Melt Flow Index (MFI) A melt flow analysis method that determines the ease of flow of plastic materials

Why it s useful:

Because the melt flow rate depends on molecular weight, additives, and other ingredients, the melt flow index value allows for direct comparison of materials to each other. The melt flow rate values are also used as specification values to allow for the sourcing of raw materials from multiple suppliers. Significantly different MFI values can be used to alert a purchaser that the material has changed compared with previous lots, batches, or suppliers of the plastic. MFI values can also be used to differentiate different grades of material. When used to compare "good" samples with "bad" samples, MFI values can provide insight into material degradation resulting from processing, transportation, storage, and drying conditions. MFI analysis is frequently used as one of the first tests when conducting failure analysis.

Sample Requirements:

A single MFI determination requires about 10 grams of material, and samples are typically evaluated in triplicate. Usually a few trial runs are needed to set the proper mass charge for the tester, so ideally we like to have about 100 grams of sample.

Typically samples are in the form of pellets, sheets, or powders. However, we are capable of custom sample preparation in order to grind unusually shaped products or components into the ideal form. Because we can convert manufactured products into plastic powder, the melt flow analysis can be reliably determined for finished products. Applications

Raw material certification Good vs. Bad comparisons Failure analysis Limitations

Does not provide a direct measure of molecular weight Best suited for direct comparison

> Melt Flow Index case study Melt flow index From Wikipedia, the free encyclopedia

Photograph of a machine used to determine the Melt Flow Rate of thermoplastics according to ISO 1133.

Melt flow index or MFI is a measure of the ease of flow of the melt of a thermoplastic polymer. It is defined as the mass of polymer, in grams, flowing in ten minutes through a capillary of a specific diameter and length by a pressure applied via prescribed alternative gravimetric weights for alternative prescribed temperatures. The method is described in the similar standards ASTM D1238 and ISO 1133.

Melt flow rate is an indirect measure of molecular weight, with high melt flow rate corresponding to low molecular weight. At the same time, melt flow rate is a measure of the ability of the material's melt to flow under pressure. Melt flow rate is inversely proportional to viscosity of the melt at the conditions of the test, though it should be borne in mind that the viscosity for any such material depends on the applied force. Ratios between two melt flow rate values for one material at different gravimetric weights are often used as a measure for the broadness of the molecular weight distribution.

Melt flow rate is very commonly used for polyolefins, polyethylene being measured at 190C and polypropylene at 230C. The plastics converter should choose a material with a melt index so high that he can easily form the polymer in the molten state into the article intended, but on the other hand so low that the mechanical strength of the final article will be sufficient for its use. [edit]

Measurement

The procedure for determining MFI is as follows: A small amount of the polymer sample (around 4 to 5 grams) is taken in the specially designed MFI apparatus which is nothing but a miniature extruder. The apparatus consists of a small die inserted into the extruder, with the diameter of the die generally being around 2 mm. The material is packed properly inside the extruder barrel to avoid formation of air pockets. A piston is introduced which acts as the medium that causes extrusion of the molten polymer. The sample is preheated for a specified amount of time: 5 min at 190C for polyethylene and 6 min at 230C for polypropylene. After the preheating a specified weight is introduced onto the piston. Examples of standard weights are 2.16 kg, 5 kg, etc. The weight exerts a force on the molten polymer and it immediately starts flowing through the die. A sample of the melt is taken after desired period of time and is weighed accurately. MFI is expressed as grams of polymer/10 minutes of flow time.

Synonyms of Melt Flow Index are Melt Flow Rate and Melt Index. More commonly used are their abbreviations: MFI, MFR and MI.

Confusingly, MFR may also indicate "melt flow ratio", the ratio between two melt flow rates at different gravimetric weights. More accurately, this should be reported as FRR (flow rate ratio), or simply flow ratio. FRR is commonly used as an indication of the way in which rheological behavior is influenced by the molecular mass distribution of the material.
Melt Flow Index

EMA 4161C PHYSICAL PROPERTIES OF POLYMERS MELT FLOW INDEX LABORATORY PURPOSE: To familiarize the student with the operation of an extrusion plastometer, and demonstrate the relationship between the melt flow index (MFI) and molar mass. OVERVIEW: The extrusion plastometer is a simple form of capillary rheometer, which is commonly used to compare different grades of the same polymer type. The plastometer itself is simply a heated cylinder

that is used to extrude a polymer melt. The cylinder is charged with polymer and held for sufficient time to ensure complete melting. A piston carrying a static weight then loads the charge from above. As the load on the piston drives the melt through a die at the bottom of the cylinder, sections of the extrudate are cut-off at measured time intervals. By definition, the MFI is the mass of extrudate driven through the die in a 10-minute interval. Therefore, the index is an indirect measure of viscosity at specified load/temperature combinations. The principal difference between grades of the same polymer that is reflected in the MFI is molar mass. Because of the inverse proportionality between the MFI and viscosity, in general, polymer grades with a higher melt flow index possess lower molar mass. However, the presence of additives, e.g., plasticizers and impurities, can also affect viscosity and consequently, the MFI. The melt flow index is commonly used by suppliers of polymer stock and those in the injection molding or extrusion industries to determine processing conditions for different grades of polymer. For instance, a manufacturer of computer keyboards, which are injection molded, might increase the injection pressure, mold temperature, or hold time for a grade of ABS with a lower than average melt flow index. MATERIALS: ~5g of Dow Styron polystyrene ~5g of Dow acrylonitrile-butadiene-styrene (ABS) ~5g of Philips 66 HLN-120-01 ~5g of Philips 66 HLN-200 ~5g of Philips 66 HLN-350 EQUIPMENT: Tinius-Olsen extrusion plastometer and accessories Scoopula or a pair of scissors to manually cut the extrudate Small beakers Electronic balance High temperature gloves Safety glasses PROCEDURE: Melt Flow Index

1. Turn on the extrusion plastometer and place the plunger in the sample cylinder. Set the initial operating temperature at 200 C. 2. Allow 15-20 min to stabilize temperature at precisely 200 C. 3. Weigh ca. 5g of both PS and ABS into small beakers. 4. Once the plastometer is thermally stable, pour 5g of PS into the plastometer sample cylinder, and replace the plunger into the cylinder atop the PS sample. (CAUTION: The top of the sample cylinder is ca. 200 C so do not touch the cylinder) 5. Place the 4900g weight atop the plunger, and allow 6-8 min for the PS to melt and produce a bubble-free extrudate (longer preheat time may be required). 6. Cut-off the generated extrudate, and allow the bubble-free extrudate to be produced for the 3 min. 7. Once again, cut-off the extrudate and weigh this sample. 8. Continue taking samples in 3 min. intervals, until no more extrudate is produced, weigh and record each (make sure to keep track of the order in which these samples are taken). 9. Calculate the amount of extrudate that would have been produced in 10 min. This amount per 10 min is the melt flow index for the tested temperature/load combination. 10. Clean-out the sample cylinder using the provided bore cleaner. 11. Repeat the same process for the ABS. 12. Ramp the temperature of the plastometer up to 230 C, and allow 20-15 min for the instrument to stabilize. 13. Repeat the same procedure for the 3 PP samples, with the exception that a 2060g load will be used for testing. 14. Ramp the instrument down to 25 C, and turn the instrument off. 15. Clean up the workspace, plunger, and die. ANALYSIS: Determine the average melt flow index and sample standard deviation for each of the 5 different polymers tested above. Tabulate the polymers tested, load/temperature combinations and MFI values. QUESTIONS: 1. Does there appear to be a trend indicating a dependency of the melt flow index on the order in which the samples for a given polymer were obtained? 2. Compare the MFI of the PS with that of the ABS. What structural or morphological aspects of each polymer give rise to the differences? 3. Compare the MFI of the 3 different grades of PP. What are the factors that give rise to the radically different MFI values for these 3 samples of the same polymer? (Hint: discuss the effect of additives, and the molar mass requirements for each of the intended methods of processing the three polymers) 4. Can MFI values of two different polymers, each obtained under a different temperature/load combination, be used to compare the apparent viscosities of the two polymers? REFERENCES: Melt Flow Index

1. Morton-Jones, D.H., Polymer Processing, Chapman and Hall, New York, (1989), pp. 44-45. 2. ASTM D 1238-90b.
EMA 4666C - POLYMER PROCESSING LABORATORY EXPERIMENT 2 - MELT FLOW INDEX SUPPLEMENTAL TABLE This sheet Temp (C) / Sample Mass Charge Time provides a Load (kg) (g) w/o Load listing of the (sec) polymers and temperature/l oad combinations found to be satisfactory by ASTM. Polymer Polystyrene 200 / 5 3.5 180 ABS 200 / 5 4 180 PP 230 / 2.16 3.2 180 (Ext. Grade) PP 230 / 2.16 5 240 (Gen. Purp.) PP 230 / 2.16 5 300 (Inj. Mold. Gr. )

Charge Time w / Load (sec)

Sampling Time (sec)

180 180 180 120 60

180 120 120 15 15

MASTERBATCHES

Melt Flow Index Melt Flow Index

One of the properties most often quoted for both natural polymers and masterbatches is Melt Flow Index (MFI). What is MFI and why is it significant ? Melt Flow Index is the output rate (flow) in grammes that occurs in 10 minutes through a standard die of 2.0955 0.0051 mm diameter and 8.000 0.025mm in length when a fixed pressure is applied to the melt via a piston and a load of total mass of 2.16 kg at a temperature of 190C (some polymers are measured at a higher temperature, some use different weights and some even different orifice sizes). Melt Flow Index is an assessment of average molecular mass and is an inverse measure of the melt viscosity; in other words, the higher a MFI, the more polymer flows under test conditions. Knowing the MFI of a polymer is vital to anticipating and controlling its processing. Generally, higher MFI polymers are used in injection moulding, and lower MFI polymers are used with blow moulding or extrusion processes. What affects the melt flow properties of polymers ? Many factors affect polymers' flow properties. Molecular weight distribution, the presence of co-monomers, the degree of chain branching and crystallinity influence a polymer's MFI as well as heat transfer in polymer processing.

How is MFI important to masterbatches ? In addition to its importance to natural polymers, the MFI of a masterbatch is also important because the MFI indicates the relative ease with which a masterbatch can be distributed during a compounding operation or in injection moulding machines, film extruders, etc.
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Flow Properties of Masterbatches of Carbon Black in Melt Index 2.0 Low Density Polyethylene
MFI g/10 min (190rC - 10 kg)
100.0 50.0 10.0 5.0 1.0 0.5 0.1 0.05 0.01 % Carbon Black 16 20 24 28 32 36 40 44 48

20 NANOMETRE BLACK 60 NANOMETRE BLACK Though all fillers and additives influence the flow properties of masterbatches, which ones have the greatest effect ? Carbon blacks have the most pronounced effect, and unless very high flow polymers are used as carriers, resultant masterbatches have little or no flow when measured using a standard 2.16 kg weight. For this reason most data sheets quote values measured using higher weights (e.g. 21.6 kg). For example, a typical masterbatch containing 40% carbon black in LDPE could have the following flow rates all measured at 190C: Test weight (kg) MFI (g/10 min.) 21.6 150 2.16 < 1 The main parameters of carbon blacks that influence the MFI are the particle size, structure and surface chemistry. Melt viscosity of polymer carbon black mixtures increases as the carbon black content increases and also the particle size of the black decreases. Narrow carbon black particle size distribution also leads to higher viscosity; this reinforcing characteristic of carbon blacks limits the practical levels at which they can be incorporated into thermoplastic polymers. Although there are some exceptions, 50% is widely accepted as the upper limit for 60 nanometre particle size carbon blacks incorporation with resin and 40% for 20 nanometre blacks. Effects of particle size on flow over a range of carbon black loadings is shown, as an example, in the following graph: How does someone choose a masterbatch for a specific use ? The ideal choice of a masterbatch for a specific end use is one that matches the MFI of the masterbatch as closely as possible with the MFI of the base resin. This is reasonably easy to do with titanium dioxide-based (white) masterbatches and some additive masterbatches, but not as simple

with black masterbatch because of the reinforcing nature described above. If the masterbatch is to be compounded into the base polymer using, for example, high shear mixing equipment, an internal mixer or twin screw extruder, it is possible to choose a fairly low MFI carrier resin and still achieve excellent incorporation. Polymer producers generally follow this practice when making pipe or cable compounds in order not to affect the final performance properties of the compound. If poor distribution occurs when simultaneously feeding masterbatch and resin into an injection moulding or extrusion process where the shear forces are somewhat lower, the processor can adjust equipment operation conditions (such as increased back pressure, use of turbine mixing heads, or cavity transfer mixers at the end of the extruder screw). To maintain output rates, usually the processor specifies a masterbatch that is compatible with the base resin and the operating conditions. If necessary, adjustments to increase the MFI of black masterbatches are possible. Three suggestions are to use: a higher flow carrier resin; a less reinforcing grade of carbon black; or process aids (e.g. stearates). If none of these are acceptable, then reducing the carbon black content in the masterbatch may be the only answer (for example use a 25% or 30% masterbatch instead of a 40% or 50%). When combinations of masterbatches are used, the high flow nature of one can adversely affect the proper incorporation of the other. In the manufacture of tackified silage film, for instance, some manufacturers add a PIB masterbatch (PIB = polyisobutylene) and black masterbatch simultaneoulsy. If distribution problems occur because the PIB reduces the shear in the system, the black masterbatch must be respecified.
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Titanium dioxide-based masterbatches (white), inert filler masterbatches, and additive masterbatches (for example, UV stabilisers) affect processing differently than carbon black masterbatches. Because materials like titanium dioxide and calcium carbonate do not have a significant reinforcing effect on resins, meaningful MFI values using a 2.16 kg weight can be measured, and much closer matching of masterbatch and base resin in MFI is possible even with loadings as high as 80%. Take, for example, a 75% titanium dioxide pigment masterbatch incorporating an LDPE carrier of melt index 20 gr/10 min. This masterbatch would have a melt index somewhere around 4 gr/10 min (2.16 Kg/190C), which is similar to a melt index of 2 gr/10 min.(LDPE film grade commonly used by processors). Thus, the masterbatch and dilutent polymers melt indices are broadly equivalent. Many of the additives used in additive masterbatches are low melting point materials (UV stabilisers, slip agents such as oleamides or erucamides, or antistatic agents) and can melt before the carrier resin causing difficulties for the masterbatch producer and significantly increasing the effective MFI of the masterbatch. MFI is vital knowledge for polymer processing. If you want to find out more about MFI, you can refer to the following references: ASTM Standard D1238 "Standard Test Method for Flow Ratios

of Thermoplastics by Extrusion Plastometer" ISO1133 "Plastics - Determination of the Melt Mass-Flow Rate (MFR) and Melt Volume-Flow Rate (MVR) of Thermoplastics". In addition, your Cabot representative can assist you with recommendations of Cabot masterbatches to meet your requirements.
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MFI/07.03/E

Cabot (headquarters) Interleuvenlaan 5 B - 3001 Leuven BELGIUM Tel.: (32) 016.39.24.00 Fax: (32) 016.39.24.44 Cabot Plastics Belgium S.A. (plant & sales office) Rue Prevochamps 78 B - 4860 Pepinster BELGIUM Tel.: (32) 087.39.27.11 Fax: (32) 087.46.98.69 Cabot Plastics Deutschland (sales office) Tel.: (0800) 182 40 86 Fax: (0800) 182 40 87 Cabot Plastics Ltd (plant and sales office) Gate Street Dukinfield SK16 4RU ENGLAND Tel.: (44) 161.934 4500 Fax: (44) 161.934 4501 Cabot Italiana S.p.A. (plant) Plastics Division Zona Industriale 4 I - 38055 Grigno (TN) ITALIA Tel.: (39) 0461. 775 211 Fax: (39) 0461.765.146 Cabot Latin America Division (sales office) Av. Joao Castaldi 88 04517-900 Sao Paulo, SP BRAZIL Tel.: (55) 11.5091 8300 Fax: (55) 11.5542 6037 Cabot Plastics Hong Kong Ltd (plant & sales office) 18 Dai Kwai Street Tai Po Industrial Estate/Tai Po (NT) HONG KONG SAR PRC Tel.: (852) - 2666-2666 Fax: (852) - 2666-0807 Cabot Shanghai Liaison Office Rm 606-617, Shanghai Central Plaza 381 Huai Hai Zhong Road 200 020 Shanghai CHINA Tel.: (86) 21-538 20 534 Fax: (86) 21-538 27 782

Notice and Disclaimer. The data and conclusions contained herein are based on work believed to be reliable; however, Cabot cannot and does not guarantee that similar results and/or conclusions will be obtained by others.

This information is provided as a convenience and for informational purposes only. No guarantee or warranty as to this information, or any product to which it relates, is given or implied. CABOT DISCLAIMS ALL WARRANTIES EXPRESS OR IMPLIED, INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AS TO (i) SUCH INFORMATION, (ii) ANY PRODUCT OR (iii) INTELLECTUAL PROPERTY INFRINGEMENT. In no event is Cabot responsible for, and Cabot does not accept and hereby disclaims liability for, any damages whatsoever in connection with the use of or reliance on this information or any product to which it relates. (c) Cabot Corporation, M.A., U.S.A. All rights reserved. http://www.cabot-corp.com/plastics PLASBLAK, PLASWITE, PLASADD, PLASGREY and RAINBOW are registered trademarks of Cabot Corporation.

Melt-Flow Index Testing

Among the first instruments plastics molders, extruders, and compounders are likely to consider when outfitting a new lab is a melt-flow indexer or melt indexer. Known as an extrusion plastometer in more technical jargon, this apparatus has long been used to determine the melt-flow rate or mass-flow rate (MFR) of virgin and compounded thermoplastic resins. With the increased pressure on plastics processors to comply with quality standards for quality management, more of them are using these instruments to evaluate incoming material and test finished products.

The melt-flow test detailed in the ASTM D1238 and ISO 1133 standards quickly measures one point on the viscosity curve under standard conditions. While the relative simplicity of this test has remained the same, melt indexers have evolved considerably since they appeared in the 1950s. Computerization and automation have reduced operator-to-operator variables, yielding results with greater accuracy and repeatability. How a Melt Indexer Works

The melt indexer consists of a heated barrel and piston assembly to contain a sample of resin. A specified load (weight) is applied to the piston, and the melted polymer is extruded through a capillary die of specific dimensions.

Figure 1. Tinius Olsen's model MP600 shown in Procedure A configuration

Properties Determined by Melt Flow Indexers

The mass of resin, in grams, that is extruded in 10 minutes equals the MFR, expressed in units of g/10 min. (This value is also commonly called the melt index, MI, or melt-flow index, MFI.) Some instruments can also calculate the shear rate, shear stress, and viscosity in centipoise. What is Measured During a Melt Flow Test

The basic property measured by the melt flow test is the melt viscosity or flow resistance of the polymer at a particular shear stress (related to the applied load) and temperature. Polymer chains of short length and simple geometry slide past one another relatively easily and offer little flow resistance. In contrast, long chains of high molecular weight and more complex structure yield greater flow resistance or viscosity. The Relationship of Mass Flow Rate to other Properties

The MFR, then, is an indicator of average molecular weight and is inversely related to it. A resin with an MFR of 50 g/10 min indicates a lower molecular weight than one with an MFR of 10 g/10 min. While a higher MFR material may be easier to process, physical properties related to molecular weight, such as impact resistance, are often lower.

Figure 2. Cross section of melt indexer furnace. Mass Flow Rate or MFR and Quality Control

Thus, MFR is commonly used as a material-acceptance specification by processors and also as a means of comparing resins from different vendors. It also has many uses in quality control. Not only can variations in polymerization and compounding affect MFR of incoming resin, but it is also a valuable indicator of resin degradation caused by transport or storage conditions or improper drying. Regular MFR testing after molding or extrusion can help pinpoint improper processing conditions. It also

provides a simple indicator of how addition of in-plant regrind or post-consumer reclaim may affect the virgin resin s processability and end-use performance. Scope: Melt Flow Rate measures the rate of extrusion of thermoplastics through an orifice at a prescribed temperature and load. It provides a means of measuring flow of a melted material which can be used to differentiate grades as with polyethylene, or determine the extent of degradation of the plastic as a result of molding. Degraded materials would generally flow more as a result of reduced molecular weight, and could exhibit reduced physical properties. Typically, flow rates for a part and the resin it is molded from are determined, then a percentage difference can be calculated. Alternatively, comparisons between "good" parts and "bad" parts may be of value.

Test Procedure: Approximately 7 grams of the material is loaded into the barrel of the melt flow apparatus, which has been heated to a temperature specified for the material. A weight specified for the material is applied to a plunger and the molten material is forced through the die. A timed extrudate is collected and weighed. Melt flow rate values are calculated in g/10 min.

Specimen size: At least 14 grams of material is needed.

Data: Flow rate = ( 600/t x weight of extrudate ) t = time of extrudate in seconds melt flow rate = g/10 min.

**Please note that this test description is intentionally generic in nature and aimed at providing a descriptive summary to enhance test understanding. For more information please contact a Intertek PTL Technical Representative at iptl@intertek.com . Due to copyright restrictions, we are not able to provide copies of standards. Standards can be obtained from appropriate standards authorities.