FCFC TAIRILAC ABS RESINS TECHNICAL INFORMATIONS

Transcription

1 FCFC TAIRILAC ABS RESINS TECHNICAL INFORMATIONS High Flow Grade TAIRILAC AF3500 TAIRILAC AF3800 FORMOSA CHEMICALS & FIBRE CORPORATION PLASTICS DIVISION 1

2 Contents 1. Introduction...1 Table 1. Properties of High Flow Grade ABS of FCFC Physical Properties Mechanical Properties Thermal Properties Weather Resistance Chemical Resistance...3 Table 2. Chemical Resistance Injection Molding High Fluidity Molding Conditions and Physical Properties Injection Molding Examples...5 Figure 1. Relationship between Izod Impact Strength and Temperature...6 Figure 2. Stress and Strain Curve...7 Figure 3. Relationship Between Tensile Strength and Temperature...7 Figure 4. Relationship between Flexural Strength and Temperature...8 Figure 5. Relationship between Flexural Modulus and Temperature...8 Figure 6. Flexural Fatigue Curve...9 Figure 7. Tensile Creep Curve...9 Figure 8. Relationship between Heat Deflection Temperature and Fiber Strength...9 Figure 9. Thermal Shrinkage...10 Figure 10.Relationship between Tensile Strength and Carbon Arc Radiation Time in the Accelerated Weather Resistance Test...10 Figure 11. Relationship between Izod Impact Strength and Carbon Arc Radiation Time in the Accelerated Weather Resistance Test

3 Figure 12. Relationship between DuPont Impact Strength and Carbon Arc Radiation Time in the Accelerated Weather Resistance Test...11 Figure 13. Accelerated Weather Resistance Test of Black Material (Tensile Strength)...12 Figure 14. Accelerated Weather Resistance Test of Black Material (Izod Impact Strength)...12 Figure 15. Accelerated Weather Resistance Test of Black Material (DuPont Impact Strength)...13 Figure 16. Relationship between Flow Length/Thickness (L/T) and Molding Temperature...13 Figure 17. Relationship between Spiral Flow Length and Molding Temperature...14 Figure 18. Relationship between Flow Length/Thickness (L/T) and Molding Temperature of AF Figure 19. Relationship between Molding Product Shrinkage and Injection Pressure...15 Figure 20. Relationship between Tensile Strength and Material Temperature...15 Figure 21. Relationship between Molding Temperature and Izod Impact Strength...16 Figure 22. Relationship between Retention Time in the Screw and Izod Impact Strength of AF Figure 23. Relationship between Gloss and Mold Temperature...17 Figure 24. Relationship between Gloss and Molding Temperature...17 Figure 25. Relationship between Izod Impact Strength and Recovery Frequency

4 1. Introduction The high flow grade ABS resins AF3500 and AF3800 possess not only excellent moldability and physical properties, and fluidity that is 2 times that of the traditional ABS resin and equal to that of HIPS. The characteristics of FCFC high flow grade ABS resins are summarized as follows: (1) Medium impact strength and good physical properties (2) Excellent workability suitable for the molding of large scale products and complex products, no apparent flow marks and lines (3) The molding temperature of high flow grade ABS is 20 lower than that of common ABS due to the excellent workability. As a result, the molding period is shorter and the productivity is thus increased. The operation temperature and pressure during the production of the present grade are both lower leading to the increase of the life span of the injection machine. (4) The design of the mold requires less gates as a result of the excellent workability. The major difference between AF3500 andaf3800 lies in the higher stiffness of AF3800. Both have the same degree of workability. The physical properties of AF3500 and AF3800 are illustrated in Table 1. Table 1. Properties of High Flow Grade ABS of FCFC Item Tensile Strength 1/8 Thick ASTM Test Method Condition Unit Flexural Strength 1/8 x1 x4 Rod Flexural Modulus 1/8 x1 x4 Rod Rockwell Hardness Specific Gravity Izod Impact Strength 1/4 x1/2 x2 1/2 Rod 30 Heat Deflection Temperature(Unannealed) 88 1

5 2. Physical Properties 2-1 Mechanical Properties The relationship between impact strength and temperature of AF3500 and AF3800 is illustrated in Figure 1. They exhibit the same excellent behavior at low temperature as the general grade ABS resins. Figure 2 illustrates the relationship between stress and strain. Figure 3. illustrates the relationship between tensile strength and temperature. Figure 4. illustrates the relationship between flexural strength and temperature. Figure 5. illustrates the relationship between flexural modulus and temperature. The relationship between the mechanical properties and temperature of high flow grade ABS resin is the same as that of the general grade ABS. As the temperature reaches above 60, the mechanical properties decline rapidly. Figure 6 illustrates the relationship between the stress obtained from the flexural fatigue test using method A of ASTMD671 and the frequency. Under certain stress, the flexural fatigue life span of the ordinary ABS resin is longer than that of HIPS. The life span of the high flow grade ABS resin is between that of the ordinary ABS resin and HIPS. Therefore, the thickness of the high flow grade ABS should be increased slightly when applied for the uses in the repetitive force exertion or wedging in metal objects. The repetitive force exertion shall be limited under 100 kg/cm2 and the repetitive strain shall be limited within 1% for the safety consideration. Figure 7 illustrates the creep behavior. The creep behavior of the high flow grade is similar to that of the general grade ABS resins. However, the initial creep of the high flow grade is slightly higher. 2-2 Thermal Properties Figure 8 illustrates the relationship between stress and heat deflection temperature. Figure 9 illustrates the relationship of thermal shrinkage and temperature. The heat deflection temperature of AF3500 is slightly lower than that of AF3800, but the temperatures of both AF3500 and AF3800 are lower than the general grade ABS resins. 2-3 Weather Resistance Aging will lead to the decline of mechanical properties. From the accelerated weather resistance tests using the accelerated weather resistance test machine, the relationship with the tensile strength is illustrated in Figure 10, the relationship with Izod impact strength is illustrated in Figure 11, and the relationship with DuPont impact strength is illustrated in Figure 12. The test results reveal that the weather resistance of the high flow grade is similar to that of the general grade ABS resins. The tensile strength starts to decline after 200 hours and by about 30% after 600 hours. The Izod impact strength declines by 20% after 600 hours. During the weather resistance study, the surface of the molding product deteriorates and the physical properties decline. Although the deterioration is rather slow, the notch effect from the surface deterioration may cause a significant decline of the physical properties under certain circumstances. 2

6 Figure 12 illustrates the DuPont drop dart impact strength test where the impact strength declines by 60% after 600 hrs which is more significant than the Izod impact strength in Figure 11. From the effect of the weather resistance on the molding product, the Izod impact strength (Fig. 11) is more important to the thick product, while the DuPont drop dart impact strength is more useful to the thin product. Painting, carbon black colorization, and galvanization can protect the ABS products from deterioration. Figures 13, 14, and 15 illustrate the protecting effects of the carbon black colorization and galvanization on ABS. The results demonstrate that the carbon black colorization is more effective. Therefore, carbon black colorization can be applied to products with weather resistance problems where colors are not specified. 2-4 Chemical Resistance The chemical resistance of high flow grade ABS is illustrated in Table 2. It is resistant to chemicals such as organic acids, bases, and salts like ordinary ABS resins. However, it is soluble in organic solvents such as esters, ketones, and halogenated hydrocarbons. It becomes swollen in alcohol, gasoline, and acetic acid. The chemical resistance of the molding product needs to be tested in advance according to the practical application to ensure the applicability. 3

7 Table 2. Chemical Resistance Weight Change after Soaking at Room Temperature for 7 Days (%) Chemical AF3500 AF3800 Appearance Water No Change 10% Ammonium Hydroxide No Change 5% Acetic Acid No Change 10% Hydrochloric Acid No Change 5% Sulfuric Acid No Change 10% Sodium Hydroxide No Change 9% Ethanol Slightly White n-hexane No Change Gasoline - - Swollen Machine Oil No Change Corn Oil No Change Dioctyl Phthalate (DOP) No Change 3. Injection Molding Property 3-1 Fluidity The fluidity is measured using the spiral flow method. Figure 16 illustrates the relationship between the flow length converted from the spiral flow (the farthest point from nozzle to molding product) and the thickness (L/T). The fluidity of AF3500 is almost the same as that of AF3500. It is twice as much as the fluidity of the ordinary ABS resin and very similar to the fluidity of HIPS. Figure 17 illustrates the relationship between the spiral flow value and the temperature. Figure 18 illustrates the L/T value converted from the spiral flow test at different injection temperatures and injection pressures. The figure indicates that the injection pressure is required to be 1100 kg/cm2 when the L/T of the product is 100 and the material temperature is 210. When the material temperature is 240, the injection pressure is 790 kg/cm2. The appropriate molding conditions during molding can be determined from the L/T value of the molding product. 4

8 3-2 Molding Conditions and Physical Properties The molding shrinkage of the high flow grade ABS resins is slightly less than that of the ordinary ABS. Figure 19 illustrates the relationship between the molding shrinkage and the molding pressure. The molding shrinkage of AF3500 and AF35800 is approximately %. Figure 20 illustrates the relationship between the tensile strength and the molding temperature. Like ordinary ABS resins, the tensile strength slightly decreases with increasing molding temperature of the molding material. Figure 21 illustrates the relationship between the impact strength and the molding temperature. When the molding temperature exceeds 250, the impact strength starts to decline and deterioration such as the change of color occurs. Therefore, the molding temperature should be kept below 250. Figure 22 illustrates the relationship between the retention time in the screw and the impact strength of the plastic material. Figures 23 and 24 illustrate the relationship between the gloss of the molding product and the molding conditions. When the material temperature exceeds 250, the gloss of the high flow grade ABS resin will decrease. Figure 25 illustrates the relationship between the recovery frequency and the impact strength. Like the general grade ABS resins, the high flow grade can be used after frequent recoveries without any problems. However, the mixing ratio of the recovered material and the new material should not exceed 20%. 4. Injection Molding Example (1) Specification: AF3500 Molding Product: Outer Shell of Business Machine, Net Weight: 340 g Injection Machine: Kawaguchi 240Z Molding Conditions: Screw Temperature C1 ( ) 170 C2 ( ) 175 C3 ( ) 190 C4 ( ) 210 Nozzle Temperature ( ) 210 Injection Pressure (kg/cm2) 1000 Mold Temperature ( ) 50 5

9 (2) Specification: AF3800 Molding Product: Box, Net Weight: 150 g Injection Machine: Toshiba IS OZ Molding Conditions: Gate Direct Gate 2 Pinpoint Gates L/T Injection Pressure First Pressure (kg/cm 2 ) Second Pressure (kg/cm 2 ) Back Pressure Mold Temperature Screw Temperature C1( C) C2( C) C3( C) Material Temperature( C) Figure 1. Relationship between Izod Impact Strength and Temperature Test Sheet: 1/4 x1/2 x2 1/2 Rod Izod Impact Strength(kg-cm/cm) Temperature( C) 6

10 Figure 2. Stress Strain Curve Test Sheet: ASTM Dumb Bell I Elongation Speed 50 mm/min Temperature: 23 Tensile Strength(kg/cm 2 ) Elongation (%) Figure 3. Relationship between Tensile Strength and Temperature Test Sheet: ASTM Dumb Bell I Elongation Speed: 50 mm/min Tensile Strength (kg/cm 2 ) Temperature ( ) 7

11 Figure 4. Relationship between Flexural Strength and Temperature Test Sheet: 1/2 x1/4 x5 Rod Elongation Speed: 15 mm/min Flexural Strength (kg/cm 2 ) Temperature ( ) Figure 5. Relationship between Flexural Modulus and Temperature Test Sheet: 1/2 x1/4 x5 Rod Elongation Speed: 15 mm/min Flexural Modulus (kg/cm 2 ) Temperature ( ) 8

12 Figure 6. Flexural Fatigue Curve Stress (kg/cm 2 ) Break Times Figure 7. Tensile Creep Curve Test Sheet: ASTM Dumb Bell Temperature 23 Elongation (%) Time (hrs) Figure 8. Relationship between Heat Deflection Temperature and Fiber Strength Test Sheet (Unannealed): 1/2 x1/2 x5 Rod Heat Deflection Temperature ( ) Fiber Stress (kg/cm 2 ) 9

13 Figure 9. Thermal Shrinkage Test Sheet: ASTM Dumb Bell I Heating Time: 2 hr Thermal Shrinkage (%) Temperature ( ) Figure 10. Relationship between Tensile Strength and Carbon Arc Radiation Time in the Accelerated Weather Resistance Test (uncolored material) Carbon Arc Radiation Temperature: 40 Water Injection Time: 1 min/ 40 min Tensile Strength (kg/cm 2 ) Carbon Arc Radiation Time 10

14 Figure 11. Relationship between Izod Impact Strength and Carbon Arc Radiation Time in the Accelerated Weather Resistance Test (uncolored material) Carbon Arc Radiation Temperature: 40 Water Injection Time: 1 min/ 40 min Izod Impact Strength (kg-cm/cm) Carbon Arc Radiation Time Figure 12. Relationship between DuPont Impact Strength and Carbon Arc Radiation Time in the Accelerated Weather Resistance Test (uncolored material) Carbon Arc Radiation Temperature: 40 Water Injection Time: 1 min/ 40 min DuPont Impact Strength (kg-cm/mm) Carbon Arc Radiation Time 11

15 Figure 13. Accelerated Weather Resistance Test of Black Material (Tensile Strength) Carbon Arc Radiation Temperature: 40 Water Injection Time: 1 min/ 40 min Tensile Strength (kg/cm 2 ) Carbon Arc Radiation Time Figure 14. Accelerated Weather Resistance Test of Black Material (Izod Impact Strength) Carbon Arc Radiation Temperature: 40 Water Injection Time: 1 min/ 40 min Izod Impact Strength (kg-cm/cm)) Black Uncolored Carbon Arc Radiation Time Figure 15. Accelerated Weather Resistance Test of Black Material (DuPont Impact Strength) DuPont Impact Strength (kg/-cm/mm) 12

16 DuPont Impact Strength (kg-cm/cm) Black Uncolored Carbon Arc Radiation Time Figure 16. Relationship between Flow Length/Thickness (L/T) and Molding Temperature 1 oz Injection Machine Injection Pressure: 950 kg/cm2 Mold Temperature: 50 Flow Length/Thickness (L/T) Ordinary ABS Molding Temperature ( ) 13

17 Figure 17. Relationship between Spiral Flow Length and Molding Temperature 1 oz Injection Machine Injection Pressure: 950 kg/cm2 Mold Temperature: 50 Spiral Flow (cm) Molding Temperature ( ) Figure 18. Relationship between Flow Length/Thickness (L/T) and Molding Temperature of AF oz Injection Machine Mold Temperature: 50 Flow Length/Thickness (L/T) Molding Temperature ( ) 14

18 Figure 19. Relationship between Molding Product Shrinkage and Injection Pressure 5oz Injection Machine Molding Temperature: 200 Test Sheet: ASTM Dumb Bell I Molding Product Shrinkage (%) Ordinary ABS Injection Pressure (kg/cm 2 ) Figure 20. Relationship between Tensile Strength and Material Temperature Elongation Speed: 50 mm/min Test Sheet: ASTM Dumb Bell I Tensile Strength (kg/cm 2 ) Ordinary ABS Molding Temperature ( ) 15

19 Figure 21. Relationship between Molding Temperature and Izod Impact Strength Test Sheet: 1/4 x1/2 x2 1/2 Rod Izod Impact Strength (kg-cm/cm) Ordinary ABS Molding Temperature ( ) Figure 22. Relationship between Retention Time in the Screw and Izod Impact Strength of AF3500 Test Sheet: 1/4 x1/2 x2 1/2 Rod Izod Impact Strength (kg-cm/cm) Material Temperature Retention Time of Plastic Material in the Screw (min) 16

20 Figure 23. Relationship between Gloss and Mold Temperature 10 oz Injection Machine Molding Temperature: 200 Injection Pressure: 700 kg/cm2 Gloss (%) Mold Temperature( ) Figure 24. Relationship between Gloss and Molding Temperature 10 oz Injection Machine Mold Temperature: 40 Gloss (%) Molding Temperature( ) 17

21 Figure 25. Relationship between Izod Impact Strength and Recovery Frequency 10 oz Injection Machine Molding Temperature: 220 Test Sheet: 1/4 x1/2 x2 1/2 Rod Izod Impact Strength (kg-cm/cm) Ordinary ABS Recovery Frequency 18

22 Formosa Chemicals & Fiber Corporation, Plastics Division Company Address: No. 201, Tung Hwa North Road, Taipei, Taiwan Tel: Customer Service: Fax:

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