Plastics Testing Solutions
Plastics Testing Solutions
Introduction 3
Life Cycle of Plastics From Raw Material to Finished Component
p6 p10 p14
A successful plastic product starts with choosing of plastic materials are filled with data obtained In this section, you will see examples of challenges
suitable raw materials and by setting up a controlled by basic tests like melt flow rate, impact resistance offered by the QC and R&D world of raw material
supply chain. Given a certain application, should (resilience), softening point, and tensile properties. testing on plastics and composites, and our solutions
a commodity polyethylene be used or some When new products are developed, new based on the range of Instron® products.
engineered polymer? What will be the right matrix formulations are tested and you need to check if the
for a composite? Are you equipped to assess the material can be processed easily, and determine the
consistency of lots by one or more suppliers, and mechanical and thermal properties. Research and
to predict and monitor critical aspects related to Development (R&D) requires a deeper insight based
storage, processing, and final properties? Testing on the same types of tests routinely carried out for
the flow properties of the granulated material, QC, but with a more versatile approach, a bigger
and preparing standard specimens for further amount of data collected and processed, and more
mechanical and thermal tests, is the basis for sophisticated instrumentation to control the test.
Quality Control. The ‘ID cards’ or data sheets
Applicable Standards
ISO 1133, ISO 11443, ASTM D1238, ASTM D3835
Applicable Standards
ISO 75, ISO 306, ASTM D648, ASTM D1525
Even though a portfolio of materials and a of tests are required to sample the material at the In this section, you will see challenges in the field
processing technology is selected, engineers different stages of the process. Pre-series finished of process optimization and the tools offered by
and technicians in the plastics industry still products obtained from the process are also tested. our products to give adequate solutions. Our goal
face big challenges. When they optimize a process Several processing parameters are consequently is to support the job of qualified technicians and
they make it faster, cheaper, more accurate,more chosen and adjusted. Today, everyone wants to engineers of the plastics industry and related
productive, and consistent with time. They need to avoid running trial sessions with the real processing testing laboratories.
handle known limitations of each process, including machines, which wastes energy, materials, and
the onset of thermal degradation. The properties manpower. Simulations can run via software, but
and quality of finished products are greatly affected. a reliable and comprehensive set of material data
To achieve the desired improvements, a better is required, which can be obtained due to suitable
knowledge of the behavior of materials under testing instruments.
processing conditions is needed, and a series
Evaluation of Thermal
Degradation During Processing
One of the most common concerns over plastics
processing is the degradation of the material
caused by heat. This results in different chemical
and structural properties, and eventually lower
mechanical and physical properties of the final
product. Higher temperatures are often sought
when looking for increased productivity, but
suitable dwelling times must be determined,
and the effects on the material must be studied
in detail.
Applicable Standards
ISO 1133, ISO 11443, ASTM D1238, ASTM D3835
Applicable Standards
ISO 6603-2, ASTM D3763, Industry/Customer Specific
12 Process Optimization Testing
The Challenge Our Solution
Applicable Standards
ISO 11443, ASTM D3835
Evaluating the mechanical properties of plastics evaluations of new materials and to ensure material specific standards. Some of the tests may include
is important to material engineers, designers, performance doesn’t change during production or tensile, compression, flexural, fatigue, impact,
processing groups, and others within organizations over time. Instron® offers a variety of testing systems hardness, and more.
that deal with plastics products. Mechanical for evaluating these properties, some of which In this section, you will see examples of challenges
properties, among other properties, are used include universal, impact, dynamic fatigue, and related to determination of various mechanical
for characterizing plastics and creating material hardness testing systems. These systems are used properties and our solutions based on the range
specifications for different types of products. to test plastics to international standards, such as of Instron products available.
They are important in R&D and QC during the ASTM D638, as well as, other national and customer
14 Mechanical Properties
The Challenge Our Solution
For most plastics, we recommend using a biaxial, high-resolution extensometer that measures both
axial and transverse strain simultaneously. It is important to ensure that the appropriate grips and test
methods are utilized. Pneumatic side-acting grips are preferred since they are self-aligning and permit
adjustable clamping pressures. This allows for consistent clamping forces from one specimen to the
next. Wedge style grips may work as well, but be cautious of moving jaw face wedge grips as opposed
to moving wedge body grips. With moving jaw face style grips, specimens are susceptible to significant
compressive loads prior to the start of the test. Compressive loads may cause the material to bow and
in some cases even yield; both of which could impact the accuracy of the results.
Setting up an appropriate test method is also critical for achieving accurate and repeatable results.
Studies have shown that a “preload” can improve repeatability of results by removing compressive
loads applied during gripping and allow each test to begin at the same positive load or stress values.
The preload value should be high enough that it will straighten a specimen without stretching it.
Applicable Standards
ISO 527-1,-2, ASTM D638, JIS K7162
Mechanical Properties 15
The Challenge Our Solution
There are several extensometer options available, some more suitable for particular situations than
others. In the case of ASTM D638, the AutoX750 Automatic Contacting Extensometer, the Advanced
Video Extensometer 2 (AVE 2), and some static clip-on extensometers are all acceptable solutions.
When it is desired to measure strain to failure with an extensometer, the extensometer suitability is
dependent on the amount of travel it can accommodate. Clip-on style extensometers have limited
travel, usually 50%, when used to measure modulus, making them more suitable for rigid or filled
plastics. The AutoX750 and AVE 2 can accommodate far more travel and are appropriate for semi-rigid,
rigid as well as even elastomers. For ISO 527-2, we recommend the AutoX750, AVE 2, or some static
clip-on extensometers. Similar to ASTM D638, if it desired to measure strain through failure with the
extensoemter, the device must be able to accommodate the particular material being tested.
Applicable Standards
ISO 527-1,-2, ASTM D638, JIS K7162
16 Mechanical Properties
The Challenge Our Solution
Applicable Standards
ISO 527-3, ASTM D882, JIS K7127
Mechanical Properties 17
The Challenge Our Solution
and System Compliance systems are extremely stiff and offer significantly
less frame compliance when compared to most
When conducting compression testing to ASTM D695,
other testing systems.
it is important to understand how system compliance
and stiffness can impact results. Stiffness may vary Stiffer testing frames will reduce system compliance,
considerably for the different frame capacities, as but for overall compliance, it is important to consider
well as between manufacturers. When significantly grips, fixtures, and adaptors. The most effective means
high forces are expected, systems with inadequate of eliminating the affect of compliance on test results
frame stiffness are susceptible to absorbing energy is by using a strain measuring device, such as an
from a specimen during testing and transferring it back extensometer, which attaches directly to the specimen,
into the specimen, resulting in a premature failure. or, a Linear Variable Differential Transducer (LVDT)
Compliance or elastic “give” becomes more of an issue that measures accurate displacement of the platens.
at lower forces and will typically occur within the load If a strain measuring device cannot be used, it is
string. When compliance is not corrected or dealt with possible to compensate for system compliance using
appropriately, load and extension data may not be Bluehill Universal Software, which offers a load frame
®
entirely representative of the material being tested. compliance correction calculation that can be applied
to the test results.
Applicable Standards
ISO 604, ASTM D695, JIS K7181
Applicable Standards
ISO 527-1, 2, 3, ASTM D638, JIS K7162
18 Mechanical Properties
The Challenge Our Solution
Applicable Standards
ISO 178, ASTM D790, JIS K7171
Mechanical Properties 19
The Challenge Our Solution
Increasing Throughput using Automated
Specimen Handling Systems Fully-automated specimen handling systems allow
When throughput requirements surpass output potential, for unattended testing throughout the day and evening
laboratories face a difficult challenge and must figure out shifts. These systems improve efficiency and reduce
a way to increased throughput and efficiency. There are a inaccurate data that may result from human error.
few different paths laboratories can take. Operators could Automated handling systems are designed to work
be encouraged to work overtime. While this could certainly with a range of sample sizes and geometries, so if
increase daily output, overtime rates are typically much throughput requirements drop drastically, minimal
higher than standard rates so the increased output will come changes would be necessary to accommodate new
with a cost. Additionally, increased work hours are likely to samples. If desired, automated handling systems can
tire employees, resulting in poor morale, lower quality work, easily be rolled away from a testing frame, allowing
and higher injury-related expenses. Another option may be the frame to be operated manually.
to purchase more equipment and hire more operators. This
would certainly be ideal but if testing volumes decrease Applicable Standards
there could be a lot of equipment downtime and inefficient ISO 178, ISO 527-1,-2, ISO 527-3,
use of manpower. A third option may be to operate a second ASTM D638, ASTM D882, ASTM D790, JIS K7162
shift (if applicable) and that would certainly increase daily
throughput; however, more operators would need to be
hired and additional expenses for running a laboratory
for extended hours are likely to develop.
Impact Testing of PVC Vinyl Material A CEAST 9350 impact drop tower was configured
Homeowners looking to meet ASTM D4226, an industry specified test for
to remodel the exterior identifying the energy required to fracture a specimen
of their house often of PVC vinyl siding material. The Data Acquisition
turn to vinyl siding System (DAS) instrumentation package collects
for its appearance, detailed data plots comparing the performance levels
low maintenance and of vinyl panels with different surface textures and
resistance to weather, and color additives. While the ASTM standard prescribes
insects. Since consumers a nominal striker and support geometry, optional
also value design flexibility, tools are developed to better simulate and study the
manufacturers must offer a effects of balls, rocks, and drills impacting the vinyl
portfolio of impact-resistant siding samples at various speeds and drop heights.
styles. The siding needs to withstand accidental impact Moreover, PVC profiles can be punched in order
from tools and rough handling during installation. Over the to obtain specimens to be tested by means of
lifetime of the house the product must be durable enough pendulum instrument according to Charpy testing
to resist rain, ice, and other weather-induced impacts, as or tensile-impact tests according to different
well as sudden blows from objects such as lawn furniture, international standards.
children’s toys, balls, and rocks. Damaged panels and
unrepaired cracks can propagate allowing penetration
of insects and harmful moisture. Applicable Standards
ISO 179, ISO 8256, ASTM D4226
20 Mechanical Properties
The Challenge Our Solution
Penetration Resistance of
Protective Body Armor
Standards for compliance To test the stab resistance of personal body armor,
testing related to the stab we suggest a CEAST 9350 drop tower with a special
resistance of personal body setup that includes an instrumented tup equipped
armor determine with a blade instead of a standard insert. This method
the minimum performance specifies the minimum requirements for body armor
requirements for the designed to protect the torso against slash and stab
commercially available threats. Penetration of the blade can be directly
equipment. Based upon measured on the armor and compared with software
this testing method, calculations. It can be used for standard control
the equipment’s key according to standard or to study the performances of
attributes are evaluated to ensure the suitable level new materials and combinations.
of protection from sharply pointed instruments and
weapons. The test results from justice agencies and
technology organizations show that stab threats are Applicable Standards
by far the more difficult to defeat due to the contact NIJ 0115.00, Industry/Customer Specific
characteristics, angle of incidence, and number of
hits applied per armor.
Nearly everything you see has been tested during Component testing includes simulation of loading may decide to make the lumber thicker or find a
its development and manufacture. Component conditions representative of potential and likely different material with properties more appropriate
testing will continue to be an important aspect of conditions a product may encounter when in use. for the application.
product development and quality control. Advances An example would be to apply a constant load Component testing is also important in QC
in software and simulation tools have lowered to plastic lumber with a 4-Point bend test over a settings to ensure products coming off a line
the need to test some components during the period of time to measure creep. The test would be perform as expected. When out-of-spec products
earlier phases of development. More often than to ensure the plastic lumber will not permanently reach a customer, safety concerns and tarnished
not, component testing continues to be a major deform under the weight of a heavy object or other reputations can have serious implications on
requirement for OEMs at some point during the structure. Data generated from component tests the well-being of a company.
development and manufacturing of products. could very well influence the design and material
used in a product. For instance, if the plastic lumber
were to permanently deform significantly, a designer
22 Component Testing
The Challenge Our Solution
Our standard syringe fixture determines breakaway forces at the beginning of injections and sustaining
forces throughout the injection process. Data is produced as the crosshead moves down to expel the
fluid from the syringe in a compressive test mode. The test control and results are provided by Instron ®
Bluehill Materials Testing Software. Initial, mean, maximum, and minimum forces can be calculated,
®
reported or stored in industry-standard formats for further examination. When testing in accordance
with ISO 7886-1 Annex G, we designed a fixture that allows for precise friction measurement for syringe
plungers and the force measurements to eject medications from the syringe or the syringe/needle
devices. The lower grip holds the barrel, while the upper unit is designed to eject liquid from the barrel
in a compression test or inspire liquid into the barrel in a tensile test. Universal testing systems can be
configured in either an upright or horizontal position to utilize these fixturing options. In some cases,
the horizontal configuration is advantageous because it allows accurate simulation of the instrument in
its functional position. This configuration may also prevent any sediment in the liquid from clogging the
barrel or needle tip during the test.
Applicable Standards
ISO 7886-1, Industry/Customer Specific
Component Testing 23
The Challenge Our Solution
Applicable Standards
Industry/Customer Specific
24 Component Testing
The Challenge Our Solution
Impact Resistance of Soccer Shoe Soles Manufacturers need a flexible system to evaluate
the impact resistance of raw materials, as well as
One of the most common sports
the end-product. The CEAST 9300 Drop Tower series
played around the world is football
is versatile enough to guarantee the test of the raw
(American soccer). An important
material, as well as testing the finished soles of the
piece of equipment that the
shoes at different impact energies and speeds. Using
player wears is their shoes, giving
a multi-purpose plate allows the accessory to be
them the best support, stability,
placed in the correct test position. We suggest using
grip, and traction necessary.
interchangeable tup inserts of different shapes and
Furthermore, the type of sole,
sizes to simulate the effect of an impact on the lower
which is the most strategic
surface during rushes, runs, jumps, and accelerations.
component of the shoe, will
These inserts can be used in combination with an
strongly depend on the field and the weather conditions.
instrumented tup and a Data Acquisition System (DAS)
With such a great investment in research and development
to gather impact results.
to correctly design and shape the lower surface, the material
to be adopted is highly important and plastic is playing a
dominant role in this market. Applicable Standards
Industry/Customer Specific
Durability of Handheld
Electronic Devices
Many consumer electronic products ranging from
mobile phones and cameras to game controllers
and MP3 players are subject to a variety of arduous
conditions during everyday use. Repetitive operational
forces, along with accidental damage caused by drops,
bumps, and other misuses, cause damage to plastic
casings, lens covers, keypads, and buttons. Cumulative
effects can result in a buildup of microscopic damage
that may eventually result in failure of a piece part
and render the device inoperable.
With the widespread use of handheld electronic
devices in the marketplace and the growing dependence
our population places in them, it is becoming more
unacceptable to consumers for these electronic
products to fail during a reasonable product life. As
the feature gap between many products narrow and
with increased competitiveness of many devices in the
market, differentiators such as quality, robustness,
and durability of these consumer products can be
advantageous to many manufacturers. The Instron 5944 with XY stage is designed For testing the materials used to make game
to perform multi-point compression testing on controllers we recommend using either the 9350
plastic components such as buttons. The XY or the 9340 Tester with Data Acquisition System
stage offers the ability to load multiple samples (DAS) and Visual Impact software, configured
or components and conduct low force to meet ASTM D3763 and/or ISO 6603-2. With
compression testing on all the samples in one either of these systems the test can be set up
single automated run. This test is primarily to replicate a drop that the controllers may be
performed to record low deflection of the subjected to during their life. A custom fixture
components and typically measures the allows the controller to be impacted in several
stiffness of various samples. locations that are important to the controller
surviving the impact. The impact resistance
Instron’s Bluehill® 3 with multi-test feature information gathered by performing instrumented
offers user friendly approach to create methods. testing can be used to help determine the best
material and manufacturing process for the
casing, as well as making improvements to the
overall design.
Applicable Standards
26 Component Testing ISO 6603-2, ASTM D3763
The Challenge Our Solution
Impact Resistance of When testing only to the lower impact energies (12 to 60
Thermoplastic Pipes and Fittings ft-lb), we recommend using the CEAST 9340. If the product
The impact resistance of needs the maximum test conditions (300 ft-lbs), the CEAST
thermoplastic pipes and fittings 9350 with the High Energy Option is ideal. Smaller pipes
relates to its suitability for and fittings can be easily tested on either system. To
service and to the quality of the prevent a secondary impact of the falling weight onto the
processing. It may also provide a pipe or fitting, our anti-rebound device is ideal. The large
relative measure of the material area at the bottom of the testing systems offers room for
resistance during handling, larger diameter pipes up to 12 inches. For pipes wider
installation, and in non-buried than 12 inches, we offer larger, extended support tables.
applications, to in-service Additionally, to fully protect the operator from flying debris, we include a selection of interlocked safety
breakage. ASTM D2444 enclosures. Lastly, by including the instrumentation package, the operator is able to find and gather
determines the resistance of thermoplastic pipes and fittings detailed data collection of failure points.
to impact by a falling dart (tup) under defined conditions. The CEAST 9050 impact pendulum is ideal for other tests according to ISO standards. These tests allow
Results gathered can be used for establishing impact test the operator to determine the impact strength of a thermoplastic pipe by the Charpy method. A short
requirements in product standards and to measure the length of pipe, or a strip test sample, is conditioned at a selected temperature and then supported by
effect of changes in materials, processing, and any effects a horizontal beam, unnotched, and promptly struck once on a line midway between the supports by a
of the environment on the pipes or fittings. A valuable piece pendulum with a given energy (typically 15 or 50 J). After the impact, it is necessary to inspect the test
of information that may not be found without the use of piece for damage and to report the number
testing systems is the first crack or incipient damage point. and the percentage of failures in respect Applicable Standards
Pipes or fittings may fail in interior areas and remain
to the total amount of specimens tested. ISO 7628, ISO 9854, ASTM D2444
undetected when visually inspected.
Packaging materials play a critical role in the the producer as well as for the end user. Products for packaging applications, all of which can be
global market. Food, consumer goods, healthcare such as disposable medical devices, must be determined using a universal testing system.
products, toys, and electronics rely heavily on sterilized prior to use. To ensure sterilization during Puncture tests can be performed with a drop
advances and developments occurring in the shipment and storage at the customer sites, tower that utilizes a variety of clamping and striker
packaging industry. A package’s key function is appropriate packaging must be used. For the food geometries. Tensile impact tests can also be
to protect its contents from damage caused by industry, packaging is a leading concern not only carried out with pendulum machines.
improper handling, environmental factors, or due to the growing number of food products on the In this section, you will see examples of challenges
bacteria. The demand for improved materials and market, but the consequences of contamination related to various packaging applications and our
innovative types of packaging is ever-increasing. within the global food chain are enormous. solutions based on the range of Instron products.
®
For some products, faulty or inappropriate Tensile, seal, burst, and flexural strengths are just
packaging may result in serious implications for some of the many properties that are important
28 Packaging Testing
The Challenge Our Solution
Impact Testing of
Plastic Storage Containers
Reusable plastic containers - sold in a wide range of
shapes, sizes, and colors - are popular for preparing
and storing food. Designed for use in refrigerators,
freezers, microwave ovens, and dishwashers, these
versatile containers must withstand harsh temperature
extremes without deterioration. Cold containers can easily
crack or split when dropped; hot containers can become
too soft and easily separate from a lid. In either case, the
resulting food spills or contamination leads to consumer
frustration. Key for the provider of these containers is
how to strengthen the impact resistance while maintaining
costs associated with their production.
Applicable Standards
ISO 6603-2, ASTM D3763, Industry/Customer Specific
Packaging Testing 29
The Challenge Our Solution
30 Packaging Testing
The Challenge Our Solution
Applicable Standards
ASTM D903, ASTM F88, JIS K6854-2
Packaging Testing 31
Product Portfolio
Product Portfolio 33
Product Portfolio Software | Electromechanical
34 Product Portfolio
Electromechanical | Dynamic
Product Portfolio 35
Product Portfolio Automated Testing Systems
36 Product Portfolio
Index: Standards
The many standards referenced within this brochure are not intended to be a complete and comprehensive worldwide list of standards; but a list of the most
prominent and widely-used in the materials testing industry. Many of the testing solutions discussed are closely related to standards defined by other national,
international, and industry-specific standards organizations. For further information, support, or application expertise, please contact your local Instron office.
®
We also encourage you to visit the Testing Solutions section of our website at www.instron.com
*To learn more about our solution for this standard, please visit the Testing Solutions section of www.instron.com
Index: Standards 37
Index: Test Type
Analytical Standard Page
Density ISO 1183 *
Bulk Density ASTM B212, ASTM B213, ASTM B329, ASTM D1895 Method A or B, ISO R60, ISO 6186 *
Mechanical
Tensile ASTM D638, ASTM D882, ISO 527-1,2,3, ISO 1798, ISO 1926, JIS K7127, JIS K7161, JIS K7162 15, 16, 17, 19, 20, 24, 26
Flexural ASTM D790, ASTM D6272, JIS K7017, JIS K7171 18, 20
Compression ASTM D695, ASTM D1621, ASTM D3846, ISO 844, ISO 604, JIS K7092, JIS K7181 18, 23, 26
Pendulum Impact ASTM D256, ASTM D 1822, ASTM D4812, ASTM D6110, ASTM E23, ISO 179, ISO 180, ISO 8256 20, 27
Drop Impact ASTM D2444, ASTM D3763, ASTM D5628, ISO 6603, ISO 7765, FDA, NIJ 0115.00 12, 20, 21, 24-27, 29
Drawing Characteristics in the Molten State ISO 16790 13, 20
Dynamic/Fatigue ASTM F1614 21, 26, 27
Peel, Tear and Friction ASTM D903, ASTM D1894, ISO 8067, ISO 8295, ISO 6383-1, ISO 11897, JIS K6854-2, JIS K7125, ISO 7886-1 23, 31
Shear ASTM D3163, ISO 8067 *
Elmendorf Tear ASTM D1922 30
Compression Set ASTM D395 *
Falling Dart Impact ASTM D1709, ISO 7765 30
PVT tests ISO 17744 12
Environmental Stress Cracking ASTM D1693 *
Thermal
Coefficient of Thermal Expansion ASTM D696, ASTM E831, ASTM E1545, ISO 11359 *
Heat Deflection Temperature HDT ASTM D648, ISO 75 8, 9
Vicat Softening Point ASTM D1525, ISO 306 8
Thermal Conductivity of Melt ASTM D5930 12
Brittleness Temperature Test ASTM D746, ASTM D2137, ISO 974 *
Carbon Black Content ASTM D1603 *
Rheological
Melt Flow Rate (MFR) ASTM D1238, ASTM D3364, ISO 1133 7, 9, 11
Melt Flow Index (MFI) ASTM D1238, ASTM D3364, ISO 1133 7, 9, 11
Melt Volume Flow Rate (MVR) ASTM D1238, ASTM D3364, ISO 1133 7, 9, 11
Capillary Rheometry ASTM D3835, ASTM D11443 11, 12, 13, 20
Specimen Prep
Milling NA *
Bar Notching ISO 2818 17
38 Index: Test Type *To learn more about our solution for this standard, please visit the Testing Solutions section of www.instron.com
Support for the Life of Your Equipment
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materials and components testing techniques.
Support 39
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