Preface to the First Edition	8
	Preface to the Third Edition	10
	1 Introduction	24
	1.1 The 6 P’s	24
	1.2 General Information	27
	1.3 Identification of Polymers	34
	1.4 Sustainability – The 6th P	36
	References	41
	2 Historical Background	42
	2.1 From Natural to Synthetic Rubber	42
	2.2 Cellulose and the $10,000 Idea	48
	2.3 Galalith – The Milk Stone	51
	2.4 Leo Baekeland and the Plastics Industry	52
	2.5 Herman Mark and the American Polymer Education	55
	2.6 Wallace Hume Carothers and Synthetic Polymers	58
	2.7 Polyethylene – A Product of Brain and Brawn	60
	2.8 The Super Fiber and the Woman Who Invented It	63
	2.9 One Last Word – Plastics	65
	References	68
	3 Structure of Polymers	70
	3.1 Macromolecular Structure of Polymers	70
	3.2 Molecular Bonds and Inter-Molecular Attraction	71
	3.3 Molecular Weight	72
	3.4 Conformation and Configuration of Polymer Molecules	77
	3.5 Arrangement of Polymer Molecules	80
	3.5.1 Thermoplastic Polymers	81
	3.5.2 Amorphous Thermoplastics	81
	3.5.3 Semi-Crystalline Thermoplastics	83
	3.5.4 Thermosets and Cross-Linked Elastomers	93
	3.6 Copolymers and Polymer Blends	94
	3.7 Polymer Additives	96
	3.7.1 Flame Retardants	96
	3.7.2 Stabilizers	98
	3.7.3 Antistatic Agents	99
	3.7.4 Fillers	99
	3.7.5 Blowing Agents	100
	References	103
	4 Thermal Properties of Polymers	104
	4.1 Material Properties	106
	4.1.1 Thermal Conductivity	106
	4.1.2 Specific Heat	112
	4.1.3 Density	114
	4.1.4 Thermal Diffusivity	117
	4.1.5 Linear Coefficient of Thermal Expansion	118
	4.1.6 Thermal Penetration	119
	4.1.7 Glass Transition Temperature	120
	4.1.8 Melting Temperature	120
	4.2 Measuring Thermal Data	120
	4.2.1 Differential Thermal Analysis (DTA)	121
	4.2.2 Differential Scanning Calorimeter (DSC)	122
	4.2.3 Thermomechanical Analysis (TMA)	124
	4.2.4 Thermogravimetry (TGA)	125
	4.2.5 Density Measurements	126
	References	130
	5 Rheology of Polymer Melts	132
	5.1 Introduction	132
	5.1.1 Continuum Mechanics	132
	5.1.2 The Generalized Newtonian Fluid	134
	5.1.3 Normal Stresses in Shear Flow	136
	5.1.4 Deborah Number	137
	5.2 Viscous Flow Models	140
	5.2.1 The Power Law Model	140
	5.2.2 The Bird-Carreau-Yasuda Model	142
	5.2.3 The Bingham Fluid	143
	5.2.4 Elongational Viscosity	143
	5.2.5 Rheology of Curing Thermosets	146
	5.2.6 Suspension Rheology	148
	5.3 Simplified Flow Models Common in Polymer Processing	150
	5.3.1 Simple Shear Flow	150
	5.3.2 Pressure Flow Through a Slit	151
	5.3.3 Pressure Flow through a Tube – Hagen-Poiseuille Flow	151
	5.3.4 Couette Flow	152
	5.4 Viscoelastic Flow Models	153
	5.4.1 Differential Viscoelastic Models	153
	5.4.2 Integral Viscoelastic Models	156
	5.5 Rheometry	159
	5.5.1 The Melt Flow Indexer	160
	5.5.2 The Capillary Viscometer	160
	5.5.3 Computing Viscosity Using the Bagley and Weissenberg-Rabinowitsch Equations	162
	5.5.4 Viscosity Approximation Using the Representative Viscosity Method	163
	5.5.5 The Cone-Plate Rheometer	164
	5.5.6 The Couette Rheometer	165
	5.5.7 Extensional Rheometry	166
	5.6 Surface Tension	169
	References	178
	6 Introduction to Processing	184
	6.1 Extrusion	184
	6.1.1 The Plasticating Extruder	187
	6.1.1.1 The Solids Conveying Zone	189
	6.1.1.2 The Melting Zone	192
	6.1.1.3 The Metering Zone	195
	6.1.2 Extrusion Dies	196
	6.1.2.1 Sheeting Dies	197
	6.1.2.2 Tubular Dies	198
	6.2 Mixing Processes	200
	6.2.1 Distributive Mixing	202
	6.2.1.1 Effect of Orientation	203
	6.2.2 Dispersive Mixing	205
	6.2.2.1 Break-Up of Particulate Agglomerates	205
	6.2.2.2 Break-Up of Fluid Droplets	207
	6.2.3 Mixing Devices	210
	6.2.3.1 Static Mixers	211
	6.2.3.2 Banbury Mixer	211
	6.2.3.3 Mixing in Single Screw Extruders	213
	6.2.3.4 Co-Kneader	215
	6.2.3.5 Twin Screw Extruders	216
	6.2.4 Energy Consumption During Mixing	219
	6.2.5 Mixing Quality and Efficiency	220
	6.2.6 Plasticization	222
	6.3 Injection Molding	227
	6.3.1 The Injection Molding Cycle	228
	6.3.2 The Injection Molding Machine	231
	6.3.2.1 The Plasticating and Injection Unit	231
	6.3.2.2 The Clamping Unit	232
	6.3.2.3 The Mold Cavity	234
	6.4 Special Injection Molding Processes	237
	6.4.1 Multi-Component Injection Molding	237
	6.4.2 Co-Injection Molding	239
	6.4.3 Gas-Assisted Injection Molding (GAIM)	240
	6.4.4 Injection-Compression Molding	242
	6.4.5 Reaction Injection Molding (RIM)	243
	6.4.6 Liquid Silicone Rubber Injection Molding	246
	6.5 Secondary Shaping	247
	6.5.1 Fiber Spinning	247
	6.5.2 Film Production	248
	6.5.2.1 Cast Film Extrusion	248
	6.5.2.2 Film Blowing	249
	6.5.3 Blow Molding	251
	6.5.3.1 Extrusion Blow Molding	251
	6.5.3.2 Injection Blow Molding	253
	6.5.3.3 Thermoforming	254
	6.6 Calendering	256
	6.7 Coating	259
	6.8 Compression Molding	261
	6.9 Foaming	263
	6.10 Rotational Molding	265
	6.11 Computer Simulation in Polymer Processing	266
	6.11.1 Mold Filling Simulation	267
	6.11.2 Orientation Predictions	269
	6.11.3 Shrinkage and Warpage Predictions	270
	References	281
	7 Anisotropy Development During Processing	284
	7.1 Orientation in the Final Part	284
	7.1.1 Processing Thermoplastic Polymers	284
	7.1.2 Processing Thermoset Polymers	292
	7.2 Predicting Orientation in the Final Part	296
	7.2.1 Planar Orientation Distribution Function	297
	7.2.2 Single Particle Motion	299
	7.2.3 Jeffery’s Model	300
	7.2.4 Folgar-Tucker Model	301
	7.2.5 Tensor Representation of Fiber Orientation	302
	7.2.5.1 Predicting Orientation in Complex Parts Using Computer Simulation	303
	7.3 Fiber Damage	308
	References	314
	8 Solidification of Polymers	316
	8.1 Solidification of Thermoplastics	316
	8.1.1 Thermodynamics During Cooling	316
	8.1.2 Morphological Structure	320
	8.1.3 Crystallization	321
	8.1.4 Heat Transfer During Solidification	324
	8.2 Solidification of Thermosets	328
	8.2.1 Curing Reaction	329
	8.2.2 Cure Kinetics	330
	8.2.3 Heat Transfer During Cure	335
	8.3 Residual Stresses and Warpage of Polymeric Parts	337
	8.3.1 Residual Stress Models	340
	8.3.1.1 Residual Stress Model Without Phase Change Effects	342
	8.3.1.2 Model to Predict Residual Stresses with Phase Change Effects	343
	8.3.2 Other Simple Models to Predict Residual Stresses and Warpage	345
	8.3.2.1 Uneven Mold Temperature	347
	8.3.2.2 Residual Stress in a Thin Thermoset Part	348
	8.3.2.3 Anisotropy Induced Curvature Change	349
	8.3.3 Predicting Warpage in Actual Parts	350
	References	357
	9 Mechanical Behavior of Polymers	362
	9.1 Basic Concepts of Stress and Strain	362
	9.1.1 Plane Stress	363
	9.1.2 Plane Strain	364
	9.2 Viscoelastic Behavior of Polymers	364
	9.2.1 Stress Relaxation Test	365
	9.2.2 Time-Temperature Superposition (WLF-Equation)	367
	9.2.3 The Boltzmann Superposition Principle	368
	9.3 Applying Linear Viscoelasticity to Describe the Behavior of Polymers	369
	9.3.1 The Maxwell Model	370
	9.3.2 Kelvin Model	371
	9.3.3 Jeffrey Model	373
	9.3.4 Standard Linear Solid Model	375
	9.3.5 The Generalized Maxwell Model	377
	9.4 The Short-Term Tensile Test	382
	9.4.1 Rubber Elasticity	383
	9.4.2 The Tensile Test and Thermoplastic Polymers	388
	9.5 Creep Test	395
	9.5.1 Isochronous and Isometric Creep Plots	399
	9.6 Dynamic Mechanical Tests	400
	9.6.1 Torsion Pendulum	400
	9.6.2 Sinusoidal Oscillatory Test	404
	9.7 Effects of Structure and Composition on Mechanical Properties	406
	9.7.1 Amorphous Thermoplastics	406
	9.7.2 Semi-Crystalline Thermoplastics	409
	9.7.3 Oriented Thermoplastics	411
	9.7.4 Crosslinked Polymers	416
	9.8 Mechanical Behavior of Filled and Reinforced Polymers	418
	9.8.1 Anisotropic Strain-Stress Relation	420
	9.8.2 Aligned Fiber Reinforced Composite Laminates	421
	9.8.3 Transformation of Fiber Reinforced Composite Laminate Properties	423
	9.8.4 Reinforced Composite Laminates with a Fiber Orientation Distribution Function	425
	9.9 Strength Stability Under Heat	426
	References	442
	10 Failure and Damage of Polymers	444
	10.1 Fracture Mechanics	444
	10.1.1 Fracture Predictions Based on the Stress Intensity Factor	445
	10.1.2 Fracture Predictions Based on an Energy Balance	447
	10.1.3 Linear Viscoelastic Fracture Predictions Based on J-Integrals	449
	10.2 Short-Term Tensile Strength	451
	10.2.1 Brittle Failure	451
	10.2.2 Ductile Failure	455
	10.2.3 Failure of Highly Filled Systems or Composites	458
	10.3 Impact Strength	461
	10.3.1 Impact Test Methods	467
	10.3.2 Fracture Mechanics Analysis of Impact Failure	471
	10.4 Creep Rupture	476
	10.4.1 Creep Rupture Tests	477
	10.4.2 Fracture Mechanics Analysis of Creep Rupture	480
	10.5 Fatigue	480
	10.5.1 Fatigue Test Methods	481
	10.5.2 Fracture Mechanics Analysis of Fatigue Failure	489
	10.6 Friction and Wear	491
	10.7 Stability of Polymer Structures	494
	10.8 Environmental Effects on Polymer Failure	496
	10.8.1 Weathering	496
	10.8.2 Chemical Degradation	501
	10.8.3 Thermal Degradation of Polymers	503
	References	507
	11 Electrical Properties of Polymers	510
	11.1 Dielectric Behavior	510
	11.1.1 Dielectric Coefficient	510
	11.1.2 Mechanisms of Dielectrical Polarization	514
	11.1.3 Dielectric Dissipation Factor	517
	11.1.4 Implications of Electrical and Thermal Loss in a Dielectric	520
	11.2 Electric Conductivity	521
	11.2.1 Electric Resistance	521
	11.2.2 Physical Causes of Volume Conductivity	522
	11.3 Application Problems	525
	11.3.1 Electric Breakdown	525
	11.3.2 Electrostatic Charge	529
	11.3.3 Electrets	530
	11.3.4 Electromagnetic Interference Shielding (EMI Shielding)	530
	11.4 Magnetic Properties	531
	11.4.1 Magnetizability	531
	11.4.2 Magnetic Resonance	531
	References	532
	12 Optical Properties of Polymers	534
	12.1 Index of Refraction	534
	12.2 Photoelasticity and Birefringence	537
	12.3 Transparency, Reflection, Absorption, and Transmittance	541
	12.4 Gloss	547
	12.5 Color	548
	12.6 Infrared Spectroscopy	552
	12.7 Infrared Pyrometry	553
	12.8 Heating with Infrared Radiation	555
	References	557
	13 Permeability Properties of Polymers	558
	13.1 Sorption	558
	13.2 Diffusion and Permeation	560
	13.3 Measuring S, D, and P	565
	13.4 Corrosion of Polymers and Cracking [5]	566
	13.5 Diffusion of Polymer Molecules and Self-diffusion	569
	References	569
	14 Acoustic Properties of Polymers	570
	14.1 Speed of Sound	570
	14.2 Sound Reflection	572
	14.3 Sound Absorption	573
	References	574
	Appendix	576
	Appendix I	577
	Appendix II	585
	Appendix III	586
	Appendix IV – Balance Equations	605
	Continuity Equation	605
	Energy Equation for a Newtonian Fluid	605
	Momentum Balance	606
	Momentum Equation in Terms of t	606
	Navier-Stokes Equation	606
	Index	608