LIST OF TABLES. xix. TABLE No.

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1 xix LIST OF TABLES TABLE No. DESCRIPTION PAGE No. CHAPTER Forms of various fillers Typical chemical analyses of wollastonite filler grades Typical properties of wollastonite Economic benefits of using wollastonite as functional 39 filler. 2.5 Effect of filler type on properties Electroless plating (Nickel) procedure 58 CHAPTER Part Description Table Specifications of Infrared Quartz Heating Element 88 CHAPTER Technical specifications of CaSiO3 as received from Mehta sons 4.2 Blends formulation for polyamide 6 / CaSiO Properties of ABS Properties of Nylon Etching solution Details Activation solution Electroless plating solution Copper plating solution 109 CHAPTER Observation table for plastics identification Specific gravity Test Density of ABS and Nylon6 and its composites under 129 study 5.4 (a) Melting point values of Normal samples (b) Melting point observations on Electroplated samples Explanation for adhesion test ratings Observations of Heat Sink Test on ABS, N6, and CaSiO3 140 reinforced N6 samples 5.7 Details of the salt spray test on the electroplated samples Technical specifications of SEM-EDS installed in SAIF, 161 STIC, Cochin CHAPTER Properties of Normal ABS Samples Properties of Normal N6 Samples Properties of Normal ABS Samples Properties of Normal N6 Samples Tensile, flexure, and compressive properties of ABS samples. 6.6 Tensile, flexure, and compressive properties of N6 samples

2 xx 6.7 Tensile, flexure, and compressive properties of Normal N6 183 and CaSiO3 reinforced N6 composites 6.8 Tensile, flexure and compressive properties of water 184 absorbed N6 and CaSiO3 reinforced N6 composites 6.9 Results of Acetic Acid Etching on ABS, N6 and CaSiO3 197 reinforced N6 Composites 6.10 Surface Roughness Values of Uncoated (Non-plated) and 199 Coated (plated) 6.11 Coating Thickness Measurement Values of Electroplated 201 ABS and N6 Samples 6.12 Tensile, flexure and compressive properties of ABS, N6 214 and CaSiO3 reinforced N6 composites under electroplated 6.13 Wear test results of ABS: Details of changes in wear 226 coefficient and wear loss in grams for applied constant normal loads for varying velocities and constant sliding distance of 1000 m 6.14 Pin on Disk wear test results of N6: Details of changes in 236 wear coefficient and wear loss in grams for applied constant normal loads for varying velocities and constant 6.15 Hardness Values of ABS, N6 and N6/CaSiO3 samples LOI of ABS and N6 and CaSiO3 reinforced N6 composites Void Content for N6 / CaSiO3 Composites Properties of ABS and Unreinforced N Electrical Properties of ABS, N6, and CaSiO3 reinforced 263 N6 Composites under normal 6.20 Electrical Properties of ABS, N6, and CaSiO3 reinforced 266 N6 Composites under water absorbed 6.21 Breakdown Voltage and Dielectric Strength of ABS, N6 and CaSiO3 reinforced N6 Composites under Normal 268 Conditions Breakdown Voltage and Dielectric Strength of ABS, N6, 268 and CaSiO3 Reinforced N6 Composites under Water Absorbed Conditions 6.23 Chemical resistance tests in terms of percentage weight change in weight after dipping for 24 hours of the ABS, N6, and CaSiO3 reinforced N6 composites 270 CHAPTER Technical Details of the Injection Moulding Machine used in the study 298

3 xxi FIGURE NO. LIST OF FIGURES DESCRIPTION PAGE NO. CHAPTER Classification of composites Molecular structure of acrylonitrile-butadiene-styrene (ABS) 2.3 Typical molecular structure of polyamide series Kink sites, edge sites and ad atoms on electrodeposited surface. 2.5 The Haring-Blum cell Electroplating process 70 CHAPTER Line diagram of the plating unit Electroplating setup at Alpha College of Engineering, Bengaluru 3.3 Polypropylene tank used in the study Temperature controller, thermocouple and heating element Electroplating anode bags used in copper and nickel plating 3.6 Copper and nickel anodes used in the study Transformer used in the study Chemicals used in electroplating 93 CHAPTER Research flow chart Steps involved in electroplating of ABS plastics Chromic acid preparation process ABS tensile samples before etching ABS tensile samples after etching Activator solution preparation process ABS tensile samples subjected to tin chloride treatment (activator solution a) ABS tensile samples subjected to silver nitrate treatment (activator solution b) Preparation of electroless plating solution Samples dipped in electroless solution Hardness / Impact samples after electro less plating and rinsing ABS tensile samples after acid copper plating 109

4 xxii 4.13 ABS tensile samples after nickel plating ABS tensile samples after chrome flash Stepwise plating process of ABS samples from right to left (b: basic sample, i: etched samples, t: activated samples, ns: silver nitrate treated samples, es: electroless treated, c: copper plated, n: nickelplated, ch: chrome flashed) Steps involved in electroplating of N6 plastics Samples before painting Scoring of samples with sand paper Scored samples after painting Conductivity measurement using digital multimeter Conductive painting of scored tensile N6 samples Transfer of acid copper solution into electroplating tub Immersion of conductive painted flexure samples into acid copper tub Rinsing of copper plated samples Preparation of nickel plating solution Immersion of copper plated samples in nickel plating bath Nickel plated flexure samples Chrome salt solution Addition of barium carbonate to the chrome solution Chrome flashed hardness sample 121 CHAPTER Plastics identification chart Acetic acid immersion test Surface roughness measurement Samples subjected to surface roughness tests Samples subjected for microscopic coating thickness analysis Heat sink analysis samples Samples subjected to salt spray test Universal testing machine model: Tue-C 400 of 40 T Tensile test sample as per ASTM D638 (Type I) Compression and ash content test sample Flexural testing machine used in the study Dimensions of flexure test sample as per ASTMD Hardness /Drop impact / Void content test sample Modified Drop weight impact testing machine Wear test specimen used in the study 155

5 xxiii 5.16 Electronic balance with wear sample Wear testing machine used in the research 156 CHAPTER Tensile test: Stress vs. Strain diagram of ABS Samples Tensile test: Stress vs. Strain diagram of N6 Samples Flexure test: Stress vs. Strain diagram of ABS samples Flexure test: Stress vs. Strain diagram of N6 samples Compression test: Stress vs. Strain diagram of ABS samples Compression test: Stress vs. Strain diagram of N6 samples Tensile test: Stress vs. Strain diagram of ABS Samples Tensile test: Stress vs. Strain diagram of N6 samples Percentage water absorption of ABS and N6 samples Tensile test: Stress vs. Strain diagram of ABS Normal and Water absorbed samples Tensile test: Stress vs. Strain diagram of N6 Normal and Water absorbed samples Flexure test: Stress vs. Strain diagram of ABS Normal and Water absorbed samples Flexure test: Stress vs. Strain diagram of N6 Normal and Water absorbed samples Compressive test: Stress vs. Strain diagram of ABS Normal and Water absorbed samples Compressive test: Stress vs. Strain diagram of N6 Normal and Water absorbed samples Scanning electron micrograph of CaSiO3 used in the study Percentage water absorption by N6 and CaSiO3 reinforced N6 Composites Tensile test: Stress vs. Strain diagram of N6 and CaSiO3 reinforced N6 composites under normal Tensile test: Stress vs. Strain diagram of N6 and CaSiO3 reinforced N6 composites under water absorbed Scanning electron micrograph and EDS of fractured (tensile) 1% N6 samples under Normal Scanning electron micrographs of fractured (tensile) 3% N6 samples under Normal

6 xxiv 6.22 Scanning electron micrographs of fractured (tensile) 5% N6 samples under Normal Flexure test: Stress vs. Strain diagram of N6 and CaSiO3 reinforced N6 composites under normal Flexure test: Stress vs. Strain diagram of N6 and CaSiO3 reinforced N6 composites under water absorbed Compression test: Stress vs. Strain diagram of N6 and CaSiO3 reinforced N6 composites under normal Compression test: Stress vs. Strain diagram of N6 and CaSiO3 reinforced N6 composites under water absorbed (a) Activated (silver nitrate) sample (b) Copper Plated Samples (c) Nickel Plated Samples (d) Coating thickness analysis of electroplated ABS samples using SEM / EDS analysis (a) Silver Painted N6 sample (b) Copper plated N6 Sample (c) Nickel plated N6 Sample (d) Chromium plated N6 Sample Adhesion Tape Test Tension test: Stress vs. Strain diagram of ABS, N6 and CaSiO3 reinforced N6 composites under electroplated Flexure test: Stress vs. Strain diagram of ABS, N6 and CaSiO3 reinforced N6 composites under electroplated Compression test: Stress vs. Strain diagram of ABS, N6 and CaSiO3 reinforced N6 composites under electroplated Energy absorbed vs. Drop mass of samples under normal, 24 hours water absorbed and electroplated for a drop height of 400 mm and an impact speed of 2.5 m/s Energy absorbed vs. Drop mass of samples under normal, 24 hours water absorbed and electroplated for a drop height of 800 mm and an impact speed of 3.5 m/s

7 xxv 6.35 Energy absorbed vs. Drop mass of samples under normal, 24 hours water absorbed and electroplated for a drop height of 1200 mm and an impact speed of 4.5 m/s SEM of 5 % CaSiO3 reinforced N6 samples before impact SEM of 5 % CaSiO3 reinforced N6 samples after impact Pin on disk wear testing apparatus (a) 6.40 (b) 6.40 (c) 6.40 (d) Coefficient of wear and Wear loss as a function of Rubbing velocity and Load for a constant sliding distance of 1000 m for Normal ABS Samples. SEM of Normal ABS sample subjected to applied load of 7 kg, sliding velocity of 2.5 m/s and sliding distance of 1000 m SEM of Normal ABS sample subjected to applied load of 7 kg, sliding velocity of 5 m/s and sliding distance of 1000 m. (at x100 magnification) SEM of Normal ABS sample subjected to applied load of 7 kg, sliding velocity of 5 m/s and sliding distance of 1000 m. (at x1500 magnification) SEM of Normal ABS sample subjected to applied load of 7 kg, sliding velocity of 7.5 m/s and sliding distance of 1000 m Coefficient of wear and Wear loss as a function of Rubbing velocity and Load for a constant sliding distance of 1000 m for 24 hours water absorbed ABS Samples Heat generated and COW as a function of applied Load for a constant for 24 hours water absorbed ABS Samples SEM of 24 hours water absorbed ABS sample subjected to applied load of 7 kg, sliding velocity of 2.5 m/s and Coefficient of wear and Wear loss as a function of Rubbing velocity and Load for a constant sliding distance of 1000 m for Electroplated ABS Samples Heat generated and COW as a function of applied Load for a constant for electroplated ABS Samples

8 xxvi (a) 6.48 (b) 6.48 (c) (a) 6.50 (b) (a) SEM of Electroplated ABS sample subjected to applied load of 7 kg, sliding velocity of 5 m/s and sliding distance of 1000 m Coefficient of wear and wear loss as a function of Rubbing velocity and Load for a constant sliding distance of 1000 m for normal N6 Samples SEM of Normal N6 sample subjected to applied load of 7 kg, sliding velocity of 2.5 m/s and sliding distance of 1000 m SEM of Normal N6 sample subjected to applied load of 7 kg, sliding velocity of 5 m/s and sliding distance of 1000 m SEM of Normal N6 sample subjected to applied load of 7 kg, sliding velocity of 7.5 m/s and sliding distance of 1000 m Coefficient of wear and wear loss as a function of Rubbing velocity and Load for a constant sliding distance of 1000 m for 24 hours water absorbed N6 Samples Heat generated as a function of rubbing velocity and applied load for a constant for 24 hours water absorbed N6 Samples SEM of 24 hours water absorbed N6 sample subjected to applied load of 1 kg, sliding velocity of 5 m/s and Enlarged view of SEM of 24 hours water absorbed N6 sample subjected to applied load of 1 kg, sliding velocity of 5 m/s and Coefficient of wear and Wear loss as a function of Rubbing velocity and Load for a constant sliding distance of 1000 m for EP-N6 Samples Heat generated vs. sliding speed for a constant sliding distance of 1000 m for Electroplated N6 Samples under varying loads Relationship between wear coefficient of PA6 metal combination and wear rate of PA6 sample and PV value for dry sliding condition, water absorbed condition and electroplated condition Effect of sliding speed and applied load on wear coefficients of 1 %, 3 %, and 5 % CaSiO3 reinforced N6 samples under dry sliding

9 xxvii 6.54 (b) 6.54 (c) 6.54 (d) 6.54 (e) 6.54 (f) 6.54 (g) 6.54 (h) 6.54 (i) 6.54 (j) 6.55 (a) 6.55 (b) 6.55 (c) Effect of sliding speed and applied load on wear loss of 1 %, 3 %, and 5 % CaSiO3 reinforced N6 samples under dry sliding Effect of sliding speed and applied load on heat generated of 1 %, 3 %, and 5 % CaSiO3 reinforced N6 samples under dry sliding SEM of N6+1% CaSiO3 reinforced sample subjected to applied load of 1 kg, sliding velocity of 5 m/s and sliding distance of 1000 m SEM of N6+1% CaSiO3 reinforced sample subjected to applied load of 1 kg, sliding velocity of 7.5 m/s and SEM of N6+1% CaSiO3 reinforced sample subjected to applied load of 3 kg, sliding velocity of 7.5 m/s and SEM of N6+3% CaSiO3 reinforced sample subjected to applied load of 1 kg, sliding velocity of 5 m/s and sliding distance of 1000 m SEM of N6+3% CaSiO3 reinforced sample subjected to applied load of 1 kg, sliding velocity of 7.5 m/s and SEM of N6 +5% CaSiO3 reinforced sample subjected to applied load of 1 kg, sliding velocity of 5 m/s and sliding distance of 1000 m SEM of N6+5% CaSiO3 reinforced sample subjected to applied load of 1 kg, sliding velocity of 7.5 m/s and Effect of sliding speed and applied load on wear coefficients of 1%, 3%, and 5% CaSiO3 reinforced N6 samples under 24 hours water absorbed Effect of sliding speed and applied load on wear loss of 1%, 3%, and 5% CaSiO3 reinforced N6 samples under 24 hours water absorbed Effect of sliding speed and applied load on heat generated of 1%, 3%, and 5% CaSiO3 reinforced N6 samples under 24 hours water absorbed

10 xxviii 6.56 SEM image of 5% CaSiO3 reinforced N6 sample subjected to a sliding speed of 7.5 m/s and load of 7 Kg (Yellow circles: agglomerates of CaSiO3; Thin red circles: Dispersed products of hydration; Thick red circle: C-H- S; Thick green circle: presence of micropores) (a) 6.57 (b) Effect of sliding speed and applied load on Coefficient of friction of 1%, 3%, and 5% CaSiO3 reinforced N6 samples under electroplated Effect of sliding speed and applied load on Wear Loss of 1%, 3% and 5% CaSiO3 reinforced N6 samples under electroplated (c) Effect of sliding speed and applied load on Heat generated of 1%, 3% and 5% CaSiO3 reinforced N6 samples under electroplated Time taken to peel-off vs. sliding velocity and applied load for electroplated samples (1%, 3% and 5%). SEM of worn out 5% CaSiO3 reinforced N6 electroplated sample (yellow circles: dislodged electroplated particles that causes wear) Hardness Test Values of ABS, N6 and N6/CaSiO Percentage Ignition Loss of ABS, N6 and N6 / CaSiO3 Composites Percentage of Void Content in N6 / CaSiO3 Composites SEM of 1% N6/CaSiO3 Samples SEM of 3% N6/CaSiO3 Samples SEM of 5% N6/CaSiO3 Samples Comparison of Surface and Volume resistivity of ABS with N6 and CaSiO3 reinforced N6 Composites in Normal Conditions Surface and Volume Resistivity of N6 and CaSiO3 reinforced N6 Composites in Water Absorbed Conditions Breakdown voltage and Dielectric strength of N6 and CaSiO3 reinforced N6 Composites in Normal and Water absorbed (a) Chemical resistance of ABS samples (b) Chemical resistance of N6 samples 271

11 xxix 6.69 (c) 6.69 (d) Chemical resistance of N6 reinforced with 1% CaSiO3 samples Chemical resistance of N6 reinforced with 3% CaSiO3 samples (e) Chemical resistance of N6 reinforced with 5% CaSiO3 samples 272 CHAPTER Tensile test specimen (ABS) Meshed model of the tensile test specimen (ABS) Tensile strength distribution of ABS (EP) in MPa Comparison of experimental and FEA results of Tensile Strength samples Compression test specimen (N6) Meshed model of the tensile test specimen (N6) Compressive strength distribution of N6 (EP) in MPa Comparison of experimental and FEA results of Compressive Strength samples Impact test specimen (N6+1%) Meshed model of the Impact test specimen (N6+1%) Impact stress distribution of N6+1% (EP) in MPa Deformation due to impact in N6+1% CaSiO3 Electroplated Comparison of experimental and FEA results of Impact test samples Flexure test specimen with indenter and supports (N6+3%) Meshed model of the Flexure test specimen (N6+3%) Flexure stress distribution of N6+3% (EP) in MPa Comparison of experimental and FEA results of Flexural test samples 288 CHAPTER Metalized polyester film Injection moulding machine used in the development of samples at shrinidhi plastics Developed textile samples at shrinidhi plastics Electroplating procedure on ABS plastics Electroplating procedure adopted for plating on N6 / PA6 samples N6 buckles and stoppers developed in coordination with shrinidhi plastics

12 xxx LIST OF ABBREVIATIONS ABBREVIATION ABS AFM ASTM c.d CAD CAE CaSiO3 C-H-S CM CMCs COW CPs DM DSC EC EDS EI EP EP N6 EP-ABS FEA FEM FT-IR GRP HDPE HDT hrs HST HVLP IM ipp IS LDPE LOI Md DESCRIPTION Acrylonitrile Butadiene Styrene Atomic Force Microscopy American Society Of Testing Materials Current Density Computer-Aided Design Computer-Aided Engineering Calcium Inosilicate /Calcium Silicate / Calcium Meta Silicate / Wollastonite calcium silicate hydrate Compression Moulding Ceramic Matrix Composites Coefficient of Friction Conductive Paints Demineralised Differential Scanning Calorimetry Electrolytic Copper Energy-Dispersive X-Ray Spectroscopy Electromagnetic Interference Electroplated Electroplated Nylon6 Electroplated - polyacrylonitrile Butadiene Styrene Finite Element Analysis Finite Element Methods Fourier Transform Infrared Analysis Glass Fibre Reinforced Plastic High Density Polyethylene Heat Deflection Temperature Hours Heat Sink Temperature High-Volume, Low-Pressure Injection Moulding Isotactic Polypropylene Standards India Low-Density Polyethylene Loss On Ignition Measured Density

13 xxxi MMCs Metal Matrix Composites MRN Mineral-Reinforced Nylon N6 Nylon 6 NDT Nondestructive Tests PA6 Polyamide 6 PA66 Polyamide 66 PAI Polyamideimide PCB Printed Circuit Boards PDO Phosphorous De-Oxidised PE Polyethylene PEEK Polyether Ether Ketone PEK Polyetherketone PMCs Polymer Matrix Composites POM Polyoxymethylene POP Plating-On-Plastics PP Polypropylene PS Polystyrene PTFE Polytetrafluoroethylene PVC Polyvinyl Chloride RH Relative Humidity RTM Resin Transfer Moulding SAPs Solid Anode Particles SEM Scanning Electron Micrograph Td Tg Tm UHM-PE UHMWPE Theoretical Density Glass Transition Temperature Melting Temperature Ultra High Molecular Polyethylene Ultra-High Molecular Weight Polyethylene