Multifaceted Evaluation of Plastics: Differences due to PC/ABS Resin Compounding Ratio

Importance of the Topic

Polycarbonate ABS blends are widely used in automotive interior parts electronic housing and industrial components because they combine heat resistance impact strength and moldability. Precise control of the compounding ratio is critical to ensure consistent mechanical thermal and optical performance of the final product and to avoid quality deviations during large scale manufacturing.

Study Objectives and Overview

This study aimed to evaluate how varying the PC ABS ratio in molded specimens affects color thermal mechanical and microscopic properties. Five compositions ranging from pure ABS to pure PC were prepared. The relationship between input compounding ratio and the actual composition after molding was assessed. Multifaceted measurements were performed to establish predictive correlations and improve quality control of molded parts.

Methodology

Specimens with PC ABS ratios of 0 25 50 75 and 100 percent were produced by sequential kneading and injection molding under controlled temperature and time conditions. The influence of processing factors on final composition was monitored. Measurements covered optical reflection hardness tensile thermal transition and chemical composition.

Used Instrumentation

• UV 2600i UV Vis spectrophotometer with integrating sphere for yellowness index
• DUH 210 dynamic ultra micro hardness tester with Berkovich indenter
• AGX V precision universal testing machine with noncontact extensometer
• DSC 60 Plus differential scanning calorimeter for thermal transitions
• IRTracer 100 FTIR spectrophotometer with diamond ATR accessory
• SPM Nanoa scanning probe microscope Nano 3D mapping fast mode for microscopic hardness distribution

Main Results and Discussion

Measurements showed a linear increase in yellowness index with higher ABS content due to increased light absorption in the visible range Reflectance spectra confirmed this trend. Indentation hardness rose with PC content but deviated from strict linearity above 75 percent PC. Tensile strength and breaking elongation increased with PC ratio and displayed near linear relationships making them suitable for composition prediction Elastic modulus peaked between 50 and 75 percent PC. DSC analysis revealed two distinct glass transition temperatures corresponding to ABS and PC. Both transitions correlated linearly with PC fraction enabling estimation of blend composition. FTIR peak intensity at 1770 cm 1 increased proportionally with PC content confirming quantitative composition analysis. SPM images illustrated phase dispersion morphology matching the nominal compounding ratios and highlighted the island matrix structure at different blend ratios.

Benefits and Practical Applications

Establishing linear correlations between blend ratio and multiple material properties enables rapid non destructive estimation of composition in molded parts Reduced reliance on a single control criterion lowers risk of misjudgment in quality control Multifaceted evaluation enhances process monitoring and supports predictive adjustment of raw material feeds during production improving consistency of final products.

Future Trends and Opportunities

Further research may explore advanced image analysis of phase morphology with machine learning to link microstructure to mechanical performance in real time Inline spectroscopic monitoring combined with predictive models could enable closed loop control of blend ratios in injection molding Integration of new sensor technologies may facilitate automated quality assurance and optimized formulations for emerging polymer composites.

Conclusion

This multifaceted study demonstrated that optical mechanical thermal and spectroscopic measurements provide reliable linear indicators of PC ABS blend composition after molding. Combined evaluation of yellowness tensile strength DSC transitions and FTIR signals allows accurate prediction of material ratio and supports enhanced quality control in industrial applications.