Rheological weldability

Last updated

Rheological weldability (RW) of thermoplastics considers the materials flow characteristics in determining the weldability of the given material. [1] The process of welding thermal plastics requires three general steps, first is surface preparation. The second step is the application of heat and pressure to create intimate contact between the components being joined and initiate inter-molecular diffusion across the joint and the third step is cooling. [2] RW can be used to determine the effectiveness of the second step of the process for given materials.

Contents

Rheology

Rheology is the study of material flow as well as how a material deforms under an applied force. [3] Rheological properties are typically applied to Non-Newtonian fluids but can also be applied to soft solids [4] such as thermoplastics at elevated temperatures experienced during the welding process. The material properties associated with the rheological behavior include viscosity, elasticity, plasticity, viscoelasticity, and the material's activation energy as a function of temperature. [3] [2]

Rheological properties

To understand the rheological properties of a material it is also important to recognize the stress strain relationship for that material at varying temperatures.  This relationship is attained through experimental measurement of the resultant deformation as a function of an applied force. [3]

Influences of microstructure and composition

A material's rheological behavior is influenced by a combination of the material's microstructure, its composition, the temperature and pressure acting on the material at a given time.  The rheological and viscoelastic properties of a polymer melt are sensitive to the material's molecular structure; including molecular weight distribution and effects of branching. As a result, rheology can be used to develop relationships between differing material combinations. [3]

Determining microstructure

Melt rheology has shown to be an accurate method in determining the polymer's molecular structure. [3] This is beneficial in determining weld compatibility between materials; as materials with drastically different flow characteristics will be more difficult to join compared to those with more closely matched viscosity and melting temperature properties. [5] This information can also be used to help determine weld parameters for the given welding process to be used.

Viscosity

The lower the η, the better the RW

Regarding sessile drop technique, wetting is characterized by degree of interfacial contact and quantified via contact angle (θc) of a liquid on a solid surface at equilibrium, as shown in Fig. 1. Interrelation between contact angle and surface tensions at equilibrium is given by the Young equation: [6]

Fig 1: An illustration of the sessile drop technique with a liquid droplet partially wetting a solid substrate at equilibrium.
th
C
{\displaystyle \theta _{C}}
is the contact angle, and
g
S
G
{\displaystyle \gamma _{SG}\ }
,
g
L
G
{\displaystyle \gamma _{LG}\ }
,
g
S
L
{\displaystyle \gamma _{SL}\ }
represent surface tensions of the solid-gas, gas-liquid, and liquid-solid interfaces, respectively. Contact angle.svg
Fig 1: An illustration of the sessile drop technique with a liquid droplet partially wetting a solid substrate at equilibrium. is the contact angle, and , , represent surface tensions of the solid–gas, gas–liquid, and liquid–solid interfaces, respectively.

Where:

For perfectly good wetting, contact angle (θc) at equilibrium should be minimized. However, it is valid only at equilibrium, and rate of the equilibrium depends on the balance between driving force of wetting and viscosity of the liquid. In the case of polymer melts, viscosity can be very high and it may take a long time to reach the equilibrium contact angle (dynamic contact angle is likely higher than the contact angle at equilibrium).

Consequently, for the evaluation of weldability, viscosity of molten thermoplastics (polymer melts) have to be taken into account since welding is a rapid process. It can be said that the lower the viscosity during welding process (at welding temperature and pressure), the better the weldability.

Recalling that viscosity (η) decreases with increasing temperature (T) and shear rate () for most polymer melts, weldability is better where temperature and shear rate (movement) are higher within the entire cross-section of the welding region. [2] [1]

Elasticity

The lower a material's elasticity , the better the RW

Elasticity is best described by stretching a rubber band. As one pulls on the rubber band it stretches and when the pulling force is lessened and finally removed the rubber band returns to its original length. Similarly when a force or load is applied to most materials the material deforms and as long as the force has not exceeded the material's yield strength the material will return to its original shape when the force or load is removed. The material property associated with a material's Elasticity is called Young's modulus and the relationship between the amount of deformation for a given load is described by Hooke's Law. [3]

Where , or the stress experienced by the material and equals the change in length divided by the original length multiplied by the material's elasticity or Yong's modulus "E".

Plasticity

The lower a material's plasticity , the better the RW

A material's ability to deform elastically while resisting flow is called plasticity. [3] When an applied force or load exceeds the material's yield strength the material begins to deform plastically and the material will no longer return to its original shape. During the welding processes of polymers, this is experienced at temperatures above the glass transition temperature and below the material's melting temperature. [3]

Viscoelasticity

Linear viscoelasticity

Linear viscoelastic behavior can be observed when a material experiences small and slow deformation at very slow shear rates, where the relaxation process has sufficient time to keep up with the process. This can also be experienced at the onset of larger deformation forces. [3]

Nonlinear viscoelasticity

A polymer's response to fast and large deformation forces is a non linear behavior and is more representative of the reactions experienced during the welding processes. [3]

Knowing the viscoelastic behavior allows for adjustments to temperature and pressure during the weld process in order to improve the weld quality. [5]

Activation energy

The lower the |Ea|, the better the RW

During operation of a welding process, the softened or molten portion of thermoplastics (polymer articles) is able to flow through the interface. Less flow results in less diffusion at the interface and lower weld strength. In order for a polymer melt to flow, macromolecular chain segments must be able to move. When the chain segments obtain sufficient thermal energy to overcome the energy barrier, they begin to move readily. The energy barrier is called activation energy (Ea). It can be said that if a polymer’s absolute value of activation energy (|Ea|) is lower, its weldability becomes better.

|Ea| values of such polymers as PVC decrease with increasing shear rate (), implying better weldability where shear rate (movement) is higher within the entire cross-section of the welding region. [2] [1]

Using viscosity-shear rate () data at various temperatures for a polymer, activation energy (Ea) can be calculated via Arrhenius equation: [7] [8] [9]

Where:

The absolute value of the activation energy (|Ea|) can be calculated by taking the natural logarithm of the Arrhenius equation. (see Arrhenius equation).

Weldability of polymers

Welding of polymers is dependent on intimate contact resulting in molecular diffusion and chain entanglement across the weld joint.  This action requires the polymer to be in a molten state where the melt viscosity and flow behavior have a drastic influence on the amount of diffusion and entanglement. [10] Therefore, the rheological weldability is best between materials with matching or very similar melting temperatures and melt viscosity. [2] Also as a material's viscosity and activation energies are reduced the weldability of that material is improved. [2] For example, welding semi-crystalline to compatible semi-crystalline material and amorphous to compatible amorphous material have exhibited the best results. [5]  While a rheological analysis can provide reasonable insight to a material's weldability, [2] in most cases production welding is typically prefaced with a series of tests to verify compatibility between both base materials as well as the process employed. [5]

Similar to welding metals, the solidified polymer weld experiences residual stresses inherent to the joining process.  With polymers, these residual stresses are in part due to the squeeze flow rate leading to a specific molecular alignment direction, ultimately influencing the weld strength and overall quality. [10]   Having a thorough understanding of the rheological properties of the materials being joined can aid in determining the resultant residual stresses and in turn provide insight to processing methods that could reduce these stresses. [10]

MATERIALWELDABILITY
ABSGood to Excellent
AcetalFair to Good
AcrylicGood
Acrylic Multi-polymerGood
Acrylic Styrene AcrylonitrileGood
Amorphous Polyethylene TerephthalatePoor to Fair
Butadiene StyreneGood to Excellent
CellulosicsGood
Polyvinylidene Fluoride (PVDF)Good
Perfluoro Alkoxy Alkane (PFA)Poor
Liquid Crystal PolymersFair to Good
NylonGood
PBT/Polycarbonate AlloyGood
Polyamide-imideFair to Good
PolyarylateGood
Polyaryl SulfoneGood
PolybutylenePoor to Fair
Polybutylene Terephthalate (PBT)Good
PolycarbonateGood to Excellent
Polyethylene Terephthalate (PET)Fair to Good
Polyetheretherketone (PEEK)Fair
PolyethermideGood
PolyethersulfoneGood to Excellent
PolyethyleneGood
PolymethylpenteneGood
Polyphenylene OxideGood
Polyphenylene SulfideGood
PolypropyleneGood to Excellent
PolystyreneGood to Excellent
PolysulphoneGood
PolyurethanePoor to Fair
PVC (Rigid)Good
Styrene AcrylonitrileGood to excellent

[5]

See also

Related Research Articles

Rheology is the study of the flow of matter, primarily in a fluid state, but also as "soft solids" or solids under conditions in which they respond with plastic flow rather than deforming elastically in response to an applied force. Rheology is a branch of physics, and it is the science that deals with the deformation and flow of materials, both solids and liquids.

A viscometer is an instrument used to measure the viscosity of a fluid. For liquids with viscosities which vary with flow conditions, an instrument called a rheometer is used. Thus, a rheometer can be considered as a special type of viscometer. Viscometers can measure only constant viscosity, that is, viscosity that does not change with flow conditions.

The Deborah number (De) is a dimensionless number, often used in rheology to characterize the fluidity of materials under specific flow conditions. It quantifies the observation that given enough time even a solid-like material might flow, or a fluid-like material can act solid when it is deformed rapidly enough. Materials that have low relaxation times flow easily and as such show relatively rapid stress decay.

Dynamic mechanical analysis is a technique used to study and characterize materials. It is most useful for studying the viscoelastic behavior of polymers. A sinusoidal stress is applied and the strain in the material is measured, allowing one to determine the complex modulus. The temperature of the sample or the frequency of the stress are often varied, leading to variations in the complex modulus; this approach can be used to locate the glass transition temperature of the material, as well as to identify transitions corresponding to other molecular motions.

Hemorheology, also spelled haemorheology, or blood rheology, is the study of flow properties of blood and its elements of plasma and cells. Proper tissue perfusion can occur only when blood's rheological properties are within certain levels. Alterations of these properties play significant roles in disease processes. Blood viscosity is determined by plasma viscosity, hematocrit and mechanical properties of red blood cells. Red blood cells have unique mechanical behavior, which can be discussed under the terms erythrocyte deformability and erythrocyte aggregation. Because of that, blood behaves as a non-Newtonian fluid. As such, the viscosity of blood varies with shear rate. Blood becomes less viscous at high shear rates like those experienced with increased flow such as during exercise or in peak-systole. Therefore, blood is a shear-thinning fluid. Contrarily, blood viscosity increases when shear rate goes down with increased vessel diameters or with low flow, such as downstream from an obstruction or in diastole. Blood viscosity also increases with increases in red cell aggregability.

In materials science and continuum mechanics, viscoelasticity is the property of materials that exhibit both viscous and elastic characteristics when undergoing deformation. Viscous materials, like water, resist shear flow and strain linearly with time when a stress is applied. Elastic materials strain when stretched and immediately return to their original state once the stress is removed.

<span class="mw-page-title-main">Elastomer</span> Polymer with rubber-like elastic properties

An elastomer is a polymer with viscoelasticity and with weak intermolecular forces, generally low Young's modulus (E) and high failure strain compared with other materials. The term, a portmanteau of elastic polymer, is often used interchangeably with rubber, although the latter is preferred when referring to vulcanisates. Each of the monomers which link to form the polymer is usually a compound of several elements among carbon, hydrogen, oxygen and silicon. Elastomers are amorphous polymers maintained above their glass transition temperature, so that considerable molecular reconformation is feasible without breaking of covalent bonds. At ambient temperatures, such rubbers are thus relatively compliant and deformable. Their primary uses are for seals, adhesives and molded flexible parts.

<span class="mw-page-title-main">Rheometer</span> Scientific instrument used to measure fluid flow (rheology)

A rheometer is a laboratory device used to measure the way in which a viscous fluid flows in response to applied forces. It is used for those fluids which cannot be defined by a single value of viscosity and therefore require more parameters to be set and measured than is the case for a viscometer. It measures the rheology of the fluid.

Rheometry generically refers to the experimental techniques used to determine the rheological properties of materials, that is the qualitative and quantitative relationships between stresses and strains and their derivatives. The techniques used are experimental. Rheometry investigates materials in relatively simple flows like steady shear flow, small amplitude oscillatory shear, and extensional flow.

<span class="mw-page-title-main">Melt flow index</span> Ease of flow of polymer melt

The Melt Flow Index (MFI) is a measure of the ease of flow of the melt of a thermoplastic polymer. It is defined as the mass of polymer, in grams, flowing in ten minutes through a capillary of a specific diameter and length by a pressure applied via prescribed alternative gravimetric weights for alternative prescribed temperatures. Polymer processors usually correlate the value of MFI with the polymer grade that they have to choose for different processes, and most often this value is not accompanied by the units, because it is taken for granted to be g/10min. Similarly, the test conditions of MFI measurement are normally expressed in kilograms rather than any other units. The method is described in the similar standards ASTM D1238 and ISO 1133.

<span class="mw-page-title-main">Shear thinning</span> Non-Newtonian fluid behavior

In rheology, shear thinning is the non-Newtonian behavior of fluids whose viscosity decreases under shear strain. It is sometimes considered synonymous for pseudo-plastic behaviour, and is usually defined as excluding time-dependent effects, such as thixotropy.

<span class="mw-page-title-main">Manfred Wagner</span> German chemical engineer

Manfred Hermann Wagner is the author of Wagner model and the molecular stress function theory for polymer rheology. He is a Professor for Polymer engineering and Polymer physics at the Technical University of Berlin.

The upper-convected Maxwell (UCM) model is a generalisation of the Maxwell material for the case of large deformations using the upper-convected time derivative. The model was proposed by James G. Oldroyd. The concept is named after James Clerk Maxwell.

<span class="mw-page-title-main">Pressure-sensitive adhesive</span> Type of non reactive adhesive

Pressure-sensitive adhesive is a type of nonreactive adhesive which forms a bond when pressure is applied to bond the adhesive with a surface. No solvent, water, or heat is needed to activate the adhesive. It is used in pressure-sensitive tapes, labels, glue dots, stickers, sticky note pads, automobile trim, and a wide variety of other products.

In geology, a deformation mechanism is a process occurring at a microscopic scale that is responsible for changes in a material's internal structure, shape and volume. The process involves planar discontinuity and/or displacement of atoms from their original position within a crystal lattice structure. These small changes are preserved in various microstructures of materials such as rocks, metals and plastics, and can be studied in depth using optical or digital microscopy.

<span class="mw-page-title-main">Time–temperature superposition</span>

The time–temperature superposition principle is a concept in polymer physics and in the physics of glass-forming liquids. This superposition principle is used to determine temperature-dependent mechanical properties of linear viscoelastic materials from known properties at a reference temperature. The elastic moduli of typical amorphous polymers increase with loading rate but decrease when the temperature is increased. Curves of the instantaneous modulus as a function of time do not change shape as the temperature is changed but appear only to shift left or right. This implies that a master curve at a given temperature can be used as the reference to predict curves at various temperatures by applying a shift operation. The time-temperature superposition principle of linear viscoelasticity is based on the above observation.

<span class="mw-page-title-main">Viscosity</span> Resistance of a fluid to shear deformation

The viscosity of a fluid is a measure of its resistance to deformation at a given rate. For liquids, it corresponds to the informal concept of "thickness": for example, syrup has a higher viscosity than water. Viscosity is defined scientifically as a force multiplied by a time divided by an area. Thus its SI units are newton-seconds per square metre, or pascal-seconds.

An important class of non-Newtonian fluids presents a yield stress limit which must be exceeded before significant deformation can occur – the so-called viscoplastic fluids or Bingham plastics. In order to model the stress-strain relation in these fluids, some fitting have been proposed such as the linear Bingham equation and the non-linear Herschel-Bulkley and Casson models.

Squeeze flow is a type of flow in which a material is pressed out or deformed between two parallel plates or objects. First explored in 1874 by Josef Stefan, squeeze flow describes the outward movement of a droplet of material, its area of contact with the plate surfaces, and the effects of internal and external factors such as temperature, viscoelasticity, and heterogeneity of the material. Several squeeze flow models exist to describe Newtonian and non-Newtonian fluids undergoing squeeze flow under various geometries and conditions. Numerous applications across scientific and engineering disciplines including rheometry, welding engineering, and materials science provide examples of squeeze flow in practical use.

Interfacial rheology is a branch of rheology that studies the flow of matter at the interface between a gas and a liquid or at the interface between two immiscible liquids. The measurement is done while having surfactants, nanoparticles or other surface active compounds present at the interface. Unlike in bulk rheology, the deformation of the bulk phase is not of interest in interfacial rheology and its effect is aimed to be minimized. Instead, the flow of the surface active compounds is of interest.

References

  1. 1 2 3 O.Balkan, A.Ezdesir (October 15–17, 2008). Rheological Weldability of Polymers. 12. International Materials Symposium (12.IMSP) Denizli. p. 1046.
  2. 1 2 3 4 5 6 7 Balkan, Onur; Demirer, Halil; Ezdeşir, Ayhan; Yıldırım, Hüseyin (2008). "Effects of welding procedures on mechanical and morphological properties of hot gas butt welded PE, PP, and PVC sheets". Polymer Engineering & Science. 48 (4): 732–746. doi:10.1002/pen.21014.
  3. 1 2 3 4 5 6 7 8 9 10 Dealy, John M.; Wang, Jian (2013). Melt rheology and its applications in the plastics industry (2nd ed.). Dordrecht: Springer. ISBN   9789400763951. OCLC   844732595.
  4. Schowalter, William Raymond (1978). Mechanics of non-Newtonian fluids. Oxford, England: Pergamon Press. ISBN   0080217788. OCLC   2645900.
  5. 1 2 3 4 5 Plastics and composites welding handbook. Grewell, David A., Benatar, Avraham., Park, Joon Bu. Munich: Hanser Gardener. 2003. ISBN   1569903131. OCLC   51728694.{{cite book}}: CS1 maint: others (link)
  6. Young, T. (1805). "An Essay on the Cohesion of Fluids". Phil. Trans. R. Soc. Lond. 95: 65–87. doi: 10.1098/rstl.1805.0005 . S2CID   116124581.
  7. Arrhenius, S.A. (1889). "Über die Dissociationswärme und den Einflusß der Temperatur auf den Dissociationsgrad der Elektrolyte". Z. Phys. Chem. 4: 96–116.
  8. Arrhenius, S.A. (1889). "Über die Reaktionsgeschwindigkeit bei der Inversion von Rohrzucker durch Säuren". ibid. 4: 226–248.
  9. Laidler, K. J. (1987) Chemical Kinetics,Third Edition, Harper & Row, p.42
  10. 1 2 3 2nd International Conference on Mechanical, Manufacturing and Process Plant Engineering. Awang, Mokhtar. Singapore. 2017-04-28. ISBN   9789811042324. OCLC   985105756.{{cite book}}: CS1 maint: location missing publisher (link) CS1 maint: others (link)