1:30 pm – 6:00 pm:
W18-Technical Marketing: Polymer Analysis
(Moderator: Mark Spalding)-Room S320C
1:30 pm – 2:00 pm:
Laboratory Weathering for Plastics
Andy Francis, Q-Lab
Weathering testing is a critical component of research, quality control, qualification, and new product development for plastics and polymeric materials used in a variety of industries. Weathering test methods help engineers improve their products, minimize failures, and reduce raw material costs. Weathering testing is composed of two interdependent yet complementary parts: outdoor exposures and laboratory accelerated weathering tests. Outdoor testing is an important complement to accelerated testing as it provides real-time results and exposes test specimens to complex weathering patterns not easily duplicated in an accelerated laboratory environment. The most frequently used accelerated weathering testers are fluorescent UV and xenon arc devices. These accelerated laboratory weathering and lightstability testers are widely used for research and development, quality control, and material certification. They can provide fast and reproducible results. In recent years, laboratory accelerated weathering test standards have been developed that offer improved realism and correlation to outdoor exposures. This presentation compares and contrasts the light emission spectra, temperature control, methods of water simulation, and practical considerations regarding use of these two major types of accelerated testers. The inherent strengths and weaknesses of each test architecture will be discussed, including cost of ownership in addition to technical performance. Defining goals of weathering testing and development of appropriate weathering testing programs will also be presented.
2:00 pm – 2:30 pm:
Accelerated Weathering Insights into ASA Polymer UV Resistance: Xenon vs QUV vs Florida and Arizona
Steven Blazey, A. Schulman, Inc.
This presentation compares the differences in color and gloss retention between QUV, Xenon, Florida and Arizona testing for 4 different Acrylate-Styrene-Acrylonitrile (ASA) polymers in white, almond and black colors. The results show the similarities and differences between the accelerated weathering test methods versus Florida and Arizona four-year test results leading into a discussion of performance lifetime predictability for the ASA materials studied.
2:30 pm – 3:00 pm:
The Importance of How Online Rheometers Accurately Indicate Melt Flow Rate in an Extruder
Catherine Lindquist, Dynisco
Among the various methods for developing new polymeric systems, the extrusion process has been increasingly used in the thermoplastics industry in complex applications such as continuous reactors for melt compounding, mixing, and a variety of reaction applications. In any extrusion system precise testing and analysis is necessary in order to maximize the processing efficiency. The rheological testing measurements on extrudate materials are commonly performed by processors to ensure that their products are meeting the desired qualities and understand the effect of adding various components to their materials. A newly designed on-line rheometer has been developed to continuously monitor the rheological parameters of in-process compounds namely melt flow rate (MFR), intrinsic viscosity (IV), and apparent viscosity. This helps compounders to have a real-time quality control on their products and reduce the failure rates or scraps. The present work aims to describe the design of the on-line rheometer and how it can be easily connected to the extruders using existing ports and flexible adaptors. It also has been explained how the proposed on-line rheometer can duplicate the test conditions of an off-line melt flow rate tester on an extruder in any compounding or manufacturing process. Furthermore, through calculation of activation energy in a specific material and introducing a temperature correlation, it has been investigated how the on-line rheometer considers the temperature dependency of material`s MFR and accurately measures this parameter at various operating temperatures.
3:00 pm – 3:30 pm:
Characterization of Cure of Polymeric Material by Dielectric Analysis (DEA)
Yanxi Zhang, Technical Sales Support, Netzsch Instruments North America, LLC
A variety of questions may arise during the curing process for thermosetting resins. For example, at which temperature, or after how much time, does the resin begin curing? How high is the reactivity? When is curing complete? How can the curing cycle be optimized? Is there any potential for post-curing? The answers to questions such as these can be investigated by using Dielectric Analysis (DEA), not only in the laboratory environment, but also in-process. Dielectric Analysis (DEA) allows for the measurement of changes in the dielectric properties of a resin during UV curing. A sinusoidal voltage (excitation) is applied and the resulting current (response) is measured, along with the phase shift between voltage and current. These values are then used to determine the ion mobility (ion conductivity) and the alignment of dipoles. Of primary interest with regard to curing is the ion viscosity. This is the reciprocal value of the ion conductivity, which is proportional to the loss factor. This technique can be used in study of the curing behavior of thermosetting resins, adhesives, paints and coatings in nearly any application.Various application examples are included in the presentation, including cure by heat and UV cure.
3:30 pm – 4:00 pm:
Optical Metrology for Stress Determination
Steven Danyluk, Polaritek Systems, Inc.
An optical metrology method is presented for determining stresses in thin solids.
4:00 pm – 4:30 pm:
Leveraging Advanced Edge Analytics for Improved Fault Detection in Discrete Manufacturing Processes
Andrew Wilson, MKS Instruments, Inc.
Introduction Multivariate analytics data monitoring systems provides a significant fault detection improvement over typical SPC type, or Univariate, solutions currently being used in the discrete manufacturing process industry to allow manufacturers to eliminate manual and visual quality inspection and to achieve real-time process release or “lights out” manufacturing operations. Problem Statement Current method of Univariate SPC process control typically utilized by discrete manufacturing process industry is not fully capable to detect quality issues caused by combinations of signals acting jointly on a system. Process engineers also must make manual adjustments to process limits to accommodate for slowly drifting processes, or caused by environmental effects, incoming material issues, and equipment wear. How can the user be certain these limits adjustments will not result in quality issues? Solution The SenseLink™ QM system builds a multivariate model around the optimized process with an acceptable processing window, established from a design of experiments (DOE). The system generates application-specific & automatic limit setting, reducing the reliance on expert process engineers and operators tweaking process knobs causing variations to the process. New data is then compared in real-time to the alarm limits developed by the model. The multivariate alarms are then triggered if the new data is off-spec, sending a reject signal to a part containment device for real-time part containment. Overview The SenseLink™ QM system is a data acquisition system with a multivariate data analysis engine that was developed for any industrial manufacturing process, and used with manufacturing processes or secondary operations to provide improved process understanding. Each cycle is multivariate analyzed in real-time to provide variable contribution charts, which highlight process trends not seen by UVA (Univariate). Real world case studies have proven this solution effective. Conclusion Using a Multivariate fault detection system in your industrial manufacturing processes will provide the highest level of in-process fault detection available along with contribution details which provide an understanding of your process not attainable from traditional SCADA and SPC approaches.
4:30 pm – 5:00 pm:
The New Discovery DMA850 from TA Instruments
Greg Kamykowski, SPE
TA Instruments is the world leader in rheology and thermal instruments. One of our thermal/rheology instruments is the dynamic mechanical analyzer (DMA). For several years, the Q800 DMA has been the leader among DMA instruments, but, in late 2017, TA Instruments introduced the new Discovery DMA850 as the next generation DMA. The capabilities of this instrument, along with a comparison of its performance against the Q800 DMA, will be presented.
5:00 pm – 5:30 pm:
3D Line Confocal Imaging: New High-Resolution Sensor Technology for Challenging Online & Offline Plastic Measurement Applications
Juha Saily, FocalSpec, Inc.
This presentation introduces FocalSpec’s recently patented optical Line Confocal Imaging (LCI) technology that was developed to measure 3D features of various surfaces at sub-micron resolution. LCI enables quick and automatic microtopographic scan of challenging materials that are difficult or impossible to measure with traditional methods. Examples of such products include highly-reflective and transparent precision-molded parts; polymer films, sheets, coatings, profiles, filaments and medical tubing. LCI can be used to measure fast-moving surfaces in real-time as well as stationary product samples in laboratory. Operational principle of the LCI method is discussed. Several applications for LCI sensors are examined: 1. Online surface roughness measurement. 2. Online imaging of embossed and printed 3D features. 3. Online film, sheet and coating thickness measurement. 4. Other potential online imaging applications: Web edge height measurement and 3D wrinkle detection. The company’s new Line Confocal Scanner UULA for off-line and at-line 3D metrology applications is introduced too.
5:30 pm – 6:00 pm:
75% of ERP Fail – How to Avoid It
Pierre Maillet, CyFrame
Failure proof you process improvement ERP initiatives: Latest ERP Industry Stats. Major Failures by Root Cause. Part of the Puzzle consistently missing. Best Expert Advice based on 25 Years of Repetitive Occurrences to Consider: Common Flawed Evaluation Process Keys to Success – Operational Workflow Process Optimization The ERP Fail Safe Checklist.