| Introduction | 1 |
Lesson 1 | Plastics Fundamentals | 5 |
1.1 | What are Plastics? | 6 |
1.2 | What are Plastics Made Of? | 6 |
1.3 | How are Plastics Classified? | 7 |
1.4 | How are Plastics Identified? | 8 |
1.5 | What are the Physical Properties of Plastics? | 8 |
| Review Questions | 12 |
Lesson 2 | Raw Materials and Polymer Synthesis | 13 |
2.1 | Raw Materials for Plastics | 14 |
2.2 | Monomers and Polymers | 15 |
2.3 | Polyethylene Synthesis | 16 |
| Review Questions | 18 |
Lesson 3 | Methods of Polymer Synthesis | 19 |
3.1 | Addition of Polymerization | 20 |
3.2 | Polycondensation | 22 |
3.3 | Polyaddition (step addition) | 24 |
| Review Questions | 26 |
Lesson 4 | Bonding Forces in Polymers | 27 |
4.1 | Bonding Forces Within Molecules | 28 |
4.2 | Intermolecular Forces | 28 |
4.3 | Effects of Temperature | 29 |
| Review Questions | 30 |
Lesson 5 | Classification of Plastics | 31 |
5.1 | Identification of Plastics Categories | 32 |
5.2 | Thermoplastics | 32 |
5.3 | Cross-linked Plastics (Elastomers, Thermosets) | 34 |
| Review Questions | 36 |
Lesson 6 | Deformation Behavior of Plastics | 37 |
6.1 | Behavior of Thermoplastics | 38 |
6.2 | Amorphous Thermoplastics | 39 |
6.3 | Semicrystalline Thermoplastics | 40 |
6.4 | Behavior of Cross-linked Plastics | 42 |
| Review Questions | 44 |
Lesson 7 | Time-Dependent Behavior of Plastics | 45 |
7.1 | Load-bearing Behavior of Plastics | 46 |
7.2 | Effects of Time on Mechanical Behavior | 47 |
7.3 | Recovery Behavior of Thermoplastics | 48 |
7.4 | Dependence of Plastics on Time and Temperature | 49 |
| Review Questions | 52 |
Lesson 8 | Physical Properties | 53 |
8.1 | Density | 54 |
8.2 | Thermal Conductivity | 55 |
8.3 | Electrical Conductivity | 56 |
8.4 | Transparency | 57 |
8.5 | Characteristic Material Values | 58 |
| Review Questions | 60 |
Lesson 9 | Plastics Fabrication and Processing | 61 |
9.1 | Methods of Fabrication and Processing | 62 |
9.2 | Methods for Shaping Thermoplastics | 63 |
| Review Questions | 64 |
Lesson 10 | Plastics Compounding | 65 |
10.1 | Overview | 66 |
10.2 | Additives and Metering | 66 |
10.3 | Mixing | 67 |
10.4 | Plasticizing | 69 |
10.5 | Pelletizing | 70 |
10.6 | Size reduction | 71 |
| Review Questions | 72 |
Lesson 11 | Extrusion | 73 |
11.1 | Introduction | 74 |
11.2 | Extrusion Equipment | 74 |
11.3 | Coextrusion | 81 |
11.4 | Extrusion Blow Molding | 82 |
| Review Questions | 84 |
Lesson 12 | Injection Molding | 85 |
12.1 | Introduction | 86 |
12.2 | Injection Molding Machine | 87 |
12.3 | Mold | 90 |
12.4 | Process Sequence | 92 |
12.5 | Injection Molding of Thermosets and Elastomers | 95 |
| Review Questions | 96 |
Lesson 13 | Fiber-Reinforced Plastics | 97 |
13.1 | Materials | 98 |
13.2 | Process Sequence | 100 |
13.3 | Manual Processing Methods | 101 |
13.4 | Automated Processing Methods | 102 |
| Review Questions | 106 |
Lesson 14 | Plastic Foams | 107 |
14.1 | Properties of Foams | 108 |
14.2 | Foam Production | 111 |
| Review Questions | 114 |
Lesson 15 | Thermoforming | 115 |
15.1 | Fundamentals | 116 |
15.2 | Process Steps | 116 |
15.3 | Technical Equipment | 118 |
| Review Questions | 120 |
Lesson 16 | Welding Plastics | 121 |
16.1 | Fundamentals | 122 |
16.2 | Process Steps | 122 |
16.3 | Welding Methods | 123 |
| Review Questions | 128 |
Lesson 17 | Machining Plastics | 129 |
17.1 | Fundamentals | 130 |
17.2 | Technical Processes | 130 |
| Review Questions | 134 |
Lesson 18 | Adhesive Bonding of Plastics | 135 |
18.1 | Fundamentals | 136 |
18.2 | Classification of Adhesives | 139 |
18.3 | Cementing Procedure | 140 |
| Review Questions | 142 |
Lesson 19 | Plastics Products and Plastics Waste | 143 |
19.1 | Discussion of Plastics Wastes | 144 |
19.2 | Plastics in Production and Processing | 144 |
19.3 | Plastics Products and Their Life Expectancies | 145 |
19.4 | Waste Reduction and Utilization | 147 |
| Review Questions | 148 |
Lesson 20 | Recycling Plastics | 149 |
20.1 | Recycling of Plastics | 150 |
20.2 | Mechanical Recycling | 150 |
20.3 | Feedstock Recycling | 153 |
20.4 | Energy Recovery | 154 |
| Review Questions | 156 |
Appendix I | Glossary of Plastics Technology | 157 |
Appendix II | Selected Literature | 163 |
Appendix III | Example of a Training Program for Plastics Processing Operators in the US | 167 |
| Answers to Review Questions | 179 |