edited by John Moalli

Plastics Failure: Analysis and Prevention contains analysis of reasons that cause products to fail. General methods of product failure evaluation give powerful tools in product improvement. Such methods, discussed in the book, include practical risk analysis, failure mode and effect analysis, preliminary hazard analysis, progressive failure analysis, fault tree analysis, mean time between failures, Wohler curves, finite element analysis, cohesive zone model, crack propagation kinetics, time-temperature collectives, quantitative characterization of fatigue damage, and fracture maps.

Methods of failure analysis are critical to for material improvement and they are broadly discussed in this book. Fractography of plastics is relatively a new field which has many commonalities with fractography of metals. Here various aspects of fractography of plastics and metals are compared and contrasted. Fractography application in studies of static and cycling loading of ABS is also discussed. Other methods include SEM, SAXS, FTIR, DSC, DMA, GC/MS, optical microscopy, fatigue behavior, multiaxial stress, residual stress analysis, punch resistance, creep-rupture, impact, oxidative induction time, craze testing, defect analysis, fracture toughness, activation energy of degradation.

Many references are given in this book to real products and real cases of their failure. The products discussed include office equipment, automotive compressed fuel gas system, pipes, polymer blends, blow molded parts, layered, cross-ply and continuous fiber composites, printed circuits, electronic packages, hip implants, blown and multilayered films, construction materials, component housings, brake cups, composite pressure vessels, swamp coolers, electrical cables, plumbing fittings, medical devices, medical packaging, strapping tapes, balloons, marine coatings, thermal switches, pressure relief membranes, pharmaceutical products, window profiles, and bone cements.

Plastics Failure: Analysis and Prevention will be of interest to researchers and engineers in the plastics industry and all those concerned with the reasons why plastics components and parts fail and who want to increase life of a product.

Contents

1. Failure Mechanisms
   • Plastics Failure Due to Oxidative Degradation in Processing and Service
   • Durability Study of Conductive Copper Traces within Polyimide Based Substrates
   • Fatigue Behavior of Discontinuous Glass Fiber Reinforced Polypropylene
   • Ductile Failure and Delayed Necking in Polyethylene

2. Processing and Assembly
   • The Role of Heat Affected Zone (HAZ) on Mechanical Properties in Thermally Welded Low Density Polyethylene Blown Film
   • Effects of Processing Conditions on the Failure Mode of an Aliphatic Polyketone Teropolymer
   • Orientation Effects on the Weldability of Polypropylene Strapping Tape
   • Joint Performance of Mechanical Fasteners under Dynamic Load - Self-Tapping Screws in Comparison with Threaded Inserts in Brass and Plastic
   • Defect Cost Analysis

3. Environmental Effects
   • Environmental Stress Cracking of ABS IIRadiation Resistance of Multilayer Films by Instrumented Impact Testing
   • Residual Stress Development in Marine Coatings under Simulated Service Conditions
   • Estimation of Long-Term Properties of Epoxies in Body Fluids
   • Mechanical Performance of Polyamides with Influence of Moisture and Temperature
   • Temperature-Moisture-Mechanical Response of Vinyl Ester Resins and Pultruded Vinyl Ester/e-glass Laminated Composites
   • Freeze-Thaw Durability of Composites for Civil Infrastructure

4. Morphology and Fractography
   • Fractography of ABS
   • Fractography of Metals and Plastics
   • Crack Propagation in Continuous Glass Fiber/Polypropylene Composites
   • Fracture Behavior of Polypropylene Modified with Metallocene Catalyzed Polyolefin
   • Morphology and Mechanical Behavior of Polypropylene Hot Plate Welds
   • The Influence of Morphology on the Impact Performance of an Impact Modified PP/PS Alloy
   • Morphological Study of Fatigue Induced Damage in Semi-Crystalline Polymers

5. Modeling of Failures and Failure Processes
   • Failure Analysis Models for Polyacetal Molded Fittings in Plumbing Systems
   • Progressive Failure Analysis of Fiber Composite Structures
   • Calculating Thermally Induced Stresses Using a Nonlinear Viscoelastic Material Model
   • Evaluation of a Yield Criteria and Energy Absorbing Mechanisms of Rubber Modified Epoxies in Multiaxial Stress States

6. Design and Life Prediction
   • Shelf Life Failure Prediction Considerations for Irradiated Polypropylene Medical Devices
   • Determining Etch Compensation Factors for Printed Circuit Boards
   • Activation Energies of Polymer Degradation
   • Estimation of Time-Temperature-Collectives at Describing Aging of Polymer Materials

7. Test Methods
   • Standard Test Procedures for Relevant Material Properties for Structural Analysis
   • Factors Affecting Variation in Gardner Impact Testing
   • Radiation Resistance of Multilayer Films by Instrumented Impact Testing
   • Aspects of the Tensile Response of Random Continuous Glass/Epoxy Composites
   • Comparing the Long Term Behavior of Tough Polyethylenes by Craze Testing

8. Failure Prevention
   • Design Aids for Preventing Brittle Failure in Polycarbonate and Polyetherimide
   • 10 Common Pitfalls in Thin-Wall Plastic Part Design
   • Defect Analysis and High Density Polyethylene Pipe Durability
   • Practical Risk Analysis—As a Tool for Minimizing Plastic Product Failure
   • Attachment Design Analysis of a Plastic Housing Joined with Snap-Fits
   • Avoiding the GIGO Syndrome

9. Case Studies
   • Case Studies of Inadvertent Interactions between Polymers and Devices in Field Applications
   • Case Studies of Plastics Failure Related to Improper Formulation
   • Translating Failure into Success—Lessons Learned from Product Failure Analysis

Index

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