In this contribution, the influence of the reaction injection moulding process on the thermomechanical material behaviour of aliphatic hexamethylene diisocyanate (HDI) based fast curing polyurethane is demonstrated. Uniaxial tensile tests, temperature-frequency dependent dynamic mechanical thermal analysis (DMTA) and Differential Scanning Calorimetry (DSC) are used to show the differences in properties for ten different sets of process parameters. The mould and resin components temperature, the mass flow during the filling process and the residence time during the reaction process of the polyurethane are varied in several stages. Further experiments to determine the molar mass of the molecular chain between two crosslinking points of the polyurethane are used to explain the process influences on the thermomechanical properties. Thus, a direct correlation between manufacturing and material properties is shown. In addition, the mutual effect of the different parameters and their overall influence on the material behaviour is presented.

Within the scope of this contribution, a method for the determination of a strain limit for designing components made of elastomeric polyurethane systems is presented. The knowledge of a material-specific strain limit is essential for the structural-mechanical calculation of plastic components in the context of component design. Compared to a commonly used component design, based on a simplified dimensioning approach taking only linear viscoelastic deformations into account, the strain limit determined in this study allows an improved utilisation of lightweight construction potential in the dimensioning of technical components made of polyurethanes through the consideration of permissible nonlinear viscoelastic deformations. The test method comprises a sequence of quasi-static loading and unloading cycles, with a subsequent load-free recovery phase, allowing the relaxation of the viscoelastic forces. Standardised tensile and simple shear test specimens and a dynamic mechanical thermal analyser (DMTA) are used within the tests. The strain limit is determined by means of the so-called residual energy ratio, which is a characteristic quantity for the evaluation of hystereses of load–unload cycles. These hystereses are increasingly formed by deformations outside the range of linear viscoelastic deformations. The residual energy ratio relates the proportion of deformation energy recovered during unloading to the deformation work that is applied. In this contribution, the residual energy ratio is successfully used to detect a significant evolution of loss energy under increasing load and to correlate this transition to a characteristic strain. The latter is used as a dimensioning parameter for the design of components made of elastomeric polyurethane materials for quasi-static load cases. The determination of this strain limit is performed under consideration of the criterion of reversibility of deformation.

To encounter current issues regarding climate change, the hybridization of structures with lighter, often dissimilar, materials is an essential cornerstone of lightweight design. The different mechanical behavior of these materials results in challenges in terms of joining. This paper utilizes the joining process by hydraulic expansion to manufacture tube-to-tube joints of aluminum alloy AA6060 T66 and thermoplastic polycarbonate (Lexan) at room temperature. In contrast to metals, elastic and plastic strains coexist in thermoplastics from the beginning of deformation. Based on the theory of linear elasticity, an equation was derived to calculate the fluid pressure that expands the polycarbonate up to a strain value where plastic strains start to increase significantly in comparison to elastic strains. Tensile tests of the joined tubes revealed that the transferable tensile load increased approximately exponentially with increasing plastic deformation of the polycarbonate. With ongoing plastic deformation, micro-cracks appeared and merged within the thermoplastic. The appearance of these so-called crazes had no negative influence on the transferable load within the range of applied fluid pressure.