Documente Academic
Documente Profesional
Documente Cultură
Jeffrey A. Jansen
January 24, 2013
608-231-1907
jeff@madisongroup.com
Agenda
• Cracking in Plastics
• Failure Mechanisms
– Impact
– Creep
C
– Environmental Stress Cracking
– Fatigue
F ti
– Molecular Degradation
• Case Studies
Amorphous Semi-crystalline
y
Plastic Failure Analysis Jeffrey A. Jansen 608-231-1907
The Madison Group jeff@madisongroup.com
Plastics Cracking
Strain
Plastic Failure Analysis Jeffrey A. Jansen 608-231-1907
The Madison Group jeff@madisongroup.com
Plastics Cracking
Plastic deformation
Yielding Necking
Stress
S
Plastic deformation
Yielding Necking
Stress
S
Plastic deformation
Yielding Necking
Stress
S
Plastic deformation
Yielding Necking
Stress
S
• Compressive Stress
• Shear Stress
• Torsional Stress
• Flexural or Bending Stress
• Hoop Stress
Shear
Brittle-Ductile
Stress
Ductile-Brittle
Ductile Brittle
Ductile
Strain
Impact
• Crack initiation occurs when the minimum
energy is exceeded
• Crack propagates when the applied load
exceeds the crack initiation energy
• Catastrophic failure occurs when the applied
energy exceeds the combined work required
for crack initiation and complete propagation
Damping is a key consideration
Plastic Failure Analysis Jeffrey A. Jansen 608-231-1907
The Madison Group jeff@madisongroup.com
Impact Failure
• Impact
• Snap-fit Installation
• Water Hammer / Rapid p Pressurization
Catch
hness
Polypropylene copolymers
easing Tough
High density polyethylene
Nylon – dry
Poly(vinyl chloride)
Incre
Polyacetal
Poly(ethylene terephthalate)
P l
Polypropylene
l h
homopolymer
l
Poly(methyl methacrylate)
Polystyrene
Key Factors
• Polymer Type
• Overall Plastic Resin Composition
• Part Design
• Strain Rate
• Temperature
• Striker Geometry
608-231-1907
jeff@madisongroup.com
Creep Failure
Creep Creep
8% 14%
Creep
p is…..
the tendency of a solid material to
deform permanently under the influence
of constant stress ((tensile,, compressive,
p ,
shear, or flexural). It occurs as a function
of time through extended exposure to
levels of stress that are below the yield
strength of the material
material.
Plastic Failure Analysis Jeffrey A. Jansen 608-231-1907
The Madison Group jeff@madisongroup.com
Creep Failure
Creep
• Low to moderate forces exerted over an
extended time → lower ductility. Can result in
brittle fracture in normally ductile plastics
• Inherent
I h viscoelastic
i l i nature off polymers
l lleads
d to
time dependency
• Prolonged static stresses lead to a decay in
apparent modulus through localized molecular
reorganization of polymer chains
• At stresses below the yield point molecular
reorganization includes disentanglement as
there is no opportunity for yielding
Plastic Failure Analysis Jeffrey A. Jansen 608-231-1907
The Madison Group jeff@madisongroup.com
Time Under Load
Metal Plastic
Initial Deformation
Initial Placement
300 45
Stress Stress
Day 1
Plastic Failure Analysis Jeffrey A. Jansen 608-231-1907
The Madison Group jeff@madisongroup.com
Creep Failure
Metal Plastic
Initial Deformation
Initial Placement
300 45
Stress Stress
Day 100
Plastic Failure Analysis Jeffrey A. Jansen 608-231-1907
The Madison Group jeff@madisongroup.com
Creep Failure
Metal Plastic
Initial Deformation
Initial Placement
300 45
Stress Stress
Day ????
Plastic Failure Analysis Jeffrey A. Jansen 608-231-1907
The Madison Group jeff@madisongroup.com
Creep Failure
5,000 psi
2 00 psii
2,500
Brittle Failure
1,000 psi
Time
Graph from
Smithers RAPRA
http://www.rapra.net
Brittle Fracture
Adapted
p from NIST model
http://www.metallurgy.nist.gov/
The time-dependent
time dependent decrease in stress
under sustained strain. Parallels creep,
except strain is constant and the response
is a change in stress.
Fatigue
15%
Fatigue
• Low to moderate forces exerted intermittentlyy
over an extended time → lower ductility. Can
result in brittle fracture in normally ductile
plastics
• Cyclic stress application leads to a decay in
apparent modulus through localized molecular
reorganization of polymer chains
• At stresses below the yield point molecular
reorganization includes disentanglement as
there is no opportunity for yielding
Fatigue Life
Component Factors
• Polymer Type
• Molecular weight
• Crystallinity
• Modifiers
• Fillers
• Absorbed water / chemical agents
• Size and number of defects / stress conc.
• Fabrication method
Plastic Failure Analysis Jeffrey A. Jansen 608-231-1907
The Madison Group jeff@madisongroup.com
Fatigue Failure
Environmental Factors
• Amplitude
A lit d
• Frequency
• Waveform
• Temperature
25%
Plastic
Chemical
Chemical Agent
Plastic Sample
Bend Fixture
Chemical agent
permeates into plastic
surface – preferentially at
elevated stress field.
Localized plasticization
via stress enhanced fluid
absorption at stress
stress.
Plastic Failure Analysis Jeffrey A. Jansen 608-231-1907
The Madison Group jeff@madisongroup.com
Environmental Stress Cracking
Crazes rupture
C t to
t form
f a
crack
Crazes rupture
C t to
t extend
t d
the crack
Chemical
6%
4% 7%
M l
Molecular
l D Degradation
d ti M Mechanisms
h i
• Oxidation
• Ultraviolet Radiation (UV)
• Hydrolysis
• Chain Scission
• Side Chain Alteration
• Destructive Crosslinking
Oxidation
Thermal oxidation is the chemical reaction
of a polymeric material with oxygen from an
oxidizing material, including air. The rate of
th d
the degradation
d ti reaction
ti iincreases with
ith
increasing temperatures.
O id ti
Oxidation
• Most polymers undergo thermal oxidation.
• Oxidation takes places via free radical
formation.
• Chemical reaction – incorporation of
oxygen into the backbone structure,
creates carbonyl structural groups.
ROO + RH ROOH + R
Polymer
R +O2 ROO
O O O O
ROO R-C-R’, R-C-H, R-C-OR’, R-C-OH
Ketone Aldehyde Ester Organic Acid
Effects of Oxidation
• Loss of Molecular Weight • Evolution of Volatiles
– Embrittlement – Foul Odor Generation
– Loss of Mechanical Integrity
g y • Carbonyl Formation
– Cracking
– Loss of Dielectric Properties
– Catastrophic Failure
• Conjugation
j g
– Discoloration
– Loss of Gloss
– Loss of Transparency
Polypropylene
Low Density Polyethylene
High Density Polyethylene
Decreasing Nylon
Susceptibility Polyacetal
to Oxidation Poly(phenylene oxide)
Poly (ether ether ketone)
Poly(phenylene sulfide)
Poly(vinylidene fluoride)
Polytetrafluoroethylene