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Concepts of post‐yield fracture mechanics were used to characterize the crack initiation and propagation resistances of mica‐reinforced polypropylene containing different mica concentrations. Although mica addition leads to an apparently brittle composite, the crack initiation resistance is slightly increased with mica concentration up to 10 percent by weight; and significant improvement in crack propagation performance was found for polypropylene reinforced by up to 20 percent of mica in comparison to that of virgin polypropylene. The debonding of the interface between mica flakes and the matrix leads to a micro‐ductility ahead of the crack tip in which the matrix is able to pull‐out from mica particles and to stretch. This micro‐ductility also prevents the brittle, unstable crack propagation, which is due to the coalescence of voids in pure polypropylene. Above 20 percent of mica, the reduction of the effective amount of the matrix material results in a substantial drop in the resistance to crack growth of mica‐reinforced polypropylene.

Injection molding shrinkage deals with dimensional differences between a molded part and the cavity. By adding an array of orthogonal marks into a mold, local shrinkage values may be obtained by comparing dimensions of this array with dimensions of the array replicated on the surface of the parts. A profilograph is employed to obtain dimensional measurements, in the parallel to flow direction and in the cross flow direction. A sensitivity analysis is conducted to determine aspects of shrinkage evaluation causing uncertainty on the results. Prominent sources of uncertainty found are mark straightness defect and part warpage. Uncertainty on shrinkage is evaluated to 0.00025 mm/mm for a distance between the marks of 6.350 mm. Shrinkages have been evaluated locally for molded plates. Different distribution forms were observed for parallel to flow and cross flow shrinkage. Important anisotropy is also observed. The effects of holding pressure and injection velocity on shrinkages have been evaluated using a 2 3 factorial design of experiment for three locations on the plates. Finally, shrinkages for three mold geometries have been compared: constant thickness plate, variable in thickness symmetrical plate, and variable in thickness asymmetrical plate. Variable in thickness plates showed the importance of solidification dynamics on final shrinkages. POLYM. ENG. SCI., 46:1275-1283, 2006.

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