Plastics failure guide: cause and prevention
Gespeichert in:
| 1. Verfasser: | |
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| Format: | Buch |
| Sprache: | German |
| Veröffentlicht: |
Munich [u.a.]
Hanser [u.a.]
1996
|
| Schriftenreihe: | SPE books from Hanser Publishers
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| Schlagworte: | |
| Online-Zugang: | Inhaltsverzeichnis |
| Beschreibung: | XXI, 473 S. zahlr. Ill. und graph. Darst. |
| ISBN: | 3446157158 1569901848 |
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| 100 | 1 | |a Ezrin, Myer |e Verfasser |4 aut | |
| 245 | 1 | 0 | |a Plastics failure guide |b cause and prevention |c Myer Ezrin |
| 264 | 1 | |a Munich [u.a.] |b Hanser [u.a.] |c 1996 | |
| 300 | |a XXI, 473 S. |b zahlr. Ill. und graph. Darst. | ||
| 336 | |b txt |2 rdacontent | ||
| 337 | |b n |2 rdamedia | ||
| 338 | |b nc |2 rdacarrier | ||
| 490 | 0 | |a SPE books from Hanser Publishers | |
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CONTENTS
1
A
PRELIMINARY
LOOK
AT
THE
NATURE,
CAUSES,
AND
CONSEQUENCES
OF
PLASTICS
FAILURE
.
1
1.1
INTRODUCTION
.
1
1.2
PLASTICS
.
1
1.3
POLYMERS
.
2
1.4
RUBBERS
AND
ELASTOMERS
.
3
1.5
NATURAL
POLYMERS
.
3
1.6
PLASTICS
IN
THE
FAMILY
OF
MATERIALS
.
3
1.7
COMMON
FEATURES
AND
DIFFERENCES
IN
PERFORMANCE
OR
FAILURE
OF
ALL
MATERIALS
.
4
1.8
THE
UNINTENTIONAL
FACTORS
AFFECTING
FAILURE
.
5
1.9
TYPES
AND
CAUSES
OF
FAILURE
.
6
1.10
THE
PEOPLE
FACTOR
.
8
1.11
THE
CONSEQUENCES
OF
PLASTICS
FAILURE
.
9
1.12
LEGAL
AND
FINANCIAL
ASPECTS
OF
PLASTICS
FAILURE
.
9
1.13
REFERENCES
.
10
2
FUNDAMENTAL
MATERIALS
VARIABLES
AFFECTING
PROCESSING
AND
PRODUCT
PERFORMANCE
OR
FAILURE
.
11
2.1
THE
OVERALL
PICTURE
.
11
2.2
POLYMER
COMPOSITION
.
13
2.2.1
MAJOR
CATEGORIES
OF
PLASTICS
COMPOSITION
.
13
2.2.1.1
THERMOPLASTIC
AND
THERMOSETTING
PLASTICS
.
13
2.2.1.2
THERMOPLASTIC
ELASTOMERS
.
14
2.2.2
TYPES
OF
POLYMERS
.
14
2.2.2.1
ADDITION
POLYMERS
BASED
ON
VINYL
MONOMERS
.
14
2.2.2.2
THERMAL
AND
PHOTOLYTIC
STABILITY
OF
VINYL
ADDITION
POLYMERS
.
14
2.2.2.3
THERMAL
ANALYSIS
IN
THE
STUDY
OF
POLYMER
DEGRADATION
.
16
2.2.2.4
CONTROLLING
THERMAL
EFFECTS
IN
PERFORMANCE
OR
FAILURE
OF
PLASTICS
.
17
2.2.2.5
ELASTOMERIC
ADDITION
POLYMERS
BASED
ON
DIENE
MONOMERS
18
2.2.2.6
RELATIVE
SIZE
OF
PENDANT
GROUPS
.
18
2.2.2.7
CONDENSATION
POLYMERS
.
19
2.2.2.8
OTHER
POLYMER
TYPES
.
20
2.2.2.9
HOMOPOLYMERS,
COPOLYMERS,
TERPOLYMERS,
AND
BLENDS
.
20
2.3
COMPOSITION
-
INTENTIONAL
ADDITIVES
.
21
2.3.1
TYPES
OF
ADDITIVES
.
21
2.3.2
FAILURE
EFFECTS
OF
INTENTIONAL
ADDITIVES
.
21
2.3.2.1
PLASTICIZERS
.
22
2.3.2.2
COLORANTS
.
23
2.3.2.3
FLAME
RETARDANTS
.
24
2.3.2.4
UNANTICIPATED
EFFECT
OF
ADDITIVE
.
26
2.3.2.5
POOR
DISPERSION
OF
ADDITIVES
-
ANTIOXIDANT
.
27
XII
CONTENTS
2.3.2.6
VOLATILITY
OF
ADDITIVES
-
ANTIOXIDANT
.
28
2.4
COMPOSITION
-UNINTENTIONAL
ADDITIVES
.
29
2.4.1
TYPES
OF
UNINTENTIONAL
ADDITIVES
.
29
2.4.2
FAILURE
EFFECTS
OF
UNINTENTIONAL
ADDITIVES
.
29
2.4.2.1
EXTRANEOUS
DIRT,
LINT,
AND
OTHER
CONTAMINANT
MATERIALS
.
.
29
2.4.2.2
RESIDUAL
MONOMER,
SOLVENT
OR
OTHER
LOW
LEVEL
CHEMICALS
.
30
2.4.2.3
WATER
.
31
2.4.2.4
COMPOUNDING
PROCESS
AIDS
IN
ADDITIVES
CONCENTRATES
.
33
2.4.2.5
ADDITIVES
IN
FORMULATION
INGREDIENTS
TO
IMPROVE
THEIR
PERFORMANCE
.
34
2.4.2.6
IONIC
IMPURITIES
FROM
WATER
IN
SERVICE
.
35
2.4.2.7
IONIC
IMPURITIES
IN
CARBON
BLACK
.
35
2.4.2.8
TRACE
METAL
FROM
EXTRUDER
BARREL
AND
SCREW
COATING
.
35
2.4.2.9
IMPURITIES
IN
INTENTIONAL
ADDITIVES
OR
PROCESSING
MATERIALS
35
2.5
MOLECULAR
WEIGHT
.
35
2.6
INTERMOLECULAR
ORDER
.
39
2.6.1
CRYSTALLINITY
.
39
2.6.2
CROSSLINKING
.
41
2.6.3
ORIENTATION
DUE
TO
PROCESSING
.
41
2.6.4
DEGREE
OF
FUSION
.
43
2.7
COMBINED
EFFECT
OF
MOLECULAR
WEIGHT
AND
CRYSTALLINITY
.
43
2.8
REFERENCES
.
45
3
FAILURES
RELATED
TO
DESIGN
AND
MATERIAL
SELECTION
.
46
3.1
INTRODUCTION
.
46
3.2
BASIC
AND
PRACTICAL
CONSIDERATIONS
IN
DESIGN-RELATED
FAILURES
.
46
3.2.1
THE
PEOPLE
FACTOR
.
46
3.2.2
DECLARING
WAR
ON
FAILURE
.
47
3.2.3
TO
TEST
OR
NOT
TO
TEST
-
OR
HOW
MUCH
IS
ENOUGH?
.
47
3.2.4
THE
PERFECT
DESIGN
AND
PRODUCT
-
DOES
IT
EXIST?
.
48
3.2.5
THE
PROTOTYPE
.
49
3.2.6
EFFECT
OF
DESIGN
ON
PROCESSING
.
49
3.2.7
DESIGN
CHECKLIST
.
49
3.2.8
THE
MOST
COMMON
MISTAKES
IN
DESIGN
OF
PLASTICS
.
50
3.2.8.1
CREEP
.
50
3.2.8.2
STRESS
.
51
3.2.8.3
HOSTILE
ENVIRONMENT
.
52
3.2.8.4
SHRINKAGE
.
52
3.2.8.5
COLOR
VARIANCE
.
52
3.2.8.6
GATE
MARKS
.
52
3.2.8.7
INADEQUATE
DRAFT
.
52
3.2.8.8
SINK
MARKS
.
52
3.2.8.9
UNANTICIPATED
USE
.
53
3.2.8.10
TIME
.
53
3.2.9
THE
PRODUCT
SPECIFICATIONS
.
53
3.2.9.1
MATERIALS
.
53
3.2.9.2
DESIGN
SPECIFICATIONS
.
53
3.2.9.3
PERFORMANCE
SPECIFICATIONS
.
53
3.2.10
DESIGN
FOR
SERVICE
LIFE
AND
SERVICE
CONDITIONS
.
54
3.2.11
THE
HAZARDS
OF
SIMULTANEOUS
SERVICE
FACTORS
.
54
3.2.12
BRITTLE
FRACTURE
-
A
BALANCING
ACT
OF
DESIGN
AND
MATERIAL
.
55
3.2.13
COMPARISON
OF
PLASTICS
AND
METALS
.
56
CONTENTS
XIII
3.2.14
CRACK
PHENOMENA
IN
FRACTURE
.
57
3.2.15
FAILURE
BY
FATIGUE
.
59
3.2.15.1
FAILURE
BY
CRACK
PROPAGATION
.
60
3.2.15.2
FAILURE
BY
SOFTENING
DUE
TO
HYSTERETIC
HEATING
.
61
3.2.15.3
EFFECT
OF
ENVIRONMENT
.
63
3.2.16
FAILURE
BY
CREEP
.
63
3.2.17
FAILURE
BY
IMPACT
.
64
3.2.17.1
DESIGN
EFFECTS
.
64
3.2.17.2
MATERIAL
EFFECTS
.
65
3.2.17.3
MOLDING
EFFECTS
.
65
3.2.17.4
MOLECULAR
WEIGHT
EFFECTS .
65
3.2.17.5
POLYMER
COMPOSITION
AND
CRYSTALLINITY
EFFECTS
.
65
3.2.18
ELECTRICAL
STRESS
.
66
3.2.19
SURFACE
EFFECTS
IN
FAILURE
RELATED
TO
DESIGN
.
66
3.2.20
WELD
LINES
.
67
3.2.21
WARPAGE
.
68
3.3
REFERENCES
.
70
4
EXAMPLES
OF
FAILURE
DUE
TO
DESIGN
AND
MATERIAL
SELECTION
.
72
4.1
INTRODUCTION
.
72
4.2
PART
OR
PRODUCT
DESIGN
.
74
4.2.1
EXAMPLES
OF
FAILURE
DUE
MAINLY
TO
DESIGN
.
74
4.2.1.1
A
PROCESS-RELATED
PROBLEM
DUE
TO
DESIGN
.
74
4.2.1.2
POOR
DESIGN
AND
STRESS
CONCENTRATIONS
IN
AUTOMOBILE
COOLANT
RESERVOIR
TANK
.
75
4.2.1.3
MISLEADING
OR
UNWISE
INSTRUCTIONS
IN
DESIGN
DIAGRAMS
.
75
4.2.1.4
STRESSES
IN
INTERFERENCE
FIT
-
FRACTURE
OF
NYLON
HEAD
HARNESS
INSIDE
HARD
HAT
.
76
4.2.1.5
FAILURE
TO
CONSIDER
OCCASIONAL
IMPACT
IN
DESIGN
OF
UMBRELLA
77
4.2.1.6
ATTACHMENT
STRESSES
-
FRACTURE
OF
BOSSES
ATTACHING
MOTOR
HOUSING
TO
LAWNMOWER
.
77
4.2.1.7
MULTIPLE
MODES
OF
FAILURE
OF
A
POORLY
DESIGNED
PS
PITCHER
78
4.2.1.8
DESIGN
OF
HOUSINGS
OVER
METAL
COMPONENTS
-
FRACTURED
KITCHEN
BLENDER
.
78
4.2.1.9
FLEXIBLE
HINGES
REQUIRE
SPECIAL
DESIGN
-
POLYETHYLENE
SOAP
DISH
.
80
4.2.1.10
PLASTIC
PART
DESIGN
BASED
LARGELY
ON
METAL
PARTS
DESIGN
MAY
LEAD
TO
FAILURE
-
ACETAL
VALVE
BODY
IN
HYDRAULIC
OIL
SYSTEM
80
4.2.1.11
MAKE
DIMENSIONAL
SPECIFICATIONS
REALISTIC
-
THE
OVERSPECIFIED
PART
.
82
4.2.1.12
INSERTS
.
82
4.2.1.13
WELD
LINES
.
83
4.3
PART
DESIGN
AND/OR
MATERIAL
SELECTION
.
84
4.3.1
WARPAGE
.
84
4.3.2
STATIC
LOAD
IMPOSED
BY
SCREWS
AND
RIVETS
.
86
4.3.2.1
CRACKING
AT
MOLDED-IN
SCREW
HOLES
.
86
4.3.2.2
CRACKING
AT
SCREW
HOLES
DRILLED
INTO
PLASTIC
SHEET
.
88
4.3.3
FRACTURE
OR
TEARING
OF
FLEXIBLE
PVC
PRODUCTS
DUE
TO
FLEXURAL
FATIGUE
88
4.3.3.1
FAILURE
IN
THE
FLEXIBLE
SHEET
ITSELF
.
88
4.3.3.2
FAILURE
IN
PRODUCTS
WITH
ATTACHED
PARTS
.
90
4.3.4
STYRENICS
PS,
IMPACT
PS
(HIPS),
ABS,
SAN
.
90
4.3.4.1
PS
HOMOPOLYMER
.
92
XIV
CONTENTS
43.4.2
HIPS
.
94
4.3.43
ABS
.
98
43.4.4
SAN
.
99
4.3.5
POLYOLEFINS
.
99
43.5.1
EXAMPLES
OF
FAILURE
OF
OLEFINIC
PLASTICS
.
101
43.5.2
POLYPROPYLENE
.
110
4.3.53
ETHYLENE
COPOLYMERS
.
112
4.3.6
RIGID
PVC
.
112
43.6.1
PIPES
AND
FITTINGS
.
112
43.6.2
FAILURE
DUE
TO
EXCESSIVE
HEATING
IN
SERVICE
.
112
4.3.7
THERMOPLASTIC
ENGINEERING
RESINS
THAT
FAILED
BECAUSE
T
G
WAS
TOO
LOW
FOR
THE
SERVICE
REQUIREMENT
OR
BECAUSE
OF
CREEP
-
PBT,
PPO,
PPS,
AND
OTHER
THERMOPLASTICS
.
113
43.7.1
EXAMPLES
OF
THERMOPLASTICS
FAILURES
.
113
4.3.8
CELLULOSICS
.
114
43.8.1
THE
SHOWERHEAD
MADE
WITH
CELLULOSE
ACETATE
SCRAP
RESIN
114
4.3.9
ACRYLICS
(PMMA)
.
115
4.3.10
NYLON
.
115
4.3.11
RUBBER
.
116
4.3.11.1
EXAMPLES
OF
RUBBER
FAILURE
.
117
4.4
LESSONS
.
119
4.4.1
FAILURES
DUE
MAINLY
TO
DESIGN
.
119
4.4.2
FAILURES
DUE
TO
PART
DESIGN
AND/OR
MATERIAL
SELECTION
.
120
4.5
REFERENCES
.
123
5
PROCESSING-RELATED
FACTORS
IN
FAILURE
.
126
5.1
INTRODUCTION
.
126
5.2
FACTORS
AND
VARIABLES
COMMON
TO
PROCESSING
METHODS
IN
GENERAL
.
126
5.2.1
INTENTIONAL
AND
UNINTENTIONAL
STEPS
IN
PROCESSING
.
126
5.3
COMPOUNDING
AND
MIXING
.
131
5.4
FUSION
.
132
5.5
PROCESSING
METHODS
.
132
5.5.1
INJECTION
MOLDING
.
132
5.5.2
EXTRUSION
.
135
5.5.3
THERMOFORMING
PLASTIC
FILM
AND
SHEET
.
137
5.5.4
BLOW
MOLDING
.
139
5.5.5
ROTATIONAL
MOLDING
.
139
5.6
IMPROVEMENTS
IN
PROCESSING
METHODS
.
139
5.7
PROCESS
CONTROL
METHODS,
TROUBLESHOOTING,
FAILURE
ANALYSIS
AND
TEST
METHODS
140
5.7.1
PROCESS
CONTROL
METHODS
.
140
5.7.2
TROUBLESHOOTING
AND
FAILURE
ANALYSIS
.
140
5.7.3
TEST
METHODS
.
143
5.8
SECONDARY
OPERATIONS
.
145
5.8.1
WELDING
METHODS
.
146
5.8.2
PUNCHING
.
147
5.8.3
PAINTING
AND
DECORATING
.
148
5.8.4
SURFACE
SMOOTHING
BY
BUFFING
.
148
5.9
FAILURE
PROBLEMS
RELATED
TO
TRANSPORTATION
AND
INSTALLATION
.
148
5.10
LESSONS
.
149
5.10.1
GENERAL
.
149
5.10.2
COMPOUNDING,
FUSION,
AND
DISPERSION
.
149
5.10.3
PRIMARY
PROCESSING
.
150
CONTENTS
XV
5.10.4
SECONDARY
OPERATIONS
.
150
5.10.5
TESTING,
QUALITY
CONTROL,
AND
FAILURE
ANALYSIS
.
150
5.10.6
TRANSPORTATION,
STORAGE,
AND
INSTALLATION
.
151
5.11
REFERENCES
.
151
6
FAILURE
RELATED
TO
SERVICE
CONDITIONS
.
154
6.1
INTRODUCTION
.
154
6.2
GENERAL
NATURE
AND
PRINCIPLES
OF
SERVICE
CONDITION-RELATED
FAILURE
.
154
6.3
SPECIFIC
EFFECTS
AND
EXAMPLES
OF
SERVICE
CONDITIONS
.
157
6.3.1
CHEMICAL
AND
SOLVENT
RESISTANCE
.
157
6.3.1.1
CHEMICAL
REACTIONS
.
159
6.3.1.2
FAILURES
DUE
TO
PHYSICAL
EFFECTS
IN
CHEMICAL
AND
SOLVENT
RESISTANCE
IN
THE
ABSENCE
OF
STRESS
.
164
6.3.1.3
CHEMICAL
RESISTANCE
IN
THE
PRESENCE
OF
STRESS
(ENVIRONMENTAL
STRESS-CRACKING)
.
165
6.3.1.4
APPLICATION
AREAS
WITH
MAJOR
EFFECTS
ON
CHEMICAL-RELATED
FAILURE
.
166
6.3.1.5
AIR
POLLUTION
.
167
6.3.2
WEATHERING
EFFECTS
(OUTDOOR
AGING)
.
168
6.3.3
PHYSICAL
EFFECTS
OF
THERMAL
CONDITIONS
IN
SERVICE
.
170
6.3.4
PLASTICS
IN
BUILDING
MATERIALS
.
171
6.3.5
FAILURE
DUE
TO
DIMENSIONALLY
UNSTABLE
NATURE
OF
THE
ENVIRONMENT
OF
PLASTIC
PRODUCTS
.
171
6.3.6
MECHANICAL
EFFECTS
-
WEAR
AND
IMPACT
.
171
6.3.7
BIOLOGICAL
AND
MEDICAL
.
173
6.3.8
ELECTRICAL
.
174
6.3.9
FAILURES
DUE
TO
UNINTENTIONAL
AND
UNANTICIPATED
SERVICE
CONDITIONS
.
174
6.4
LESSONS
.
177
6.4.1
GENERAL
CONSIDERATIONS
.
177
6.4.2
THERMAL
EFFECTS
INCLUDING
EXPANSION
AND
CONTRACTION
.
179
6.4.3
DEGRADATION
BY
CHEMICAL
REACTION
.
180
6.4.4
CHEMICAL
AND
SOLVENT
EFFECTS
OTHER
THAN
CHEMICAL
REACTION
.
180
6.4.5
MECHANICAL
EFFECTS
.
181
6.4.6
ELECTRICAL
EFFECTS
.
181
6.4.7
UNINTENTIONAL
AND
UNEXPECTED
SERVICE
CONDITIONS
.
181
6.5
REFERENCES
.
182
7
FAILURE
ANALYSIS
AND
TEST
PROCEDURES
.
184
7.1
BASIC
CONSIDERATIONS
.
184
7.2
FAILURE
ANALYSIS
GENERAL
PROCEDURES
.
185
7.2.1
TYPES
OF
INFORMATION
NEEDED
.
185
7.2.1.1
VISUAL
EXAMINATION
.
185
7.2.1.2
HISTORY
AND
CIRCUMSTANCES
OF
FAILURE
.
186
7.2.1.3
IDENTIFICATION
OF
THE
PRODUCT
SOURCE
AND
PLASTIC
TYPE,
GRADE
AND
SOURCE
.
186
7.2.1.4
DID
FAILED
PRODUCT
MEET
ALL
SPECIFICATIONS
AS
PRODUCED?
.
.
186
7.2.1.5
FRACTOGRAPHY
.
186
7.2.1.6
STRESS
EVALUATION
OR
ANALYSIS
.
186
7.2.2
FAILURE
ANALYSIS
REPORT
.
187
7.3
FLOW
CHARTS
AND
CHECK
LISTS
.
187
XVI
CONTENTS
7.3.1
UNITED
STATES
AIR
FORCE
PLAN
FOR
COMPOSITES
.
187
7.3.1.1
EXAMPLES
OF
APPLICATION
OF
THE
U.S.
AIR
FORCE
PLAN
FOR
COMPOSITES
.
192
7.3.2
GENERAL
ELECTRIC
PLASTICS
COMPANY
PLAN
FOR
THERMOPLASTICS
.
192
7.3.2.1
EXAMPLES
OF
APPLICATION
OF
THE
GE
PLAN
FOR
THERMOPLASTICS
.
192
7.4
ANALYTICAL
AND
TEST
PROCEDURES
IN
SUPPORT
OF
FAILURE
.
201
7.4.1
BASIC
CONSIDERATIONS
.
201
7.4.2
CATEGORIES
OF
ANALYTICAL
AND
TEST
METHODS
.
202
7.4.3
MATERIALS
CHARACTERIZATION
.
203
7.4.3.1
QUALITATIVE
IDENTIFICATION
OF
FORMULATION
COMPONENTS
.
.
.
203
7.4.3.2
PHYSICAL
CHEMICAL
CHARACTERIZATION
OF
POLYMERS
.
204
7.4.3.3
IDENTIFICATION
OF
CONTAMINANTS
.
207
7.4.3.4
SURFACE
ANALYSIS
.
208
7.5
MECHANICAL
TEST
METHODS
AND
MATERIAL
CHARACTERISTICS
OF
MECHANICAL
FAILURE
.
210
7.5.1
INTRODUCTION
.
210
7.5.2
TENSILE,
FLEXURAL,
AND
COMPRESSIVE
PROPERTIES
.
211
7.5.3
FATIGUE
FAILURE
AND
TESTS
.
212
7.5.4
MICROSCOPIC
EXAMINATION
OF
FATIGUE
AND
OTHER
FRACTURE
TYPES
.
215
7.5.5
IMPACT
FAILURE
.
221
7.5.6
WEAR
AND
ABRASION
.
222
7.6
CHEMICAL
RESISTANCE
AND
ENVIRONMENTAL
STRESS-CRACKING
.
222
7.7
STRESS
ANALYSIS
.
225
7.8
NON-DESTRUCTIVE
TESTING
AND
EVALUATION
METHODS
.
228
7.8.1
INTRODUCTION
.
228
7.8.2
ULTRASONIC
TESTING
.
229
7.8.3
ACOUSTIC
EMISSION
.
230
7.8.4
ACOUSTIC
WAVE
GUIDE
.
234
7.9
CONFIRMING
FAILURE
ANALYSIS
CONCLUSIONS
BY
DEMONSTRATING
RESPONSE
TO
SERVICE
CONDITIONS
IN
CONTROLLED
EXPERIMENTS
.
234
7.10
LESSONS
.
235
7.10.1
LESSONS
FOR
FAILURE
ANALYSIS
.
235
7.10.2
LESSONS
FOR
ANALYSIS
AND
TESTING
IN
CONNECTION
WITH
FAILURE
ANALYSIS
.
235
7.11
REFERENCES
.
236
8
QUALITY
CONTROL
-
PREVENTIVE
FAILURE
ANALYSIS
.
241
8.1
BASIC
CONSIDERATIONS
.
241
8.1.1
TERMINOLOGY
AND
CONCEPTS
OF
QC,
QA,
SPC,
SQC,
TQC,
TQM
.
241
8.1.2
WHERE
QA
FITS
IN
CORPORATE
MANAGEMENT
.
243
8.1.3
QA
PAST
AND
PRESENT
.
243
8.1.4
PREVENTIVE
FAILURE
ANALYSIS
.
246
8.1.5
THE
ROLE
OF
PEOPLE
.
246
8.1.6
QC
TEST
METHODS
AND
STATISTICAL
METHODS
.
247
8.1.7
WHY
MATERIALS,
PROCESSES
AND
PRODUCTS
VARY
-
RANDOM
AND
NON-RANDOM
VARIABLES
.
248
8.1.7.1
RANDOM
VARIABLES
.
248
8.1.7.2
NON-RANDOM
MATERIAL
VARIABLES
.
248
8.1.7.3
STATISTICAL
CONTROL
.
249
8.1.7.4
NON-RANDOM
PROCESS
VARIABLES
.
249
8.1.7.5
GRAPHICAL
REPRESENTATION
OF
RANDOM
(COMMON
CAUSE)
AND
NON-RANDOM
(SPECIAL
CAUSE)
VARIATIONS
.
249
8.1.7.6
PRODUCT
QUALITY
CONTROL
.
251
8.2
QC/QA
SYSTEMS
.
252
CONTENTS
XVII
8.3
QC
TEST
METHODS
-
GENERAL
CONSIDERATIONS
AND
SAMPLING
PLANS
.
255
8.4
QC
OF
MATERIALS
TO
BE
PROCESSED
.
257
8.4.1
CATEGORIES
OF
MATERIALS
.
257
8.4.2
TEST
METHODS
FOR
MATERIALS
IN
QC
RELATIVE
TO
FAILURE
ANALYSIS
.
257
8.4.3
CALIBRATION
AND
REFERENCE
STANDARDS
.
258
8.4.4
ANALYTICAL
METHODS
.
258
8.4.4.1
CHEMICAL
COMPOSITION
-
TO
ANALYZE
OR
NOT
TO
ANALYZE
.
258
8.4.4.2
CONTAMINANTS
.
261
8.4.5
MOLECULAR
WEIGHT
METHODS
.
261
8.4.6
CRYSTALLINITY
AND
CROSSLINKABILITY
.
261
8.4.7
RHEOLOGICAL
METHODS
.
262
8.4.8
VISUAL
METHODS
.
263
8.4.9
MECHANICAL
PROPERTIES
.
263
8.4.10
BEWARE
OF
CHANGES
DURING
TRANSPORTATION
AND
STORAGE
.
263
8.5
QC
OF
MATERIALS
IN
PROCESS
-
STATISTICAL
PROCESS
CONTROL
.
263
8.5.1
PROCESS
CONTROL
IN
INJECTION
MOLDING
.
265
8.5.2
PROCESS
CONTROL
IN
EXTRUSION
.
268
8.5.3
PROCESS
CONTROL
IN
COMPOUNDING
.
270
8.5.4
PROCESS
CONTROL
IN
BLOW
MOLDING
.
271
8.5.5
PROCESS
CONTROL
IN
SMC
(SHEET
MOLDING
COMPOUND)
.
272
8.5.6
PROCESS
CONTROL
IN
COMPOSITES
.
272
8.5.7
PROCESS
CONTROL
IN
REACTION
INJECTION
MOLDING
(RIM)
.
275
8.5.8
ON-LINE
METHODS
OF
PROCESS
CONTROL
.
276
8.5.8.1
INFRARED
SPECTROSCOPY
.
276
8.5.8.2
RHEOLOGY
.
277
8.5.8.3
OTHER
ON-LINE
METHODS
.
278
8.5.9
PROCESS
CONTROL
METHODS
OTHER
THAN
ON-LINE
METHODS
.
278
8.5.10
PROCESS
CONTROL
IN
PIPE
PROCESSING
.
278
8.6
QUALITY
CONTROL
OF
PRODUCTS
.
278
8.7
IN-SERVICE
QC
TESTING
.
280
8.8
LESSONS
FOR
QC/QA
OF
MATERIALS,
PROCESSES,
AND
PRODUCTS
.
281
8.9
REFERENCES
.
282
9
LEGAL
ASPECTS
OF
PLASTICS
PRODUCT
LIABILITY
AND
FAILURE
.
287
9.1
INTRODUCTION
.
287
9.2
THE
HARSH
REALITIES
OF
PRODUCT
LIABILITY
.
288
9.3
BASIC
LEGAL
ASPECTS
OF
PRODUCT
LIABILITY
.
289
9.4
COMMON
CAUSES
OF
FAILURE
THAT
COULD
RESULT
IN
LITIGATION
.
292
9.4.1
DESIGN-RELATED
CAUSES
.
294
9.4.2
MATERIAL-RELATED
CAUSES
.
295
9.4.3
ENGINEERING-RELATED
CAUSES
.
296
9.4.4
PRODUCTION-RELATED
CAUSES
.
296
9.4.5
TESTING-RELATED
CAUSES
.
297
9.4.6
SALES
AND
CUSTOMER
SERVICE-RELATED
CAUSES
.
297
9.5
PREVENTION
OF
LEGAL
PROBLEMS
.
298
9.5.1
PRODUCT
LIABILITY
CONTROL
PROGRAM
-
GENERAL
CONSIDERATIONS
.
298
9.5.2
DESIGN
AND
PRODUCT
DEVELOPMENT
.
299
9.5.2.1
HAZARDS
ANALYSIS
.
300
9.5.2.2
FAILURE
MODES
AND
EFFECTS
ANALYSIS
(FMEA)
AND
FAULT
TREE
ANALYSIS
(FTA)
.
300
9.5.3
TESTING
AND
PRODUCT
EVALUATION
.
301
9.5.4
RECORD
KEEPING
AND
DOCUMENTATION
.
301
XVIII
CONTENTS
9.5.5
ENGINEERING
AND
PRODUCTION
.
302
9.5.6
QUALITY
CONTROL
.
302
9.5.7
WARRANTIES,
INSTRUCTIONS,
WARNINGS,
AND
CLAIMS
.
303
9.5.8
RESPONSE
TO
FIELD
FAILURES
AND
PROBLEMS
.
303
9.6
PRODUCT
LIABILITY
INSURANCE
.
304
9.7
HOW
TO
RESPOND
TO
CLAIMS
AND
TO
LITIGATION
.
304
9.8
THE
EXPERT
WITNESS
.
306
9.9
CASE
STUDIES
OF
PLASTICS
FAILURE
LITIGATION
.
307
9.9.1
CASE
STUDIES
INVOLVING
PERSONAL
INJURY
OR
HEALTH
PROBLEMS
.
308
9.9.1.1
RECREATIONAL
PRODUCTS
.
308
9.9.1.2
PACKAGING
PRODUCT
FAILURE
.
310
9.9.1.3
HOME
CONSTRUCTION
AND
OTHER
UNREACTED
MONOMER
PROBLEMS
.
313
9.9.1.4
MEDICAL
DEVICES
.
315
9.9.1.5
ELECTRICAL
EQUIPMENT
.
315
9.9.1.6
TRANSPORTATION
PRODUCTS
.
316
9.9.1.7
INFANT
PRODUCTS
-
DETACHMENT
OF
A
SNAPFIT
BABY
SEAT
.
317
9.9.2
PRODUCT
QUALITY
LITIGATION
.
318
9.10
LESSONS
FROM
CASE
STUDIES
.
320
9.11
REFERENCES
.
321
10
COMPOSITES
.
323
10.1
THE
NATURE
AND
PURPOSE
OF
FIBER-REINFORCED
PLASTICS
.
323
10.2
DEFECTS
AND
FLAWS
AND
OTHER
COMPOSITIONAL
AND
DESIGN
FACTORS
THAT
AFFECT
FAILURE
.
325
10.3
CAUSES,
MODES,
AND
MECHANISMS
OF
FAILURE
.
326
10.3.1
INTRODUCTION
.
326
10.3.2
SHORT
FIBER-REINFORCED
PLASTICS
.
327
10.3.3
LONG
FIBER-REINFORCED
PLASTICS
.
328
10.3.3.1
BASIC
MODES
OF
FRACTURE
OF
LONG
FIBER
LAMINATED
COMPOSITES
.
329
10.3.3.2
MATERIALS
FACTORS
IN
FAILURE
.
330
10.3.3.3
DESIGN
FACTORS
IN
FAILURE
.
331
10.3.3.4
MANUFACTURING
DEFECTS
AND
PROBLEMS
CONTRIBUTING
TO
FAILURE
332
10.3.3.5
SERVICE-RELATED
CAUSES
OF
FAILURE
.
334
10.4
FAILURE
ANALYSIS
PROCEDURES
FOR
COMPOSITES
.
335
10.4.1
MATERIALS
CHARACTERIZATION
.
335
10.4.1.1
CONFIRMATION
OF
ADHERENCE
TO
SPECIFICATIONS
.
335
10.4.1.2
IDENTIFICATION
OF
CONTAMINANTS
.
337
10.4.2
NON-DESTRUCTIVE
EVALUATION
(NDE)
.
338
10.4.3
FRACTOGRAPHY
.
339
10.4.4
STRESS
ANALYSIS
.
340
10.5
EXAMPLES
OF
FAILURE
OF
FIBER-REINFORCED
PLASTICS
.
343
10.5.1
PULTRUDED
RODS
.
343
10.5.1.1
LONG
COMPOSITE
SUSPENSION
INSULATOR
RODS
FOR
ELECTRIC
TRANSMISSION
LINES
.
343
10.5.1.2
LONG
GUY
STRAIN
INSULATOR
RODS
FOR
ELECTRIC
TRANSMISSION
SYSTEMS
.
344
10.5.2
PIPE,
TANKS,
AND
VESSELS
.
345
10.5.2.1
SAND-FILLED
SEWER
LINING
MATERIALS
.
346
10.5.2.2
LARGE
SCALE
CHEMICAL
PROCESS
AND
STORAGE
EQUIPMENT
.
346
10.5.3
EFFECT
OF
VARIABILITY
OF
E-GLASS
FIBER
ON
FAILURE
.
349
CONTENTS
XIX
10.6
EXAMPLES
OF
FAILURE
OF
ADVANCED
COMPOSITES
IN
AIR
DEFENSE
AND
AEROSPACE
SERVICE
.
350
10.6.1
DELAMINATION
OF
A
GLASS
FABRIC/POLYIMIDE
COMPONENT
IN
SERVICE
.
.
.
350
10.6.2
GRAPHITE/POLYBENZIMIDAZOLE
.
350
10.6.3
ELEVATOR
TEST
BOX
.
351
10.6.4
WING
TEST
BOX
.
352
10.6.5
WING
SECTION
.
353
10.6.6
CARBON
FIBER
REINFORCED
NOVOLAC-EPOXY
RESIN
I-BEAM
.
353
10.6.7
CARBON
FIBER/PEEK
PEEL
AND
SHEAR
FAILURES
.
353
10.7
PROBLEMS
OF
GRP
AUTOMOTIVE
BODIES
.
353
10.8
LESSONS
.
354
10.8.1
LESSONS
FOR
LONG
PULTRUDED
RODS
.
354
10.8.2
LESSONS
FOR
GLASS
FIBER
REINFORCED
COMPOSITES
IN
LARGE
VOLUME
APPLICATIONS
.
354
10.8.3
LESSONS
FOR
AEROSPACE
APPLICATIONS
.
354
10.9
REFERENCES
.
355
11
PIPES
AND
FITTINGS
.
358
11.1
INTRODUCTION
.
358
11.1.1
LEGAL
AND
PUBLIC
RELATIONS
ASPECTS
OF
PIPE
AND
FITTINGS
FAILURES
.
358
11.1.2
THE
NATURE
OF
PIPE
AND
FITTINGS
MATERIALS
AND
SERVICE
.
359
11.1.3
FACTORS
AFFECTING
FAILURE
OR
SERVICE
LIFE
.
360
11.2
PIPE
FAILURES
-
CAUSE
AND
PREVENTION
.
361
11.2.1
THE
NATURE
OF
PIPE
FAILURE
.
361
11.2.2
DESIGN
.
362
11.2.3
COMPOSITION
.
364
11.2.3.1
FUNDAMENTAL
MATERIALS
ASPECTS
.
364
11.2.3.2
SOLID
SMALL
PARTICLE
CONTAMINANTS
.
365
11.3
PROCESSING,
JOINING,
AND
INSTALLATION
.
366
11.3.1
PROCESSING
.
366
11.3.2
JOINING
.
369
11.3.3
INSTALLATION
.
370
11.4
SERVICE
CONDITIONS
.
370
11.4.1
OVERALL
SERVICE
FAILURE
EXPERIENCE
AND
CAUSES
.
371
11.4.2
CASE
HISTORIES
OF
FIELD
FAILURES
.
374
11.4.2.1
POLYETHYLENE
GAS
DISTRIBUTION
SYSTEMS
.
374
11.4.2.2
POLYETHYLENE
SEWER
PIPE
.
377
11.4.2.3
PE
WATER
DISTRIBUTION
SYSTEMS
.
377
11.4.2.4
PB
WATER
DISTRIBUTION
SYSTEMS
.
377
11.4.2.5
PB
LARGE
DIAMETER
WATER
PIPE
.
378
11.4.2.6
PVC
WATER
PIPE
FRACTURE
FOR
LONG
DISTANCES
.
379
11.4.2.7
PVDF
FAILURE
AT
SOCKET
JOINTS
.
379
11.4.3
CASE
HISTORIES
OF
SMALL
DIAMETER
PE
AND
PB
WATER
SYSTEM
FAILURES
DUE
TO
FITTINGS
AND
CONNECTIONS
.
379
11.4.3.1
ACETAL
FITTINGS
.
379
11.4.3.2
PIPE
FAILURES
DUE
TO
METAL
STIFFENERS
USED
WITH
COMPRESSION
FITTINGS
.
380
11.4.3.3
FAILURES
DUE
TO
PULLOUT
OF
PIPE
FROM
COMPRESSION
FITTINGS
380
11.4.4
FAILURES
OF
IMPROPERLY
FORMULATED
ABS
FITTINGS
AND
JOINTS
USED
IN
DWV
SERVICE
(DRAIN,
WASTE,
AND
VENT)
.
380
11.5
FAILURE
ANALYSIS
.
380
11.5.1
TESTS
TO
SIMULATE
SURFACE
EMBRITTLEMENT
OF
PE
PIPE
GRADE
RESIN
.
.
.
384
XX
CONTENTS
11.5.2
SHORT-TERM
TESTS
FOR
RESIN
AND
PIPE
QUALITY
.
385
11.5.2.1
RESIN
TESTS
.
385
11.5.2.2
PIPE
QUALITY
TESTS
.
387
11.5.3
TESTS
FOR
JOINTS
AND
SEALS
.
394
11.6
LESSONS
FOR
PIPES
AND
FITTINGS
.
395
11.7
REFERENCES
.
396
12
MEDICAL
APPLICATIONS
.
401
12.1
INTRODUCTION
.
401
12.2
SPECIAL
REQUIREMENTS
AND
BASIC
ASPECTS
OF
MEDICAL
PLASTICS
.
402
12.2.1
MATERIALS
ASPECTS
AND
STERILIZATION
.
403
12.2.2
DESIGN-RELATED
PROBLEMS
.
405
12.2.3
PROCESSING-RELATED
PROBLEMS
.
405
12.2.4
PACKAGING-RELATED
PROBLEMS
.
406
12.2.5
FAILURES
RELATED
TO
SERVICE
CONDITIONS
.
408
12.3
EXAMPLES
OF
FAILURES
AND
LIMITATIONS
OF
MEDICAL
PRODUCTS
.
409
12.3.1
PACEMAKER
INSULATION
LEADS
.
409
12.3.2
UHMWPE
HIP
AND
KNEE
JOINT
PROSTHESES
.
411
12.3.3
SILICONE
AND
SALINE
BREAST
IMPLANTS
.
414
12.3.4
CARDIOVASCULAR
AND
TOTAL
ARTIFICIAL
HEART
IMPLANTS
.
415
12.4
LESSONS
FROM
MEDICAL
PLASTICS
EXPERIENCE
.
416
12.5
REFERENCES
.
417
13
ELECTRICAL
AND
ELECTRONIC
APPLICATIONS
.
420
13.1
INTRODUCTION
.
420
13.2
BASIC
ASPECTS
OF
PLASTICS
IN
ELECTRICAL
AND
ELECTRONIC
APPLICATIONS
THAT
CONTRIBUTE
TO
FAILURE
.
421
13.2.1
IMPORTANT
PROPERTIES
OF
INSULATING
MATERIALS
.
421
13.2.2
IMPORTANT
PROPERTIES
OTHER
THAN
ELECTRICAL
.
422
13.3
LOW
VOLTAGE
ELECTRICAL
AND
ELECTRONIC
APPLICATIONS
.
424
13.3.1
MATERIALS-RELATED
PROBLEMS
.
426
13.3.1.1
FLAME-RETARDANT
FORMULATIONS
BASED
ON
HALOGEN-CONTAINING
POLYMERS
AND
COMPOUNDS
.
426
13.3.2
DESIGN-RELATED
PROBLEMS
.
427
13.3.3
PROCESSING-RELATED
PROBLEMS
.
427
13.3.4
SERVICE
CONDITION-RELATED
PROBLEMS
.
428
13.3.4.1
PREDICTABLE
FAILURES
.
428
13.3.4.2
UNPREDICTABLE
FAILURES
.
429
13.3.4.3
FAILURES
DUE
TO
IMPROPER
INSTALLATION
.
430
13.3.5
CORROSION
AND
HIGH
RESISTANCE
EFFECTS
OF
PLASTICS
ON
METAL
CONTACTS
AND
OTHER
PARTS
.
430
13.3.6
ENCAPSULATED
APPLICATIONS
.
431
13.3.6.1
SEMICONDUCTORS
AND
INTEGRATED
CIRCUIT
DEVICES
.
431
13.3.6.2
PHOTOVOLTAIC
SOLAR
CELL
.
434
13.3.7
TELECOMMUNICATIONS
.
434
13.3.8
PIEZOELECTRIC
FILM
AND
PRINTED
CIRCUIT
BOARDS
.
435
13.3.9
IGNITION
SYSTEMS
FOR
SMALL
GASOLINE
ENGINES
.
436
13.4
FIRE,
SMOKE,
AND
TOXICITY
EFFECTS
.
436
13.5
MEDIUM
AND
HIGH
VOLTAGE
APPLICATIONS
.
436
13.5.1
INTRODUCTION
.
436
CONTENTS
XXI
13.5.2
FAILURE
MODES
AND
EXPERIENCE
.
439
13.5.2.1
MATERIALS-RELATED
FAILURES
.
441
13.5.2.2
DESIGN-RELATED
FAILURES
.
443
13.5.2.3
PROCESSING-RELATED
FAILURES
.
444
13.5.2.4
SERVICE
CONDITION-RELATED
FAILURES
.
445
13.5.2.5
WATER
TREEING
.
446
13.5.2.6
UNFORESEEN
EFFECTS
EXPERIENCED
IN
THERMAL
OVERLOAD
TESTING
449
13.5.2.7
FAILURES
OF
CABLE
JACKETS
.
452
13.6
LESSONS
.
454
13.6.1
GENERAL
FOR
ELECTRICAL/ELECTRONIC
AND
LOW
VOLTAGE
APPLICATIONS
.
.
.
454
13.6.2
MEDIUM
AND
HIGH
VOLTAGE
APPLICATIONS
.
455
13.7
REFERENCES
.
456
INDEX
.
459 |
| any_adam_object | 1 |
| author | Ezrin, Myer |
| author_facet | Ezrin, Myer |
| author_role | aut |
| author_sort | Ezrin, Myer |
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| building | Verbundindex |
| bvnumber | BV010926378 |
| callnumber-first | T - Technology |
| callnumber-label | TA455 |
| callnumber-raw | TA455.P5 |
| callnumber-search | TA455.P5 |
| callnumber-sort | TA 3455 P5 |
| callnumber-subject | TA - General and Civil Engineering |
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| classification_tum | TEC 780f WER 550f WER 099f |
| ctrlnum | (OCoLC)35096121 (DE-599)BVBBV010926378 |
| dewey-full | 620.1/9236 |
| dewey-hundreds | 600 - Technology (Applied sciences) |
| dewey-ones | 620 - Engineering and allied operations |
| dewey-raw | 620.1/9236 |
| dewey-search | 620.1/9236 |
| dewey-sort | 3620.1 49236 |
| dewey-tens | 620 - Engineering and allied operations |
| discipline | Physik Technik Werkstoffwissenschaften Werkstoffwissenschaften / Fertigungstechnik |
| format | Book |
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| id | DE-604.BV010926378 |
| illustrated | Illustrated |
| indexdate | 2024-08-14T00:26:27Z |
| institution | BVB |
| isbn | 3446157158 1569901848 |
| language | German |
| oai_aleph_id | oai:aleph.bib-bvb.de:BVB01-007309288 |
| oclc_num | 35096121 |
| open_access_boolean | |
| owner | DE-210 DE-29T DE-12 DE-91G DE-BY-TUM DE-92 DE-703 DE-1102 DE-634 |
| owner_facet | DE-210 DE-29T DE-12 DE-91G DE-BY-TUM DE-92 DE-703 DE-1102 DE-634 |
| physical | XXI, 473 S. zahlr. Ill. und graph. Darst. |
| publishDate | 1996 |
| publishDateSearch | 1996 |
| publishDateSort | 1996 |
| publisher | Hanser [u.a.] |
| record_format | marc |
| series2 | SPE books from Hanser Publishers |
| spelling | Ezrin, Myer Verfasser aut Plastics failure guide cause and prevention Myer Ezrin Munich [u.a.] Hanser [u.a.] 1996 XXI, 473 S. zahlr. Ill. und graph. Darst. txt rdacontent n rdamedia nc rdacarrier SPE books from Hanser Publishers Plastics Fracture Schadensanalyse (DE-588)4130826-8 gnd rswk-swf Kunststoff (DE-588)4033676-1 gnd rswk-swf Werkstofffehler (DE-588)4122412-7 gnd rswk-swf Kunststoff (DE-588)4033676-1 s Werkstofffehler (DE-588)4122412-7 s DE-604 Schadensanalyse (DE-588)4130826-8 s DNB Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=007309288&sequence=000001&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis |
| spellingShingle | Ezrin, Myer Plastics failure guide cause and prevention Plastics Fracture Schadensanalyse (DE-588)4130826-8 gnd Kunststoff (DE-588)4033676-1 gnd Werkstofffehler (DE-588)4122412-7 gnd |
| subject_GND | (DE-588)4130826-8 (DE-588)4033676-1 (DE-588)4122412-7 |
| title | Plastics failure guide cause and prevention |
| title_auth | Plastics failure guide cause and prevention |
| title_exact_search | Plastics failure guide cause and prevention |
| title_full | Plastics failure guide cause and prevention Myer Ezrin |
| title_fullStr | Plastics failure guide cause and prevention Myer Ezrin |
| title_full_unstemmed | Plastics failure guide cause and prevention Myer Ezrin |
| title_short | Plastics failure guide |
| title_sort | plastics failure guide cause and prevention |
| title_sub | cause and prevention |
| topic | Plastics Fracture Schadensanalyse (DE-588)4130826-8 gnd Kunststoff (DE-588)4033676-1 gnd Werkstofffehler (DE-588)4122412-7 gnd |
| topic_facet | Plastics Fracture Schadensanalyse Kunststoff Werkstofffehler |
| url | http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=007309288&sequence=000001&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |
| work_keys_str_mv | AT ezrinmyer plasticsfailureguidecauseandprevention |