Vishu Shah - Handbook of Plastics Testing and Failure Analysis

1 COVER

2 TITLE PAGE HANDBOOK OF PLASTICS TESTING AND FAILURE ANALYSIS FOURTH EDITION VISHU SHAH Consultek Diamond Bar, California

3 COPYRIGHT PAGE

4 PREFACE TO THE FOURTH EDITION

5 PREFACE TO THE THIRD EDITION

6 PREFACE TO THE SECOND EDITION

7 PREFACE TO THE FIRST EDITION

8 BIOGRAPHY OF VISHU SHAH

9 ABOUT THE COMPANION WEBSITE

10 1 BASIC CONCEPTS AND ADVANCEMENT IN TESTING TECHNOLOGY1.1. BASIC CONCEPTS 1.2. SPECIFICATION AND STANDARDS 1.3. PURPOSE OF SPECIFICATIONS 1.4. BASIC SPECIFICATION FORMAT 1.5. ADVANCEMENTS IN TESTING TECHNOLOGY 1.6. NEW DEVELOPMENTS AND TRENDS IN TESTING TECHNOLOGY REFERENCES

11 2 MECHANICAL PROPERTIES2.1. INTRODUCTION 2.2. TENSILE TESTS (ASTM D 638, ISO 527‐1) 2.3. FLEXURAL PROPERTIES (ASTM D 790, ISO 178) 2.4. COMPRESSIVE PROPERTIES (ASTM D 695, ISO 604) 2.5. CREEP PROPERTIES (ISO 899‐1, ISO 899‐2, ASTM D2990, ISO 16770) 2.6. STRESS RELAXATION 2.7. IMPACT PROPERTIES 2.8. SHEAR STRENGTH (ASTM D 732) 2.9. ABRASION 2.10. FATIGUE RESISTANCE 2.11. HARDNESS TESTS REFERENCES SUGGESTED READING

12 3 THERMAL PROPERTIES3.1. INTRODUCTION 3.2. TESTS FOR ELEVATED TEMPERATURE PERFORMANCE 3.3. THERMAL CONDUCTIVITY (ASTM C 177, ISO 8302) 3.4. THERMAL EXPANSION 3.5. BRITTLENESS TEMPERATURE (ASTM D 746, ISO 974) REFERENCES SUGGESTED READING

13 4 ELECTRICAL PROPERTIES4.1. INTRODUCTION 4.2. DIELECTRIC STRENGTH (ASTM D 149, IEC 243‐1) 4.3. DIELECTRIC CONSTANT AND DISSIPATION FACTOR (ASTM D 150, IEC 250) 4.4. ELECTRICAL RESISTANCE TESTS 4.5. ARC RESISTANCE (ASTM D 495) 4.6. UL REQUIREMENTS 4.7. EMI/RFI SHIELDING (10) REFERENCES SUGGESTED READING

14 5 WEATHERING PROPERTIES5.1. INTRODUCTION 5.2. ACCELERATED WEATHERING TESTS 5.3. OUTDOOR WEATHERING OF PLASTICS (ASTM D 1435, ISO‐877) 5.4. RESISTANCE OF PLASTIC MATERIALS TO FUNGI (ASTM G 21) 5.5. RESISTANCE OF PLASTIC MATERIALS TO BACTERIA (ASTM G 22) 5.6. LIMITATIONS OF ACCELERATED MICROBIAL GROWTH RESISTANCE TESTING 5.7. OUTDOOR EXPOSURE TEST FOR STUDYING THE RESISTANCE OF PLASTIC MATERIALS TO FUNGI AND BACTERIA AND ITS LIMITATIONS REFERENCES SUGGESTED READING

15 6 OPTICAL PROPERTIES6.1. INTRODUCTION 6.2. REFRACTIVE INDEX (ASTM D 542, ISO 489) 6.3. LUMINOUS TRANSMITTANCE AND HAZE (ASTM D 1003) 6.4. PHOTOELASTIC PROPERTIES 6.5. COLOR 6.6. SPECULAR GLOSS (ASTM D2457, D523) REFERENCES SUGGESTED READING

16 7 MATERIAL CHARACTERIZATION TESTS7.1. INTRODUCTION 7.2. MELT INDEX TEST (ASTM D 1238, ISO 1133) 7.3. RHEOLOGY 7.4. VISCOSITY TESTS 7.5. GEL PERMEATION CHROMATOGRAPHY 7.6. THERMAL ANALYSIS TECHNIQUES 7.7. SPECTROSCOPY 7.8. MATERIAL CHARACTERIZATION TESTS FOR THERMOSETS REFERENCES GENERAL REFERENCES SUGGESTED READING

17 8 FLAMMABILITY8.1. INTRODUCTION 8.2. FLAMMABILITY TEST (NONRIGID SOLID PLASTICS) (ASTM D 4804) 8.3. FLAMMABILITY TEST (SELF‐SUPPORTING PLASTICS IN HORIZONTAL POSITION) (D 635) 8.4. FLAMMABILITY TEST (SOLID PLASTICS IN VERTICAL POSITION) (D 3801) 8.5. IGNITION PROPERTIES OF PLASTICS 8.6. OXYGEN INDEX TEST (ASTM D 2863, ISO 4589) 8.7. SURFACE BURNING CHARACTERISTICS OF MATERIALS 8.8. FLAMMABILITY OF CELLULAR PLASTICS—VERTICAL POSITION (ASTM D 3014) 8.9. FLAMMABILITY OF CELLULAR PLASTICS—HORIZONTAL POSITION (ASTM D 1692) 8.10. FLAME RESISTANCE OF DIFFICULT‐TO‐IGNITE PLASTICS (FEDERAL STD. NO 406 METHOD 203) 8.11. SMOKE GENERATION TESTS 8.12. UL 94 FLAMMABILITY TESTING 8.13. MEETING FLAMMABILITY REQUIREMENTS REFERENCES SUGGESTED READING

18 9 CHEMICAL PROPERTIES9.1. INTRODUCTION 9.2. IMMERSION TEST (ASTM D 543, ISO 22088) 9.3. STAIN RESISTANCE OF PLASTICS 9.4. SOLVENT STRESS‐CRACKING RESISTANCE 9.5. ENVIRONMENTAL STRESS‐CRACKING RESISTANCE (ASTM D 1693, ISO 22088) REFERENCES

19 10 ANALYTICAL TESTS10.1. INTRODUCTION 10.2. DENSITY AND SPECIFIC GRAVITY (ASTM D 792, ISO 1183) 10.3. DENSITY‐BY‐DENSITY GRADIENT TECHNIQUE (ASTM D 1505, ISO R 1183‐2) 10.4. BULK (APPARENT) DENSITY TEST (ASTM D 1895) 10.5. WATER ABSORPTION (ASTM D 570, ISO 62) 10.6. MOISTURE ANALYSIS 10.7. SIEVE ANALYSIS (PARTICLE SIZE) TEST (ASTM D 1921) REFERENCES

20 11 CONDITIONING PROCEDURES11.1. CONDITIONING (ASTM D 618, ISO 291) 11.2. DESIGNATION FOR CONDITIONING REFERENCES SUGGESTED READING

21 12 MISCELLANEOUS TESTS 12.1. TORQUE RHEOMETER TEST (ASTM D 2538) 12.2. PLASTICIZER ABSORPTION TESTS 12.3. CUP VISCOSITY TEST 12.4. BURST STRENGTH TEST 12.5. CRUSH TEST 12.6. ACETONE IMMERSION TEST (ASTM D 2152) 12.7. ACETIC ACID IMMERSION TEST (ASTM D 1939) 12.8. END‐PRODUCT TESTING 12.9. ASH CONTENT (ASTM D 5630, ASTM D 2584, ISO 3451) REFERENCES GENERAL REFERENCES

22 13 IDENTIFICATION ANALYSIS OF PLASTIC MATERIALS13.1 INTRODUCTION 13.2. ADVANCED METHODS FOR IDENTIFICATION 13.3. IDENTIFICATION OF PLASTIC MATERIALS REFERENCES GENERAL REFERENCES

23 14 TESTING OF CELLULAR PLASTICS14.1. INTRODUCTION 14.2. RIGID FOAM TEST METHODS 14.3. FLEXIBLE CELLULAR MATERIALS TEST METHODS 14.4. FOAM PROPERTIES GENERAL REFERENCES

24 15 FAILURE ANALYSIS15.1. INTRODUCTION 15.2. TYPES OF FAILURES 15.3. ANALYZING FAILURES 15.4. CASE STUDIES REFERENCES GENERAL REFERENCES

25 16 QUALITY CONTROL16.1. INTRODUCTION 16.2. STATISTICAL QUALITY CONTROL 16.3. INTRODUCTION TO STATISTICAL PROCESS CONTROL 16.4. QUALITY CONTROL SYSTEM 16.5. GENERAL 16.6. SUPPLIER CERTIFICATION REFERENCES GENERAL REFERENCES

26 17 PRODUCT LIABILITIES AND TESTING17.1. INTRODUCTION 17.2. PRODUCT/EQUIPMENT DESIGN CONSIDERATIONS 17.3. PACKAGING CONSIDERATIONS 17.4. INSTRUCTIONS, WARNING LABELS, AND TRAINING 17.5. TESTING AND RECORDKEEPING 17.6. SAFETY STANDARDS ORGANIZATIONS REFERENCES SUGGESTED READING

27 18 NONDESTRUCTIVE TESTING AND MEASUREMENTS18.1. INTRODUCTION 18.2. ULTRASONIC 18.3. APPLICATION OF ULTRASONIC NDT IN PLASTICS 18.4. GAMMA BACKSCATTER 18.5. BETA TRANSMISSION 18.6. SCANNING LASER 18.7. X‐RAY FLUORESCENCE 18.8. HALL EFFECT 18.9. CT SCANNING (X‐RAY COMPUTED TOMOGRAPHY) REFERENCES SUGGESTED READING GENERAL REFERENCES

28 19 PROFESSIONAL AND TESTING ORGANIZATIONS19.1. AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI) 19.2. ASTM INTERNATIONAL 19.3. FOOD AND DRUG ADMINISTRATION (FDA) 19.4. NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY (NIST) 19.5. NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA) 19.6. NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) 19.7. NATIONAL SANITATION FOUNDATION (NSF) 19.8. SOCIETY OF PLASTICS ENGINEERS (SPE) 19.9. PLASTICS INDUSTRY ASSOCIATION 19.10. UNDERWRITERS LABORATORIES (UL) 19.11. INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

29 20 UNIFORM GLOBAL TESTING STANDARDS20.1. INTRODUCTION 20.2. ISO/IEC STANDARDS 20.3. ISO AND ASTM 20.4. TEST DATA ACQUISITION AND REPORTING 20.5. COMPUTER‐AIDED MATERIAL PRESELECTION BY UNIFORM STANDARDS (CAMPUS) 20.6. PLASTIC MATERIAL DATABASES REFERENCES

30 APPENDIX A: INDEX OF TEST EQUIPMENT MANUFACTURERS ALPHABETICAL INDEX OF COMPANIES ADDRESSES, PHONE NUMBERS, AND WEBSITES

31 APPENDIX B: ABBREVIATIONS: POLYMERIC MATERIALS

32 APPENDIX C: GLOSSARY

33 APPENDIX D: TRADE NAMES*

34 APPENDIX E: STANDARDS ORGANIZATIONS

35 APPENDIX F: LINKS TO RECOMMENDED OPEN SOURCE FOR QUICK LEARNING

36 APPENDIX G: WEB RESOURCES

37 APPENDIX H: FIGURE 15‐5. NEW APPLICATION CHECKLIST (Courtesy of Covestro)

38 INDEX

39 END USER LICENSE AGREEMENT

1 Chapter 1 TABLE 1‐1. POM Polyoxymethylene (Acetal) Materials, Detail Requirements, hNatural ...

2 Chapter 2 TABLE 2‐1. Characteristic Features of Stress–Strain Curve as It Relates to Po... TABLE 2‐2. Creep Property Data of a Commercially Available Plastic MaterialTABLE 2‐3. Typical Hardness Values of Some Common Plastic Materials

3 Chapter 3TABLE 3‐1. Relative thermal indices based upon past field‐test performance an...TABLE 3‐2. Thermal Conductivity of Different Materials Including Solid and Ce...TABLE 3‐3. Comparison to Thermal Expansion Values for Some Common Materials