Sofia Martinez
Testing raw plastics is an important step in the manufacturing process, as it helps industries maintain regulatory compliance and ensures that the final product meets specific standards, regulations, and safety requirements. There are various methods to test raw plastics, and the choice of testing method depends on the plastic material's composition, intended use, and the specific properties being inspected. For example, different tests are performed on plastic films compared to injection-molded plastic caps. Testing raw plastics can also help manufacturers identify the impact of changes in the manufacturing process, such as increasing the amount of filler or reducing the plasticizer, to ensure high-quality product performance. Some common testing methods include mechanical testing, which helps determine the characteristics of plastic materials and detect quality issues, and FTIR analysis, which uses infrared radiation to identify surface contamination and additives in polymers. Other tests include moisture analysis to determine water content, melt flow tests to understand the behaviour of thermoplastics during molding, and radiographic testing to identify flaws and contaminants in plastic components.
| Characteristics | Values |
|---|---|
| Purpose | To determine the characteristics of the raw material and detect possible quality issues |
| Testing Type | Mechanical, fundamental, imitative, moisture analysis, melt flow, ultrasonic inspection, optical haze and transmission measurements, physical, thermal, rheological, aging, barrier, surface, flammability, and mechanical |
| Testing Focus | Safety, quality, recycling, processability, process development, biodegradability, regulatory compliance, and performance |
| Testing Entities | UL Solutions, Intertek, Measurlabs |
| Testing Standards | Standards vary across industries and manufacturers |
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What You'll Learn
Moisture analysis
There are several methods available for moisture analysis in plastics. One common approach is to use a moisture analyzer, such as the HX204 moisture analyzer from METTLER TOLEDO. This instrument offers high resolution, with a readability of 0.001% moisture content (MC) and a capacity of 200g, making it suitable for plastics with typically low moisture levels. The HX204 provides an accurate and easy alternative to the official Karl Fischer Titration method, which is the ASTM standard for determining residual moisture in plastics. However, the Karl Fischer method may not be practical for continuous use in a production setting.
Another technique for moisture analysis is to utilize a halogen lamp or a similar heat source. This method involves drying a sample of the plastic under the heat source and then weighing it. By comparing the weight before and after heating, you can determine the moisture content, as any difference in weight indicates the amount of moisture lost during the process. This gravimetric method is widely used and essentially involves using a sensitive balance within an oven to measure weight changes.
To ensure accurate results, it is recommended to perform multiple replicates, such as five or ten, to identify any issues with biased results. Additionally, verifying the performance of the moisture analyzer is crucial. This can be achieved through methods like SmartCal, which involves a simple 10-minute test to confirm the accuracy of the analyzer. Sending a split sample to an outside laboratory for testing with a Karl Fischer-type titration instrument or a moisture analyzer with a relative humidity (RH) detector can also help validate the moisture content.
Overall, moisture analysis is a critical aspect of testing raw plastics, and accurate results are essential for producing high-quality plastic parts. By controlling the moisture content in polymer resins, manufacturers can ensure smooth surfaces, ideal mechanical properties, and trouble-free compounding and injection molding processes. Therefore, selecting the appropriate testing methods and instruments is vital to achieving reliable and consistent results.
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Radiographic testing
There are two primary methods of radiographic inspection: Conventional Radiography (XR) and Computed Radiography (CR). XR utilizes industrial film to capture images, while CR provides digital results. Both methods offer unique advantages and can be selected based on specific requirements. XR produces fine-grain industrial film that serves as a permanent record of the test, which can be stored and referenced for years. On the other hand, CR provides digital results that can be easily shared and analyzed using advanced software tools.
When considering radiographic testing for raw plastics, it is essential to choose a reputable testing facility with experienced technicians. The testing parameters, such as flow velocity, impact angle, and particle size, can be customized to meet specific requirements. By utilizing radiographic testing, manufacturers can ensure the quality and integrity of their plastic products, providing confidence to their customers and maintaining high standards in their respective industries.
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Mechanical testing
One common test is the trouser tear test, which measures the resistance of plastic films to tearing. A sample strip is cut from the middle and pulled in two directions while measuring the energy required to tear it. This test is usually performed at room temperature, but it can be modified for elevated or lowered temperatures. Other tests that assess the thermal characteristics of plastics include the heat deflection temperature (HDT) test and the Vicat softening point test, which measures the temperature at which a plastic sample softens. Dynamic mechanical analysis (DMA) is another method used to evaluate the thermal properties of plastics and provide additional information about their viscoelastic behaviour.
UL Solutions offers a range of mechanical tests for plastics, including the three-point loading test, which determines the strength and dimensional change properties of plastics under tensile, compressive, and shear stresses. The elasticity modulus (E modulus) is a parameter for comparing the stiffness of different materials. The tensile impact test measures the impact energy consumed during deformation, while the Izod and Charpy impact tests facilitate comparative material assessments and investigate the effects of changed formulations or injection moulding conditions.
Other organisations, such as Intertek and Advanced Plastiform, also offer mechanical testing services for plastics. Intertek provides a wide range of techniques, including Ultra-Violet/Visible (UV/VIS) spectrophotometry, differential scanning calorimetry (DSC), dynamic mechanical thermal analysis (DMTA), and thermogravimetric analysis (TGA). Advanced Plastiform offers ultrasonic inspection, which uses high-frequency sound waves to detect flaws in the material, and radiographic testing to assess the quality of plastic components during the injection moulding process.
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Thermal conductivity testing
There are two main categories of methods for measuring thermal conductivity: dynamic and steady-state. The dynamic method is suitable for high-temperature conditions or materials with relatively high thermal conductivity. It includes the hot wire method and the laser heat conduction method. On the other hand, the steady-state method is designed for materials with low to medium temperature conditions and low to medium thermal conductivity. This method encompasses the heat flow, protective plate, and protective hot wire approaches.
To enhance the thermal conductivity of plastics, fillers such as metal or graphite powders can be added. In one experiment, polypropylene homopolymer (PP), polyamide (PA), and polycarbonate (PC) were selected as base polymers, and aluminium, copper, and graphite powders were used as fillers. These fillers were mixed with the polymers at varying ratios, and the resulting granules were dried and moulded into test specimens. Thermal conductivity measurements were then performed using a tool such as the Hot Disk TPS 2200, which sandwiches the sensor between the specimen's shoulder parts. The measurements were taken at room temperature, and each sample was evaluated in triplicates, ensuring a clean surface and proper positioning of ejector pin impressions.
The results of these thermal conductivity tests showed a positive correlation between filler content and thermal conductivity. As the volume fraction of fillers increased, the thermal conductivity also increased. This was expected, as the base polymers had lower thermal conductivity values compared to the fillers. For instance, virgin PP exhibited a thermal conductivity of 0.23 W/m K, while copper, aluminium, and graphite displayed values over 100 W/m K.
Additionally, moisture analysis is another critical aspect of testing raw plastics. It involves drying a sample under a heat source, such as a halogen lamp, and then weighing it to determine the water content. This is important because residual moisture can lead to polymer chain degradation, affecting the material's properties and performance.
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Materials analysis
Mechanical Testing
Mechanical testing is performed on raw plastic materials or intermediate-stage products to determine their characteristics and detect potential quality issues. This type of testing can be fundamental or imitative. Fundamental testing involves evaluating standardised plastic pieces rather than finished products, allowing for direct comparisons between different materials or batches. Imitative testing, on the other hand, subjects a finished plastic product to a specific type of mechanical stress. Mechanical testing helps identify possible shortcomings before bringing products to market, ensuring that they meet performance and regulatory compliance requirements.
Moisture Analysis
Moisture analysis is essential to determine the water content in raw plastics. This test involves drying a sample under a heat source, such as a halogen lamp, and then weighing it. The weight difference before and after heating indicates the moisture content in the material. Moisture content is crucial as it can impact other measurements, such as MVR, where residual moisture can lead to polymer chain degradation.
Melt Flow Test
The melt flow test is particularly relevant for injection moulding processes. It involves melting plastic granules and pouring the molten plastic through an orifice for a set time, typically ten minutes. The amount of plastic that flows through is then weighed and compared to the original amount to determine the melt flow index. A poor melt flow index indicates that the plastic did not flow well and left a significant amount of material in the melting container.
Physical Tests
Physical tests for plastics can assess a wide range of material properties, including dimensional stability at elevated temperatures, density, water content, and scratch resistance. One such test is the determination of apparent density, which helps in calculating cavity dimensions during injection moulding. Another test method involves heating the specimen to release and analyse the water content.
Ultrasonic Inspection
Ultrasonic inspection is a more intensive test used to detect flaws in the material. It requires a source of high-frequency sound waves to penetrate the plastic and identify any internal defects or inconsistencies.
Polymer Testing
Polymer testing services offered by companies like Intertek can help address challenges related to safety, quality, recycling, process development, and regulatory compliance. Their dedicated polymer testing labs enable a deeper understanding of material properties and composition, facilitating the evaluation of materials for specific applications.
By utilising these testing methods and working with specialised laboratories, innovators and manufacturers can ensure the quality, performance, and compliance of their raw plastics and final products.
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Frequently asked questions
You can test the quality of raw plastics at a laboratory that specializes in plastic testing, such as UL Solutions or Innovatech Labs. These laboratories offer a range of tests to determine the quality and characteristics of plastic materials, including moisture analysis, mechanical testing, and radiographic testing.
There are several tests available to assess the quality of raw plastics. Some common tests include:
- Moisture analysis: This test determines the water content in the plastic by drying a sample under heat and weighing it before and after to detect any differences.
- Melt flow test: This test is used to understand how thermoplastics will behave during the injection molding process. It involves melting plastic granules and pouring them through an orifice for a set time, then weighing the amount that comes out.
- Ultrasonic inspection: This method uses high-frequency sound waves to detect flaws or defects in the plastic material.
- Radiographic testing: This test uses X-rays or gamma rays to expose the plastic material to radiation and identify any flaws, contaminants, or variations in thickness.
- Mechanical testing: These tests are performed to determine the characteristics and performance of plastic materials under tension, compression, and impact.
Testing raw plastics is crucial for several reasons:
- Quality assurance: Testing helps ensure that the plastic materials meet specific standards, regulations, and safety requirements set by government agencies and industry organizations.
- Product performance: By analyzing the composition and chemistry of plastic materials, manufacturers can make informed decisions about the production process and ensure high product performance.
- Cost savings: Testing raw plastics before full-scale production can help identify potential issues early on, preventing costly problems associated with product failures or non-compliance.
- Supply chain management: Testing allows companies to verify that the products or components supplied by external sources meet their required specifications and standards.
