PROPERTIES OF IRON POWDER FILLED HIGH
DENSITY POLYETHYLENE
Mihai Rusu *, Nicoleta Sofian Daniela Rusu 2,
Eugen Neagu 3 and Rodica Neagu 3
1
"Gh Asachi" Technical University, Faculty of Industrial Chemistry,
Department of Macromolecules, Bd. D.Mangeron, No.71, 6600 Iasi,
Romania
2
"Gr. Τ. Popa" University of Medicine and Pharmacy, Faculty of
Biomedical Engineering, Biomaterials Department, Str. Universitatii,
No. 16, 6600 Iasi, Romania
"Gh. Asachi" Technical University, Faculty of Materials Science,
Department of Physics, Bd. D.Mangeron, No. 68, 6600 Iasi,
Romania
ABSTRACT
HDPE/iron powder composites have been characterized from the point of
view of mechanical, thermal and electrical properties. Results for iron
powder contents varying between 0 and 24 % by volume are presented.
Generally, the composites show poorer mechanical properties as compared
with
the unfilled polymer. The density and hardness of
HDPE/iron
composites are higher than those of HDPE. The incorporation of iron powder
in HDPE increases the thermal diffusivity and conductivity and decreases the
specific heat and the electrical resistivity. The experimental data were
interpreted using appropriate theoretical models.
Key Words: Polymer composites; Highdensity polyethylene; Iron powder;
Metalfilled polymers.
Corresponding author. Fax: +4032271311; Email: mrusu@ch.tuiasi.ro
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Iron Powder Filled High Density Polyethylene
INTRODUCTION
Within the group of composite materials, those containing powder fillers
/1,2/ occupy a special place and, among them, special mention should be
made of the mixtures consisting of thermoplastic polymers and metal fillers
/39/. Composites consisting of highly conductive filler powder dispersed in a
flexible, insulating polymer matrix are commonly
used in electronic
applications for die attach, solderless connectors, thermistors and pressure
sensing elements. Other uses of such composites include electromagnetic
shielding and antistatic devices as well as chemical sensors 111.
The composites made by incorporation of powdery metal fillers into
thermoplastic polymers combine the advantageous properties of metals and
plastics, offering cost effectiveness and rapid fabrication rate with a wide
range of design flexibility, light weight, noncorrosiveness etc 111.
In this paper, we report a study of the mechanical, thermal and electrical
properties of highdensity polyethylene (HDPE)/iron powder composites.
EXPERIMENTAL
Materials
The following materials have been used in the study:
•
highdensity polyethylene (HDPE), RIGIDEX type, A 52 BB/088 (British
Resin Products Ltd., England), with a melt flow index of 0.88g/10 min.;
•
iron powder with particle size in the range of 50100 μ πι (S.C. Sinterom
S.A.ClujNapoca, Romania), with a density of 7.8 g/cm 3 , and a thermal
conductivity of 80.2 W/mK.
Composites preparation
The composite materials have been prepared by compounding HDPE with
different amounts of metallic powder on a laboratoryrolling machine with
rollers heated at 155°C. The mixing time was about 10 min after the
formation of the HDPE sheet on the anterior cylinder of the rolling machine
and addition of the iron powder. The mixtures have been transformed through
pressing (preheating for 10 min, pressure for 5 min at 160°C and 15 MPa,
cooling through pressure) in 1 mm and 4 mm thick plates respectively, from
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samples have been cut for the determination
of the
physical,
mechanical, thermal and electrical characteristics. Thus, composite materials
with iron powder concentrations ranging between 0 and 24 % by volume
have been prepared.
Measurements
Tensile measurements were carried out using a TIRA TEST 2200
(Germany) (5 cm initial gap between clamps, and the mobile clamp speed of
5 cm/min.), according to ASTM D638.
Flexural modulus was measured with an Instron Universal
Testing
Machine (Type 1121), with a three points charge applicator, according to
ASTMD790. The Izod notched impact tests were performed on a FIE (Type
IT0.42) machine, according to ASTMD256, at room temperature (samples
were previously notched with a "V" shape).
Thermal
conductivity,
thermal
diffusivity and
specific
heat
were
measured using the transient method, based on the heat transfer in a semi
infinite solid theory /10/.
The volume resistivity was measured at room temperature, between
parallel copper plate electrodes, using a Keithley 602 electrometer.
In this paper most of the composite properties are expressed as relative
values (ratio between composite properties and those of unfilled polymer).
RESULTS AND DISCUSSION
1. Mechanical properties
Tensile characteristics have been determined from the stressstrain curves
(Figure
1). From these curves one may easily notice the increase in
composites brittleness with the increase in iron powder content /11,12/.
The tensile strength experimental data were analyzed by comparison with
some predictive models, in order to understand the formation of weak
structures in these composites /13,14/. The most common expressions of
tensile strength dependence on the composition of twophase composites are
based on the first power law [Eq. (1)] and the twothirds power law [Eq. (2)]:
—
= (1Φ)
(1)
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0
2
4
6
8
10
trnmigaSIF
12
St r a i n (mm)
Fig. I :yxwvutsrponmlihgfedcbaTSPHFED
Stressstrain curves for HDPE/iron
composites
with
different
concentrations of iron powder: 0% vol.(l); 4 % vol.(2); 8% vol.(3);
12% vol.(4); 16% voi.(5); 20% vol.(6) and 24% vol.(7).
= (1Φ2/3)
^
σ
(2)
Ρ
where σ ς and σ ρ denote the tensile strength of the composite and matrix
respectively, and Φ is the volume fraction of filler.
The power laws originate from the relation between the area fraction and
inclusions volume fraction /15/. For a completely random distribution of the
dispersed phase, the first power law relationship, and for the case of spherical
inclusions, the twothirds power law with appropriate weighting factor, can
be derived on a simple mathematical consideration. The following models
were used:
^ ( Ι Φ ) * !
σ
472
(3)
Ρ
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Μ. Rusu et αϊ.
σ
σ
2,3
)K2
(4)
(1Κ3Φ2/3)
(5)
= (1Φ
Ρ
=
Ρ
= exp (ΑΓ 4 Φ)
( 6)
These equations describe the nonadhesion type structure. In the first
power law [Eq. (3)] the parameter K | accounts for the weakness in the
structure introduced through discontinuity in stress transfer or formation of
stress concentration points at the fillerpolymer interface, in analogy to
parameter K 2 from Nielsen's model [Eq. (4)] /15/. When K| (or K 2 ) are equal
to 1, it means that there is no stress concentration effect. In the meantime, the
lower the value of Κ ι (or K 2 ), the greater the stress concentration effect.
The weighting factor K 3 from Eq. (5) describes the adhesion quality
between polymer matrix and inclusions and depends on the details of the
model. For example, K 3 = l . l represents dense hexagonal packing in the plane
of highest density; K 3 =l .21 describes the extreme case of poor adhesion, with
spherical inclusions for the minimum cross section between spherical beads,
and K 3 =l stands for strain consideration. In general, the lower the value of
K 3 , below 1.21, the better the adhesion is /13/.
In analogy to some nonpolymeric materials, such as metals and ceramics,
and according to the porosity model [Eq. (6)] inclusions may be considered
as pores or voids in polymer blends and composites. As a result of non
adhesion at the interface, the pores are assumed to play no significant role on
the mechanical properties of the composites. The K 4 parameter describes
stress
concentration;
the
higher
the
value
of
K4,
the
higher
stress
concentration /13/.
Figure 2 shows the relative tensile yield strength as a function of iron
volume
fraction.
The
experimental
data
and
the
predicted
curves
corresponding to the theoretical models presented above are plotted on the
same diagram, in order to determine the model parameters and for a better
interpretation of the results. One may observe that the experimental curve
approaches the diagrams corresponding to Eqs. (2), (3), (4), (5) and (6), for
which the fitting parameters are K,=0.90, K 2 =0.98, K 3 =1.21 and respectively,
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Polyethylene
1.0
eq.(1)
•eq.(3), IK·, =0.901
eq.(2)
eq.(4),lK 2 =0.98}
eq.(5),(K 3 =1.21)
eq.(6UK4=3)
ο
0)
α
0.4
0
Fig. 2:
5
10
15
20
Iron powder ( %, vol. )
25
Relative tensile yield strength (Δ ) of HDPE/iron composites as a
function of filler content and comparison with theoretical models
described by the eqs. (l)(6).
K 4 =3. T h e s e values indicate a poor adhesion between the t w o phases and a
small stress concentration effect.
An explanation of the relative tensile yield strength decrease
when
increasing the iron powder content consists in the incorporation of large
defects (the iron particles) that act as stress concentration points.
Furthermore, it is known that H D P E is a carbohydrate polymer, with a
relatively low level of intermolecular
interaction forces; its mechanical
strength is considerably due to the semicrystalline structure. Incorporation of
any inclusions in this polymer, and especially of fillers, induces modification
of the degree of crystallinity and, implicitly, of its mechanical characteristics
121.
T w o mathematical models have been considered for calculating tensile
elongation of the polymeric composites with p o w d e r fillers [Eqs. (7) and (8)]
/10.13/:
= (1φ1/3)
(7)
ερ
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)
= (1Κ5Φ2/1yxwvutsrqponmlihgfedcbaTRPKHFEDA
(8)
ε
Ρ
where:
e c tensile elongation of the composite;
ε ρ tensile elongation of the polymer;
Φ — volume fraction of filler;
K 5 constant depending on the dimension of disperse particles and
on the treatments applied to them (K 5 =1.21).
The diagrams plotted according to these models and the experimental
curve on relative tensile yield elongation are presented in Figure 3.
Analysis of these diagrams shows that for low (up to 8% vol.) and high
(above 16% vol.) iron powder contents the tensile yield elongation decreases
slowly, but the decrease becomes more significant for a concentration range
between 8 and 16% vol., which corresponds to the formation of particles
agglomerates.
Fig. 3:
Relative tensile yield elongation (Δ ) of HDPE/iron composites as a
function of filler content and comparison with theoretical models
described by the eqs. (7) and (8).
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For low contents of metal powder in the mixtures the experimental
diagram plotting the evolution of relative tensile yield elongation is placed
above
the
diagram
obtained
for Eq. (8). The
increase of the
filler
concentration above 16% vol. produces a decrease of the experimental data
below the predicted values.
The breaking of a material under impact is caused by the rapid crack
propagation through the bulk. The crack propagation rate is inversely
proportional to the material impact strength. A polymeric material with good
impact strength absorbs most of the impact energy, while crack propagation
is
very
slow.
The
formation
of
microfissures
perpendicular
on
the
propagating direction of the main fissure is one of the mechanisms that
explain the slowing down of the rate of fissure propagation. The capacity of
forming microfissures during the impact, the rate of their formation and the
amount of absorbed energy depend on the polymer nature, on its morphology
and molecular weight etc /14Λ
In the case of HDPE/iron composite materials, both Charpy notched
impact strength and Izod notched impact strength decrease considerably with
the introduction of the first amounts of iron powder in the polymer (Figure
4). Such a sudden decrease of impact strength is recorded up to a 4 % vol.
iron powder
content. This behavior
may
be explained
by
the
rapid
propagation of the fissures induced as a result of the impact along the
particlepolymer interface, due to the weak adhesion between the two phases.
The flexural modulus of the HDPE/iron composite materials decreases
with the increase of the iron powder content in the mixtures (Figure 5). The
decrease
is more significant in the concentration
domain
assuring an
individually dispersion of the metal particles (up to 4 % vol.). For filler
contents between 4 and 12% vol. the flexural modulus is less influenced by
the increase of iron particle concentration, but the increase of filler content
above 12% induces its sharper decrease.
A general analysis of the mechanical properties of HDPE/iron powder
composites indicates that the introduction of the metallic filler into HDPE
causes a decrease of the most of these properties /11,12/. However, the
mechanical properties of HDPE/iron composites are still interesting for many
applications, as one can see from Table 1.
Both the density and the hardness of the HDPE/iron composites increase
with the increase of the filler content in the mixture. Nevertheless, while the
increase of density is directly proportional with the content of iron powder,
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Iron p o w d e r (Vi.vol.)
Fig. 4:zyxvutsrponmlihgfedcaVRPIHEDC
Relative Izod notched impact strength (1) and relative
Charpy
notched impact strength (2) of H D P E / i r o n composites as a f u n c t i o n
of filler content.
Fig. 5:
Variation
of
relative
flexural
modulus
(o)
of
HDPE/iron
composites as a function of filler content.
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Table 1
Mechanical, thermal and electrical properties of HDPE/iron composites
VOLUME CONCENTRATION
OF IRON P O W D E R (%)
^^QOMPOSITES
NO
4
0
8
12
16
20
24
PROPERTIES
1
Tensile yield strength,
N/mm
2
33.1 28.7 27.6 24.0
23.8 20.5
18.2
2
Tensile yield elongation, 10.3
9.6
9.5
6.1
9.1
6.0
5.1
%
3
4.09
1.03 0.93 0.91
0.87 0.82 0.81
215
73.8 71.9 69.2
56.9 51.8 35.9
Density, g/cm 3
0.96
1.31
Shore D hardness,
62.0 62.3 63.8 64.0
64.8 65.0 65.6
124
125
127
128
134
1.52
1.44
1.65
1.93
1.86 2.89 4.29
Charpy notched impact
strength, N cm/cm 2
4
Izod notched impact
strength, KJ/m
5
6
2
1.68
1.99 2.31 2.56 2.99
°Sh D
7
Vicat softening
140
142
temperature, °C
8
Thermal difusivity, m 2 /s
•ΙΟ"7 •ΙΟ"7 •ΙΟ"7 •ΙΟ"7 •ΙΟ"7 •ΙΟ"7 •ΙΟ"7
9
Thermal conductivity,
0.50 0.51
0.61
0.66
0.68 0.79
1.33
3.62 2.54 2.14
1.59
1.51
1.34
1.04
•106
•106
•106
•106
•106
•106
8.59 2.42
1.52
1.01
6.31
5.59 6.11
14
4
3
W/mK
10
Specific heat, J/kgK
•106
11
Electrical volume
resistivity, Ω m
•10
14
•10
14
•10
•10'
•10
•103
•102
the diagram corresponding to hardness exhibits an Sshape (Figure 6).
Analysis of this latter diagram demonstrates that the most important increase
of composite hardness occurs in the range of filler contents that corresponds
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Ifl
U)
υ ca
c
•o
ί
ο
•C
Ο
ν
c.
ο
n
in
ν
>
a
€j
a.
Iron powder (% f voll tsrpomlihgeaTF
Fig. 6: Variation of relative density (o) and relative Shore D hardness
(Δ ) of HDPE/iron composites as a function of file content
to the coexistence of both individually dispersed particles and particle
agglomerations (5 20% vol.).
2.Thermal properties
Vicat softening temperature increases slowly with the increase of iron
powder content (Figure 7). The largest slope of the diagram appears once
again in the filler concentration domain in which the metal particles are
dispersed both individually and as agglomerates.
A melting heat of 39.87 J/g characterizes the composite material
containing 24% vol. iron powder, which is much lower than that of HDPE,
i.e. 155.0 J/g (Figure 8). In the composite containing 24% vol. iron powder
only the polyethylene present as 28% by weight melts. Keeping this in
mind and calculating the theoretical melting heat, a value of 142.14 J/g
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Fig.yxwvutsrponmlihgfedcbaXVTQPMJHFEDA
7: Variation of relative Vicat softening temperature of HDPE/iron
composites as a function of filler content.
which is slightly lower than that corresponding to the unfilled HDPE may
be obtained. This slight decrease in the melting heat of the polyethylene
contained in the composite may be explained through the decrease of its
crystallinity degree. The above assertion is also supported by the result
obtained from the estimation of the crystallinity degree (X), with the
following relation /16/:
X =^100,
ίioo
where:
[%]
(9)
Q „ melting heat of polyethylene, J/g;
Q J O O
melting heat of a 100% crystalline polyethylene, whose value
is estimated at 270.03 J/g.
All these calculations lead to the conclusion that the crystallinity degree
of the H D P E from the composite is of 52.64%, versus 62.4% for the
unfilled polymer.
The modification of the melting heat does not influence to any great
extent the melting point of HDPE from the composite material (Figure 8).
The literature provides several relations trying to approximate the thermal
conductivity
480
of the composites
containing
fillers, such
as:
Maxwell's
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Fig. 8:
Journal of Polymer Engineering
DSC diagrams for HDPE (full lines) and HDPE/iron (24% vol.)
composite (dashed lines).
equation (10), Cheng and Vachon's equation (11), Lewis and Nielsen's
equation (12), and Agari and Uno's equation (13)/17,18/:
Kc
_Km+2Kp+
Kp
2Φ(Κη,
K
p
)
Kc
K
1Λ/3Φ/2
Kc
1 + ΑΒΦ
K
1βφψ '
P
P
(10)
Km+2Kp<t>(KmKp)
log Kc = Φ • C 2 · lc
(11)
K„. / Κ pn — 1
1—Φ
Β = ——
and Ψ = 1 + — ^ ^ Φ
Km/Kp+A
Φ„2
(12)
(13)
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where:
Kc,Kp and K m represent the thermal conductivity values of the composite,
polymer and, respectively, filler;
Φ
the volumetric fraction of the disperse filler;
A
constant depending on the shape and orientation of the disperse
particles (for randomly distributed spherical particles, A = l , 5
while for randomly distributed aggregates of spherical particles,
A=3);
the maximum packing fraction of disperse phase (for randomly
C,, C 2
experimentally determined constants of order unity. C, is a
Φη,
distributed spherical particles, Φ„,=0,637);
measure of the effect of the dispersed particles on the secondary
structure of the polymer, like crystallinity and the crystal size.
C 2 measures the ease of the particles to form conductive chains.
The more easily particles are gathered to form conductive chains,
the more thermal conductivity of the particles contributes to
change thermal conductivity of the composite and C 2 becomes
closer to 1.
Thermal diffusivity and thermal conductivity of the composite material
increase, while specific heat decreases with the increase of filler content in
mixtures (Figure 9, Table 1). For iron powder contents below 20% vol. the
experimental
diagram
of thermal
conductivity
approaches
the
curves
corresponding to Eqs. (10), (12) (with A=1.5) and Eq. (13) (with C,=0.99 and
C 2 =0.30).
When
filler
concentration
increases
above
20%
vol.,
the
experimental conductivity becomes higher than the values predicted by the
theoretical models.
It is known that percolation conductivity appears when the ratio between
filler conductivity and polymer conductivity is above 10 s /1921/. Because
the ratio between iron thermal conductivity (80.2 W/mK) and HDPE thermal
conductivity (0.505 W/mK) is only 158.81, the thermal conductivity of
HDPE /iron composite does not have a percolation threshold.
For a possible
explanation
of the manner
in which the
thermal
conductivity varies when increasing the iron powder content, an attempt was
made to correlate the values obtained for this characteristic with the structure
of the composite, by means of optical microscopy (Figure 10).
For filler content up to 5% vol., the studies of optical microscopy showed
that the metal powder particles are dispersed individually in the polymeric
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σ
αι
•C
If
11
ν a,
>
>
o 5
Φ <u
er a
Iron powder (%,vol.)
Fig. 9:
Relative thermal conductivity ( · ) , relative thermal diffusivity
(ο) and relative specific heat (Δ ) for HDPE/iron composites as a
function of filler content and comparison with theoretical models for
thermal conductivity described by the eqs. (10), (11), (12) and (13).
matrix (Figure 10 a). An increase of the filler content in the mixture initiates
particles agglomeration, so that in the concentration interval ranging between
5 and 20% vol., the metal powder is found inserted in the polymeric matrix
both as individual particles and as agglomerations of particles (Figure
10 b,c). When the content of iron powder exceeds 20% vol., almost all filler
particles form agglomerates, being in direct contact with each other (Figure
10 d). Under such circumstances a 3D networktype structure made of metal
particles is formed and the thermal conductivity of composite material
presents a sharp increase.
The propagating rate of the thermal flow through a nonmetallic solid
depends on the coupling intensity of the vibration movements of the atoms
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(c)
(d)
Fig. 10:ywvutsrponmlkjihgfedcbaPMIHED
Microscopic photographs of HDPE filled with 4% (a), 12% (b),
16% (c) and 2 4 % (d) by volume iron particles.
and groups of adjacent atoms. Intense couplings occur in the materials with
covalent bonds, the thermal transmission showing a slight deficit in the case
of highly ordered crystalline networks. In the case of metals, the process of
thermal energy transmission from one point to another, by means of mobile
electrons,
conceals
the
contribution
of the
atomic
network
vibration
movements to thermal conduction, the first one being a much more efficient
process.
In the case of HDPE/iron composite we can assume that when the filler
content reaches 2 0 % vol., a change of thermal conduction mechanism occurs,
from conduction through atomic network vibration movements, specific for
polymers, to conduction by means of mobile electrons, specific for metals.
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3.ELECTRICAL PROPERTIES
The electrical conductivity of HDPE is dramatically influenced by the
addition of iron powder. The electrical volume resistivity of HDPE decreases
by 12 orders of magnitude with the addition of iron powder (see Table 1),
which corresponds to a proportional increase of electrical conductivity.
Figure 11 shows the plot of log (electrical volume resistivity) against metal
content.
The sudden decline in the electrical resistivity of composite material is
explained by the percolation theory 1221. The theory implies network or path
arrays for conduction not necessarily by metaltometal contact. A quantum
mechanical tunneling mechanism has been proposed, whereby the electrons
can hop or tunnel through the insulating region between adjacent particles up
to distances of several nanometres. The electric field strength between
neighboring filler entities may be high enough to cause complete breakdown
of the matrix or adsorbed surface layers. The socalled percolation threshold
I
5
Fig. 11:
I
I
I
10
15
20
Iron p o w d e r (%,vol.)
I
25
—
Variation of log(electrical volume resistivity) for HDPE/iron
composites as a function of filler content.
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represents the lowest concentration
of conducting particles at which
continuous conducting chains are formed /23/.
The percolation threshold for the studied composite material corresponds
to an iron powder content of 12% by volume, for which a sharp fall in
electrical resistivity (of 11 orders of magnitude) has been observed.
CONCLUSIONS
The results reported here demonstrate that the addition of iron powder to
HDPE induces a decrease of the mechanical properties, in comparison with
those of the unfilled polymer. The density and hardness of HDPE/iron
composites are higher than those for the unfilled polymer and increase with
the filler content. The incorporation of iron powder in HDPE increases the
thermal diffusivity and thermal conductivity and decreases the specific heat.
The electrical resistivity of HDPE is greatly decreased by addition of iron
powder, indicating a proportional increase of electrical conductivity.
BIBLIOGRAPHY
1. A.A. Berlin, S.A. Volfson, S.S. Enikolopian and S.S. Negmatov,
Principles of Polymer Composites, Akademie Verlag, Berlin, 1986.
2. V.A.
Paharenko,
V.G.
Zverlin
and
E.M.
Kirienko,
Filled
Thermoplastics, Tehnika, Kiev, 1986.
3. Ed. S.K. Bhattacharya, MetalFilled
Polymers,
Marcel Dekker Inc.,
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