Processing controlled properties of vibration welded

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Lin, Schlarb
Vibration Welded Thermoplastic Nanocomposites
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Zeitschrift Kunststofftechnik
Journal of Plastics Technology
© 2013 Carl Hanser Verlag, München
www.kunststofftech.com
archivierte, peer-rezensierte Internetzeitschrift des Wissenschaftlichen Arbeitskreises Kunststofftechnik (WAK)
archival, peer-reviewed online Journal of the Scientific Alliance of Polymer Technology
www.kunststofftech.com; www.plasticseng.com
eingereicht/handed in:
angenommen/accepted:
08.01.2013
27.03.2013
L.Y. Lin1, A. K. Schlarb1, 2, 3
1
Composite Engineering, University of Kaiserslautern, Kaiserslautern, Germany
INM-Institute for New Materials, Saarbrucken, Germany
3
Research Center OPTIMAS, University of Kaiserslautern, Kaiserslautern, Germany
2
PROCESSING CONTROLLED PROPERTIES OF
VIBRATION WELDED THERMOPLASTICBASED NANOCOMPOSITES
In the present work, polypropylene based nanocomposites were compounded using a twin-screw extruder followed by injection molding. The related plaques were joined by linear vibration welding. The
mechanical performances were examined by using Charpy impact testing. It was found that the incorporation of rigid particles improved the impact strength of polypropylene. The maximal impact strength
was achieved at 1 vol.% TiO2 filled polypropylene. By contrast, the impact strength of the welds decreased with increased nanoparticle contents. The highest weld strength was achieved at low welding
pressure without nanoparticles. In comparison to non-welded samples low mechanical performance
currently do not allow to transfer the reinforcing effects of nanoscale fillers into welded structures.
PROZESSGESTEUERTE EIGENSCHAFTEN
VON VIBRATIONSGESCHWEISSTEN THERMOPLASTBASIERTEN NANOKOMPOSITEN
In einem Doppelschneckenextruder wurden Polypropylen Nanokomposite compoundiert und anschließend spritzgegossen. Die spritzgegossenen Fügeteile wurden im Vibrationsschweißverfahren
stoffschlüssig verbunden und im Anschluss die mechanischen Eigenschaften im Schlagversuch nach
Charpy charakterisiert. Die Resultate zeigen, dass die Einarbeitung von Nanopartikeln die Kerbschlagzähigkeit von Polypropylen erhöht, wobei ein Optimum bei 1 Vol.-% TiO2 erreicht wird. Im Gegensatz dazu fällt die Schlagzähigkeit von geschweißten Nanokompositen extrem ab. Die höchste
Scheißnahtfestigkeit wird bei niedrigen Schweißdrücken erreicht. Die im Vergleich zu ungeschweißten
Proben niedrigen Schlagzähigkeiten erlauben es derzeit nicht die verstärkende Wirkung nanoskaliger
Füllstoffe in geschweißten Strukturen umzusetzen.
© Carl Hanser Verlag
Zeitschrift Kunststofftechnik / Journal of Plastics Technology 9 (2013) 3
Lin, Schlarb
Processing Controlled Properties of Vibration
Welded Thermoplastic-based Nanocomposites
L.Y. Lin, A. K. Schlarb
1
INTRODUCTION
In industrial series production, vibration welding is a commonly used welding
method to join thermoplastics. It is well known that the processing history has a
decisive influence on the structure and properties of thermoplastic materials. In
particular, welding processes lead to high gradients in stress and therefore in
the material morphology and properties. In the last 30 years, the basic relationships between welding process, morphology and properties are well understood
for unreinforced thermoplastics; however, there is a lack of knowledge especially in the field of welding of a new class of composites such as thermoplastics
reinforced with nano-sized fillers, so-called nanocomposites.
At the beginning of vibration welding, the parts to be welded are clamped into
upper and lower tools, and then they are pressed together under defined pressure. After this, one of these parts is brought to vibration at adjusted frequency
of 80-300 Hz over amplitude between 0.25-2.5 mm (Figure 1). Energy is initiated by frictional forces at the contact surface, which causes the melting of the
material at the interface. As a result, a molten layer appears between the welding parts. The melt squeezes out of the interface under externally applied normal pressure and a welding bead is formed outside of the contact surface. After
cooling, two parts are joined together. The relative movement of the weld parts
is defined as weld penetration s [1].
Figure 1. Schematic representation (left) and video demonstration (right) of
vibration welding process.
As a new class of materials, polymer nanocomposites (PNC) achieve more and
more attentions in the last decade. The extremely high surface areas of nano-
Journal of Plastics Technology 9 (2013) 3
130
Lin, Schlarb
particles can result in a great amount of interphase in the composite and thereby a strong interaction between filler and matrix is created [2, 3]. The incorporation of inorganic nanoparticles into polymer matrices has been proved to be one
of the effective ways for improving the mechanical properties of the matrix [4-8].
The improvement of the properties is dependent on the type, geometry and location of particles to the direction of stress in the component and the particle/matrix interphase as well as the matrix material itself. Therefore, it is of great
interest to check whether or not the high mechanical performance can be exploited in welded joints. In the present study, polypropylene based
nanocomposites were used as the welding parts, in order to examine the relationship between processing parameters, morphology and mechanical properties.
2
EXPERIMENTAL
2.1
Materials and sample preparation
Commercial polypropylene homo-polymer (HD120MO) was provided by Borealis group. The melt flow rate and the density of this product are 8 g/10 min (230
°C/2.16 kg) and 0.908 g/cm3, respectively. Hombitec RM 130 F was used as
nanofiller, which was supplied by Sachtleben Chemie GmbH. This type of TiO2nanoparticles exhibits an acicular form and has a mean diameter of about 15
nm. All of the materials were used as received.
Polypropylene nanocomposites with 5 vol.% content of TiO2 particles were first
extruded by a Theysohn co-rotating twin-screw extruder under the screw speed
of 160 rpm. The temperatures were set from 190 °C near the hopper to 210 °C
at the die. The obtained PP/TiO2 nanocomposites were then diluted to 0.5, 1
and 4 vol.% TiO2 particle content using the same extruder under the identical
conditions. Then neat PP and PP/TiO2 nanocomposites were injection molded
to 50x50x4 mm3 sheets, which were used as welding components in the vibration welding experiments.
2.2
Welding experiments
Welding experiments were performed on a fully automatic Branson Ultraschall
Lab.-Vibration welding machine M112H. The friction force, amplitude and penetration of the parts were recorded during the whole welding process. The welding pressure varied from 0.4 to 4.0 MPa, while the amplitude and frequency of
vibration were kept at constant values of 0.7 mm and 240 Hz, respectively. The
welding time was chosen such that all the welding process reached the steady
state.
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2.3
Measurement of the Impact strength
The Charpy impact strength of the specimens (50x6x4 mm3) was tested according to DIN 53453 by using an impact pendulum at following conditions: room
temperature, incident impact speed: 2.9 m/s, incident energy of the hammer: 4
J. Prior to the Charpy impact tests, the welding bead on the impact side was
removed. At least 10 samples were tested. The samples were sawed perpendicular to the welding plane (xy-plane) from the welds.
2.4
Characterization of the morphology
The morphology of the joints was analyzed on a light microscope (Zeiss
AxioSkop A1. M) using microtomed thin sections of approximately 10 µm thickness cut from the yz-plane of the welded plaque (Figure 1).
3
RESULTS AND DISCUSSION
3.1
Impact strength
The results of Charpy impact strength of unwelded (notched) and welded specimens are illustrated in Figure 2. The values are normalized on the data of the
neat polypropylene (filler loading = 0 vol.%).
Lin, Schlarb
Figure 2. Relative impact strength of different materials: left: unwelded materials, right: joints with different welding parameters and nanoparticle
contents.
132
Considering the Charpy-notched impact strengths of the parent materials, one
can recognize that the incorporation of nanoparticles into PP slightly improves
the impact strength of the basic matrix. The maximum of impact strength was
obtained at 1 vol.% TiO2 reinforcement, which is improved by approximately
7.7% compared to the neat matrix.
By contrast, the nanoparticles affect the Charpy impact strength of welds markedly. The addition of nanoparticles into PP reduces the impact strength at any
given welding pressure, as shown in Figure 2 (right side). For instance, at a
welding pressure of 2.0 MPa the impact strength of PP/TiO2 nanocomposite
with 1 vol.% particle content drops by about 43% compared to that of neat PP.
3.2
Microstructure of welds
The microstructure of the joints depends on the actual thermal, mechanical and
flow conditions in the welding seam, which all affect the crystallization behavior
of the molten layer during welding and consequently the mechanical properties.
Figure 3 shows, representatively, the polarization micrographs of PP and PP/
TiO2 nanocomposites.
Lin, Schlarb
Figure 3.
Light microscopic photographs of various welds:
(a) neat PP welded at 0.4 MPa, (b) PP with 0.5 vol.% TiO2 welded at
0.4 MPa,
(c) neat PP welded at 4.0 MPa and (d) PP with 0.5 vol.% TiO2 welded at 4.0 MPa.
133
Lin, Schlarb
It is obvious that the incorporation of nanofillers into polymer matrix leads to a
decrease of molten-film thickness at any given welding pressure in the studied
range. The reason might be the reduction of viscosity after addition of nanoparticle, which has been reported in the literatures [9, 10]. Similar to addition of nanoparticles, an increase in welding pressure also causes a decrease in moltenfilm thickness.
Figure 4a depicts the dependence of molten-film thickness on the welding pressure and filler content, high welding pressure as well filler content lead to a decrease in molten-film thickness. As a consequence, lower impact strength is
obtained at small molten-film thickness for all the studied materials (Figure 4b).
The possible reason may be that small weld area restricts the dissipation of
stress imposed during the mechanical testing due to different structure compared to bulk materials, and therefore reduces the load bearing capacity of the
joints.
Figure 4. (a) Dependence of molten-film thickness on welding pressure and
filler content and
(b) correlation between impact strength and molten-film thickness
(the measuring points correlate with different welding pressures).
4
CONCLUSIONS
The incorporation of Nano-TiO2 particles into a polypropylene matrix slightly
increases the impact strength of the bulk material. In contrast the impact
strength of the welds significantly decreases with the addition of nanofillers
even at a very low filler loading. The low mechanical performance currently
134
Lin, Schlarb
does not allow transferring the reinforcing effects of nanoscale fillers into welded structures.
Due to the incorporation of nanosized fillers the size and morphology of the
welded area converts. Even at low welding pressure with nanocomposites the
thickness of the molten layer decreases by about 25%. This indicates that the
nanoscaled TiO2 facilitates undoubtedly the flowability of the polypropylene.
As a first approximation the impact strength of the welded specimens correlates
with the thickness of the welding area.
Acknowledgements
The authors thank the German Research Foundation for the financial support
according to the DFG-graduate program 814. The authors are also grateful to
Mr. K.P. Schmitt, INM, Saarbrucken, for the helpful cooperation. We also thank
Borealis group and Sachtleben Chemie GmbH for the kindly supply of experimental materials.
This paper is mainly based on a talk presented at the ECCM15, Venice, Italy,
24-28 June 2012
References
[1]
Schlarb A.K.,
Ehrenstein G.W.
The impact strength of butt welded vibration welds
related to microstructure and welding history.
Polymer Engineering and Science, 37, pp. 16771682 (1989).
[2]
[3]
Ma D.L.,
Akpali Y.,
Li Y.,
Siegel R.,
Schardler L.
Effect of Titania Nanoparticles on the Morphology of
Low Density Polyethylene.
Lee K.Y.,
Goettler L.
Structure-Property Relationships in Polymer Blend
Nanocomposites.
Journal of Polymer Science: Part B: Polymer Physics, 43, pp. 488-497 (2005).
Polymer Engineering and Science, 44, pp. 11031111 (2004).
[4]
[5]
Schlarb A.K.,
Yang J.,
Zhang Z.
Creep Resistance of Thermoplastic
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Lehmann B.,
Schlarb A.K.,
Friedrich K.,
Modeling of Mechanical Properties of Nanoparticle
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Key Engineering Materials, 345-346, pp. 1621-1624
(2007).
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Lin, Schlarb
81-100 (2008).
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Tria S.,
Schlarb A.K.,
Elkedim O.
Tensile and tribological behaviors of PEEK/ nanoSiO2 composites compounded using ball milling
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Knör N.,
Gebhard A.,
Haupert F.,
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Polyetheretherketone (PEEK) Nanocomposites for
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Mechanical Properties.
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Stichworte:
Polypropylen, Nanokomposite,
Eigenschaftsbeziehungen
Vibrationsschweißen,
Prozess-Struktur-
Keywords:
Polypropylene nanocomposites, vibration welding, Process-structure-property
relationship.
136
Autor/author:
Dipl.-Ing. Leyu Lin
Prof. Dr.-Ing. Alois K. Schlarb
Lehrstuhl für Verbundwerkstoffe
Technische Universität Kaiserslautern
Gottlieb-Daimler-Straße, Geb. 44
67663 Kaiserslautern
Herausgeber/Editor:
Europa/Europe
Prof. Dr.-Ing. Dr. h.c. Gottfried W. Ehrenstein, verantwortlich
Lehrstuhl für Kunststofftechnik
Universität Erlangen-Nürnberg
Am Weichselgarten 9
91058 Erlangen
Deutschland
Phone: +49/(0)9131/85 - 29703
Fax.:
+49/(0)9131/85 - 29709
E-Mail-Adresse: ehrenstein@lkt.uni-erlangen.de
Verlag/Publisher:
Carl-Hanser-Verlag
Jürgen Harth
Ltg. Online-Services & E-Commerce,
Fachbuchanzeigen und Elektronische Lizenzen
Kolbergerstrasse 22
81679 Muenchen
Tel.: 089/99 830 - 300
Fax: 089/99 830 - 156
E-mail-Adresse: harth@hanser.de
E-Mail: alois.schlarb@mv.uni-kl.de
Webseite: http://www.mv.uni-kl.de/cce
Tel.: +49(0)631/205-5116
Fax: +49(0)631/205-5141
Amerika/The Americas
Prof. Prof. h.c Dr. Tim A. Osswald,
responsible
Polymer Engineering Center, Director
University of Wisconsin-Madison
1513 University Avenue
Madison, WI 53706
USA
Phone: +1/608 263 9538
Fax.:
+1/608 265 2316
E-Mail-Adresse: osswald@engr.wisc.edu
Beirat/Editorial Board:
Professoren des Wissenschaftlichen
Arbeitskreises Kunststofftechnik/
Professors of the Scientific Alliance of
Polymer Technology
Lin, Schlarb
137

Processing controlled properties of vibration welded

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