thermal Properties
1) HDT:
Temperature at which a standard test bar deflects
a specified distance under a specified load.
Significance -
The deflection temperature test results are a
useful measure of relative service temperature
for a polymer when used in load-bearing parts.
HDT is a short-term test and should not be used
alone for product design. Other factors such as
the time of exposure to elevated temperature,
the rate of temperature increase, and the part
geometry all affect the performance.
Does not represent the upper temperature limit
Heat Deflection Temperature
Heat Deflection Temperature

For HDT Test - ASTM D 648 & ISO 75 1

&
Sr. 2
No. Parameters
HDT
ASTM ISO
1 Specimen dimensions 127*13*3mm 80*10*4 mm

0.455 MPa, 0.450 MPa,

2 Stress
1.82 MPa 1.8 MPa

3 Temperature Rate 2 0.2C/min 120 10C

Liquid Paraffin,
Liquid Paraffin,
transformer oil,
4 Heating Medium
glycerol and silicon
transformer oil,
glycerol and silicon oil
oil
Start Temperature
5 Temp.
27C 27C

6 Deflection 0.25 mm 0.35 mm

7 Span 100 mm 64 mm
Heat Deflection Temperature-
Values
Vicat Softening Temperature

1) VST: ASTM D 1525 & ISO 306

The Vicat softening temperature is the temperature at

which a flat-ended needle penetrates the specimen to the
depth of 1 mm under a specified load using a selected
uniform rate of temperature.
The temperature reflects the point of softening to be
expected when a material is used in an elevated
temperature application.

Test Methods
A 50 Force 10 N & Heating Rate 50 C
B 50 - Force 50 N & Heating Rate 50 C
A 120 - Force 10 N & Heating Rate 120 C
B 120 - Force 50 N & Heating Rate 120 C
Vicat Softening Temperature

For VST Test - ASTM D 1525 & ISO 306

VSP
Sr. No. Parameters
ASTM ISO

Specimen 3 mm to 6.5 mm thick & 10 3 mm to 6.5 mm thick & 10

1
dimensions mm square or 10 mm dia. mm square or 10 mm dia.

a)Method A50 & A120 = 10 a)Method A50 & A120 =

0.2 N, b) Method 10 0.2 N,
2 Stress
B50 & B120 = 50 1 N , b) Method B50 & B120 =
50 1 N ,
50 5C/hr 50 5C/hr
3 Temperature Rate
120 10C/hr 120 10C/hr

Liquid Paraffin, Transformer oil, Liquid Paraffin Transformer

4 Heating Medium
glycerol and silicon oil oil, glycerol and silicon oil

5 Start Temperature 25C 25C

6 Deflection 1 mm 1 mm
HDT & VSP Difference
Vicat Softening
Temperature
Significance-
Ranks the thermal performance of plastics
according to the temperature that causes
a specified penetration by a lightly loaded
probe
Used as a general indicator of short term,
high temperature performance
Less sensitive to sample thickness and
molding effects
Test Standards HDT & VST

Standards
ASTM D 648:16 - Standard Test Method for
Deflection Temperature of Plastics Under Flexural
Load in the Edgewise Position
ISO 75-1 & 2:13 - Plastics Determination of
temperature of deflection under load Part1:
General test method & Part 2
ASTM D 1525:09- Standard Test Method for Vicat
Softening Temperature of Plastics
ISO 306:13 - Plastics Thermoplastic materials
Determination of Vicat softening temperature
(VST)
Flammability

Most Plastics are carbon based materials & will burn

and give off gases and smokes when subjected to
flame.
Plastics degrade at high temperatures into volatile
and gaseous combustion products.
Flammability test
1. UL 94
2. Limiting Oxygen Index(LOI)
3. Rate of burning(ROB)
4. Smoke density
 Flammability Testing -UL94 Standard

L 94- Underwriters Laboratory 94

Method of classifying a materials tendency to either

extinguish or spread a flame once it has been ignited
Type of tests
1) Horizontal burning (HB)
2) Vertical burning (V0, V1, V2)
3) 500 w Vertical Burning test (5VA, 5VB)
4) Thin Material vertical burning (VTM-0, VTM-1,VTM-2)
5) Radiant panel flame spread test
6) Horizontal burning foamed material test (HBF,HF-1, HF-2)
 UL94-Horizontal Burning

Test
variesSpecimen : Length-125 5 mm, width-13 0.5 mm, thickness
from 3 to 13 mm
Test Condition:
Flame application 20 mm high burner flame
Flame application time 30 s

If the flame front reaches the first mark within 30 s, flame application is discontinued.

Rate of Burning (V)

L= damaged length
t= time to burn

Test criteria Burning rate V Flammability

rating

Test specimen thickness 3-13 mm 40 mm/min HB

Test specimen thickness 3 mm 75 mm/min HB

Flame is extinguished before first

=0 mm/min HB
mark
Limiting Oxygen
Index(LOI)
Definition-
Thelimiting oxygen index (LOI)is the minimum concentration
ofoxygen, expressed as a percentage, that will supportcombustionof
apolymer. It is measured by passing a mixture of oxygen
andnitrogenover a burning specimen, and reducing the oxygen level
until a critical level is reached.
Significance
Limiting Oxygen Index Testing (LOI), is a very widely used method for
determining the relative flammability of polymeric materials.
Describes the tendency of a material to sustain a flame, is widely used
as a tool to investigate the flammability of polymers.
Standard:
ASTM D 2863: Standard Test Method for Measuring the Minimum
Oxygen Concentration to Support Candle-Like Combustion of Plastics
(Oxygen Index)
ISO 4589:Plastics -- Determination of burning behavior by oxygen
index -- Part 3: Elevated-temperature test
 Limiting Oxygen
Index(LOI)
Test specimen:
Limiting Oxygen
Index(LOI)
The result is usually expressed as:
LOI values of different material
Flammability Testing Standards

Standards:
ASTM D 635:Standard Test Method for Rate of Burning and/or
Extent and Time of Burning of Plastics in a Horizontal Position.
ASTM D 3801:Standard Test Method for Measuring the Comparative
Burning Characteristics of Solid Plastics in a Vertical Position.
ASTM D 4804:Standard Test Method for Determining the
Flammability Characteristics of Non rigid Solid Plastics.
ISO 1210:Plastics -- Determination of the burning behavior of
horizontal and vertical specimens in contact with a small-flame
ignition source
ISO 9773: Plastics -- Determination of burning behavior of thin
flexible vertical specimens in contact with a small-flame ignition
source
ISO 10351:Plastics -- Determination of the combustibility of
specimens using a 125 mm flame source
ISO/DIS 9772.3:Cellular plastics -- Determination of horizontal
burning characteristics of small specimens subjected to a small
flame
Fogging
What is fog Testing ?
Fogging

Significance: The purpose of the testing is to

assist material manufactures & the companies
that uses their products in identifying &
developing products that outgas VOC at reduced
rate.
Fogging Methods
Photometric Method
The test sample is placed in a sealed beaker -
the inside surface of the cooled beaker cover is
glass.
The bottom of the beaker is placed in a
controlled temperature oil bath for a specified
period of time - typically 3 hours.
For the photometric method, gloss readings of
the glass cover before the test and after
conditioning following the test are compared.
Fogging Methods
Gravimetric Method
The test sample is placed in a sealed beaker
- the inside surface of the cooled beaker
cover is aluminum foil.
The bottom of the beaker is placed in a
controlled temperature oil bath for a
specified period of time - typically 16 hours.
weights of the test sample and the
aluminum foil before the test and
immediately after the test are compared.
Fogging Standards
Chemical Resistance
Ability of plastic materials to resist the action towards
various chemicals.
Significance: Basis for standardization and serve as a guide
to compare the relative resistance of various polymers to
typical reagents and selection of plastics materials for
specific applications.
Standard Specimen
Product/part level testing
Subjecting the specimen/part to specific condition-immersion
of specimen in chemical for specific time at specified
temperature
Checking various properties after exposure:
-Surface appearance
-Change in weight
-Change in dimension
-Change in geometry
Chemical Resistance
Resistance to fuel/chemicals-Automotive parts
Petrol Diesel break fluid clutch fluid
Rubbing the specimen/part with by cotton wet with the fluid
10 times
Observe the part for surface appearance /any residue left
on cotton
Resistance to fuel/oil-Rubber hose
ASTM reference oils
Rubber hoses immersed in oils having different composition
for specified time & temperature
Different properties observed after exposure
- Swelling
- Change in geometry/dimension : shape distortion
- Mechanical properties : Hardness , Tensile strength ,
Elongation
Chemical resistance

Standards
ASTM D 543: Standard Practices for Evaluating the
Resistance of Plastics to Chemical Reagents.
ASTM D 4398: Standard Test Method for Determining the
Chemical Resistance of Fiberglass-Reinforced Thermosetting
Resins by One-Side Panel Exposure.
ASTM D 1239: Standard Test Method for Resistance of
Plastic Films to Extraction by Chemicals.
ASTM C 581: Standard Practice for Determining Chemical
Resistance of Thermosetting Resins Used in Glass-Fiber-
Reinforced Structures Intended for Liquid Service
OEM Standards
Sample Preparation

Operational requirement of characterizing

materials by means of different testing
method.
Integral part for accurate analysis &
interpretation of results.
Techniques
1) Molding/Casting
2) Machining/cutting
3) Part testing
Sample Preparation

Factors affecting- Test results

1. Specimen geometry
2. Thermal & shear history
3. Polymer chain orientation/crystallinity/
morphology
4. Residual stresses
5. Machining/ cutting methods
6. Conditioning
Sample preparation
Methods
Thermoplastics
1. Injection Molding
-Most common method
-highly oriented, good surface finish, dimensional accuracy
.Factors affecting
-Process Temperature : degradation/incomplete melting
-Injection Pressure : material packing
-Mold temperature : crystallization behavior
2. Compression Molding
-Isotropic : equal properties in all direction
Factors affecting
-Molding temperature & time
-Mold design: cooling & surface finish
-Packing pressure : flow &cooling inconsistency
Sample preparation Methods

Thermosetting
1. Compression Molding
2. Transfer Molding

Rubber/Elastomer
1. Compression Molding
-Punching/ cutting specimen

Part/Product testing
-Parts/finished product
-Cutting/ punching , finishing
Sample Preparation-Standards

Standards
1.ISO 294 : Plastics - Injection molding of test specimens of
thermoplastic materials
2.ASTM D 3641 : Standard Practice for Injection Molding Test
Specimens of Thermoplastic Molding and Extrusion Materials
3.ASTM D 4703 :Standard Practice for Compression Molding
Thermoplastic Materials into Test Specimens, Plaques, or
Sheets
4.ASTM 618 : Standard Practice for Conditioning Plastics for
Testing
5.ISO 291: Plastics -- Standard atmospheres for conditioning and
testing
6. Processing/Molding standard for each material
available.
Sample Preparation-Standards
content

Raw material pretreatment

-RM physical form
-Pre-drying
Processing conditions
-Melt temperature
-Mold temperature
-Hold pressure /back pressure/ injection pressure
-Cycle time (Cooling time/curing time)
Specimen dimension
Cutting or punching method
-Punch dimensions
Mold dimension
-no. of cavities
-Cavity configuration
Conditioning of specimen
-Storage condition
-Temperature & humidity
Sample Preparation Standard-
Polypropylene