Basic Rubber Testing - ASTM International

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Basic Rubber Testing:S e l e c t i n g M e t h o d s for aRubber Test ProgramJohn S. Dick, editorA S T M Stock Number: MNL39@INTERNATIONALA S T M International100 Barr H a r b o r DrivePO Box C700West Conshohocken, PA 19428-2959Printed in the U.S.A.

Library of Congress Cataloging-in-Production DataDick, John S.Basic rubber testing: selecting methods for a rubber test program/John S. Dick.p. cm."ASTM Stock Number: MNL39."Includes bibliographical references and index.ISBN 0-8031-3358-81. Rubber--Testing. I. Title.TA455.R8D53 2003678'.21'0287--dc212003056053Copyright 9 2003 ASTM International, West Conshohocken, PA. All rights reserved.This material may not be reproduced or copied, in whole or in part, in any printed,mechanical, electronic, film, or other distribution and storage media, without thewritten consent of the publisher.Photocopy RightsAuthorization to photocopy items for internal, personal or educational classroomuse, or the internal personal, or educational classroom use of specific clients, isgranted by ASTM International provided that the appropriate fee is paid to theCopyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923; Tel: 978750-8400; online: http://www.copyright.com/.NOTE: This manual does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this manual to establish appropriate safety and health practices and determine the applicability of regulatorylimitations prior to use.Bridgeport, NJAug. 2003

ForewordTHIS PUBLICATION,Basic Rubber Testing: Selecting Methods for a Rubber Test Program, w a s s p o n s o r e d b y C o m m i t t e e D l l on R u b b e r a n d D24 on C a r b o nBlack. This is M a n u a l 39 in ASTM International's m a n u a l series.

Contents 1 7 6 1 7 6ForewordPrefaceAcknowledgment111XV. . .VlllCHAPTER 1Introduction--by John Dick1.1 History1.2 ASTM D l l Standards1.3 Purpose1.4 Economic Savings for Users and Producers Through TestMethod Rationalization1.5 Importance of Quality1.6 Standard Target Values and "Tolerance Stack-up"1.7 Testing Bias1.8 What Makes for a Good Standard Test Method?1.8.1 Accuracy1.8.2 Repeatability1.8.3 Reproducibility1.8.4 Stability1.8.5 Linearity1.9 The Rubber Process1.10 Raw Rubber and Compounding Ingredients1.11 The Recipe1112245789991011121313CHAPTER 2General Test Methods--by John Dick2.1 Introduction to the Rubber Test Laboratory2.1.1 Compounding Ingredient Storage System2.1.2 Weighing Systems2.1.3 Mixer Systems2.1.4 Curing Procedure2.2 General Methods2.2.1 Mooney Viscometer ASTM D 16462.2.1.1 Mooney Viscosity1717181920202022

CONTENTS2.2.22.2.32.2.42.2.52.2.62.2.72.2.82.2.1.2 Mooney Stress Relaxation Test2.2.1.3 Measuring Pre-Vulcanization CharacteristicsOscillating Disk Curemeter ASTM D 20842.2.2.1 ODR Cure Test ParametersRotorless Curemeter ASTM D 5289Rotorless Shear Rheometer ASTM D 62042.2.4.1 Elastic Torque (S')2.2.4.2 Viscous Torque (S")2.2.4.3 Tangent 8 (Delta)2.2.4.4 Storage (Elastic) Modulus (G')2.2.4.5 Loss (Viscous) Modulus (G')2.2.4.6 Dynamic Viscosity 0', 0", q*Tensile Properties ASTM D 412After-Cure Dynamic Properties for QualityAssurance and Development ASTM D 6601Other Cured Physical Property Measurements2.2.7.1 Tear Resistance ASTM D 6242.2.7.2 Air Oven Aging ASTM D 5732.2.7.3 Goodrich Flexometer Heat BuildupASTM D 6232.2.7.4 Flex Cracking Resistance2.2.7.5 Liquid Immersion Properties ASTM D 4712.2.7.6 Compression Set ASTM D 3952.2.7.7 Rubber Hardness ASTM D 22402.2.7.8 Abrasion Resistance ASTM D 22282.2.7.9 Low Temperature Properties ASTM D 10532.2.7.10 Ozone Resistance D 1171The Standard Classification System for RubberProducts used in Automotive Applications ASTM 5555657CHAPTER 3Testing Natural Rubber--by Alek Vare3.1 Introduction and History3.2 Sampling and Sample Preparation by ASTM D 14853.3 Technical Grades and Basis for Classification by ASTMD 22273.4 Methods for Chemical Analysis of Natural Rubber byASTM D 12783.4.1 Percent Dirt3.4.2 Volatile Matter3.4.3 Copper Content3.4.4 Manganese Content616163646566666667

CONTENTS3.53.63.73.83.4.5 % Ash3.4.6 Iron Content3.4.7 Acetone Extract3.4.8 NitrogenPlasticity Retention Index, ASTM D 3194Color Index ASTM D 3157Standard Test Method for Evaluation of Natural RubberASTM D 3184New Standard Test Method for Characterizing NaturalRubber Grades--ASTM D 6204, Part Bvii6767676868696970CHAPTER 4Testing Synthetic Rubber--by Julia B. Zimmerman4.14.24.34.44.54.6Synthetic Rubber History and NomenclatureConsumer-Producer AgreementPhysical Tests for Synthetic RubberStandard Test Recipes and Test ProceduresProcessability of SBR with the Mooney ViscometerChemical Tests for Synthetic Rubbers4.6.1 Organic Acids, Soap, Oil, Total Extractables4.6.1.1 Total Extractables4.6.1.2 Organic Acid and Soap4.6.1.3 Oil4.6.2 Volatile Matter4.6.3 Total and Water Soluble Ash4.6.4 Determination of Carbon Black in Masterbatch4.6.5 Percent Gel, Swelling Index, and Dilute SolutionViscosity4.6.6 Nitrogen Content of NBR (or HNBR)4.6.7 Test Methods for HNBR4.6.7.1 Unsaturation of HNBR by Iodine Value4.6.7.2 Unsaturation of HNBR by InfraredSpectrophotometry4.6.8 EPDM Tests4.6.8.1 Percent ENB or DCPD in EPDMTerpolymers4.6.9 SBR Tests4.6.9.1 Bound Styrene in SBR4.6.10 Tests for CIIR or BIIR4.6.10.1 Determination of Bromine in the Presenceof Chlorine by Oxygen Combustion4.6.11 General Comment on Determination of Metals 868686878788

viiiCONTENTSCHAPTER5Testing Carbon Black--by ]effery A. Melson5.1 Introduction5.1.1 How is Carbon Black Used?5.1.2 What are Surface Area, Structure and SurfaceActivity--Why are they important?5.2 Classification5.2.1 Basis for Classification (D 1765)5.3 Standard Reference Blacks5.3.1 Validation of Test Method Precision and Bias(D 4821)5.3.2 Improving Test Reproducibility Using ASTMReference Blacks (D 3324)5.4 Tests that Relate to Surface Area (Particle Size)5.4.1 Iodine Adsorption Number (D 1510)5.4.2 Nitrogen Adsorption5.4.3 CTAB (CetyltrimethylammoniumBromide) SurfaceArea (D 3765)5.4.4 Primary Aggregate Dimensions from ElectronMicroscope Image Analysis (D 3849)5.5 Tests which Relate to Structure (Aggregates andAgglomerates)5.5.1 Oil Absorption Number (D 2414)5.5.2 Oil Absorption Number of Compressed Sample(D 3493)5.5.3 Compressed Volume Index (D 6086)5.6 Pellet Quality5.6.1 Pour Density (ASTM D 1513)5.6.2 Pellet Size Distribution (ASTM D 1511)5.6.3 Pelleted Fines and Attrition (ASTM D 1508)5.6.4 Sieve Residue (ASTM D 1514)5.6.5 Individual Pellet Hardness5.6.5.1 Individual Pellet Hardness (ASTM D 3313)5.6.5.2 Automated Individual Pellet Hardness(ASTM D 5239)5.6.5.3 Mass Strength (D 1937)5.7 Rubber Test Recipes and Properties5.7.1 Carbon Black in Styrene-Butadiene Rubber-Recipe and Evaluation Procedure (ASTM D 3191)and Carbon Black Evaluation in Natural Rubber(ASTM D 101101101102102102102102

CONTENTSixCHAPTER 6Testing Silica and Organosilanes--by Jeffery A. Melson6.1 Introduction6.2 Silica Types6.2.1 Silica Applications versus Carbon Black6.2.2 Classification6.3 Surface Area6.3.1 Surface Area by BET Nitrogen Adsorption6.3.1.1 Surface Area by Single Point B.E.T. NitrogenAdsorption (D 5604)6.3.1.2 Surface Area by Multipoint B.E.T. NitrogenAdsorption (D 1993)6.3.2 Surface Area by CTAB (CetyltrimethylammoniumBromide)6.3.2.1 CTAB (Cetyltrimethylammonium Bromide)Surface Area (D 6845)6.4 Structure (Aggregates and Agglomerates)6.4.1 n-Dibutyl Phthalate Absorption Number (D 6854)6.5 General Methods6.5.1 Volatiles (D 6738)6.5.2 pH Value (D 6739)6.6 Organosilanes6.6.1 Determination of Residue on Ignition (D 6740)6.6.2 Determination of Sulfur in Silanes (D 6741)6.6.3 Silanes used in Rubber Formulations (bis(triethoxysilylpropyl)sulfanes): Characterizationby High Performance Liquid Chromatography-(D 6843)6.6.4 Silanes used in Rubber Formulations (bis(triethoxysilylpropyl)sulfanes): Characterization byGas Chromatography (D 109109109109110110CHAPTER7Testing Mineral Fillers for Use in Rubber--by John Dick7.1 Ground Coal7.1.1 Particle Size7.1.2 Sieve Testing7.1.3 Ash7.1.4 Alpha Quartz7.1.5 Heat Loss (moisture)111111111113113113114

xCONTENTS7.1.6 Acidity7.1.7 Volatile Matter7.1.8 Density7.2 Titanium Dioxide7.2.1 Titanium Dioxide Purity7.2.2 pH Measurements7.2.3 Coarse Particles7.2.4 Moisture Content7.2.5 Rutile Content7.2.6 Tint Strength and Brightness7.3 Clay7.4 Natural Calcium ER 8Oils, Plasticizers, and Other Rubber Chemicals--by John Dick8.1 Rubber Processing and Extender Oils8.1.1 Aromaticity8.1.2 Average Molecular Weight8.1.3 Volatility8.1.4 Polar Compounds8.1.5 Asphaltenes8.1.6 Wax Content8.1.7 ASTM Oil Classification8.1.8 ASTM Oil Tests8.1.8.1 Clay-Gel Analysis, A ColumnChromatographic Method (D 2007)8.1.8.2 Viscosity-Gravity Constant (D 2501)8.1.8.3 Kinematic Viscosity (D 445)8.1.8.4 Aniline Point and Mixed Aniline Point(D 611)8.1.8.5 Pour Point (D 97)8.1.8.6 Acid and Base Number by Titration (D 974)8.1.8.7 AP1 Gravity (D 1298)8.1.8.8 Color (D 1500)8.1.8.9 UV Absorbance (D 2008)8.1.8.10 Flash Point Open Cup (D 92)8.2 Synthetic Plasticizers8.2.1 Standard Abbreviations8.2.2 Standard Test Methods8.2.2.1 Specific Gravity (D 70, D 891, and D 2111)8.2.2.2 Color (D 1209 and D 1544)8.2.2.3 Refractive Index (D 129130132132132132132134134134135

CONTENTS8.2.2.4 Saponification Value (D 1962)8.2.2.5 Brookfield Viscosity (D 2196)8.2.2.6 Heat Loss (D 2288)8.2.2.7 Karl Fischer (E 203)8.2.2.8 Flash Point Open Cup (D 92)8.3 Curat es8.3.1 Sulfur8.3.1.1 Sulfur Insolubles (D 4578)8.3.1.2 Percent Oil (D 4573)8.3.1.3 Acidity (D 4569)8.3.1.4 Wet Sieve (D 4572)8.3.1.5 Percent Ash (D 4574)8.3.2 Rubber Accelerators8.3.2.1 Standard Abbreviations8.3.2.2 Initial Melting Point (D 1519)8.3.2.3 Wet Sieve (Similar to D 4572)8.3.2.4 Percent Ash (D 4574)8.3.2.5 Percent Heat Loss (D 4571)8.3.2.6 Percent Moisture in Sulfenamides (D 4818)8.3.2.7 Percent Insolubles in Sulfenamides (D 4934)8.3.2.8 Assay for Sulfenamides (D 4936)8.3.2.9 MBTS Assay (D 5051)8.3.2.10 Assay for DPG and DOTG (D 5054)8.3.2.11 MBT Assay (D 1991)8.3.3 Zinc Oxide8.3.3.1 American Process or Direct Type8.3.3.2 French Process or Indirect Type8.3.3.3 Secondary Zinc Oxide--Chemical Type8.3.3.4 Secondary Zinc Oxide--Metallurgical8.3.3.5 Zinc Oxide Treatment8.3.3.6 Zinc Oxide Test Methods8.3.3.6.1 Surface Area (D 3037 and D 4315)8.3.3.6.2 Percent Lead and Cadmium(D 4075 and D 4315)8.3.3.6.3 Percent Residue on 45 m Sieve(D 4315)8.3.3.6.4 Percent Heat Loss at 105 (D 280)8.3.3.6.5 Percent Sulfur (D 3280 and D 4315)8.3.3.6.6 Percent Zinc Oxide Purity (D 3280and D 4315)8.3.3.6.7 Test Recipe (D 4620)8.3.4 Stearic Acid8.3.4.1 Iodine Value (D 1959)8.3.4.2 Titer (D 153153153153154154154154156157

xiiCONTENTS8.3.4.3 Acid Value (D 1980)8.3.4.4 Saponification Value (D 1962)8.3.4.5 Percent Ash (D 1951)8.3.4.6 Unsaponfication Matter (D 1965)8.3.4.7 Trace Metal (D 4075)8.4 Antidegradants8.4.1 Class I: p-Phenylenediamine (PPDs)8.4.1.1 Type 1: N,N'-dialkyl-p-phenylenediamines8.4.1.2 Type II: N-alkyl-N'aryl-pphenylenediamines8.4.1.3 Type III: N,N'-diaryl-p-phenylenediamines8.4.2 Class 2 Trimethyl-dihydroquinolines (TMQs)8.4.3 Class 3, Phenolics8.4.3.1 Type I: Monofunctional Phenols8.4.3.2 Type II: Bifunctional Phenols8.4.3.3 Type III: Multifunctional Phenols8.4.4 Class 4, Alkylated Diphenylamines8.4.5 Class 5, Aromatic Phosphites8.4.6 Class 6, Diphenylamine-Ketone Condensates8.4.7 Standard Abbreviations8.4.8 Test Methods for Antidegradants8.4.8.1 Purity of p-PhenylenediamineAntidegradant by Gas Chromatography(D 4937)8.4.8.2 Purity of Phenolic Antioxidants8.4.8.3 Purity of TMQs, Alkylated Diphenylaminesand Phosphite Antidegradants8.4.8.4 Volatile Materials for PPDs8.4.8.5 Percent Ash8.4.8.6 Softening Point8.4.8.7 Hydrolysis Stability8.5 Protective Waxes8.5.1 Test Methods8.5.1.1 Boiling Point, Determination by GCDistillation (D 2887)8.5.1.2 Melting Point a n d / o r Congealing Point(D 87, D 938, D 3944, D 4419)8.5.1.3 Refractive Index (D 1747)8.5.1.4 Percent Oil (D 721)8.5.1.5 Viscosity (D 445)8.5.1.6 Color (D 1500)8.5.1.7 Needle Penetration (D 5165166166166

CONTENTS xiiiCHAPTER 9Recycled Rubber--by Krishna C. Baranwal9.1Definition and Rubber Recycling Processes9.1.1 Reclaiming9.1.2 Ground Rubber9.1.3 Cryogenic Ground Rubber9.1.4 Wet Ground Rubber9.1.5 "Devulcanization" Process9.1.6 Need for Standards9.2 Storage, QA Sampling and Test Plans9.2.1 Material and Safety Data Sheets (MSDS)9.2.2 Crumb Rubber Storage9.2.3 Sampling and Test Plans9.3 Test Methods9.3.1 Particle Size (PS) and Particle Size Distribution (PSD)9.3.2 Particle Size Classification (ASTM D 5603)9.3.3 Chemical Analysis (ASTM D 5603)9.3.3.1 Percent Extractables (ASTM D 297,Section 19)9.3.3.2 Percent Ash (ASTM D 297, Section 35)9.3.3.3 Percent Carbon Black (ASTM D 297,Section 39)9.3.3.4 Percent Moisture Content (ASTM D1509) or Heating Loss9.3.3.5 Percent Natural Rubber Content (ASTM D297, Section 53)9.3.3.6 Percent Rubber Hydrocarbon (ASTM D 297)9.3.3.7 Iron and Fiber Content (ASTM D 5603,Section 7)9.4 Evaluation of Recycled Rubber in 2174174174174175175175175176176C H A P T E R 10Standard Test Methods--Insuring High-Quality Output-by Alan G. Veith10.1 Introduction10.2 Part 1: Fundamentals of Testing Operations10.2.1 Step 1--Planning10.2.2 Step 2--Measurement Methodology: Selecting TestMethods10.2.2.1 Precision178178179180180180

xivCONTENTS10.2.2.2 Sensitivity10.2.2.3 Calibration10.2.2.4 Traceability10.2.3 Step 3--Basic Sampling Principles10.2.3.1 Sampling10.2.3.2 Intuitive Sampling10.2.3.3 Statistical Sampling10.2.3.4 Protocol Sampling10.2.4 Step4 Measurement, Data Reporting and Analysis10.2.4.1 Reference Materials: ASTM D 4678 andD 590010.2.4.2 Reference Materials: D 3324, D 412210.3 Part 2: Testing--Using Specific Standards10.3.1 Natural and Synthetic Rubber, Carbon Black10.3.2 Process Performance and Capability Indexes10.4 Part 3: Recent Developments in Test Method TechnicalMerit10.4.1 Test Method Precision: D 448310.4.1.1 Background10.4.1.2 Outlier Detection10.4.1.3 Outlier Rejection10.4.1.4 Outlier Deletion or Replacement10.4.2 Test Sensitivity: D 660010.4.2.1 Background10.4.2.2 The Measurement Process10.4.2.3 Test Sensitivity ConceptsAppendix--ASTM Test 7188188188188190190191207207207208213229

PrefaceTODAY THERE IS A NEW initiative in the rubber industry, brought on bynew quality programs such as Six Sigma, to reduce variation and eliminatequality problems significantly in the manufacture of a very wide scope of different rubber products. For example, the automotive manufacturers are beginning to design vehicles to last 150 000 miles with minimum maintenance.This severely challenges m a n y rubber part manufacturers, perhaps morethan other groups in the automotive supply base, to improve their qualityand reduce variation.One large source of product variation in the rubber industry can be nonuniformity of received raw rubber and other compounding ingredients.There are currently over 140 ASTM Standard Methods that are actively usedto test these raw materials used in the rubber industry. The mixing processalso is a very large source of variation in the factory. There are another 25ASTM methods that are used to test the quality of mixed batches. This bookis designed to be a practical guide to the rubber technologist in selecting theappropriate methods for use in a testing program of raw materials, compounding ingredients, or mixed stock.This book characterizes each group of raw materials. It explains what aresome of the important chemical and physical properties that should be usedin making judgements on the quality of a raw material and its usability in theproduction plant. It gives a basic description of the test methods that are currently available. More importantly, this book compares and contrasts the advantages and disadvantages of selecting various test methods. However, thisbook is not a substitute for reading the actual ASTM method itself. This bookwill help the reader in deciding which ASTM methods should be selected fortesting a given raw material or mixed stock. This information is important toassure that a rubber laboratory is running efficiently. In today's business climate where testing resources are being restricted in many cases, it is vital thatthe most important tests be selected and that redundant testing be eliminated. Selecting the wrong tests wastes valuable resources and money.John S. DickXV

Award of Merit Recipients (continued)YEAR RECEIVED AWARD RECIPIENTS1981Edwin English1982Charles E. Tidd, Jr.1984William J. Holley19871989Charles P.GerstenmaierRodney McGarry1989Bobby Buffington1990John S. Dick1993Thomas H. SpurlockACHIEVEMENTSWas secretary of D l l from 1975 to 1976. Was leaderof the U.S. delegation to ISO TC45 for 12 years(succeeding R. Stiehler and retained this until1992)Was Chairman of D l l , Rubber. Also contributed toPhysical Testing (Dl1.10). Active with ISO TC45as wellVery active w i t h Synthetic Rubber standards(Dll.23). Also active with ISO TC45Major contributions in the development of CarbonBlack Test Methods. Also active in ISO TC45Past C h a i r m a n of D24, Carbon Black. Majorcontributions in the development of Carbon BlackTest Standards. Also active in ISO TC45Major contributions in the development of CarbonBlack Test Standards. Also active in ISO TC45C h a i r m a n of D l l . 2 0 on C o m p o u n d i n g Materialsfrom 1981 to 1991. Involved in Rubber Processability Test Methods. Became the leader of theU.S. Delegation to ISO TC45 in 1992Major contributions in the development of CarbonBlack Test MethodsDistinguished Service AwardAWARD RECIPIENTYEAR RECEIVED1998Peter Surette1998Julia Zimmerman1998John Bailey19981999Charles GillinghamClair Harmon1999Paul Gatza199920002001Jack ThompsonRicky MaGeeIvan Erwin2001Denise Kotz2001Frank Lussier2001Jeff Melsom20012002Lee CoatesAlec Vare2002Charles Rader2002Tom PowellACHIEVEMENTSFor his work in D l l Rubber, including physicaltesting (Dl1.10), time-temperature dependentproperties (Dl1.14)For her contributions in D l l , Rubber, includingChemical Analysis (Dl1.11)For his activities in D24, Carbon Black, includinghis extensive statistical contributionsFor his activities in D24, Carbon BlackFor his participation in D l l , Rubber, including hisinvolvement with Natural Rubber (Dll.22)For his contributions to D l l , Rubber, includingphysical testing, and rubber productsFor his achievements in D24, Carbon BlackFor his contributions in D24, Carbon BlackFor his accomplishments in D l l , Rubber,including his chairmanship of Dl1.15, RubberDegradation TestingFor her contributions to D l l , Rubber, includingphysical testingFor his contributions to D l l , Rubber, andespecially toward Chemical Analysis (Dl1.11)For his leadership and contributions to D24,Carbon Black, and his chairmanship of D24For his contributions in D24, Carbon BlackFor his accomplishments in D l l - - R u b b e r , andespecially his chairmanship of D l l and Dll.22on Natural RubberFor his activities in D l l , Rubber, and especially forhis chairmanship of Dll.08 (Nomenclature andTerminology)For his contributions in D24, Carbon Black and hisactivities in the Executive Subcommittee

AcknowledgmentAcknowledgment of Contributors to ASTM Rubber StandardsThe many ASTM standards discussed in this book were created throughthe excellent technical knowledge, strong commitments, and hard work ofhundreds of rubber technologists who volunteered their time and

6.4 Structure (Aggregates and Agglomerates) 108 6.4.1 n-Dibutyl Phthalate Absorption Number (D 6854) 108 6.5 General Methods 109 6.5.1 Volatiles (D 6738) 109 6.5.2 pH Value (D 6739) 109 6.6 Organosilanes 109 6.6.1 Determination of Residue on Ignition (D 6740) 109

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