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This informative blog allows plastics professionals to discuss plastics training and technology. Brought to you by Routsis Training: the plastic industry's premiere training provider.

The Affect of Moisture on Injection Pressure…

The other week, I received a multiple part question regarding many aspects of materials, this is one part…

Nathan
Although the 1st stage injection time is the same, the virgin PC/ABS (<0.06% moisture) has a 1RMPa higher peak injection pressure than virgin PC/ABS (0.08% moisture). Is this change in pressure common?
My Response
Moisture in the polymer causes hydrolysis to occur. As the water molecule is heated, one of the hydrogen atoms breaks away and both the H+ and OH- ions look for pairs along the polymer chain. In hygroscopic polymers such as PC/ABS these ions break up the long polymer chains resulting in a lower average molecular weight. This drop in molecular weight results in a drop in overall material viscosity.
Additional Thoughts
Because water has a molecular weight of only 18, it alone acts as a plasticizer which reduces the overall viscosity of the material. This is one reason we often recommend molders of non-hygroscopic materials ensure they remove surface moisture from their materials.
-Andy

Determining Intensification Ratio Using Specifications…

I was asked this question during an on-site visit earlier this week…

Technician
I know this machine is rated with a maximum injection pressure of 38,000psi, but I am not sure how to convert this to an intensification ratio.

note: The intensification ratio is a factor which is used to
convert the hydraulic pressure being applied to the hydraulic injection
cylinders into the actual pressure being applied to the polymer melt at the
front of the screw.

 

My Response
If you know the maximum plastic pressure (Pp-max) along with the maximum hydraulic pressure (Ph-max) for your machine, you can estimate the intensification ratio (Ri) for your machine. /  = 

Pp-max / Ph-max = Ri

 -Andy

The Importance of Consistency…

Many processors often experiment in training without a clear-cut goal. One year, they might send some people to a seminar, another year, they might buy some products or try making something themselves. 

Develop a Structured Approach
Although most industry training has some merit, you need to develop a structured approach. For instance, if one form of training turns out to be beneficial for a technician, then it should be evaluated as part of an overall structured training plan for all technicians, both current and future.
-Andy

Attribute Data vs. Variables Data…

I have often encounter confusion on these two terms when talking to molders…

Attribute Data
Attribute data has two different outcomes. An example of such an outcome would be a GO / NO-GO gauge which is used when testing parts. This test results in only two different outcomes, Pass or Fail.
Variable Data
Variables are those aspects measured using a scale. An example of this would be a dimension measured using calipers. This device provides a wide variety, or scale, of results based on the accuracy of the instrument and ability of the person taking the measurements.
-Andy

MW vs. MWD…

I was discussing polymers with a technician and was asked this question:

John
I understand how molecular weight affects the process, but how does molecular weight distribution affect the process?

My Response
Polymer chain mobility is highly dependent on the length, or molecular weight, of the polymer chain. If most of the polymer chains have a similar molecular weight, or smaller distribution, then they are all more likely to soften at similar temperatures typically resulting in a more narrow temperature range at which the polymer can be processed.
Adversely, a broad molecular weight distribution often results in a wider processing window due to the mobility of some polymer chains while other chains remain highly entangled.
Additional Thoughts
Semi-crystalline polymers with a narrow molecular weight distribution can often achieve a higher degree of crystallinity than polymers with a wide distribution. 
-Andy