The effects of residual stress on the mechanical properties of glassy polymers

Residual stresses can have either beneficial or detrimental effects on the mechanical properties of plastics. Manufacturing processes frequently impose residual stresses on plastics. In this study, controlled thermal processes were used to impose surface compressive stresses on polycarbonate beam samples (6.4 by 12.5 by 80 mm). Resistance strain gage and photoelastic techniques were developed to measure the magnitude of these stored stresses. The compressive surface stresses were found to be between 14 MPa (2000 psi) and 31 MPa (4500 psi) and to vary with process method and cooling rate. The mean fatigue life (in bending) of the treated beam samples was found to improve by a factor of 10 over that of untreated samples. The increase in the fatigue life of the treated samples appears to be directly related to the magnitude of the surface compressive residual stress in the samples. The imposed residual stress, as determined by photoelastic measurements, has not appreciably relaxed after 1 year of storage at room temperature.     

A non-destructive technique of measuring residual stresses in circular rods of transparent polymers

Residual stresses, generally present in solid polymers, arise as a result of temperature gradients during solidification. These stresses influence the mechanical behavior of polymers and therefore it is important to measure them; most conventional methods are destructive. In the present work, a non-destructive photoelastic technique is discussed and applied to circular rods of poly(methyl methacrylate) (PMMA). This technique involves the measurement of the distribution of total birefringence across a diameter; the residual stress distribution is obtained numerically from the birefringence distribution. The influence of the birefringence caused by molecular orientation is also investigated. This technique is also applied to a glass rod, in which case the molecular birefringence is minimum. It is seen that the residual stresses obtained in this case are consistent with equilibrium considerations.     

Influence of Surface Stress on indentation Cracking

A simple, two-dimensional fracture mechanics analysis was used to determine the influence of nonuniform residual surface stresses on the formation of radial indentation cracks. The indentation behavior depends on the depth of the compressive stresses, such that the apparent fracture toughness passes through a maximum with increasing indentation load. The analysis was used to estimate the surface stress from indentation data for a zirconia-toughened ceramic and was compared to previous X-ray diffraction measurements of this stress. The comparison gives only fair agreement; the sources of possible error are discussed. Such surface stresses also influence the accuracy of K _{I C} measurements when an indentation crack length technique is used; surface preparation is a critical factor in the measurement. Finally, the K _{I C} values obtained from indentation crack sizes were compared with those obtained by the double-cantilever-beam technique.     

A study of the residual microstress at the matrix interface in filled epoxy resins

Using the technique of photoelasticity, we have studied in detail the magnitude of the residual microstress at the matrix interface between epoxy resin and rubber particles or glass beads. A spheric stress-optic equation applicable to these composites was derived. The photoelastic figures induced by the interfacial residual microstresses and the factors affecting the intensity of light are discussed. The experimental results show that the residual microstresses at the matrix interface are independent of the particle size of rubbers or glass beads, but depend on the nature of fillers, which have different thermal expansion coefficients and mechanical properties. Thermal history and interfacial chemical bonding of filled epoxy resins have distinct effects on the residual interfacial microstresses and the matrix internal stresses.     

Heat treatment of thin carbon films and the effect on residual stress, modulus, thermal expansion and microstructure

Thin carbon films are used to hermetically seal and improve the performance of devices exposed to extreme conditions. Such films, which are deposited by chemical vapor deposition, develop residual thermal stresses due to a mismatch in the coefficient of thermal expansion between the film and substrate. Residual stresses reduce the adhesion of the film, and are a common cause of coating failure. This work investigates heat treatment as a potential technique to reduce residual stresses in thin carbon films. The magnitude of the residual stress has been challenging to measure due to the associated size scales and mechanical properties. In this study, experimental measurements of mechanical properties and residual stresses in thin carbon films are performed using nanoindentation and Raman spectroscopy. The results relate surface residual stresses to film thickness and heat treatment temperature. The approach presented in this study is a nondestructive and non-intrusive method for measuring residual surface stress and properties in thin films, and is ideal for small or curved-surface specimens such as optical fibers and other photonic devices.     

Analysis and Measurement of Glue-Spall Stresses in Glass-Epoxy Bonds

An approximate analysis is presented of the glue-spall stresses introduced by an organic sealant in the glass substrate to which it adheres. The results given by this analysis are compared with those obtained by the finite element method, as well as with the photoelastic measurements in glass at T=25 to −78°C during cooling. Good agreement is found between theory and experiment, if proper account is taken of the stress release due to creep of the organic sealant. Methods for minimizing glue-spall stresses are outlined.     

Impact strength of polymers 2: The effect of cold working and residual stress in polycarbonates

The influence of cold working on the toughness improvement in glassy amorphous polycarbonates was studied. Cold working processes, namely rolling and. Steckel rolling were used to produce thickness reductions up to 40 percent in flat-strip specimens. The notched Izod impact strength and tensile properties were measured as a function of strip thickness reduction. It was shown that the toughness enhancement in polycarbonates cold worked to low thickness reductions was due to the residual stress state present as opposed to molecular orientation which becomes significant at higher degrees of cold work. Residual stress measurements were made by using the layer removal technique. Residual tensile stresses as high as 2100 psi were present in 1/4-in. cold-rolled polycarbonate at the surface. The maximum stress in the center of the specimen was 1100 psi in compression. The residual stresses at the surface decreased with increasing thickness reduction. The residual stress state for Steckel rolled. 1/2-in. polycarbonate was also measured and found to be more complex than for the thinner samples, The results demonstrated that surface tensile stresses and interior compressive stresses can produce large values of impact strength if the notch is to be machined after cold working. Thus, the values of impact strength measured from the notch Izod specimen are sensitive to the residual stress state in the polymer. This behavior is in contrast to earlier studies on thermally quenched material in which the material was quenched after notching. The thermal quenching produced surface compressive stresses which were also present at the notch tip. The presence of compressive residual stresses at the center of the notch suppressed the formation of a craze leading to toughness enhancement in cold worked polycarbonate strips. It is shown that by control of residual stresses in polycarbonate, strips at least 1/2 in. in thickness can be made to exhibit ductile failure in the notched Izod impact test.     

Non-contact stress measurement in PET preforms

ABSTRACT

Residual stresses in PET preforms is thought to be an important cause in the stress cracking of blown bottles but there is no data yet that can be linked to stress and cracking. An important step in this link is the measurement of stresses in the preform base and neck region of the preforms. This paper reports on the usage of photoelastic methods to measure residual stresses in preforms. It is found that the residual stresses vary from preform to preform and how cracks develop is due to the qualitative and quantitative presence of residual stresses and its orientation.     

Residual stresses and density gradient in injection molded starch/synthetic polymer blends

Residual stress distribution in injection molded starch/synthetic polymer blends was evaluated using the layer removal technique. The synthetic polymers in the blend were either polybutylene succinate (PBS) or polycaprolactone (PCL). The starch content ranged from 0 to 70% by weight in the PBS blend and was held constant at 70% in the PCL blend. The effects of various molding conditions, aging and starch content were investigated. The residual stress profiles were found to be parabolic in nature with surface compressive stresses and interior tensile stresses. Increasing the injection pressure and mold temperature decreased the tensile stresses but had no significant effect on the surface compressive stresses. Decreasing the packing pressure produced a significant decrease in the magnitude of residual stresses. Varying melt temperature and packing time did not significantly affect the residual stress distribution for the range of values investigated. The residual stresses relaxed with time, decreasing over a period of 57 days. The magnitude of residual stresses increased as the starch content in the PBS blends was varied from 0 to 70%. Density gradient measurements were made in a 70% starch/PBS blend. The density was found to be higher in the interior than at the surface with a steep gradient close to the surface. Varying the molding conditions had a complex effect on the average density and the density distribution.     

Residual stress distribution modification caused by weathering in polypropylene and polystyrene

A study has been made of changes in residual stress distributions caused by weathering in polypropylene and polystyrene. Chemi-crystallization has a major effect in polypropylene and an analysis based on the volumetric changes that occur on crystallization has been developed. Close to the surface, fractional crystallinity changes up to 4% are caused by photodegradation (X-ray measurements by Rabello and White (18)). It is estimated that this would cause a tensile residual stress of ～2MNm^?2 to form at the surface if there were no preexisting residual stresses; in the case examined here, the effect of this shrinkage stress was to reduce the compressive residual stress to a small value (<1MNm^?2). Additional changes caused by stress relaxation prior to completion of chemi-crystallization resulted in net tensile stresses near to the surface of the photo-degraded polypropylene. The changes occur almost symmetrically in polypropylene even if the molding is exposed on one surface only. A similar analysis has been made for thermoplastics in which the changes occur only at the exposed surface, comparing the results with measurements made on a glass fiber reinforced grade of polypropylene. In this case the analysis predicts that the stress changes by 2–3MNm^?2 near the surface, enough to develop tensile stresses up to 2MNm^?2 there if the compressive residual stress at the beginning is fairly small, in fairly good agreement with observed changes. Glass fiber reinforced polypropylene does not relax as readily as unfilled polypropylene and better agreement is to be expected without any allowance for stress relaxation. The analysis for one-sided chemi-crystallization allows calculation of the resulting distortion in terms of the curvature: this was estimated at 0.33m^?1, compared to the measured value of 0.44 m^?1. Volumetric changes also occur in noncrystalline polymers and a similar analysis based on data obtained with polystyrene (17) confirms that these changes can explain the observed development of tensile residual stresses on weathering. In the example studied here surface stress changes of 2–3MNm^?2 are predicted and this accounts for a large proportion of the change in residual stress obtained by direct measurement.     

On the measurement of residual stress in plastic pipes

Recent work on the determination of residual stress in drawn pipes has revealed an error in previous methods used. Such pipes have residual stresses very different from those induced by melt extrusin during conventional pipe processing. In particular, it appears that there are considerable compressive stresses at the bore, and the hoop and axial values are not equal. In an attempt to measure these values, tests were performed on slit rings of varying length, and a pronounced dependence of ring overlap on length was observed. This was contrary to previous assumptions, and a corrected version of the analysis has been developed, which enables the true hoop and axial stresses to be determined by testing rings of various lengths. For isotropic pipes, it has been shown that hoop and axial stresses are roughly equal. Previous results obtained on thin pipe rings can now be corrected by multiplying by the factor 1/(1-v). For anisotropic drawn pipes, a combination of rings and thin axial strips is used to determine the residual stresses. These pipes can show remarkably low stresses at the bore, which may play a significant part in determining their performance.     

Residual Stresses in Silicon Carbide–Zircon Composites from Thermal Expansion Measurements and Fiber Pushout Tests

Coefficients of thermal expansion (CTE) in the axial direction of two types of SiC fibers, monolithic zircon, monolithic SiC, and several SiC_f-zircon composites were measured in the temperature range of 50 to 1380C. The measured CTE values of composites were compared with values predicted by the rule-of-mixtures approach, and a small difference in measured and calculated values was ascribed to the nature of interfacial bonding and assumptions implicit in the rule-of-mixtures approach. Fiber pushout tests were performed on these composites and the residual stresses were extracted from the analysis of the load–displacement plots in terms of the shear-lag and progressive debonding models. The radial and axial residual stresses arising from the mismatch in CTE were calculated and compared with values obtained from the fiber pushout tests. The fiber pushout tests in general produced lower values of the residual stresses, but the residual stresses obtained using shear-lag analysis were in good agreement with the calculated values based on the CTE mismatch in composites with lower values of the interfacial shear stress. The influence of anisotropic fiber expansion in the radial and axial directions on the radial and axial residual stresses in composites were also examined.     

New Method to Measure Thermal Shock Resistance in Ceramics Using a Piezo-Spectroscopic Technique

A new method for assessing the critical temperature in thermally shocked ceramics is proposed. It is based on the measurement of stress relaxation of residual stresses as a consequence of thermal shock. The change in the stress-field is determined by piezo-spectroscopic technique. The technique is described and the results analyzed. The values obtained are compared with those obtained by the conventional method based on strength degradation measured on test pieces quenched at different temperatures. The agreement among the data is very good.     

Residual stresses,shrinkage, and warpage of complex injection molded products: Numerical simulation and experimental validation

A numerical simulation model for predicting residual stresses and residual deformations which arise during the injection molding of thermoplastic polymers in the post-packing stage has been developed. A thermoviscoelastic model with volume relaxation is used for the calculation of residual stresses. The finite element method employed is based on the theory of shells as an assembly of flat elements. This theory is well suited for thin injection molded products of complex shape. The approach allows the prediction of residual deformations and residual stresses layer by layer like a truly three-dimensional calculation, while reducing the computational cost significantly. The hole drilling technique is used to measure the residual stresses across the thickness of the product. A three-dimensional laser digitizing system, an image processing technique and a dual displacement transducer system are used to measure the warpage. Experiments are carried out on polycarbonate and high density polyethylene parts. Numerical results are in qualitative agreement with experimental observations, i.e., the skin of the box is surrounded by a compressive region while the core region is in traction. The trend of both the experimental and the predicted residual stress profiles is close. Different examples are presented to illustrate the influence of the geometrical complexity of the shape on the final deformations and residual stresses. The influence of the mold temperature on residual stresses and warpage is also analyzed.     

Residual Stresses in Machined MgO Crystals

The residual stresses introduced in MgO crystals by grinding on {100} surfaces in 〈100〉 directions were measured using photoelastic techniques. Grinding was conducted with two wheels; a 100-grit diamond wheel removed material by brittle fracture, and a 46-grit alumina wheel caused plastic flow and burnishing. Both wheels introduced a discrete, highly deformed layer adjacent the machined surface. In all cases the machined surfaces were under a residual tensile stress which became compressive within the deformed region. Beneath the deformed layer the residual stress patterns were distinctly different. In crystals ground with the alumina wheel the stresses became tensile again within 0.5 mm of the ground surface, whereas the subsurface stresses in crystals ground with the diamond wheel remained compressive to distances ≥1 mm. These residual stress distributions are discussed in terms of a simple model based on the superposition of mechanically and thermally induced stresses.     

Simulation of PTFE sintering: Thermal stresses and deformation behavior

A finite element model has been used to study the sintering process of polytetrafluoroethylene (PTFE) cylinders in order to predict residual thermal stresses; both solid (rods) and hollow (billets) blocks were studied. The simulation of the process was performed considering three separate stages: thermal, deformation, and stress analysis. For each stage, relevant material properties were determined experimentally. In particular, the deformation behavior of PTFE was thoroughly investigated by means of thermo‐mechanical analysis (TMA). It is shown that experimental results can be explained considering deformation recovery and orientation effects. Predictions of the model are compared with experimental measurements performed on real PTFE‐sintered cylinders. Temperature and deformation distributions determined with the model agree well with experimental data. Fair agreement between predicted and experimentally measured residual stresses is obtained, and the influence of cylinder size and applied cooling rate on residual stresses is correctly predicted. Polym. Eng. Sci. 44:1368–1378, 2004. © 2004 Society of Plastics Engineers.     

THE MECHANISM OF SPALLING1

A study has been made of the stresses and fractures developed in a solid when rapidly heated or cooled. The stresses were measured in bakelite specimens by the photoelastic method. High stresses in all cases were found to occur near the surface of the solids, but no high tension stresses were present when the specimens were being heated. A number of vitreous clay spheres and bricks were heated and cooled rapidly and the nature of the cracks was noted. In practically every case the fractures occurred as predicted from the measured stresses. Torque-deflection curves were obtained for a number of fire brick in torsion at different temperatures. The temperature at which plastic flow occurs for every material tested was approximately the same as the temperature of the initial deflection under compressive loads in a standard load test.     

Determination of Subcritical Crack Growth Parameters by In Situ Observation of Indentation Cracks

A technique to determine stress intensity factor—crack velocity (K— v ) relationships for subcritical crack growth from in situ observation of indentation cracks is described. To minimize the effect of residual contact stresses and lateral crack interaction, measurements were made only on cracks that had undergone significant subcritical crack growth. Crack shapes were determined fractographically from crack-arrest markings, produced by temporary unloading during the crack extension process. The subcritical crack growth parameters obtained by this technique were in excellent agreement with those determined from dynamic fatigue and previous studies.     

Determination of Residual Stress in Coatings by a Membrane Deflection Technique

A membrane deflection technique has been developed to measure the isotropic residual stress in biaxially-constrained coatings. The technique has been demonstrated on various materials, including polyimide, latex rubber and photoresist coatings. Stress values obtained from membrane deflection compared well with results obtained from time-averaged vibrational holographic interferometry except for values obtained from samples where rigidity effects were found to be important. A criterion based on the thickness, rigidity, stress and sample radius is also discussed, establishing the applicability of the technique to samples of low rigidity.     

Determination of Residual Stress in Coatings by a Membrane Deflection Technique

A membrane deflection technique has been developed to measure the isotropic residual stress in biaxially-constrained coatings. The technique has been demonstrated on various materials, including polyimide, latex rubber and photoresist coatings. Stress values obtained from membrane deflection compared well with results obtained from time-averaged vibrational holographic interferometry except for values obtained from samples where rigidity effects were found to be important. A criterion based on the thickness, rigidity, stress and sample radius is also discussed, establishing the applicability of the technique to samples of low rigidity.