Material Characterization Tier III (Part 3 Of 3) Richie .
September 2021The Madison GroupTMG NewsSeptember 2021Material CharacterizationTier III— (Part 3 of 3)Richie AnfinsenIn the second part of this series, we explored the second tier of material characterization. At this level, adesigner will have a much better chance of selecting a material based on data sheet values for theirapplication. The second tier of material characterization is even more important now with the higher level ofpolymer supply issues making alternative material selection an all-to-familiar issue in the industry. However,this level of characterization will miss several important pieces of data on the additives utilized to modify theproperties of the material for exposure conditions. At the second tier, we will not understand if an unknownmaterial has antioxidant additives for stability (e.g., hindered phenols for processing), flame-retardantadditives, or UV stabilizers to allow for better long-termperformance of the parts. This is where we need additionaltests from a Tier III characterization to help us understandthe additives that will be of great importance to theperformance of the part in the expected environment.Figure 1. Diagram showing the levels of characterizationand the frequency that the analysis level is utilized in amaterial characterization.Tier III of material characterization is typically reserved fordetailed characterizations of the lower concentrationadditives that shape the special properties of a material.These additives are typically under 1% by weight withinthe material and are incorporated into the resin to ensureproper performance over the lifetime of the part. Theseadditives would include antioxidants (to help withprocessing stability and environmental exposure), slipagents for molding, tackifiers for rubber materials,compatibilizers for blends, flame-retardant additives, andmany others. Typically, this level of characterization isemployed by designers to reverse engineer materials, resinsuppliers, or in cases where part failure has occurredprematurely due to some environmental conditions.The primary techniques utilized in a Tier IIIcharacterization could include mass spectroscopictechniques (GC/MS, LC/MS, HPLC), trace elemental analyses (XRF and ICP),Inside This Issue:nuclear magnetic resonance spectroscopy (NMR), and gel permeationchromatography (GPC). This is certainly not a comprehensive list of all the Material CharacterizationTier III—(Part 3 of 3)1higher-level techniques that are utilized to understand the additives in the3material. Other techniques can be utilized to meet regulatory standards Training(RoHS, USP VI, etc.). These tests should be discussed on a project-to-project Moldflow Training Courses 4basis. However, these are the “workhorses” of identifying additives that are5commonly used in polymer applications.Webinars6The mass spectroscopy techniques are utilized to look at antioxidants, flow UWM Plastics Online Course 7aids, tackifiers, and other lower molecular weight substances. This technique Through the Lens ofprovides a spectrum that is used for identification of chemical compounds at The Madison Group8Page 1madisongroup.com 2021 The Madison Group All Rights Reserved.
September 2021The Madison GroupMaterial Characterization (cont.)Tier III— (Part 3 of 3)TMG NewsRichie Anfinsenvery low (PPM) concentration. Shown in Table 1, are typical results you can expect from this type of analysis.The analysis provides a list of chemical compounds that were in the detectible range of molecular weights foreach technique. If you are just running the sample, this is typically just a qualitative identification withlimited ability to quantify the amounts of the additives. Quantification is possible with a calibrationexperiment to a known reference of the additives identified in the material. However, practical designers willrely on material suppliers to determine the correct amount of lower-level additives in a material and testingon the back-end to determine if enough additives are present for the expected exposure and lifetime needs.Two of the most populartechniques for identifying andquantifying the elemental make-upof a material are ICP and XRF. Inthe context of a Tier IIIcharacterization, these techniquesare typically utilized to help withidentification of some flameretardants and stabilizers. Forexample, the use of ICP and XRFcan help to identify if a copperiodide stabilizer is being utilized ina polyamide material.Nuclear magnetic resonancespectroscopy (NMR) is a techniquethat is basically an FTIR test onsteroids. While FTIR is useful to tellTable 1. Table of results from an LC/MS test of a thermoplastic elastomer. The resultswhat type of bonds are in ashow that the material had a stabilizer package with multiple different antioxidants.material, NMR can construct thebackbone structure and determine where in the polymer backbone, those bonds are located. This makes NMRa powerful technique to deconstruct complex molecules such as thermoplastic urethane elastomers and otherthermoplastic elastomeric materials. Additionally, it can provide information on polymer blends andbranching, which can be extremely important to polymer performance. It should be noted that a deeper levelof knowledge of molecular structure is required to properly interpret these results.GPC testing is utilized to providean exact measurement of themolecular weight of a material,including information on thedistribution of polymer chainlengths, Figure 2. In a Tier IIIanalysis, GPC analysis would beused to identify more performance-based metrics of molecularweight. Specifically, this methodFigure 2– Molecular weight curves for two materials that showed minimal differences inis useful to compare the molecularmolecular weight and molecular weight distribution. In a material characterization setweight distribution, which willting, these results would show that these materials are similar in molecular weight andwould be expected to have similar properties if all else is equal in the material composition.Page 2madisongroup.com 2021 The Madison Group All Rights Reserved.
September 2021The Madison GroupMaterial CharacterizationTier III—(Part 3 of 3)TMG NewsRichie Anfinsenaffect the processability and mechanical performance of a polymeric material. In general, this technique isbest applied as a comparative analysis between two materials as there is little published data on exactmolecular weights of commercial polymers. However, if you need to investigate the molecular weight curvedue to concerns about performance, GPC can be used over MFR to investigate the material.While these are certainly not all of the techniques that can be used to identify polymeric materials, thesetechniques are definitely the most utilized techniques in material characterization. The next time you have aquestion of what material is or should be used within a product, take a minute to think about how involvedyour analysis needs to be. Whether you need a lower-level identification or a complete materialdeformulation, there are techniques that can help you move your project forward. The Madison Group hassignificant experience with all levels of material characterization and would be happy to assist you with all ofyour testing needs.Click here to read Part 1.Click here to read Part 2.Information regarding additional case studies can also be found raining TopicsIf you are interested to haveThe Madison Groupprovide training to yourteam, please feel freeto contact us atinfo@madisongroup.com.Page 3 madisongroup.comFailure AnalysisPlastic Material SelectionPlastic Part DesignMoldflowOther 2021 The Madison Group All Rights Reserved.
September 2021The Madison GroupTMG NewsAnnouncementsTMG—Industry NewsThe Madison Group is excited to offer our training for all Autodesk Moldflowproducts, both Insight and Advisor.The need for optimizing our plastic part designs, processes andmold designs prior to first shots, is more critical than ever.Autodesk Moldflow has multiple products to help assist andoptimize your project at any stage. Whether you are a partdesigner that is interested in better understanding yourexternally provided Moldflow reports, a user that is looking totake full advantage of the tools you already have, or explorewhat additional tools are available to take you to the next level,we have a training package that can help you accomplish justthat.The Madison Group has a training plan option for anycircumstance and budget.Choose any of the following options: On-site Training Remote Instructor-Led Training Private TrainingBenefits of Investing inMoldflow Training Keep up to date on the newest solversand simulation tools for all the Autodesk Moldflow Products designed tosave you time. Improve your results interpretationskills and help optimize your design. Increase your internal knowledgequickly and economically to improvecommunication and create a culture ofinnovation. Explore additional simulation capabilities to improve overall customer satisfaction.Benefits of Remote Instructor-Led Training Sessions: Allow any of your employees to gain the training without being out of the office. Eliminate travel costs so you can have more employees trained. Choose interactive, live, instructor-led classes for one-on-one assistance with solver set-up and resultsinterpretation. Installation of software not needed prior to training opportunities.Find a listing of all of our Upcoming Training Sessions here.Page 4madisongroup.com 2021 The Madison Group All Rights Reserved.
September 2021The Madison GroupJune 2020The Madison GroupPage 5cmadisongroup.comUpcoming Educational WebinarsTMG NewsTMG News 2020 The Madison Group All Rights Reserved.Backlit image of the internal diameter of a cracked pipe.Tuesday, October 12, 2021 - Jack DeSousa(composed of 12 stitched micrographs)“Plastics In” Series: Appliance ApplicationsImage of the internal diameter of a cracked pipe.(composed of 12 stitched micrographs)10:00 AM (CST)The use theof plasticmaterials ofin electronicapplianceshas been a Groupgrowing market. This webinarThroughLensTheMadisonwill introduce the types of plastics being used in these applications, review common designThe MadisonconsiderationsGroup has acquireda new copeVHXwhen choosinga plastic material,and goovercase studiesshowingwhat cango7000. This tiestothenextlevelby:wrong when plastics are not properly implemented. With automatic 3D technology it is possible to examine rough and deep fractures in one image.Click here for more information. The magnification capabilities up to 2,000x makes it possible to measure the thickness of coatings andTuesday,films. October 26, 2021 - Melissa KurtzSustainabilityIntroductionoptions allow for backlighting, multi-angled oblique lighting, polariza PlasticsThe newadvanced –illumination10:00AMand(CST)tionan optical shadow effect mode that allows the visualization of crack features and textures notvisible in a SEM microscope.Plastics have enabled innovations in numerous industries. With their popularity Stitching of high magnification images allows for a large field of view to improve analysis and visualizacome concerns surrounding end of life. As the desire for sustainable productstion.grow, so does confusion on what sustainability means. This webinar will define With remote capabilities, this microscope also opens the door for remote inspections for our customers.the language surrounding plastic sustainability and take an in-depth look at avariety of approaches.Click here for more information.Starting with this issue of the TMG Newsletter, we will be showing images to highlight the enhanced analysiscapabilitiesmade possibleby- microscopy.Tuesday,November9, 2021Javier Cruz The images below show the examination of a half pipe taken withthe automatic3D modeand backlighting of the VHX-7000. The pipe being translucent allows for the light toTheDegradationof PlasticstravelAMthrough10:00(CST)the thickness to reveal defects not otherwise visible. These images are made from stitching 12separate micrographs to create a large high magnification view of the pipe. This analysis allowed for the exNothing lasts forever and degradation is just one of the many mechanisms that dictates the endamination of multiple cracks in the pipe wall that otherwise, were not visible without the proper illuminaof life for plastic products. This webinar will introduce the concept of degradation and presenttion.different mechanisms that can lead to degradation. In addition, techniques for identifying andpreventing degradation will be discussed.Click here for more information.Tuesday, November2021—ErikFoltzIf you are 30,interestedto learnmore about the capabilities that we have at The Madison Group,An Overview of DFMEA ConsiderationsCommonProcesses for Plastic Assembliesplease feel freeforto contactus atSecondaryinfo@madisongroup.com.10:00 AM (CST)for thethefundamentalsFirst Time!Many presentations have been Appearinggiven that highlightof proper plastic elyusedasastand-aloneproduct. ThisVHX-7000—Microscope Capability at The MadisonGrouppresentation will highlight how selection of common secondary joining operations couldAnnouncementsinfluence your part design, and material selectionconsiderations.Click here for more information.Tuesday,December14, 2021- Jeffrey A. JansenNEW VHX-7000at The MadisonGroup.The Structure and Properties of Polypropylene10:00 AM (CST)Polypropylene is a versatile thermoplastic that can be processed through a variety oftechniques and utilized in a wide range of applications. This webinar will provideattendees with an understanding of the properties of polypropylene as well as theirdependency on molecular weight, crystallinity, comonomer content and tacticity.Click here for more information.Information regarding upcoming educational opportunities can also be found at:http://www.madisongroup.com/events.htmlPage 5madisongroup.com 2021 The Madison Group All Rights Reserved.
September 2021The Madison GroupJune 2020The Madison GroupPage 6cmadisongroup.comWebinars/SeminarsWebinar SeriesTMG NewsTMG News 2020 The Madison Group All Rights Reserved.Backlit image of the internal diameter of a cracked pipe.(composed of 12 stitched micrographs)Image of the internal diameter of a cracked pipe.(composed of 12 stitched micrographs)Failure of PlasticsSession 1: Wednesday, October 13, 2021 - Jeffrey A. Jansen—SPEClick here for more information.andThe Madison Group has acquired a new state-of-the-art Keyence High Definition Digital Microscope VHXSession2: microscopeThursday, October14, 2021—JeffreyJansen– SPEcapabilities to the next level by:7000. Thishas greatlyexpandedourA.examinationhereautomaticfor more 3Dinformation. ClickWithtechnology it is possible to examine rough and deep fractures in one image.pm (CST) (bothdays) up to 2,000x makes it possible to measure the thickness of coatings and Noon-1:00The magnificationcapabilitiesfilms.This 2-part webinar series will cover a considerable range of topics important in understanding, diagnosing, The new advanced illumination options allow for backlighting, multi-angled oblique lighting, polarizaand preventing plastic component failure. The most efficient and effective approach to plastic componenttion and an optical shadow effect mode that allows the visualization of crack features and textures notfailure is by performing a systematic failure analysis. Someone once said, “if you don’t know how somethingvisible in a SEM microscope.broke, you can’t fix it,” and this certainly highlights the importance of a thorough understanding of how and Stitching of high magnification images allows for a large field of view to improve analysis and visualizawhy a product has failed. This webinar series will introduce the attendees to information they need to gaintion.this understanding. With remote capabilities, this microscope also opens the door for remote inspections for our customers.The material covered will include:StartingEssentialwith thisknowledgeissue of theofTMGwe will fail.be showing images to highlight the enhanced analysis why Newsletter,plastic componentscapabilitiesmadepossibleby microscopy.images below show the examination of a half pipe taken with The fivefactorsaffectingplastic partTheperformance.the automatic3D modeand backlightingthe VHX-7000.pipe beingtranslucent allowsforwhythe lightto The processof conductinga failure ofinvestigationand Themethodsfor understandinghow andatravel throughproductthehasthicknessfailed. to reveal defects not otherwise visible. These images are made from stitching 12separatemicrographsa large hightransitionsmagnificationviewroleof thepipe. Thisanalysisfailure.allowed for the ex Theimportancetoofcreateductile-to-brittleand theirin s.the pipe wall that otherwise, were not visible without the proper illumina The ofmajorplasticfailuretion. Failure analysis case studies.Through the Lens of The Madison GroupThe webinar series will focus on practical problem-solving techniques and will utilize case studies toillustrate key aspects of plastic failure and prevention. Participants will gain a better understanding of whyplastic components fail, and how to avoid future failures by applying the knowledge learned.If you are interested to learn more about the capabilities that we have at The Madison Group,please feel A.freeJansen–to contactus at info@madisongroup.com.Thursday, November 11, 2021—JeffreySPEPlastic Datasheets: What They Do and Don’t Tell UsNoon-1:00 pm (CST)Appearing forthe First Time!UL Prospectortens of thousands of different plasticresins. Whenmaterial attaskedThewithMadisonGroup99.44%of us turn to the typical property data sheet. Those of us who have been around a while are careful not to callAnnouncementsit a "technical data sheet." What are the issues with the single point numbers listed? Why does that often leadto a failed product? What should we be doing instead?NEW VHX-7000The MadisonGroup.Clickhere for atmoreinformation.Information regarding upcoming educational opportunities can also be found at:http://www.madisongroup.com/events.htmlPage 6madisongroup.com 2021 The Madison Group All Rights Reserved.
September 2021The Madison GroupJune 2020The Madison GroupPage 7cmadisongroup.comTMG NewsTMG News 2020 The Madison Group All Rights Reserved.The Madison Group Teaches Failure Analysis, Design & PreventionBacklit image of the internal diameter of a cracked pipe.Monday-Wednesday, October 25-27th,(composed2021of 12 stitched micrographs)Via Zoom—Live—OnlineImage of the internal diameter of a cracked pipe.12 stitchedPresenters: Jeffrey A. Jansen, Dr. Antoine(composedRios, Dr.ofJavierCruz,micrographs)and Erik FoltzPlastic Part Failure: Analysis, Design & Prevention8:00 am—4:00 pm (CST)The Madison Group has acquired a new state-of-the-art Keyence High Definition Digital Microscope VHXThe University of Wisconsin—Milwaukee School of Continuing Education is offering an online 3-day course7000. This microscope has greatly expanded our examination capabilities to the next level by:entitled, “Plastic Part Failure: Analysis, Design & Prevention” taught by The Madison Group Engineers. With automatic 3D technology it is possible to examine rough and deep fractures in one image.The course will cover a broad range of topics essential to understanding and preventing plastic failure. The magnification capabilities up to 2,000x makes it possible to measure the thickness of coatings andDivefilms.into a broad range of topics essential to understanding and preventing plastic failure. The most efficient andThenew advancedoptions allowfor approach illuminationto plastic componentfailureperforming multi-angleda systematic obliquefailure ic method. Someone once said, “If you don’t know how something broke, you can’t fix notit,”visible in thea SEMmicroscope.highlightingimportanceof a thorough understanding of how and why a product has failed. Stitching of high magnification images allows for a large field of view to improve analysis and visualizaBenefitstion. and Learning Outcomes:Get introduced to the strategies behind analysis, design and prevention with course material that includes: With remote capabilities, this microscope also opens the door for remote inspections for our customers. Learn the essentials of why plastic components fail. StartingUnderstandfiveoffactorsaffectingplastic wepartwillperformance.with thistheissuethe TMGNewsletter,be showing images to highlight the enhanced analysis- Material,design, processing,installation,and servicecapabilitiesmade possibleby microscopy.The imagesbelow show the examination of a half pipe taken with the Learnthe processof conductinga failureinvestigation.automatic3D modeand backlightingof theVHX-7000. The pipe being translucent allows for the light tothroughthe thicknessto reveal defects transitionsnot otherwiseTheseimagesare made failure.from stitching 12 travelKnowthe importanceof ductile-to-brittleandvisible.their rolein or the ex Understand how and why a product has failed.aminationmultiple cracksin quicklythe piperespondwall thatotherwise,notvisible without Exploreofapproachesto moreto andresolvewereplasticcomponentfailure.the proper illumination. Learn methods and techniques to avoid future failures.Outline:Through the Lens of The Madison Group Introduction to Plastics Failure of Plastics Overview-Overview of Plastic Failure abilitiesthat weat TheFactorMadisonGroup, The elfreetocontactusatinfo@madisongroup.com.and Statistical Distribution in Plastic Part-PropertiesFailure-Plastic Part FailureFailureFailure Correction and PreventionAppearing for theFirstAnalysisTime!-Problem Solving / Investigation Tech-Part DesignNEWVHX-7000—Microscope CapabilityMadison Groupniques –atFATheand RCA-Mold Design-Failure Analysis Test MethodsAnnouncements-Material Selection-Case Studies-Processing-Validation TestingNEW VHX-7000 at The Madison Group.CEUs: 2.0, PDHs: 20Enrollment Limit: 30Program Number: 4830-13805Registration Deadline: Oct 22Click here for more information.Information regarding upcoming educational opportunities can also be found at:http://www.madisongroup.com/events.htmlPage 7madisongroup.com 2021 The Madison Group All Rights Reserved.
September 2021The Madison GroupTMG NewsThrough the Lens ofThe Madison GroupThe Madison Group’s acquisition of a new state-ofthe-art Keyence High-Definition Digital MicroscopeVHX-7000 greatly expands our analysis capabilitieswith: Automatic 3D imaging to permit the examinationof rough and deep fractures. High-magnification capabilities (up to 2500x) topermit measurements of coatings and films. Advanced illumination options of backlighting,multi-angled oblique lighting, polarization and anoptical shadow effect mode that allows the visualization of crack features and textures not visible ina SEM. Stitching of high-magnification images to providea large field of view to improve visualization. Remote/virtual capabilities to provide our cus- New Keyence Microscopetomers with access to inspections and analysis.With the advanced capabilities of The Madison Group’s Keyence High-Definition Digital Microscope, the surface metrology of molded polymeric materials can be evaluated. For instance, the dynamic 3D analysis toolsof the system permit the surface features to be evaluatedon molded parts. Consider the red polyurethane surfaceshown to the left at 200x. At that magnification, the surface appears glossy and without any discernable features.However, when imaged using the enhanced 3D stackingwith full coaxial lighting, the finely dispersed surfaceparticles become visible as shown below. Furthermore,Enhanced 3D View (200x)the analysis includes mapping tools that can be extended to provided color contours of the surfaceheights for the texture. Such analyses can then beused to help diagnose friction and wear issues or toevaluate processing-induced differences in the surface metrology.Polyurethane Surface (200x)If you are interested to learn moreabout the capabilities that we have atThe Madison Group,please feel free to contact us atinfo@madisongroup.com.Page 8madisongroup.com 2021 The Madison Group All Rights Reserved.
The Madison Group is excited to offer our training for all Autodesk Moldflow products, both Insight and Advisor. Benefits of Investing in Moldflow Training Keep up to date on the newest solvers and simulation tools for all the Auto-desk Moldflow Products designe
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