PLASTINET-MASTER

European Union Project for the mobility of

Post graduated Students in Polymer Engineering

Project:

Assessment of mouldings produced in hot runner injection moulds

Grant holder:

Matas Rafael Martnez Gamba

Institution:

INTEMA Universidad Nacional de Mar del Plata - Argentina

Project Supervisor: Prof. Antnio Srgio Pouzada

Host Institution:

DEP - Universidade do Minho - Portugal

Grant Period:

May 2004 Nov 2004.

Project Objectives
To assess the influence of processing conditions and filler contents in the mechanical
properties and weld line strength of mouldings obtained with hot runner moulds.
Techniques
Injection moulding using a hot runner mould with the possibility of producing three
dimensional parts with and without weld lines.
Mechanical characterization, including micro hardness and tensile impact.
Assessment of mechanical properties as function of temperature and filler content

Schedule of Project
1.- Literature review on weld line characterisation month
2.- Injection moulding programme months 2, 3
3.- Simulation using Moldflow and Moldex months 3, 4
4.- Measurement of properties months 4, 5
5.- Analysis of the experimental data and structure of dissertation months 5, 6

Abstract
Weld lines always occur in multi gated injection mouldings and parts of complex shapes.
Their occurrence affects the mechanical performance and may cause aesthetical problems.
When glass filled materials are used these problems are enhanced. The characterisation of
weld lines, which is important in performance injection mouldings, may be experimentally
demanding. Microhardness is seen as a simple non-destructive test for characterising
injection mouldings.
Several grades of PP, with variable glass fibre contents (20%, 30% and 40%) were studied in
injection moulded plates produced in a double gate hot runner mould. Variable processing
conditions were used, these including temperatures of injection and injection time. The
characterisation of the weld lines in the mouldings was done by microstructure analysis,
microhardness measurement and tensile impact.

PROJECT REPORT

Introduction
Polypropylene (PP) is characterized for being a commonly used material due mainly to the
very interesting cost/performance ratio. Different grades of glass reinforced PP are being
chosen by the manufacturers for structural parts. On the other hand, the presence of
discontinuities in the microstructure, such as the weld lines (WL), also reduces the
mechanical performance. Weld lines are almost impossible to avoid in production situations
(multi gated pieces, presence of inserts, or the filling path in the impression of the mould).
In this project a hot runner mould was used, and the WL in the products where characterized.
The non destructive technique of microhardness is used and its data compared with those of
tensile impact.

Experimental
Materials
Four grades of polypropylene PP (homo, 20%, 30% and 40% GF); MFR (ISO 1133)
Material

Glass fibre content

MANUFACTURER -

MFR

Grade

g/600 s 2,16 kg/230C

SUNOCO
PP homopolymer

10,92
FTI20WV2
HOSTACOM

PP20%GF

20

1,68
PP G2 N01
HOSTACOM

PP30%GF

30

1,35
PP G3 N01
HOSTACOM

PP40%GF

40

3,00
PP G4 R01

Density determination
By means of a analytic balance with the aid of kit of determination of density SCALTEC.

Fluid container: Propanol = 0.7846 g/cm3.

PP Homo:

: 0,91 Mg.m-3

PP20%GF:

: 1,04 Mg.m-3

PP30%GF:

: 1,13 Mg.m-3

PP40%GF:

: 1,22 Mg.m-3

Fibre characterisation
By calcination routine, at 625C for 30 minutes.

W C+2ndF
W C+S
Material

W C [gr]

W S [gr]

[gr]

2ndF [%]

nd

[gr] W(C)
+ W(S)

W 2ndF [gr]
W(C+2 F)

625C

(P)

P(2ndF)/W(S)

30m
PP20%GF

26,925

15,016

41,941

30,030

3,105

20,7

PP30%GF

26,350

15,003

41,353

30,942

4,592

30,6

PP40%GF

24,635

15,006

39,641

30,680

6,045

40,3

W C: Weight cresol; W S: Weight sample; W 2nd F: Weight 2nd faze.

L and fibre
PP20%GF:

L Mean: 115.27 ; Std Dev: 59.51; = 14.1 (> 98%)

25
20
15
10
5
0
0.
01
90
.0 3 0 .
0
1
- 1 0:
18
2
0.
0 1 0.0
0:
27
0. 210
01
.0
0:
36
0. 300
01
.0
0:
45
0. 390
01
.0
0:
54
0. 480
01
.0
0:
63
0. 570
01
.0
0
:
72
0. 660
01
.0
- 7 0:
81
5
0.
0 1 0.0
0:
90
0. 840
01
.0
0
:
99
0. 930
01
.
- 1 00:
02
0.
00

% de fibras

(sobre un conteo de 500)

L GF PP20%

Longitud de las fibras [micrones]

PP30%GF:

L Mean: 293.26 ; Std Dev: 173.60; = 13,4 (25%) - 18,3 (75%)

20
15
10
5
0
0.
01
-3
90
0.
.0
1
00
-1
18
2
0.
0 1 0.0
0:
27
0. 210
01
.0
0:
36
0. 300
01
.0
0:
45
0. 390
01
.0
0:
54
0. 480
01
.0
0:
63
0. 570
01
.0
0:
72
0. 660
01
.0
0
:
81
0. 750
01
.0
- 8 0:
90
4
0.
0 1 0.0
0:
99
0. 930
01
.0
0:
-1
02
0.
00

% de fibras

(sobre un conteo de 500)

L GF PP30%
25

Longitud de las fibras [micrones]

PP40%GF:

L Mean: 394.99 ; Std Dev: 163.15 = 13,4 (> 98%)

25
22,5
20
17,5
15
12,5
10
7,5
5
2,5
0
0.
01
90
.0 30 .
00
1
:
18
0. 1 20
01
.0
- 2 0:
27
1
0.
0 1 0.0
0:
36
0. 300
01
.0
- 3 0:
45
9
0.
0 1 0.0
0:
54
0. 480
01
.0
- 5 0:
63
7
0.
0 1 0.0
0:
72
0. 660
01
.0
- 7 0:
81
5
0.
0 1 0.0
0:
90
0. 840
0
.0
0:
99 1 9
0.
0 1 30.
- 1 00:
02
0.
00

% de fibras

(sobre un conteo de 500)

L GF PP40%

Longitud de las fibras [micrones]

Injection Parameters
The injection settings of the Klckner Ferromatic FM20, used for moulding the rectangular
products of 1,4 mm thickness, shown in Figure 1, are :
Ti: 250C 280C; Tm: 50C
ti: 0,5 s 1 s 1,5 s; p2: 60%/pmax (3 MPa)
The weld lines were analysed in the characterization zones shown in the Figure 2: WL
centre, WL centre-edge and WL edge.
The symbols , and 45 correspond to the direction of skin fibre alignment.

Fig. 1: Details of the moulded part.

Fig. 2: Location of the testing specimens

Techniques
Microhardness measurements were performed using a Leica tester, with a Vickers squarebased diamond indenter. To minimize the effect of the 2nd fase and creep, a load of ca. 20 N
and indentation times of 5 s were used.
For the impact tests a Ceast pendulus was used.
Microstructure was observed by Reflected and Transmission Optical Microscopy (Olympus
BH-2).

Computer simulation.
The attendance of software by means of finite element analysis has become a strategic
weapon from the genesis of the product. Nevertheless, it takes special importance to attend
in the construction of the toolbox, and therefore on the properties of the material solidified in
this cavity. Forms, sizes and thicknesses to obtain, the location of the injection tips, the
distribution of the cooling channels, can numerically be predicted without they are necessary
techniques of test and error. In this work the made analyses were attended by Moldflow.
The variables simulation was: geometry of the piece to inject; location, size (diameter) and
types of tips of injection (Hot Runner); material to inject and type of mould and its form of
refrigeration.

Results and Discussion

Microhardness
The graphics 3 and 4 show the hardness profiles at the WL and at the bulk, to 250C and
280C injection temperature. A decrease on the hardness values is observed when the
measuring point is moved to the edge of the part. This results from the different
thermomechanical conditions in those locations. In fact when the measuring point is moved
to the edge of the part, the flow path distance is higher and consequently the pressure and
temperature evolution changes. For 280C the effect is major.

PP: GF 20% - 30% - 40%

PP: GF 20% - 30% - 40%

30

25
20
15

WL 20% GF
WL 30% GF
WL 40% GF
Bulk 20% GF
Bulk 30% GF

10
5

Bulk 40% GF

0
WL Centro

WL C-B

WL Borde

Fig. 3: HV in WL and bulk, Ti:250C, ti:1s

Microhardness [HV]

30
Microhardness [HV]

Ti: 280C; ti: 1s

Ti: 250C; ti: 1s

25
20
15

WL 20% GF
WL 30% GF
WL 40% GF
Bulk 20% GF
Bulk 30% GF
Bulk 40% GF

10
5
0
W L Centro

WL C-B

W L Borde

Fig. 4: HV in WL and bulk, Ti:280C, ti:1s

Impact tests
The impact data obtained from tensile impact tests on the PP 20%, PP 30% and PP 40% GF
reinforced PP show a decrease of the toughness in the presence of weld lines and also its
increment when the processing temperatures increase. This effect is clear by the PP 30%
GF and PP 40% GF (fig.5 and fig.6). This will be motivated by the long and orientation of the
fibre in the skin and in the centre of the part; the long of fibre is critical in this case.
At this stage, it is not evident a direct correlation between the microhardness data and the
impact ones, but both techniques are sensitive to the variation of the processing parameters
and the glass fibre contents. The figure 7 shows a first approximation to relation between HV
and energy impact.

Impact Energy [kJ/m2]

140
120
100
80
60
40
20
0
ti: 0,5 ti: 1 ti: 1,5 ti: 0,5 ti: 1 ti: 1,5
WL Ti:
Center
Bulk - FV
250C WL Edge Ti: 280C
Bulk 45
FV PP
Bulk
FV [kJ/m2}
Impacto
30%GF

Fig. 5: Energy Impact for PP 30%GF

Energy Impact [kJ/m2]

140
120
100
80
60
40
20
0
ti: 0,5 ti: 1 ti: 1,5 ti: 0,5 ti: 1 ti: 1,5
WLTi:
Centro
250C

WL Borde Ti: 280C

Bulk - FV

Bulk 45
FV PP
Bulk
FV [kJ/m2]
Impacto
40%GF

Fig. 6: Energy Impact for PP 40%GF

PP GF 20%-30%-40%
30
25
20
15
10
5
0

20%GF 250C
20%GF 280C
30%GF 250C
30%GF 280C
40%GF 250C

13
0

12
0

11
0

10
0

90

80

40%GF 280C

70

60

Microhardness [HV]

Ti: 250C- 280C; ti: 1s

Energy Impact [kJ/m2]

Fig. 7: First approximation to relation between HV and energy impact.

Conclusions
The microhardness technique was used for assessing the morphology of products with weld
lines produced under variable processing conditions and with variable fibre contents. The
technique is sensitive to those variables.
The tensile impact tests are adequate to assess the toughness of the products and they are
also sensitive to the variables analysed ion this work.
At this stage, it is not clear yet how to fully correlate the microhardness and the impact data.
The Moldflow simulation works satisfactorily. Also the microstructure characterization.
The schedule of the project was followed strictly.

Acknowledgements
The grant holder acknowledges the support given by the EU programme ALFA through the
network PLASTINET.

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