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Growing More Ductile Epoxies: An Essential Work of Fracture Study. Frederick A. Pfaff Stonhard A Division of the StonCor Group, Inc. Twofold Goal of This Study. Feasibility of Using Difunctional Amines as Chain Extenders in Amine-Cured Epoxy Formulations
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Growing More Ductile Epoxies:An Essential Work of Fracture Study Frederick A. Pfaff Stonhard A Division of the StonCor Group, Inc.
Twofold Goal of This Study • Feasibility of Using Difunctional Amines as Chain Extenders in Amine-Cured Epoxy Formulations • Suitability of the Method of Essential Work to Determine Fracture Toughness of Thermoset Epoxy Compositions
OUTLINE • Amine-Cured Epoxy Formulation Considerations • Fracture Toughness Test Methods • Experimental Details • Tensile Test Results • Fracture Toughness Results • Solvent Uptake • Conclusions
Formulation Perspectives Amine – Cured Epoxies
Formulation Trends • Lower VOC Lower MWt. Resins • Liquid Epoxy • Amidoamine, Aliphatic & Cycloaliphatic Amine Hardeners • Diluents & Plasticizers • High Crosslink Density • Tend to be Relatively Brittle
Cure & Glass Transition Temperature (Tg) • Two Components – Epoxy & Amine • Cures to Solid Crosslinked Mass • Tg of Reacting Mixture Increases as Cure Proceeds • Tg ≤ Cure Temperature + 30ºC • Vitrification Effect • Properties of Epoxies Used Within Approx. 30ºC of Tg Are Not Completely Glass-like
Managing Formula Tg • Most Unmodified Amines Cure Liquid Epoxy To a High Tg • Ultimate Tg 80 - 150ºC or Greater • Will Not Cure to Completion Under Normal Ambient Conditions • Tg Reduced by Inclusion of Plasticizing Modifiers • Term Includes All Non-Fugitive Diluents & Plasticizers
Plasticizing Modifiers • Reactive • Mono-epoxide Diluents • Stoichiometric Excess • Non-Reactive • Benzyl Alcohol, Ester & Hydrocarbon Plasticizers • Lower Tg • Reduce Viscosity • Important Impact on Cured Properties Proper Choice Critical to Performance!
Side-Effects in Cured State • Stoichiometric Excess & Monofunctional Diluents • Dangling Chain Ends • Non-Reactive Plasticizers • Not Chemically Bound − Extractable • Plasticizer Migration • Sometimes Count as VOC • Can Result in Lower Strength & Poorer Chemical Resistance A Fresh Approach Could Be Helpful
Chain Extension • Reactants With Functionality = 2 • Amines with Two Active Hydrogens Would be Chain Extenders • Mono-Primary Amines • Di-Secondary Amines • “Grow” Higher MWt. Simultaneous With Crosslinking Reaction
Goals • Partial Replacement for Traditional Plasticizing Modifiers • Viscosity & Tg Reduction • Better Cured Property Balance • Reduced Brittleness • Minimal Negative Effect on Other Mechanical Properties & Chemical Resistance
Need For a New Method • Linear Elastic Fracture Method for Brittle Break Materials • Example: ASTM D5045 • ASTM E1820 for Ductile Materials • J-Integral Method • Successive Loadings & Unloadings • Careful Measurement of Crack Length After Each Loading Cycle Inconvenient For Most Industrial Coatings Labs
Method of Essential Work • First Proposed by Cotterell & Reddel • Basically a Tensile Test on Notched Specimens Notches Ligament “DENT” Configuration
Method of Essential Work, cont’d. Wf = We + Wi (1) wf = Wf / l*t = we + βwi*l (2)
EWF Constraints • Dimensional Requirements • Full Yielding Before Failure • Self-Similarity of Load Curves at All Ligament Lengths • Plastic Zone Constraint l < 2rp
Primary Materials IPDA BzOH Bis A Epoxy
Epoxy Materials n Bisphenol A Epoxy C13 Epoxy Diluent
Amine Chain Extenders N-Dodecyl Amine N-Amyl Amine N, N’-Dimethyl Ethylene Diamine
Solvent Uptake Testing • Weight Change After 6 Hour RT Immersion • Weight Change After 24 Hour 90ºC Immersion • Weight Change After Dry Bake • Final Weight Change %Δmf = 100 * [(mw – min(mi, md) ) / mi]
Mechanical Properties Summary • Chain Extension Via Difunctional Amines Provides: • Reduction of Viscosity & Tg with Less Plasticizer • Tensile Strength Comparable to Strength Obtained With Higher MWT. Epoxy • Superior to Mono-Epoxide Modification • Superior Balance of Tensile Strength & Fracture Toughness Combined with Tg Reduction
Conclusions • Method of Essential Work Appears to be Applicable to Ductile Thermoset Epoxy Compositions • Plastic Zone Requirement Not Met • More Work Needed • Chain Extension Via Difunctional Amine Insertion Provides: • Superior Balance of Mechanical Properties • Little to No Adverse Effect on Solvent Uptake
Conclusions • Solvent Uptake Excessive With Large Stoichiometric Excess of Epoxy • Best Overall Properties Obtained From Non-Pendant Chain Extender, DM-EDA