QUESTION 6

a) Two types of polymer structure I. PE = Polyethylene Polyethylene (abbreviated PE) or polythene (IUPAC name polyethene or poly (methylene) is the most common plastic. The annual production is approximately 80 million metric tons. Its primary use is in packaging (plastic bag, plastic films, geomembranes, and containers including bottles). Many kinds of polyethylene are known, with most having the chemical formula (C2H4) nH2. Thus PE is usually a mixture of similar organic compounds that differ in terms of the value of n. II. PS = Polystyrene Polystyrene (PS) is a synthetic aromatic polymer made from the monomer styrene, a liquid petrochemical. Polystyrene can be rigid or foamed. General purpose polystyrene is clear, hard and brittle. It is a very inexpensive resin per unit weight. It is a rather poor barrier to oxygen and water vapor and has relatively low melting point. Polystyrene is one of the most widely used plastics, the scale of its production being several billion kilograms per year. Polystyrene can be naturally transparent, but can be colored with colorants. Uses include protective packaging (such as packing peanuts and CD and DVD cases), containers (such as "clamshells"), lids, bottles, trays, tumblers, and disposable cutlery.

b) Two (2) differences of thermosetting and thermoplastic There are a few differences between the two. Thermoplastics usually contain additives to change the properties of the material such as polypropylene. Thermosets usually contain catalysts that change the state of the material at the molecular level.

The main difference between thermoplastics and thermosets is that: -Thermoplastics can be re-melted and recycled fairly easily -Thermosets typically are cured and molded into shape and are not recycled as easily

Thermoplastics: A plastic material, which can be repeatedly melted-molded again and again by simple heating, is called a thermoplastic. Another name of thermoplastic material is thermoplastic polymer. Thermoplastics become soft and moldable on heating. They can then be recast in different shapes and cooled. On cooling the thermoplastic material hardens. Polyethylene with a series of chains of (----CH2---CH2----)n and is obtained by polymerization of ethane.

Thermosetting plastics: A plastic material, which cannot be repeatedly melted-molded again, is called a thermosetting plastic. Another name of thermosetting plastic material is thermosetting polymer. Thermosetting plastics are long chain molecules, which have crosslinks to other long chains. In case of thermoplastics, the long chain molecules are held to other long chain molecules by van der Waals forces. When heated, these chains slip off from each other and the material melts. When cooled, the long chain molecules return back to be held together again. On the other hand, in case of thermosetting plastics, the cross-links prevent displacement of the polymer chains on heating. Thus thermosetting plastics do not become soft on heating and they do not change their shape on heating. Bakelite is one example of a thermosetting plastic. The diagram below shows the difference between a thermoplastic such as a polythene and a thermosetting plastic such as Bakelite.

c) I) The types of molding shown in schematic drawing below Injection molding method II) Process involved

The plastic injection moulding process produces large numbers of parts of high quality with great accuracy, very quickly. Plastic material in the form of granules is melted until soft enough to be injected under pressure to fill a mould. The result is that the shape is exactly copied. Once the plastic moulding has cooled sufficiently to harden the mould opens releasing the part. The whole injection moulding process then repeats.

Close Mould CLAMPING - the moving and fixed platens of the injection moulding machine holds the mould tool together under pressure.

Inject Molten Plastic INJECTION - the molten plastic that has been melted from pellet form in the barrel of the moulding machine is injected under pressure into the mould.

Hold Mould Closed DWELLING - after the molten plastic has been injected into the mould pressure is applied to ensure all cavities are filled. COOLING - the plastic parts are then allowed to solidify in the mould.

Open Mould and Eject Part OPENING - the moving platen moves away from the fixed platen separating the mould tool. EJECTION - rods, a plate or air blast then aids ejection of the completed plastic moulding from the injection mould tool. The length of time from closing the mould to ejecting the finished plastic moulding is the cycle.

D) Two (2) advantages and two (2) disadvantages of using plastics in engineering field Advantages Reduction in weight Good wear properties Disadvantages Increased management Greater initial costs