ENR116 – Mod. 4- Slide No.
Polymer processing and
applications
ENR116 – Mod. 4- Slide No. 2
Intended Learning Outcomes
At the end of this section, students will be able to:
• Describe typical polymer applications in relation to
polymer classes.
• Describe some of the commonly used polymer processing
techniques.
ENR116 – Mod. 4- Slide No. 3
Melting and glass
transition temperatures
Tg and Tm define the upper
and lower working
temperature limits
Specific volume (ν) is the
volume occupied by a unit of
mass of a material.
Adapted from Fig. 15.18,
Callister & Rethwisch 8e.
ENR116 – Mod. 4- Slide No. 4
Factors that influence melting and
glass transition temperatures
Melting: Rearrangement of the molecules, in a
transformation from an ordered to disordered molecular state.
• Presence of double bonds - increase Tm
• Bulky or large side groups - increase Tm
• Polar groups – increase Tm
• Molecular weight (when relatively low) increases Tm
• Degree of branching - introduces defects in crystalline
polymers and lowers Tm
ENR116 – Mod. 4- Slide No. 5
Factors that influence melting and
glass transition temperatures
Glass Transition Temperature: Solid polymer transforms from a
rigid to a rubbery state.
Tg increases with:
• Presence of double bonds in the backbone.
• Bulky side groups
• Polar groups
• Increasing the molecular weight
Branching - small amount lowers Tg, high amount
however elevates Tg.
Crosslinking - raises Tg .
High density of crosslinks - no glass transition.
ENR116 – Mod. 4- Slide No. 6
Polymer types
Seven categories:
Plastics
Elastomers (or rubber) Dowcorning.com
Fibres
Coatings
Adhesives
Foams Pittsburghplastics.com
Films
Wisegeek.com
ENR116 – Mod. 4- Slide No. 7
Polymer types: Plastics
Plastics:
Solid materials that have some structural rigidity under load
and are used in general-purpose applications.
Variety of properties possible!
• Rigid and brittle.
• Flexible, exhibiting both elastic and
plastic deformations.
• May have any degree of crystallinity.
• Linear or branched.
Thermoplastic or Thermosetting
ENR116 – Mod. 4- Slide No. 8
Polymer types: Elastomers
Elastomers: Experience large and reversible elastic
deformations
• Natural rubber styrene
• Synthetic rubber
butadiene
• Silicone rubber
Example: polydimethylsiloxane (PDMS)
ENR116 – Mod. 4- Slide No. 9
Polymer types: Fibres
Fibres: Length/diameter ratio >100
Mainly used in the textile industry and in the manufacture of
composites (aramid fibres)
Must have high tensile strength:
• Usually highly crystalline
• Formed of linear, symmetrical chains
• Regular repeat units
• Polar function groups
ENR116 – Mod. 4- Slide No. 10
Polymer types: Other
Coatings:
Thin film of polymer on surfaces - i.e. paint, varnish.
Used to protect item, improve appearance, provide electrical
insulation.
Adhesives:
Produce bond between two adherends.
Bonded via mechanical or chemical mechanism.
Films:
Blown film extrusion for packaging, etc.
Foams:
Gas bubbles in plastic for packaging, insulation.
ENR116 – Mod. 4- Slide No. 11
Polymer additives
Additives are used to improve mechanical properties,
processing, durability, etc.
Fillers:
Added to improve tensile strength & abrasion resistance,
toughness & decrease cost.
Example: carbon black in rubber
Plasticizers:
Added to reduce the glass transition temperature Tg
Migration of plasticizers can be problematic
ENR116 – Mod. 4- Slide No. 12
Polymer additives
Stabilizers:
Antioxidants
UV protectants
Lubricants:
Added to allow for easier handling during processing i.e.
‘slides’ through dies easier. Example: Na stearate.
Colorants:
Dyes or pigments for aesthetic purposes.
Flame Retardants:
Cl/F & B
ENR116 – Mod. 4- Slide No. 13
Polymer Processing
Thermoplastics Thermosets
Soften upon heating, Degrade or burn upon
harden when cooled reheating
General process: General process:
• Heat until soft • Prepolymer is
• Shape molded
• Set via cooling • Set via cooling
ENR116 – Mod. 4- Slide No. 14
Processing of polymers: Molding
Compression and transfer molding:
Used for both thermoplastics or thermosets.
Male mold
Female
mold
Adapted from Fig. 15.23,
Callister & Rethwisch 8e.
ENR116 – Mod. 4- Slide No. 15
Processing of polymers: Molding
Injection molding:
Used for thermoplastics and some thermosets (RIM)
Adapted from Fig. 15.24,
Callister & Rethwisch 8e.
ENR116 – Mod. 4- Slide No. 16
Processing of polymers: Extrusion
Adapted from Fig. 15.25, Callister &
Rethwisch 8e. (Fig. 15.25 is from
Encyclopædia Britannica, 1997.)
ENR116 – Mod. 4- Slide No. 17
Blown-Film Extrusion
Adapted from Fig. 15.26, Callister &
Rethwisch 8e. (Fig. 15.26 is from
Encyclopædia Britannica, 1997.)
ENR116 – Mod. 4- Slide No. 18
Summary
• Polymers are widely used as plastics,
elastomers, fibres, coatings, adhesives, films
and foams.
• Typical polymer processing includes
compression and injection moulding, extrusion
and blown film extrusion.
