ASTM D4101-24

This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
Designation: D4101 − 24
Standard Classification System and Basis for Specification for
Polypropylene Injection and Extrusion Materials
This standard is issued under the fixed designation D4101; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
This standard has been approved for use by agencies of the U.S. Department of Defense.
INTRODUCTION
This classification system is not intended for the selection of materials but only as a means to call
out plastic materials to be used for the manufacture of parts. The selection and specification of these
materials is to be made by personnel with expertise in the plastics field where other factors including
the use environment, inherent properties of the materials, performance of the part, part design,
manufacturing process, and economics are considered.
1. Scope* 1.4 The following safety hazards caveat pertains only to the
test methods portion, Section 13, of this specification: This
1.1 This classification system covers polypropylene materi-
standard does not purport to address all of the safety concerns,
als suitable for injection molding and extrusion. Polymers
if any, associated with its use. It is the responsibility of the user
consist of homopolymer, copolymers, and elastomer com-
of this standard to establish appropriate safety, health, and
pounded with or without the addition of impact modifiers, for
environmental practices and determine the applicability of
example, ethylene-propylene rubber, polyisobutylene rubber,
regulatory limitations prior to use.
and butyl rubber, colorants, stabilizers, lubricants, or reinforce-
ments.
NOTE 2—This classification system and ISO 19069-1 and -2 address the
same subject matter, but differ in technical content.
1.2 This classification system allows for the use of those
1.5 This international standard was developed in accor-
polypropylene materials that can be recycled, reconstituted,
dance with internationally recognized principles on standard-
and reground, provided that: (1) the requirements as stated in
ization established in the Decision on Principles for the
this classification system are met, and (2) the material has not
Development of International Standards, Guides and Recom-
been modified in any way to alter its conformance to food
mendations issued by the World Trade Organization Technical
contact regulations or similar requirements. The proportions of
Barriers to Trade (TBT) Committee.
recycled, reconstituted, and reground material used, as well as
the nature and the amount of any contaminant, cannot be
2. Referenced Documents
practically covered in this classification system. It is the
2.1 ASTM Standards:
responsibility of the supplier and the buyer of recycled,
C177 Test Method for Steady-State Heat Flux Measure-
reconstituted, and reground materials to ensure compliance.
ments and Thermal Transmission Properties by Means of
(See Guide D7209.)
the Guarded-Hot-Plate Apparatus
1.3 The values stated in SI units are to be regarded as
D149 Test Method for Dielectric Breakdown Voltage and
standard. No other units of measurement are included in this
Dielectric Strength of Solid Electrical Insulating Materials
standard.
at Commercial Power Frequencies
NOTE 1—The properties included in this classification system are those D150 Test Methods for AC Loss Characteristics and Permit-
required to identify the compositions covered. If other requirements are
tivity (Dielectric Constant) of Solid Electrical Insulation
necessary to identify particular characteristics important to specific
D256 Test Methods for Determining the Izod Pendulum
applications, these shall be designated by using the suffixes given in
Impact Resistance of Plastics
Section 1.
D257 Test Methods for DC Resistance or Conductance of
Insulating Materials
This classification system is under the jurisdiction of ASTM Committee D20 on
Plastics and is the direct responsibility of Subcommittee D20.15 on Thermoplastic
Materials. For referenced ASTM standards, visit the ASTM website, www.astm.org, or
Current edition approved Feb. 1, 2024. Published March 2024. Originally contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
ɛ1
approved in 1982. Last previous edition approved in 2017 as D4101 - 17 . DOI: Standards volume information, refer to the standard’s Document Summary page on
10.1520/D4101-24. the ASTM website.
*A Summary of Changes section appears at the end of this standard
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
D4101 − 24
D495 Test Method for High-Voltage, Low-Current, Dry Arc Thermoplastic Molding and Extrusion Materials
Resistance of Solid Electrical Insulation D3763 Test Method for High Speed Puncture Properties of
D523 Test Method for Specular Gloss Plastics Using Load and Displacement Sensors
D543 Practices for Evaluating the Resistance of Plastics to D3835 Test Method for Determination of Properties of
Chemical Reagents Polymeric Materials by Means of a Capillary Rheometer
D570 Test Method for Water Absorption of Plastics D3892 Practice for Packaging/Packing of Plastics
D618 Practice for Conditioning Plastics for Testing D4000 Classification System for Specifying Plastic Materi-
D638 Test Method for Tensile Properties of Plastics als
D648 Test Method for Deflection Temperature of Plastics D4329 Practice for Fluorescent Ultraviolet (UV) Lamp Ap-
Under Flexural Load in the Edgewise Position paratus Exposure of Plastics
D695 Test Method for Compressive Properties of Rigid D4364 Practice for Performing Outdoor Accelerated Weath-
Plastics ering Tests of Plastics Using Concentrated Sunlight
D696 Test Method for Coefficient of Linear Thermal Expan- D4812 Test Method for Unnotched Cantilever Beam Impact
sion of Plastics Between −30°C and 30°C with a Vitreous Resistance of Plastics
Silica Dilatometer D5279 Test Method for Plastics: Dynamic Mechanical Prop-
D732 Test Method for Shear Strength of Plastics by Punch erties: In Torsion
Tool D5420 Test Method for Impact Resistance of Flat, Rigid
D746 Test Method for Brittleness Temperature of Plastics Plastic Specimen by Means of a Striker Impacted by a
and Elastomers by Impact Falling Weight (Gardner Impact)
D785 Test Method for Rockwell Hardness of Plastics and D5630 Test Method for Ash Content in Plastics
Electrical Insulating Materials D5947 Test Methods for Physical Dimensions of Solid
D790 Test Methods for Flexural Properties of Unreinforced Plastics Specimens
and Reinforced Plastics and Electrical Insulating Materi- D6110 Test Method for Determining the Charpy Impact
als Resistance of Notched Specimens of Plastics
D792 Test Methods for Density and Specific Gravity (Rela- D6290 Test Method for Color Determination of Plastic
tive Density) of Plastics by Displacement Pellets
D883 Terminology Relating to Plastics D7209 Guide for Waste Reduction, Resource Recovery, and
D1238 Test Method for Melt Flow Rates of Thermoplastics Use of Recycled Polymeric Materials and Products (With-
by Extrusion Plastometer drawn 2015)
D1435 Practice for Outdoor Weathering of Plastics E29 Practice for Using Significant Digits in Test Data to
D1505 Test Method for Density of Plastics by the Density- Determine Conformance with Specifications
Gradient Technique E313 Practice for Calculating Yellowness and Whiteness
D1525 Test Method for Vicat Softening Temperature of Indices from Instrumentally Measured Color Coordinates
Plastics E831 Test Method for Linear Thermal Expansion of Solid
D1531 Test Methods for Relative Permittivity (Dielectric Materials by Thermomechanical Analysis
Constant) and Dissipation Factor by Fluid Displacement 2.2 Military Standard:
Procedures (Withdrawn 2012)
MIL-STD-105 Sampling Procedure and Tables for Inspec-
D1822 Test Method for Determining the Tensile-Impact tion by Attributes
Resistance of Plastics
2.3 SAE Standards:
D2117 Test Methods for Carbon Black—Surface Area by SAE J1545 Instrumental Color Difference Measurement for
Nitrogen Adsorption (Withdrawn 1999)
Exterior Finishes, Textiles and Color Trim
D2240 Test Method for Rubber Property—Durometer Hard- SAE J1767 Instrumental Color Difference Measurement for
ness
Colorfastness of Automotive Interior Trim Materials
D2565 Practice for Xenon-Arc Exposure of Plastics In- SAE J2412 Accelerated Exposure of Automotive Interior
tended for Outdoor Applications
Trim Components Using a Controlled Irradiance Xenon-
D2584 Test Method for Ignition Loss of Cured Reinforced Arc Apparatus
Resins
SAE J2527 Performance Based Standard for Accelerated
D2990 Test Methods for Tensile, Compressive, and Flexural Exposure of Automotive Exterior Materials Using a Con-
Creep and Creep-Rupture of Plastics
trolled Irradiance Xenon-Arc Apparatus
D3012 Test Method for Thermal-Oxidative Stability of SAE J1976 Outdoor Weathering of Exterior Materials
Polypropylene Using a Specimen Rotator Within an Oven
2.4 ISO Standards:
D3418 Test Method for Transition Temperatures and Enthal- ISO 19069-1 Plastics—Polypropylene (PP) moulding and
pies of Fusion and Crystallization of Polymers by Differ-
extrusion materials—Part 1: Designation system and basis
ential Scanning Calorimetry
for specifications
D3641 Practice for Injection Molding Test Specimens of
Available from Standardization Documents Order Desk, Bldg. 4 Section D, 700
Robbins Ave., Philadelphia, PA 19111-5094.
3 5
The last approved version of this historical standard is referenced on Available from Society of Automotive Engineers (SAE), 400 Commonwealth
www.astm.org. Dr., Warrendale, PA 15096-0001, http://www.sae.org.
D4101 − 24
ISO 19069-2 Plastics—Polypropylene (PP) moulding and no other functional group, added in situ or physically blended
extrusion materials—Part 2: Preparation of test specimens into the polypropylene matrix.
and determination of properties
3.2.15 polypropylene homopolymer (PP-H)—a propylene
plastic prepared by the polymerization of propylene only.
3. Terminology
3.2.16 polypropylene random copolymer (PP-R)—a propyl-
3.1 Definitions—For definitions of terms pertaining to plas-
ene plastic containing another olefinic monomer (or mono-
tics used in this test method, refer to Terminology D883.
mers) having no functional group other than the olefinic group
3.2 Definitions of Terms Specific to This Standard:
copolymerized with propylene.
3.2.1 back pressure, n—the constant pressure that is applied
3.2.16.1 Discussion—Polypropylene random copolymers
to the end of the screw while the screw is rotating and
containing more than one additional monomer are often called
retracting to prepare for the next injection.
“terpolymers.”
3.2.2 brittle failure, n—one where the specimen test area is
broken into two or more pieces, with sharp edges and shows 4. Classification
almost no plastic flow.
4.1 Unreinforced polypropylene materials are classified into
3.2.3 cooling time, n—the time in which the material is in
groups according to basic composition. These groups are
the closed mold with no pressure applied.
subdivided into classes and grades, as shown in Table PP.
3.2.4 cycle time, n—the time required to complete a full
NOTE 3—An example of this classification system is as follows. The
injection molding cycle, including injection time, cooling time,
designation PP0113 would indicate: PP = polypropylene, 01 (group) =
homopolymer, 1 (class) = general purpose, and 3 (grade) = with
and mold open time.
requirements given in Table PP.
3.2.5 ductile brittle transition temperature, n—the tempera-
4.1.1 To facilitate the incorporation of future or special
ture at which a 80% of the specimens exhibit ductile failure
materials not covered by Table PP, the “other/unspecified”
3.2.6 ductile failure, n—one where the specimen deforms
category for group (00), class (0), and grade (0) is shown on the
plastically before fracturing or one where the puncture of a test
table with the basic properties to be obtained from Table A,
plaque does not have cracks radiating more than 10 mm
Table B, Table C, Table G, Table H, and Table T, as they apply
beyond the center of the impact point.
(see 4.3).
3.2.7 injection pressure, n—the constant pressure that is
4.2 Reinforced versions of the polypropylene materials are
applied to the end of the screw causing the melted material to
classified in accordance with Table PP, Table A, Table C, Table
fill the mold.
G, and Table T. Table PP, Table B, and Table H specify the
3.2.7.1 Discussion—The injection pressure along with the
properties of the unreinforced material, and Tables A, C, G, or
injection speed determines the volumetric fill rate of the mold.
T specify the properties after the addition of reinforcements,
3.2.8 injection speed, n—the forward velocity of the screw
pigments, fillers, or lubricants, at the nominal level indicated
during the injection step.
(see 4.2.1)
3.2.8.1 Discussion—Injection speed is a set position on the
4.2.1 Reinforcements and Additive Materials—A symbol
injection molding machine ranging from slow to fast. The
(single letter) will be used for the major reinforcement or
injection speed along with the injection pressure determines the
combinations thereof, along with two numbers that indicate the
volumetric fill rate of the mold.
percentage of addition by mass, with the tolerances as tabu-
3.2.9 injection time, n—the time in which a constant speci-
lated as follows:
fied pressure is applied to the melted material.
Symbol Material Tolerance
G Glass reinforced—
3.2.10 melt temperature, n—the temperature of the material
<15 % ±2 percentage points
as it is being injected into the mold, measured by a pyrometer,
>15 % ±3 percentage points
or equivalent.
L Lubricant (that is, graphite, to be specified
silicone, and stearates)
3.2.11 mold open time, n—the time beginning when the
M Mineral-reinforced—
mold is opened and ending when the mold is closed.
<15 % ±2 percentage points
>15 % ±3 percentage points
3.2.12 mold temperature, n—the temperature of the mold
R Reinforced-combinations/ ±3 percentage points based on
during the molding cycle, measured in all mold cavities and on
mixtures of reinforcements the total reinforcement
or other fillers/reinforcements
both platens, measured by a pyrometer, or equivalent.
NOTE 4—This part of the system uses the type and percentage of
3.2.13 polypropylene (PP)—a propylene plastic prepared by
additive to designate the modification of the base material. To facilitate
the polymerization of propylene or propylene with other alpha
this designation, the type and percentage of additive can be shown on the
olefins. (See also PP-B, PP-H, and PP-R.)
supplier’s Technical Data Sheet, unless it is proprietary in nature. If
necessary, additional requirements shall be indicated by the use of the
3.2.14 polypropylene heterophasic copolymers (PP-B,
suffix part of the system as given in Section 5.
PP+EPR, or PP+EPDM)—a propylene plastic consisting of
two or more separate phases. 4.2.2 Specific requirements for reinforced, pigmented,
3.2.14.1 Discussion—The phases consist of a polypropylene filled, or lubricant polypropylene materials will be shown by a
homopolymer (PP-H) or a polypropylene random copolymer six-character designation. The designation will consist of the
(PP-R) matrix containing a dispersed olefinic elastomer having letter A, B, C, G, or T and the five digits comprising the cell
D4101 − 24
numbers for the property requirements in the order in which
5 = <–30°C ductile-brittle transition temperature
they appear in Table A, Table B, Table C, Table G, or Table T.
For Table H the designation will consist of the letter H and
5. Suffixes
three digits comprising the cell numbers for the property
5.1 When additional requirements are needed for the mate-
requirements in the order in which they appear in Table H.
rials covered in this specification that are not covered in Table
4.2.2.1 Although the values listed are necessary to include
PP, Table A, Table B, Table C, Table G, Table H, and Table T,
the range of properties available in existing materials, they
those requirements shall be designated through the use of
should not be interpreted as implying that every possible
suffixes. The primary suffix list can be found in Suffix
combination of the properties exists or can be obtained.
Requirements, Section 7, of Classification D4000. Other suf-
4.2.3 When the grade of the basic materials is not known or
fixes that pertain only to the material requirements in this
is not important, the use of “0” grade classification is to be used
specification are listed as follows. In general, the suffix letter
for reinforced materials in this system. (See Note 5.)
indicates the requirement needed; the first number (digit)
NOTE 5—An example of this classification system for a reinforced-
indicates the test condition, and the second number (digit)
polypropylene material is as follows. The designation PP0110M20A21130
indicates the specimen requirement.
would indicate the following, with the material requirements from Table
A: NOTE 9—Suffixes from Classification D4000 will contain two letters
followed by three digits while suffixes from this specification will contain
a single letter followed by two or three numbers. An example would be
PP0110 = General-purpose polypropylene homopolymer from Table
weatherability; a designation of WA510 would indicate that it is a
PP
Classification D4000 suffix with the following requirements:
M20 = Mineral reinforced, 20 %,
A = Table A property requirements.
2 = 35-MPa tensile stress, min, W = Weather resistant,
1 = 1000-MPa flexural modulus (1 % secant), min, A = Practice D1435,
5 = Elongation properties, and
1 = 15-J/m Izod impact, min,
10 = 10 % change.
3 = 110°C deflection temperature, min, and
0 = Unspecified.
A designation of W110 would indicate that it is a Specification D4101
suffix with the following requirements:
If no properties are specified, the designation would be PP0110M20-
A00000.
4.3 Table B has been incorporated into this specification to
W = Weatherability,
facilitate the classification of special materials where Table PP 1 = Practice D2565, Test Cycle 1, specimens exposed in a xenon-arc
accelerated test apparatus,
does not reflect the required properties of that unreinforced
1 = 200-h exposure, and
material. This table is to be used in a manner similar to Tables
0 = Change in properties to be specified.
A, C, G, and T. Table H has been incorporated into this
Suffıxes:
specification to improve the callout of random copolymers and
impact copolymers. Table H has a reduced callout based on
E = Electrical requirements as designated by the following digits:
flexural modulus, Izod impact, and the Multiaxial Impact
First Digit
Ductile-Brittle Transition Temperature. If a full line callout is
required, use Table B.
0 = To be specified by user.
1 = Specimens preconditioned 40 h at 23°C and 50 % relative
NOTE 6—Mechanical properties of polypropylene materials with pig-
humidity, then 14 days in distilled water at 23 6 1°C.
ments or colorants can differ from the mechanical properties of natural
Second Digit
material, depending on the choice and the concentration.
NOTE 7—An example of a special material using this classification
0 = To be specified by user.
system is as follows. The designation PP0110B67253 would indicate the
1 = Insulation resistance, dielectric constant, and dissipation factor
following with the material requirements from Table B:
meet property limits as shown below. These are electrical limits
usually applied to unreinforced polypropylene when control of
their electrical properties is required.
PP0110 = homopolymer, general purpose, other,
B = Table B property requirements, Electrical Properties:
6 = 30-MPa tensile stress at yield, min,
Dielectric constant, Test Methods D1531 or 2.30
7 = 1500-MPa flexural modulus, min,
max D150
2 = 50-J/m Izod impact resistance, min, Dissipation factor, max Test Methods D1531 0.0005
Insulation resistance, Test Methods D257 1 × 10
5 = 90°C deflection temperature, min, and
min, Ω
3 = >1.0 to 3.0 nominal melt flow rate.
Water immersion Test Methods D1531 or Shall meet the di-
NOTE 8—An example of a polypropylene copolymer material using
stability D150 electric constant
Table H would be as follows. The designation PP0500H585 would
and dissipation
indicate a material with the following requirements:
factor require-
ments
PP0500 = copolymer or impact modified,
W = Weatherability requirements as designated by the following digits:
H = Table H property requirements,
First Digit
5 = 1200-MPa flexural modulus, min,
8 = Izod impact resistance, non-break failure mode, no value
reported, and 0 = To be specified.
D4101 − 24
1 = Specimens exposed in a xenon arc accelerated test apparatus that 9 = Colorfastness by SAE J1767, for interior materials, CIELAB color
conforms to Practice D2565 using Test Cycle 1 for exterior difference, 10° observer, Illuminant D65, specular included, ∆E =
applications. 3.0 max.
2 = Specimens exposed in a fluorescent UV/condensation accelerated Z = Reserved for other special requirement characteristics (for
test apparatus that conforms to Practice D4329 using Test Cycle A example, internal mold release agent) not covered by existing
for exterior applications. call-out capabilities. These are to be assigned and be spelled out in
detail and identified in sequence, that is, 01 UV-stabilized, 02
3 = Specimens exposed in a xenon-arc accelerated test apparatus that
conforms to SAE J2527 or equivalent for exterior applications. special color, and 03, etc.
4 = Specimens exposed in a xenon-arc accelerated test apparatus that
Additional suffixes will be added to this specification as test methods
conforms to SAE J2412 or equivalent for interior applications.
and requirements are developed or requested, or both.
5 = Specimens exposed to concentrated natural sunlight in accordance
with Practice D4364 without water spray. 6. Basic Requirements
6 = Specimens exposed to concentrated natural sunlight in accordance
6.1 Basic requirements from property or cell tables, as they
with Practice D4364 with water spray (Table 1, Cycle 1).
apply, are always in effect unless these requirements are
7 = Specimens exposed to natural sunlight in accordance with Practice
D1435 using a rack angle of 45° from the horizontal facing the superseded by specific suffix requirements in the “Line Call-
equator , unless specified otherwise.
Out.”
8 = Specimens exposed to natural sunlight in accordance with SAE
J1976 Procedure A, unless specified otherwise.
7. General Requirements
Second Alphanumeric
7.1 The plastic composition shall be uniform and shall
0 = To be specified by user.
conform to the requirements specified herein. The color and
1 = 200-h exposure.
form of the material shall be specified. Note specification
2 = 500-h exposure.
changes due to the effects of colorants and, when necessary,
3 = 1000-h exposure.
cover them by suffixes.
4 = 2000-h exposure.
5 = 1240.8 kJ/(m .nm) at 340 nm.
7.2 For recycled, reconstituted, and reground materials the
6 = 2500 kJ/(m .nm) at 340 nm.
level of contamination by nonpolymeric materials other than
7 = 1000 MJ/m solar total UV irradiation (approximately 3 years).
fillers and additives shall not be of a significant level that it
8 = 336-h exposure
prevents the product from meeting the performance criteria for
9 = 720-h exposure
which it was manufactured.
A = 5000-h exposure
B = 10000-h exposure
C = 225.6 kJ/(m .nm) at 340 nm 8. Detail Requirements
D = 601.6 kJ/(m .nm) at 340 nm.
8.1 Test specimens for the various materials shall conform
NOTE 10—Conversion from hours to kilojoules (kJ) varies with
to the requirements prescribed in Table PP, Table A, Table B,
irradiance and the light/dark cycle. Conversion to kJ from actual light
Table C, Table G, Table H, Table T and to the suffix require-
hours (h) is based on the following relation:
ments as they apply.
kJ 5 Irradiance in Watts × 3.6 kJ/h × h of light
8.2 Observed or calculated values obtained from analysis,
Thus, at an irradiance level of 0.55 W/(m .nm) at 340 nm, the multipli-
measurement, or test shall be rounded in accordance with
cation factor for converting light hours to kJ is 1.98 (0.55 × 3.6).
Practice E29 to the nearest unit in the last right-hand place of
Therefore, 100 light hours is equivalent to 396 kJ/(m .nm) at 340 nm at
figures used in expressing the specified limiting value. The
this irradiance level.
Third Alphanumeric value obtained is compared directly with the specified limiting
value. Conformance or nonconformance with the specification
is based on this comparison.
0 = To be specified by user.
1 = The exposed specimens shall not exhibit surface changes (such as
9. Sampling
dulling and chalking) or deep-seated changes (such as checking,
crazing, warping, and discoloration).
9.1 Sampling shall be statistically adequate to satisfy the
2 = The tensile strength after exposure must be no less than 50 % of
requirements of 14.4. A batch or lot of resin shall be considered
the original.
as a unit of manufacture as prepared for shipment and can
3 = The tensile strength after exposure must be no less than 90 % of
consist of a blend of two or more production runs of material.
the original.
4 = American Association of Textile Chemists and Colorists (AATCC)
10. Number of Tests
rating 4 to 5.
5 = Colorfastness by SAE J1545, for exterior materials, CIELAB color
10.1 The number of tests conducted shall be consistent with
difference, 10° observer, Illuminant D65, specular included, ∆E =
the requirements of Section 13.
2.5 max.
6 = Colorfastness by SAE J1545, for exterior materials, CIELAB color
11. Specimen Preparation
difference, 10° observer, Illuminant D65, specular included, ∆E =
2.0 max.
11.1 All test specimens other than those for heat stability
7 = Colorfastness by SAE J1545, for exterior materials, CIELAB color
testing (see 11.2) shall be injection molded in accordance with
difference, 10° observer, Illuminant D65, specular included, ∆E =
the following specific procedures:
3.0 max.
8 = Colorfastness by SAE J1767, for interior materials, CIELAB color
NOTE 11—Physical and mechanical properties are dependent upon the
difference, 10° observer, Illuminant D65, specular included, ∆E =
technique of specimen preparation. Specimen preparation by means other
2.5 max.
than those described as follows can lead to significant variation in test
D4101 − 24
results, with resultant departure from specification values.
nique shall only be used after a correlation between the
NOTE 12—Limited data have shown that, for Polypropylenes, mechani-
needle-type pyrometer and the infrared pyrometer has been
cal test values can be significantly affected by the cross sectional area of
established. This correlation shall be verified at least every six
the runner. Specimens molded using the specified minimum runner size of
months. The correlation shall be re-established each time either
5 mm D (~20 mm ) exhibited lower values of most mechanical properties
pyrometer is recalibrated.
than specimens molded using runners with cross-sectional areas of 50 and
80 mm . Higher viscosity (lower MFR) materials appear to be more
11.1.5 Back Pressure—The back pressure shall be set at 0.7
sensitive. This effect needs to be considered when comparing data
MPa (gage).
obtained from different sources.
11.1.6 Injection Pressure and Speed—All materials less
11.1.1 Specimen Mold—Molds designed in compliance with
than 30-g/10 min melt flow shall be molded using a single
Practice D3641 to mold the following test specimens:
stage pressure. For a given machine and a given mold, the
11.1.1.1 A Test Method D638, Type I tension test specimen
injection pressure and the injection speed controls shall be set
with a thickness of 3.2 6 0.1 mm.
to produce equal part weights, including sprue and runners
11.1.1.2 A rectangular bar, with dimensions of 127 mm by
(62 %) regardless of material flow rates. The injection speed
12.7 mm by 3.2 6 0.1 mm.
and injection pressure shall be set to minimize sink and flash.
11.1.1.3 Plate, with minimum dimensions of 100 mm or
The maximum amount of flash shall not exceed 1 mm and will
100-mm diameter with a thickness of 3.2 6 0.2 mm.
only be acceptable in the nontesting area. Once the injection
11.1.2 Mold Temperature—The temperature of the mold
speed and pressure are determined for a given machine and
shall be 60 6 3°C. Temperature measurements shall be made
mold they shall not be varied by more than 62 %. A single
in each cavity of the mold after machine conditions are at
stage pressure can be obtained in two different ways.
equilibrium and shall be made with a surface-type pyrometer,
11.1.6.1 Set the injection pressure to a specified pressure
or equivalent, to an accuracy of 62°C after equilibrium or
then allow a shift over to a hold pressure; the hold pressure
cycle conditions have been established.
maintains the pressure at the maximum pressure generated by
11.1.3 Cycle—The total molding cycle time shall be 45 s,
the injection pressure, fill the cavity using hold pressure only.
consisting of 20-s injection, 20-s cooling, and 5-s mold open.
11.1.6.1.1 Discussion—The first method is the preferred
11.1.4 Melt Temperature—The melt temperature for mold-
method. For materials with melt flow rates above 30 g/10 min,
ing test specimens for materials with melt flows of 1 to 30 g/10
different injection and hold pressures are permitted. Normally
min shall correlate with the polymer melt flow (Test Method
the hold pressure is set lower than the injection pressure, but
D1238, Condition 230/2.16) as shown in Table 1. Melt
must be high enough to finish filling out the molded part. It is
temperatures shall be measured on cycle by taking the tem-
recommended that, for these high melt flow rate materials, the
peratures of several successive free shots with a needle-type
manufacturer be contacted for guidance in establishing the
pyrometer, or equivalent, to an accuracy of 63°C.
injection and hold pressures. It is also recommended that screw
rotation speed be set to a minimum to allow the screw to rotate
NOTE 13—The needle should be moved around in the plastic mass, and
for 17 to 19 s of the 20-s cooling time. This slower screw speed
a sufficient number of measurements be made to establish a reliable result.
To minimize heat loss from the plastic during measurement, the mass will provide greater uniformity of the melt with respect to
should be collected in a heated container, or in one made from material of
viscosity and temperature. If necessary, adjust the screw
low thermal conductivity. The quantity of plastic in the free shot should be
rotation speed for the various material types in order to achieve
controlled to be equivalent to the weight of a complete injection-molded
the 17 to 19-s time frame. The rate of screw movement
shot.
backwards away from the mold is dependent on the back
11.1.4.1 To avoid excessive thermal history the shot size
pressure, frictional effects, various additive types, and melt
shall be kept to a minimum and the cushion shall be 5 to 10
viscosity.
mm.
11.1.7 Reporting—Report the injection molding conditions
11.1.4.2 For materials with melt flows less than 1 g/10 min,
in accordance with Practice D3641.
raise the temperature of the melt in 5°C increments from 250°C
11.2 Prepare test specimens for heat stability testing in
until the part weight of the entire shot is equivalent to the part
accordance with Test Method D3012.
weight of a 1 to 5-g/10 min material.
NOTE 14—Due to degradation and thermal expansion of the material,
12. Conditioning
the melt temperature should not exceed 270°C. If unable to obtain the
weight at 270°C, slight adjustments can be made in the injection pressure
12.1 Conditioning:
to achieve the proper weight.
12.1.1 Once specimens are molded, they shall be moved to
11.1.4.3 The melt temperature shall be 190°C for materials a standard laboratory atmosphere or a controlled laboratory
with melt flows greater than 30 g/10 min. atmosphere. For natural unfilled polypropylene the controlled
11.1.4.4 Since the needle-type pyrometer technique is some- laboratory atmosphere shall be 23 6 2°C. Specimens shall be
what tedious, a second technique using an infrared pyrometer stored in storage medium, such as boxes, paper bags or
is an acceptable alternative. The infrared pyrometer used must envelopes, plastic bags, or racks, whichever is most practical
have an accuracy of 1 % of reading or 62°C, whichever is for the laboratory storing the specimens. It is recommended
smaller, a response time of at least 0.5 s, and a distance to that specimens be allowed to cool for about 30 min on a bench
target ratio of at least 30:1. It is recommended that the infrared or in a rack before they are placed in any container where the
pyrometer have a laser beam to establish the position being specimens might come in contact with each other. For filled
measured on the molten mass of polymer. This second tech- and reinforced polypropylene or polypropylene blends, which
D4101 − 24
contain a hydrophilic comonomer or modifier the specimens 13.1.1 Flow Rate—Condition 230/2.16 of Test Method
shall be conditioned in a standard laboratory atmosphere of 23 D1238. Make two determinations on the material in the form
6 2°C and 50 6 10 % relative humidity, unless sufficient that it is to be molded (such as powder, pellets, or granules).
testing has been conducted that indicates that specific material
NOTE 17—This test method serves to indicate the degree of uniformity
type’s properties are not affected by humidity. In those cases,
of the flow rate of the polymer of a single manufacturer as made by an
the storage medium can be the same as for unfilled materials.
individual process and, in this case, is only indicative of the degree of
Materials whose properties are affected by humidity, must be uniformity of molded specimens, and therefore other properties. However,
uniformity of flow rate among various polymers of various manufacturers
stored in accordance with Practice D618, Procedure A. For all
as made by various processes does not, in the absence of other tests,
materials to be conditioned for electrical testing, conditioning
indicate uniformity of other properties and vice versa.
shall comply with the requirements of the standard test
13.1.2 Measurement of Test Specimen Dimensions—The
methods for electrical testing. In all cases the laboratory shall
width and thickness of the test specimen shall be measured to
report both the temperature and humidity conditions during the
an incremental discrimination of at least 0.025 mm. Measure-
conditioning period.
ments shall be made with a micrometer, preferably with
12.1.2 When the temperature in the molding area exceeds
ratchet, having a movable circular contact foot and a lower
28°C or the humidity level exceeds 60 % (applicable only to
anvil foot, both 6.35 6 0.025 mm in diameter. Specimens shall
materials that contain a hydrophilic comonomer or modifier)
be measured in accordance with Test Methods D5947.
specimens shall be moved as quickly as possible to the
13.1.3 Tensile Stress (Yield)—Test Type I specimens using
standard laboratory atmosphere.
Test Method D638. The material shall be tested at 50 mm/min
12.1.3 Testing, except for those tests where a test time is
when the material is one that shows a breaking strain greater
specified, shall be conducted not less than 40 h after molding.
than 10 %, or at 5 mm/min when the material breaks at a strain
The aging times as specified in this and subsequent sections
equal to or less than 10 %.
shall apply to all testing conducted for development of a line
13.1.4 Flexural Modulus (1 % Secant)—Test Methods
callout, data for publication, or for cases of dispute over testing
values. D790, Method I, Procedure A, with a 50-mm span, a 5.0 6
0.1-mm radius support and loading nose, and a 1.3-mm/min
12.1.4 Specimens that are to be tested for Izod or Charpy
impact shall be notched within 1 to 16 h after molding. Once testing speed using the center test region of a Test Method
D638, Type I specimen. It is mandatory that the toe correction
notched the specimens shall condition for a minimum of 40 h
before testing. be made to correct for the slack in the test fixture and load cell.
Center the specimen between the span flatwise and test with a
NOTE 15—Data have shown that, for some polypropylene impact
crosshead speed of 1.3 mm/min. Calculate the average value of
copolymers with higher xylene solubles or higher rubber content, Izod
the flexural modulus (1 % secant) at 1 % strain in the outer
impact values can vary significantly over time.
surface of the test specimen.
12.1.5 Specimens that are to be tested for tensile or flexural
properties shall be tested within 40 to 96 h after molding.
NOTE 18—If the Test Method D638 Type I specimens were molded on
a mold containing a draft angle, the specimens will be trapezoidal. It is
NOTE 16—Polypropylene properties change with time as a result of
possible that the flexural modulus will vary slightly depending on which
amorphous densification and, in some cases, due to a small degree of
side is placed away from the loading nose.
secondary crystallization in the rubbery phase.
13.1.4.1 Calculate the deflection of the test specimen corre-
12.2 Test Conditions—Natural unfilled polypropylene shall
sponding to 1 % strain (0.01 mm/mm) as follows:
be tested in a controlled laboratory atmosphere of 23 6 2°C.
D 5 rL /6d (1)
For filled and reinforced polypropylene and polypropylene
blends, which contain a hydrophilic comonomer or modifier
where:
the specimens shall be tested in a standard laboratory atmo-
D = deflection of the center of the test specimen at 1 %
sphere of 23 6 2°C and 50 6 10 % relative humidity, unless
strain, mm
sufficient testing has been conducted that indicates that specific
r = strain in the outer surface of the test specimen = 0.01
materials type’s properties are not affected by humidity. For all
mm/mm,
materials to be tested for electrical properties, the laboratory
L = test span = 50 mm, and
shall comply with the requirements of the standard test
d = specimen depth = 3.2 mm (nominal).
methods for electrical testing. In all cases the laboratory shall
Warning—The load measured must be a minimum of 1 %
report both the temperature and humidity conditions during
of the load cell capacity. The test span shall be known to an
testing.
accuracy of 0.05 mm, and this value shall be used in the
calculations in 13.1.4.1. The loading nose shall be precisely
13. Test Methods
centered between the supports. The test specimen shall be
13.1 Determine the properties enumerated in this specifica-
aligned perpendicular to the supports to an accuracy of 2° and
tion in accordance with the ASTM test methods as they apply,
the center of the specimen shall be directly below the center of
unless otherwise stated herein.
the loading nose.
13.1.4.2 Calculate the stress corresponding to 1 % strain as
follows:
Supporting data have been filed at ASTM International Headquarters and may
be obtained by requesting Research Report RR:D20-1213. S 5 3PL/2bd (2)
D4101 − 24
where: specifications detailed in the Tables shall be based on a
material having a complete, hinge, or partial break.
S = stress in the outer surface of the test specimen at 1 %
13.1.6 Deflection Temperature—Test Method D648 shall be
strain, MPa,
used to test a rectangular specimen 3.2 by 12.7 by 127 mm with
P = load corresponding to 1 % strain, N
a load applied at the center to give maximum fiber stresses of
L = test span = 50 mm,
d = specimen depth = 3.2 mm (nominal), and
455 kPa.
b = specimen width = 12.7 mm (nominal).
13.1.7 Multiaxial Impact Ductile-Brittle Transition
Temperature—Test Method D3763 shall be used to test speci-
The secant modulus at 1 % strain is the ratio of stress to
mens equal to or greater in dimensions than 100 mm or 100
strain or S/0.01.
mm in diameter and 3.2 6 0.2 mm in thickness. The test speed
13.1.5 Impact Resistance (Izod)—Test Method D256 (A)
shall be 2.2 m/s with the 12.7-mm diameter impact dart and
shall be used for notched specimens tested at 23°C. Specimens
76-mm support ring. The temperature at which 80 % of the
shall be cut from the center section of the Test Method D638,
specimens exhibit ductile failure shall be determined based on
Type I tensile test specimen. Before cutting the test specimen
the definitions listed in Section 3. This temperature shall be
from the tensile bar, draw a symbol of any design in the straight
determined by either a standard graphical method or through a
center section of the bar to indicate which is the gate end of the
probability graphical method. When using the standard graphic
specimen. Cut out the 57.2 mm straight center-section of the
method to determine the 80 % passing temperature, it is
bar. The specimens shall be notched in accordance with Test
necessary to repeat this procedure of testing ten specimens at a
Method D256 for tests at 23°C. Specimens shall be notched
series of temperatures differing by uniform increments of 5°C.
such that the notch is off-center on the 57.2 6 1 mm long
The transition region of the curve shall be established using
specimen. When notched, the apex of the notch shall be 25.4 6
either 5°C or 10°C increments, but -5°C increments must be
2 mm from the non-gated end and 31.8 6 1 mm from the gated
used when testing in the transition temperature region. When
end of the specimen. The more critical dimension is the 31.8 6
using probability graph paper, it is not necessary to obtain the
1 mm from the gated end of the specimen. Notched specimens
lowest no-failure temperatures, at which no failure is obtained,
must be conditioned after notching for a minimum of 40 h
or the highest failure temperature. Draw a straight line through
before testing. The specimen shall be inserted in the clamp with
a minimum of four points, two above and two below the 50 %
the 25.4 6 2 mm in the clamp and the 31.8 6 1 mm length
failure point. The temperature indicated at the intersection of
above the clamp. When testing, the specimen shall be clamped
the data line with the 20 % failure line shall be reported as the
in the grips with the minimum pressure necessary to prevent
ductile-brittle temperature or 80 % passing temperature.
any movement of the specimen upwards or downwards during
impact.
NOTE 21—In addition to visually examining the plaques for ductile
failure, review the load versus time or load versus displacement curve for
13.1.5.1 Should this pressure deform the specimen, reduce
the impact for signs of ductility.
the clamp pressure and note this in the report.
13.1.8 Reinforcement and Additive Concentrations:
NOTE 19—Although the 57.2 mm length of specimen does not comply
13.1.8.1 Glass Percentage—Use Test Method D2584.
with the minimum specimen length of 61.5 mm specified by Test Method
13.1.8.2 All Others—Method to be specified.
D256, studies with numerous types of polypropylene specimens has
shown that clamp lengths as short as 19 mm are acceptable, with no 13.1.8.3 Additional testing methods and conditions, refer to
change in test results. What is critical is that the length of material above
Appendix X1.
the clamp, which is specified as 31.8 6 1 mm. Failure to maintain the 31.8
6 1 mm above the clamp will result in reduced or increased Izod impact
14. Inspection and Certification
values depending on whether the specimen length above the clamp is
longer or shorter than that specified by Test Method D256, Method A.
14.1 Inspection and certification of the material supplied
NOTE 20—With the design of each clamping system and the capacity of
with reference to a specification based on this classification
the pendulum used different from instrument to instrument it is difficult to
system shall be for conformance to the requirements specified
specify a pressure, which will hold the specimen securely. What is
herein.
important is that the clamp pressure be maintained constant from
specimen to specimen and be sufficient to prevent specimen movement
14.2 Lot-acceptance inspection shall be the basis on which
during the impact. Too low a clamp pressure may result in slightly higher
accept
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