5/14/2012

MELT FLOW INDEX

Melt Index/ Melt Flow Rate ASTM D 1238

What is melt index What does MI tell us Significance and use. How to measure MI Factors affecting the test results.

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Melt Index/ Melt Flow Rate ASTM D 1238

What is Melt Index

Grams of material that flow through a simple die ( specified length and diameter) in 10 minutes using a loaded piston and a set temperature.
Load 2.16 kg or 5 kg or 21.6 kg TemperatureTemperature- 190 or 230 Deg C

Melt Index/ Melt Flow Rate ASTM D 1238

Generally PE 190 degC @ 2.16 KG PP 230 degC @ 2.16 kg

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Melt Index/ Melt Flow Rate ASTM D 1238

Weight Calculation

Melt Index/ Melt Flow Rate ASTM D 1238

5/14/2012

Melt Index/ Melt Flow Rate ASTM D 1238

Melt Index/ Melt Flow Rate ASTM D 1238

It is an inverse measure of melt viscosity the bigger, longer or more branched molecules get tangled up more, and therefore they flow (slide over one another) with more difficulty. The size of a molecule is sometimes referred to as molecular weight, so we can say that the higher the molecular weight, the higher the viscosity, Many factors affect polymers' flow properties. Molecular weight distribution, the presence of co-monomers, the degree of chain branching and crystallinity influence a polymer's MFI as well as heat transfer in polymer processing. Higher MW- Lower MFI vise versa

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Melt Index/ Melt Flow Rate ASTM D 1238 Knowing the MFI of a polymer is vital to anticipating and controlling its processing. Generally, higher MFI polymers are used in injection moulding, and lower MFI polymers are used with blow moulding or extrusion processes. MI is only a rough indicator of processing characteristics. It gives a rough idea of how long, or short, the molecular chains are in the sample being measured.

Melt Index/ Melt Flow Rate ASTM D 1238

High MFI Poor impact strength Poor tensile modulus

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Melt Index/ Melt Flow Rate ASTM D 1238

Effect of MI over properties Property As Melt Index Increases Molecular weight (chain length) Tensile strength (at yield) Tensile elongation Stiffness Impact strength Stress crack resistance Permeability Chemical resistance Abrasion resistance Processability Decreases Decreases Decreases Decreases Decreases Decreases Increases Decreases Decreases Increases

Melt Index/ Melt Flow Rate ASTM D 1238

The ratio of MI at two loads (e.g., HLMI/MI) is an approximate measure of the shear thinning behavior of the melt. - Higher ratio is for broader molecular weight distribution.

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Melt Index/ Melt Flow Rate ASTM D 1238

Typical Shear Rate Ranges for Processing
Shear rate range,

Process

Shear rate range, reciprocal seconds Compression molding...............1-10 Calendaring................10-100 Extrusion: in barrel............same as screw RPM (10-400) Extrusion: in die...............50-50,000 Injection molding................500-50,000 Blow molding..............100-10,000

Melt Index/ Melt Flow Rate ASTM D 1238

Importance of MFI in Masterbatch The main parameters of carbon blacks that influence the MFI are the particle size, structure and surface chemistry. Melt viscosity of polymer carbon black mixtures increases as the carbon black content increases and also the particle size of the black decreases.

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Melt Index/ Melt Flow Rate ASTM D 1238

Is a measure of Shear Viscosity and is directly proportional to the average molecular weight. Uses: Raw material control; processing quality; regrind studies; useful troubleshooting test

Melt Index/ Melt Flow Rate ASTM D 1238

5/14/2012

Melt Index/ Melt Flow Rate ASTM D 1238

Melt Index/ Melt Flow Rate ASTM D 1238

How a Melt Indexer Works The melt indexer consists of a heated barrel and piston assembly to contain a sample of resin. A specified load (weight) is applied to the piston, and the melted polymer is extruded through a capillary die of specific dimensions.

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Melt Index/ Melt Flow Rate ASTM D 1238

Test Procedures

The melt index apparatus is preheated to a specified temperature The material is loaded into the cylinder from the top and a specified weight is placed on a piston. The most commonly used test conditions are shown in Table. The initial extrudate is discarded because it may contain some air bubbles and contaminants. Depending on the material or its flow rate, cuts for the test are taken at different time intervals. The extrudate is weighed and melt index values are calculated in grams per 10 min.

Factors Affecting the Test Results

Preheat Time. If the cylinder is not preheated for a specified length of time, there is usually some nonuniformity in temperature along the walls of the cylinder even though the temperature indicated on the thermometer is close to the set point. The causes the flow rate to vary considerably. There should be zero thermal gradient along the full length of the test chamber. Moisture. Moisture in the material, especially a highly pigmented one, causes bubbles to appear in the extrudate which may not be seen with the naked eye. Frequent weighing of short cuts of the extrudate during the experiments reveals the presence of moisture. The weight of the extrudate is significantly influenced by the presence of the moisture bubbles
the rod with substantial force to allow the air entrapped between the resin pellets to escape. Once the piston is lowered, the cylinder is sealed off, and no air can escape. This causes variation in the test results.

Packing. The sample resin in the cylinder must be packed properly by pushing

Volume of Sample. To achieve the same response curve repeatedly,

the volume of the sample in the cylinder must be kept constant. Any change in sample volume causes the heat input from the cylinder to the material to vary significantly.

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