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Designation: D4101 – 10a

Standard Specification for

Polypropylene Injection and Extrusion Materials1
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 Department of Defense.

INTRODUCTION

This specification 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 of these materials is to be made by
personnel with expertise in the plastics field where the environment, inherent properties of the
materials, performance of the part, part design, manufacturing process, and economics are considered.

1. Scope* of this standard to establish appropriate safety and health

1.1 This specification covers polypropylene materials suit- practices and determine the applicability of regulatory limita-
able for injection molding and extrusion. Polymers consist of tions prior to use.
homopolymer, copolymers, and elastomer compounded with or NOTE 2—There is no known ISO equivalent to this standard.
without the addition of impact modifiers (ethylene-propylene
rubber, polyisobutylene rubber, and butyl rubber), colorants, 2. Referenced Documents
stabilizers, lubricants, or reinforcements. 2.1 ASTM Standards:2
1.2 This specification allows for the use of those polypro- C177 Test Method for Steady-State Heat Flux Measure-
pylene materials that can be recycled, reconstituted, and ments and Thermal Transmission Properties by Means of
reground, provided that: (1) the requirements as stated in this the Guarded-Hot-Plate Apparatus
specification are met, and (2) the material has not been D149 Test Method for Dielectric Breakdown Voltage and
modified in any way to alter its conformance to food contact Dielectric Strength of Solid Electrical Insulating Materials
regulations or similar requirements. The proportions of re- at Commercial Power Frequencies
cycled, reconstituted, and reground material used, as well as D150 Test Methods for AC Loss Characteristics and Per-
the nature and the amount of any contaminant, cannot be mittivity (Dielectric Constant) of Solid Electrical Insula-
practically covered in this specification. It is the responsibility tion
of the supplier and the buyer of recycled, reconstituted, and D256 Test Methods for Determining the Izod Pendulum
reground materials to ensure compliance. (See Guide D7209.) Impact Resistance of Plastics
1.3 The values stated in SI units are to be regarded as the D257 Test Methods for DC Resistance or Conductance of
standard. Insulating Materials
NOTE 1—The properties included in this specification are those re- D495 Test Method for High-Voltage, Low-Current, Dry Arc
quired to identify the compositions covered. There may be other require- Resistance of Solid Electrical Insulation
ments necessary to identify particular characteristics important to specific D523 Test Method for Specular Gloss
applications. These will be designated by using the suffixes given in D543 Practices for Evaluating the Resistance of Plastics to
Section 1. Chemical Reagents
1.4 The following safety hazards caveat pertains only to the D570 Test Method for Water Absorption of Plastics
test methods portion, Section 13, of this specification: This D618 Practice for Conditioning Plastics for Testing
standard does not purport to address all of the safety concerns, D635 Test Method for Rate of Burning and/or Extent and
if any, associated with its use. It is the responsibility of the user Time of Burning of Plastics in a Horizontal Position
D638 Test Method for Tensile Properties of Plastics
D648 Test Method for Deflection Temperature of Plastics
1
This specification is under the jurisdiction of ASTM Committee D20 on
Plastics and is the direct responsibility of Subcommittee D20.15 on Thermoplastic
2
Materials. For referenced ASTM standards, visit the ASTM website, www.astm.org, or
Current edition approved Nov. 1, 2010. Published January 2011. Originally contact ASTM Customer Service at [email protected]. For Annual Book of ASTM
approved in 1982. Last previous edition approved in 2010 as D4101 - 10. DOI: Standards volume information, refer to the standard’s Document Summary page on
10.1520/D4101-10A. 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.

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D4101 – 10a
Under Flexural Load in the Edgewise Position D3835 Test Method for Determination of Properties of
D695 Test Method for Compressive Properties of Rigid Polymeric Materials by Means of a Capillary Rheometer
Plastics D3892 Practice for Packaging/Packing of Plastics
D696 Test Method for Coefficient of Linear Thermal Ex- D4000 Classification System for Specifying Plastic Materi-
pansion of Plastics Between Ø30°C and 30°C with a als
Vitreous Silica Dilatometer D4329 Practice for Fluorescent UV Exposure of Plastics
D732 Test Method for Shear Strength of Plastics by Punch D4364 Practice for Performing Outdoor Accelerated Weath-
Tool ering Tests of Plastics Using Concentrated Sunlight
D746 Test Method for Brittleness Temperature of Plastics D4805 Terminology for Plastics Standards3
and Elastomers by Impact D4812 Test Method for Unnotched Cantilever Beam Impact
D785 Test Method for Rockwell Hardness of Plastics and Resistance of Plastics
Electrical Insulating Materials D5279 Test Method for Plastics: Dynamic Mechanical
D790 Test Methods for Flexural Properties of Unreinforced Properties: In Torsion
and Reinforced Plastics and Electrical Insulating Materials D5420 Test Method for Impact Resistance of Flat, Rigid
D792 Test Methods for Density and Specific Gravity (Rela- Plastic Specimen by Means of a Striker Impacted by a
tive Density) of Plastics by Displacement Falling Weight (Gardner Impact)
D883 Terminology Relating to Plastics D5630 Test Method for Ash Content in Plastics
D1238 Test Method for Melt Flow Rates of Thermoplastics D5740 Guide for Writing Material Standards in the Classi-
by Extrusion Plastometer fication Format
D1435 Practice for Outdoor Weathering of Plastics D5947 Test Methods for Physical Dimensions of Solid
D1505 Test Method for Density of Plastics by the Density- Plastics Specimens
Gradient Technique D6110 Test Method for Determining the Charpy Impact
D1525 Test Method for Vicat Softening Temperature of Resistance of Notched Specimens of Plastics
Plastics D6290 Test Method for Color Determination of Plastic
D1531 Test Methods for Relative Permittivity (Dielectric Pellets
Constant) and Dissipation Factor by Fluid Displacement D7209 Guide for Waste Reduction, Resource Recovery, and
Procedures Use of Recycled Polymeric Materials and Products
D1600 Terminology for Abbreviated Terms Relating to E29 Practice for Using Significant Digits in Test Data to
Plastics Determine Conformance with Specifications
D1822 Test Method for Tensile-Impact Energy to Break E313 Practice for Calculating Yellowness and Whiteness
Plastics and Electrical Insulating Materials Indices from Instrumentally Measured Color Coordinates
D1898 Practice for Sampling of Plastics3 E831 Test Method for Linear Thermal Expansion of Solid
D2117 Test Method for Melting Point of Semicrystalline Materials by Thermomechanical Analysis
Polymers by the Hot Stage Microscopy Method3 2.2 Military Standard:
D2240 Test Method for Rubber Property—Durometer MIL-STD-105 Sampling Procedure and Tables for Inspec-
Hardness tion by Attributes4
D2565 Practice for Xenon-Arc Exposure of Plastics In- 2.3 DOT Standard:
tended for Outdoor Applications MVSS-302 Federal Motor Vehicle Safety Standard 302
D2584 Test Method for Ignition Loss of Cured Reinforced Flammability of Interior Materials5
Resins 2.4 UL Standard:
D2863 Test Method for Measuring the Minimum Oxygen UL 94 Standard for Tests for Flammability of Plastic
Concentration to Support Candle-Like Combustion of Materials for Parts in Devices and Appliances6
Plastics (Oxygen Index) 2.5 SAE Standards:7
D2990 Test Methods for Tensile, Compressive, and Flex- SAE J1545 Instrumental Color Difference Measurement for
ural Creep and Creep-Rupture of Plastics Exterior Finishes, Textiles and Color Trim
D3012 Test Method for Thermal-Oxidative Stability of SAE J1767 Instrumental Color Difference Measurement for
Polypropylene Using a Specimen Rotator Within an Oven Colorfastness of Automotive Interior Trim Materials
D3418 Test Method for Transition Temperatures and En- SAE J1885 Accelerated Exposure of Automotive Interior
thalpies of Fusion and Crystallization of Polymers by Materials Using Controlled Irradiance Water Cooled
Differential Scanning Calorimetry Xenon-Arc Apparatus
D3641 Practice for Injection Molding Test Specimens of
Thermoplastic Molding and Extrusion Materials 4
Available from Standardization Documents Order Desk, Bldg. 4 Section D, 700
D3763 Test Method for High Speed Puncture Properties of Robbins Ave., Philadelphia, PA 19111-5094.
Plastics Using Load and Displacement Sensors 5
Available from U.S. Dept. of Transportation, National Highway Traffic Safety
D3801 Test Method for Measuring the Comparative Burn- Administration, Office of Public Affairs and Consumer Participation, 400 7th St.,
ing Characteristics of Solid Plastics in a Vertical Position SW, Washington, DC 20590.
6
Available from Underwriters Laboratories (UL), 333 Pfingsten Rd., North-
brook, IL 60062-2096, http://www.ul.com.
7
Available from Society of Automotive Engineers (SAE), 400 Commonwealth
3
Withdrawn. Dr., Warrendale, PA 15096-0001, http://www.sae.org.

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D4101 – 10a
SAE J1960 Accelerated Exposure of Automotive Exterior mers) having no functional group other than the olefinic group
Materials Using Controlled Irradiance Water Cooled copolymerized with propylene. Polypropylene random copoly-
Xenon-Arc Apparatus mers containing more than one additional monomer are often
SAE J1976 Outdoor Weathering of Exterior Materials called “terpolymers.”
3. Terminology
4. Classification
3.1 Definitions— See Terminologies D883 and D4805 for
4.1 Unreinforced polypropylene materials are classified into
definitions of terms related to this specification.
groups according to basic composition. These groups are
3.2 Definitions of Terms Specific to This Standard:
subdivided into classes and grades, as shown in Table PP.
3.2.1 back pressure, n—the constant pressure that is applied
to the end of the screw while the screw is rotating and NOTE 3—An example of this classification system is as follows. The
retracting to prepare for the next injection. designation PP0113 would indicate: PP = polypropylene, as found in
3.2.2 brittle failure, n—one where the specimen test area is Terminology D1600, 01 (group) = homopolymer, 1 (class) = general
broken into two or more pieces, with sharp edges and shows purpose, and 3 (grade) = with requirements given in Table PP.
almost no plastic flow. 4.1.1 To facilitate the incorporation of future or special
3.2.3 cooling time, n—the time in which the material is in materials not covered by Table PP, the “other/unspecified”
the closed mold with no pressure applied. category for group (00), class (0), and grade (0) is shown on the
3.2.4 cycle time, n—the time required to complete a full table with the basic properties to be obtained from Table A,
injection molding cycle, including injection time, cooling time, Table B, Table C, Table G, Table H, and Table T, as they apply
and mold open time. (see 4.3).
3.2.5 ductile brittle transition temperature, n—the tempera- 4.2 Reinforced versions of the polypropylene materials are
ture at which a 80% of the specimens exhibit ductile failure classified in accordance with Table PP, Table A, Table C, Table
3.2.6 ductile failure, n—one where the specimen deforms G, and Table T. Table PP, Table B, and Table H specify the
plastically before fracturing. One where the puncture of the test properties of the unreinforced material, and Tables A, C, G, or
plaque does not have cracks radiating more than 10 mm T specify the properties after the addition of reinforcements,
beyond the center of the impact point. pigments, fillers, or lubricants, at the nominal level indicated
3.2.7 injection pressure, n—the constant pressure that is (see 4.2.1)
applied to the end of the screw causing the melted material to 4.2.1 Reinforcements and Additive Materials—A symbol
fill the mold. The injection pressure along with the injection (single letter) will be used for the major reinforcement or
speed determines the volumetric fill rate of the mold. combinations thereof, along with two numbers that indicate the
3.2.8 injection speed, n—the forward velocity of the screw percentage of addition by mass, with the tolerances as tabu-
during the injection step. lated as follows:
3.2.8.1 Discussion—Injection speed is a set position on the
Symbol Material Tolerance
injection molding machine ranging from slow to fast. The G Glass reinforced—
injection speed along with the injection pressure determines the <15 % 62 percentage points
volumetric fill rate of the mold. >15 % 63 percentage points
L Lubricant (that is, graphite, to be specified
3.2.9 injection time, n—the time in which a constant speci- silicone, and stearates)
fied pressure is applied to the melted material. M Mineral-reinforced—
<15 % 62 percentage points
3.2.10 melt temperature, n—the temperature of the material
>15 % 63 percentage points
as it is being injected into the mold, measured by a pyrometer. R Reinforced-combinations/ 63 percentage points based on
3.2.11 mold open time, n—the time beginning when the mixtures of reinforcements the total reinforcement
or other fillers/reinforcements
mold is opened and ending when the mold is closed.
3.2.12 mold temperature, n—the temperature of the mold NOTE 4—This part of the system uses the type and percentage of
during the molding cycle, measured in all mold cavities and on additive to designate the modification of the base material. To facilitate
both platens. this designation, the type and percentage of additive can be shown on the
3.2.13 polypropylene (PP)—a propylene plastic prepared by supplier’s Technical Data Sheet, unless it is proprietary in nature. If
necessary, additional requirements shall be indicated by the use of the
the polymerization of propylene or propylene with other alpha suffix part of the system as given in Section 5.
olefins. (See also PP-B, PP-H, and PP-R.)
3.2.14 polypropylene heterophasic copolymers (PP-B, 4.2.2 Specific requirements for reinforced, pigmented,
PP+EPR, or PP+EPDM)—a propylene plastic consisting of filled, or lubricant polypropylene materials will be shown by a
two or more separate phases. The phases consist of a polypro- six-character designation. The designation will consist of the
pylene homopolymer (PP-H) or a polypropylene random letter A, B, C, G, or T and the five digits comprising the cell
copolymer (PP-R) matrix containing a dispersed olefinic elas- numbers for the property requirements in the order in which
tomer having no other functional group, added in situ or they appear in Table A, Table B, Table C, Table G, or Table T.
physically blended into the polypropylene matrix. For Table H the designation will consist of the letter H and
3.2.15 polypropylene homopolymer (PP-H)—a propylene three digits comprising the cell numbers for the property
plastic prepared by the polymerization of propylene only. requirements in the order in which they appear in Table H.
3.2.16 polypropylene random copolymer (PP-R)—a propy- 4.2.2.1 Although the values listed are necessary to include
lene plastic containing another olefinic monomer (or mono- the range of properties available in existing materials, they

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D4101 – 10a
should not be interpreted as implying that every possible those requirements shall be designated through the use of
combination of the properties exists or can be obtained. suffixes. The primary suffix list can be found in Suffix
4.2.3 When the grade of the basic materials is not known or Requirements, Section 7, of Classification D4000. Other suf-
is not important, the use of “0” grade classification will be used fixes that pertain only to the material requirements in this
for reinforced materials in this system. (See Note 5.) specification are listed as follows. In general, the suffix letter
NOTE 5—An example of this classification system for a reinforced-
indicates the requirement needed; the first number (digit)
polypropylene material is as follows. The designation PP0110M20A21130 indicates the test condition, and the second number (digit)
would indicate the following, with the material requirements from Table indicates the specimen requirement.
A:
NOTE 9—Suffixes from Classification D4000 will contain two letters
followed by three digits while suffixes from this specification will contain
PP0110 = General-purpose polypropylene homopolymer from Table a single letter followed by two or three numbers. An example would be
PP weatherability; a designation of WA510 would indicate that it is a
M20 = Mineral reinforced, 20 %, Classification D4000 suffix with the following requirements:
A = Table A property requirements.
2 = 35-MPa tensile stress, min,
1 = 1000-MPa flexural modulus (1 % secant), min, W = Weather resistant,
1 = 15-J/m Izod impact, min, A = Practice D1435,
3 = 110°C deflection temperature, min, and 5 = Elongation properties, and
0 = Unspecified. 10 = 10 % change.
If no properties are specified, the designation would be PP0110M20- A designation of W110 would indicate that it is a Specification D4101
A00000. suffix with the following requirements:

4.3 Table B has been incorporated into this specification to

facilitate the classification of special materials where Table PP W = Weatherability,
1 = Practice D2565, Test Cycle 1, specimens exposed in a xenon-arc
does not reflect the required properties of that unreinforced
accelerated test apparatus,
material. This table will be used in a manner similar to Tables 1 = 200-h exposure, and
A, C, G, and T. Table H has been incorporated into this 0 = Change in properties to be specified.
specification to improve the callout of random copolymers and Suffıxes:
impact copolymers. Table H has a reduced callout based on
flexural modulus, Izod impact, and the Multiaxial Impact
Ductile-Brittle Transition Temperature. If a full line callout is E = Electrical requirements as designated by the following digits:
First Digit
required, use Table B. 0 = To be specified by user.
NOTE 6—Mechanical properties of polypropylene materials with pig- 1 = Specimens preconditioned 40 h at 23°C and 50 % relative
ments or colorants can differ from the mechanical properties of natural humidity, then 14 days in distilled water at 23 6 1°C.
material, depending on the choice and the concentration. Second Digit
NOTE 7—An example of a special material using this classification 0 = To be specified by user.
1 = Insulation resistance, dielectric constant, and dissipation factor
system is as follows. The designation PP0110B67253 would indicate the
meet property limits as shown below. These are electrical limits
following with the material requirements from Table B:
usually applied to unreinforced polypropylene when control of
their electrical properties is required.
PP0110 = homopolymer, general purpose, other, Electrical Properties:
B = Table B property requirements, Dielectric constant, Test Methods D1531 or 2.30
6 = 30-MPa tensile stress at yield, min, max D150
7 = 1500-MPa flexural modulus, min, Dissipation factor, max Test Methods D1531 0.0005
2 = 50-J/m Izod impact resistance, min, Insulation resistance, Test Methods D257 1 3 1015
5 = 90°C deflection temperature, min, and min, V
3 = >1.0 to 3.0 nominal melt flow rate. Water immersion Test Methods D1531 or Shall meet the di-
stability D150 electric constant
NOTE 8—An example of a polypropylene copolymer material using and dissipation
Table H would be as follows. The designation PP0500H585 would factor require-
indicate a material with the following requirements: ments

W = Weatherability requirements as designated by the following digits:

PP0500 = copolymer or impact modified, First Digit
H = Table H property requirements,
5 = 1200-MPa flexural modulus, min,
0 = To be specified.
8 = Izod impact resistance, non-break failure mode, no value
1 = Specimens exposed in a xenon arc accelerated test apparatus that
reported, and
conforms to Practice D2565 using Test Cycle 1 for exterior
5 = <–30°C ductile-brittle transition temperature
applications.
2 = Specimens exposed in a fluorescent UV/condensation acceler-
5. Suffixes ated test apparatus that conforms to Practice D4329 using Test
5.1 When additional requirements are needed for the mate- Cycle A for exterior applications.
rials covered in this specification that are not covered in Table 3 = Specimens exposed in a xenon-arc accelerated test apparatus that
conforms to SAE J1960 or equivalent for exterior applications.
PP, Table A, Table B, Table C, Table G, Table H, and Table T,

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D4101 – 10a
4 = Specimens exposed in a xenon-arc accelerated test apparatus that Z = Other special requirement characteristics (for example, internal
conforms to SAE J1885 or equivalent for interior applications. mold release agent) not covered by existing call-out capabilities
5 = Specimens exposed to concentrated natural sunlight in accor- may be assigned. These will be spelled out in detail and identified
dance with Practice D4364 without water spray. in sequence, that is, 01 UV-stabilized, 02 special color, and 03,
6 = Specimens exposed to concentrated natural sunlight in accor- etc.
dance with Practice D4364 with water spray (Table 1, Cycle 1). Additional suffixes will be added to this specification as test methods
7 = Specimens exposed to natural sunlight in accordance with and requirements are developed or requested, or both.
Practice D1435 using a rack angle of 45° from the horizontal
facing the equator , unless specified otherwise. 6. Basic Requirements
8 = Specimens exposed to natural sunlight in accordance with
SAE J1976 Procedure A, unless specified otherwise. 6.1 Basic requirements from property or cell tables, as they
Second Alphanumeric apply, are always in effect unless these requirements are
0 = To be specified by user. superseded by specific suffix requirements in the “Line Call-
1 = 200-h exposure. Out.”
2 = 500-h exposure.
3 = 1000-h exposure. 7. General Requirements
4 = 2000-h exposure.
5 = 1240.8 kJ/(m2.nm) at 340 nm. 7.1 The plastic composition shall be uniform and shall
6 = 2500 kJ/(m2.nm) at 340 nm. conform to the requirements specified herein. The color and
7 = 1000 MJ/m2 solar total UV irradiation (approximately 3 years). form of the material shall be specified. Note specification
8 = 336-h exposure changes due to the effects of colorants and, when necessary,
9 = 720-h exposure cover them by suffixes.
A = 5000-h exposure
B = 10000-h exposure
7.2 For recycled, reconstituted, and reground materials the
C = 225.6 kJ/(m2.nm) at 340 nm level of contamination by nonpolymeric materials other than
D = 601.6 kJ/(m2.nm) at 340 nm. fillers and additives shall not be of a significant level that it
NOTE 10—Conversion from hours to kilojoules (kJ) varies with irradi- prevents the product from meeting the performance criteria for
ance and the light/dark cycle. Conversion to kJ from actual light hours (h) which it was manufactured.
is based on the following relation:
kJ 5 Irradiance in Watts 3 3.6 kJ/h 3 h of light 8. Detail Requirements
8.1 Test specimens for the various materials shall conform
Thus, at an irradiance level of 0.55 W/(m2.nm) at 340 nm, the multipli- to the requirements prescribed in Table PP, Table A, Table B,
cation factor for converting light hours to kJ is 1.98 (0.55 3 3.6). Table C, Table G, Table H, Table T and to the suffix require-
Therefore, 100 light hours is equivalent to 396 kJ/(m2.nm) at 340 nm at
ments as they apply.
this irradiance level.
Third Alphanumeric 8.2 Observed or calculated values obtained from analysis,
measurement, or test shall be rounded in accordance with
Practice E29 to the nearest unit in the last right-hand place of
0 = To be specified by user. figures used in expressing the specified limiting value. The
1 = The exposed specimens shall not exhibit surface changes (such as
value obtained is compared directly with the specified limiting
dulling and chalking) or deep-seated changes (such as checking,
crazing, warping, and discoloration). value. Conformance or nonconformance with the specification
2 = The tensile strength after exposure must be no less than 50 % of is based on this comparison.
the original.
3 = The tensile strength after exposure must be no less than 90 % of 9. Sampling
the original. 9.1 Unless otherwise specified, the materials shall be
4 = American Association of Textile Chemists and Colorists sampled in accordance with the sampling procedure prescribed
(AATCC) rating 4 to 5.
5 = Colorfastness by SAE J1545, for exterior materials, CIELAB
in Practice D1898. Adequate statistical sampling shall be
color difference, 10° observer, Illuminant D65, specular included, considered an acceptable alternative. A batch or lot of resin
DE = 2.5 max. shall be considered as a unit of manufacture as prepared for
6 = Colorfastness by SAE J1545, for exterior materials, CIELAB shipment and may consist of a blend of two or more production
color difference, 10° observer, Illuminant D65, specular included, runs of material.
DE = 2.0 max.
7 = Colorfastness by SAE J1545, for exterior materials, CIELAB 10. Number of Tests
color difference, 10° observer, Illuminant D65, specular included,
DE = 3.0 max. 10.1 The number of tests conducted shall be consistent with
8 = Colorfastness by SAE J1767, for interior materials, CIELAB the requirements of Section 13.
color difference, 10° observer, Illuminant D65, specular included,
DE = 2.5 max. 11. Specimen Preparation
9 = Colorfastness by SAE J1767, for interior materials, CIELAB 11.1 All test specimens other than those for heat stability
color difference, 10° observer, Illuminant D65, specular included, testing (see 11.2) shall be injection molded in accordance with
DE = 3.0 max.
the following specific procedures:

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D4101 – 10a
NOTE 11—Physical and mechanical properties are dependent upon the correlation between the needle-type pyrometer and the infrared
technique of specimen preparation. Specimen preparation by means other pyrometer has been established. This correlation shall be
than those described as follows can lead to significant variation in test verified at least every six months. The correlation shall be
results, with resultant departure from specification values.
re-established each time either pyrometer is recalibrated.
NOTE 12—Limited data have shown that, for Polypropylenes, mechani-
cal test values can be significantly affected by the cross sectional area of 11.1.5 Back Pressure—The back pressure shall be set at 0.7
the runner. Specimens molded using the specified minimum runner size of MPa (gage).
5 mm D (~20 mm2) exhibited lower values of most mechanical properties 11.1.6 Injection Pressure and Speed—All materials less
than specimens molded using runners with cross-sectional areas of 50 and than 30-g/10 min melt flow shall be molded using a single
80 mm2. Higher viscosity (lower MFR) materials appear to be more stage pressure. For a given machine and a given mold, the
sensitive. This effect needs to be considered when comparing data injection pressure and the injection speed controls shall be set
obtained from different sources.
to produce equal part weights, including sprue and runners
11.1.1 Specimen Mold—Molds designed in compliance (62 %) regardless of material flow rates. The injection speed
with Practice D3641 to mold the following test specimens: and injection pressure shall be set to minimize sink and flash.
11.1.1.1 A Test Method D638, Type I tension test specimen The maximum amount of flash shall not exceed 1 mm and will
with a thickness of 3.2 6 0.1 mm. only be acceptable in the nontesting area. Once the injection
11.1.1.2 A rectangular bar, with dimensions of 127 mm by speed and pressure are determined for a given machine and
12.7 mm by 3.2 6 0.1 mm. mold they shall not be varied by more than 62 %.
11.1.1.3 Plate, with minimum dimensions of 100 mm2 or
NOTE 14—A single stage pressure can be obtained in two different
100-mm diameter with a thickness of 3.2 6 0.2 mm. ways: (1) Injection pressure may be set to reach a specified pressure then
11.1.2 Mold Temperature—The temperature of the mold allowed to shift over to a hold pressure; the hold pressure maintains the
shall be 60 6 3°C. Temperature measurements shall be made pressure at the maximum pressure generated by the injection pressure, and
in each cavity of the mold after machine conditions are at (2) The cavity may be filled using hold pressure only; the first method is
equilibrium and shall be made with a surface-type pyrometer, the preferred method. For materials with melt flow rates above 30 g/10
or equivalent, to an accuracy of 62°C after equilibrium or min the injection and hold pressures may be set to different pressures.
Normally the hold pressure is set lower than the injection pressure, but
cycle conditions have been established.
must be high enough to finish filling out the molded part. For these high
11.1.3 Cycle—The total molding cycle time shall be 45 s, melt flow rate materials the injection and hold pressure shall be specified
consisting of 20-s injection, 20-s cooling, and 5-s mold open. by the manufacturer.
11.1.4 Melt Temperature—The melt temperature for mold- NOTE 15—It is recommended that screw rotation speed be set to a
ing test specimens for materials with melt flows of 1 to 30 g/10 minimum to allow the screw to rotate for 17 to 19 s of the 20-s cooling
min shall correlate with the polymer melt flow (Test Method time. This slower screw speed will provide greater uniformity of the melt
D1238, Condition 230/2.16) as shown in Table 1. Melt with respect to viscosity and temperature. It may be necessary to adjust the
screw rotation speed for the various material types in order to achieve the
temperatures shall be measured on cycle by taking the tem-
17 to 19-s time frame. The rate of screw movement backwards away from
peratures of several successive free shots with a needle-type the mold is dependent on the back pressure, frictional effects, various
pyrometer to an accuracy of 63°C. The needle should be additive types, and melt viscosity.
moved around in the plastic mass, and a sufficient number of
measurements be made to establish a reliable result. To 11.1.7 Reporting—Report the injection molding conditions
minimize heat loss from the plastic during measurement, the in accordance with Practice D3641.
mass should be collected in a heated container, or in one made 11.2 Prepare test specimens for heat stability testing in
from material of low thermal conductivity. The quantity of accordance with Test Method D3012.
plastic in the free shot should be controlled to be equivalent to
the weight of a complete injection-molded shot. To avoid 12. Conditioning
excessive thermal history the shot size shall be kept to a 12.1 Conditioning:
minimum; therefore, the cushion shall be 5 to 10 mm. 12.1.1 Once specimens are molded, they shall be moved to
a standard laboratory atmosphere or a controlled laboratory
NOTE 13—For materials with melt flows less than 1 g/10 min, the
temperature of the melt should be raised in 5°C increments from 250°C
atmosphere. For natural unfilled polypropylene the controlled
until the part weight of the entire shot is equivalent to the part weight of laboratory atmosphere shall be 23 6 2°C. Specimens shall be
a 1 to 5-g/10 min material. Due to degradation and thermal expansion of stored in storage medium, such as boxes, paper bags or
the material do not exceed 270°C. If unable to obtain the weight at 270°C, envelopes, plastic bags, or racks, whichever is most practical
make slight adjustments in the injection pressure to achieve the proper for the laboratory storing the specimens. It is recommended
weight. The melt temperature shall be 190°C for materials with melt flows that specimens be allowed to cool for about 30 min on a bench
greater than 30 g/10 min.
or in a rack before they are placed in any container where the
Since the needle-type pyrometer technique is somewhat specimens might come in contact with each other. For filled
tedious, a second technique using an infrared pyrometer may and reinforced polypropylene or polypropylene blends, which
be used. The infrared pyrometer used must have an accuracy of contain a hydrophilic comonomer or modifier the specimens
1 % of reading or 61°F or 61°C, a response time of at least shall be conditioned in a standard laboratory atmosphere of 23
0.5 s, and a distance to target ratio of at least 30:1. It is 6 2°C and 50 6 10 % relative humidity, unless sufficient
recommended that the infrared pyrometer have a laser beam to testing has been conducted that indicates that specific material
establish the position being measured on the molten mass of type’s properties are not affected by humidity. In those cases,
polymer. This second technique shall only be used after a the storage medium can be the same as for unfilled materials.

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D4101 – 10a
Materials whose properties are affected by humidity, must be 13.1.2 Measurement of Test Specimen Dimensions—The
stored in accordance with Practice D618, Procedure A. For all width and thickness of the test specimen shall be measured to
materials to be conditioned for electrical testing, conditioning an incremental discrimination of at least 0.025 mm. Measure-
shall comply with the requirements of the standard test ments shall be made with a micrometer, preferably with
methods for electrical testing. In all cases the laboratory shall ratchet, having a movable circular contact foot and a lower
report both the temperature and humidity conditions during the anvil foot, both 6.35 6 0.025 mm in diameter. Specimens shall
conditioning period. be measured in accordance with Test Methods D5947.
NOTE 16—When the temperature in the molding area exceeds 28°C or 13.1.3 Tensile Stress—Test Type I specimens using Test
the humidity level exceeds 60 % (applies only to filled materials) Method D638. The material shall be tested at 50 mm/min when
specimens shall be moved as quickly as possible to the standard laboratory the material is one that shows a breaking strain greater than
atmosphere. 10 %, or at 5 mm/min when the material breaks at a strain
12.1.2 Testing, except for those tests where a test time is equal to or less than 10 %.
specified, shall be conducted not less than 40 h after molding. 13.1.4 Flexural Modulus (1 % Secant)—Test Methods
The aging times as specified in this and subsequent sections D790, Method I, Procedure A, with a 50-mm span, a 5.0 6
shall apply to all testing conducted for development of a line 0.1-mm radius support and loading nose, and a 1.3-mm/min
callout, data for publication, or for cases of dispute over testing testing speed using the center test region of a Test Method
values. D638, Type I specimen. It is mandatory that the toe correction
12.1.3 Specimens that are to be tested for Izod or Charpy be made to correct for the slack in the test fixture and load cell.
impact shall be notched within 1 to 16 h after molding. Once Center the specimen between the span flatwise and test with a
notched the specimens shall condition for a minimum of 40 h crosshead speed of 1.3 mm/min. Calculate the average value of
before testing. the flexural modulus (1 % secant) at 1 % strain in the outer
12.1.4 Specimens that are to be tested for tensile or flexural surface of the test specimen.
properties shall be tested within 40 to 96 h after molding. NOTE 19—If the Test Method D638 Type I specimens were molded on
NOTE 17—Polypropylene properties change with time as a result of a mold containing a draft angle, the specimens will be trapezoidal.
amorphous densification and, in some cases, due to a small degree of Therefore the flexural modulus may vary slightly depending on which side
secondary crystallization in the rubbery phase. is placed away from the loading nose.
12.2 Test Conditions—Natural unfilled polypropylene shall 13.1.4.1 Calculate the deflection of the test specimen corre-
be tested in a controlled laboratory atmosphere of 23 6 2°C. sponding to 1 % strain (0.01 mm/mm) as follows:
For filled and reinforced polypropylene and polypropylene
D 5 rL2/6d (1)
blends, which contain a hydrophilic comonomer or modifier
the specimens shall be tested in a standard laboratory atmo- where:
sphere of 23 6 2°C and 50 6 10 % relative humidity, unless D = deflection of the center of the test specimen at 1 %
sufficient testing has been conducted that indicates that specific strain, mm
materials type’s properties are not affected by humidity. For all r = strain in the outer surface of the test specimen = 0.01
materials to be tested for electrical properties, the laboratory mm/mm,
shall comply with the requirements of the standard test L = test span = 50 mm, and
methods for electrical testing. In all cases the laboratory shall d = specimen depth = 3.2 mm (nominal).
report both the temperature and humidity conditions during Warning—The load measured must be a minimum of 1 %
testing. of the load cell capacity. The test span shall be known to an
accuracy of 0.05 mm, and this value shall be used in the
13. Test Methods 8 calculations in 13.1.4.1. The loading nose shall be precisely
13.1 Determine the properties enumerated in this specifica- centered between the supports. The test specimen shall be
tion in accordance with the ASTM test methods as they apply, aligned perpendicular to the supports to an accuracy of 2° and
unless otherwise stated herein. the center of the specimen shall be directly below the center of
13.1.1 Flow Rate—Condition 230/2.16 of Test Method the loading nose.
D1238. Make two determinations on the material in the form 13.1.4.2 Calculate the stress corresponding to 1 % strain as
that it is to be molded (such as powder, pellets, or granules). follows:
NOTE 18—This test method serves to indicate the degree of uniformity S 5 3PL/2bd2 (2)
of the flow rate of the polymer of a single manufacturer as made by an
individual process and, in this case, may be indicative of the degree of where:
uniformity of molded specimens, and therefore other properties. However, S = stress in the outer surface of the test specimen at 1 %
uniformity of flow rate among various polymers of various manufacturers strain, MPa,
as made by various processes does not, in the absence of other tests, P = load corresponding to 1 % strain, N
indicate uniformity of other properties and vice versa. L = test span = 50 mm,
d = specimen depth = 3.2 mm (nominal), and
b = specimen width = 12.7 mm (nominal).
8
Supporting data have been filed at ASTM International Headquarters and may The secant modulus at 1 % strain is the ratio of stress to
be obtained by requesting Research Report RR:D20-1213. strain or S/0.01.

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D4101 – 10a
13.1.5 Impact Resistance (Izod)—Test Method D256 (A) 13.1.7 Multiaxial Impact Ductile-Brittle Transition
shall be used for notched specimens tested at 23°C. Specimens Temperature—Test Method D3763 shall be used to test speci-
shall be cut from the center section of the Test Method D638, mens equal to or greater in dimensions than 100 mm2 or 100
Type I tensile test specimen. Before cutting the test specimen mm in diameter and 3.2 6 0.2 mm in thickness. The test speed
from the tensile bar, draw a symbol of any design in the straight shall be 2.2 m/s with the 12.7-mm diameter impact dart and
center section of the bar to indicate which is the gate end of the 76-mm support ring. The temperature at which 80 % of the
specimen. Cut out the 57.2 mm straight center-section of the specimens exhibit ductile failure shall be determined based on
bar. The specimens shall be notched in accordance with Test the definitions listed in Section 3. This temperature shall be
Method D256 for tests at 23°C. Specimens shall be notched determined by either a standard graphical method or through a
such that the notch is off-center on the 57.2 6 1 mm long probability graphical method. When using the standard graphic
specimen. When notched, the apex of the notch shall be 25.4 6 method to determine the 80 % passing temperature, it is
2 mm from the non-gated end and 31.8 6 1 mm from the gated necessary to repeat this procedure of testing ten specimens at a
end of the specimen. The more critical dimension is the 31.8 6 series of temperatures differing by uniform increments of 5°C.
1 mm from the gated end of the specimen. Notched specimens The transition region of the curve shall be established using
must be conditioned after notching for a minimum of 40 h either 5°C or 10°C increments, but -5°C increments must be
before testing. The specimen shall be inserted in the clamp with used when testing in the transition temperature region. When
the 25.4 6 2 mm in the clamp and the 31.8 6 1 mm length using probability graph paper, it is not necessary to obtain the
above the clamp. When testing, the specimen shall be clamped lowest no-failure temperatures, at which no failure is obtained,
in the grips with the minimum pressure necessary to prevent or the highest failure temperature. Draw a straight line through
any movement of the specimen upwards or downwards during a minimum of four points, two above and two below the 50 %
impact. Should this pressure deform the specimen, then the failure point. The temperature indicated at the intersection of
clamp pressure may be reduced. the data line with the 20 % failure line shall be reported as the
NOTE 20—Although the 57.2 mm length of specimen does not comply
ductile-brittle temperature or 80 % passing temperature.
with the minimum specimen length of 61.5 mm specified by Test Method NOTE 22—In addition to visually examining the plaques for ductile
D256, studies with numerous types of polypropylene specimens has failure, review the load versus time or load versus displacement curve for
shown that clamp lengths as short as 19 mm are acceptable, with no the impact for signs of ductility.
change in test results. What is critical is that the length of material above
the clamp, which is specified as 31.8 6 1 mm. Failure to maintain the 31.8 13.1.8 Reinforcement and Additive Concentrations:
6 1 mm above the clamp will result in reduced or increased Izod impact 13.1.8.1 Glass Percentage— Use Test Method D2584.
values depending on whether the specimen length above the clamp is 13.1.8.2 All Others—Method to be specified.
longer or shorter than that specified by Test Method D256, Method
AD256.
13.1.8.3 Additional testing methods and conditions, refer to
NOTE 21—With the design of each clamping system and the capacity of Appendix X1.
the pendulum used different from instrument to instrument it is difficult to
specify a pressure will hold the specimen securely. What is important is 14. Inspection and Certification
that the clamp pressure be maintained constant from specimen to
specimen and be sufficient to prevent specimen movement during the
14.1 Certification and inspection of the material supplied
impact. Too low a clamp pressure may result in slightly higher Izod values under this specification shall conform to the requirements
with a wider scatter of impact values within a set of specimens. Too high specified herein and in Classification D4000, Section 15.
a clamp pressure will induce stress in the specimen resulting in lower than
expected test values. This is particularly true of propylene plastics when 15. Rejection and Rehearing
tested at sub-ambient temperatures close to their brittleness temperature.
15.1 Material that fails to conform to the requirements of
Set up the test instrument with the lowest capacity pendulum this specification may be rejected. If any failure occurs, the
recognized by Test Method D256, which is the 2.7 J (2 ft-lb) materials may be retested to establish conformity. Rejection
pendulum. This pendulum shall be used for all Izod impact shall be reported to the supplier promptly and in writing. In
resistance measurements where the specimen exhibits a com- case of dissatisfaction with the results of the test, a claim for a
plete, hinge, or partial break. For specimens showing non- rehearing may be made.
break behavior, progressively increase the hammer capacity to
move the type of break from non-break with the 2.7 J hammer 16. Packaging and Package Marking
to complete, hinge, or partial break so that an impact value may
be reported. Conformance or nonconformance with the speci- 16.1 Provisions of Practice D3892 apply for packaging,
fications detailed in the Tables shall be based on a material packing, and marking of plastic materials.
having a complete, hinge, or partial break.
13.1.6 Deflection Temperature—Test Method D648 shall be 17. Keywords
used to test a rectangular specimen 3.2 by 12.7 by 127 mm with 17.1 injection and extrusion materials; materials specifica-
a load applied at the center to give maximum fiber stresses of tion; polypropylene; polypropylene test methods; recycled
455 kPa. plastics

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D4101 – 10a
TABLE PP Requirements for Unreinforced Polypropylene (Natural Color Only)

Flexural
ModulusD Izod Deflection
Tensile
Nominal Flow B (1 % Impact,E Temperature
Stress at
Rate,A Test Secant), Resistance at 455-KPa
Yield, Test
Method D1238, Test at 23°C, Stress,G
Group Description Class Description Grade Description Method
Condition Methods Test Test
D638,
230/2.16, D790, Method Method
min,C
g/10 min Procedure A, D256, min, D648H, min,
F
MPa
min,C J/m °C
MPa
01 Homopolymer 1 General purpose 1 ... <0.3 27.5 1050 32 81
2 ... >0.2 to #1.0 27.5 1000 27 81
3 ... >1.0 to #3.0 27.5 1000 25 74
4 ... >3.0 to #10 27.5 950 20 71
5 ... >10 to #20 26 850 16 71
6 ... >20 to #40 25 800 14 64
7 ... >40 to #100 24 800 12 64
8 ... >100 to #200 23 850 12 64
9 ... >200 21 850 8 74
0 Other
2 Nucleated 1 ... >1.0 to #3.0 33.5 1350 27 100
2 ... >1.0 to #3.0 30.5 1150 27 90
3 ... >3.0 to #10 30.5 1150 22 100
4 ... >3.0 to #10 30.5 1150 21 90
5 ... >10 to #30 30 1150 20 95
6 ... >10 to #30 30 1150 16 85
7 ... >30 28.5 1050 16 80
0 Other
3 High-crystallinity 1 ... <1.0 38 2000 21 100
2 ... >1.0 to #5.0 36 1800 21 100
3 ... >5.0 to #10 36 1600 21 100
4 ... >10 to #20 33 1400 22 95
5 ... >20 to #40 30 1300 24 90
6 ... >40 26 1300 26 90
0 Other
0 Other 0 Other
02 Random Copolymers Refer to Appendix
X2
03 Copolymers or Impact- Refer to Appendix
Modified X2
05 Copolymers or 0 Other 0 Other Use Table H for a reduced line callout of materials where only the ratio
impact modified of stiffness to impact is important. Use Table B when a full line callout is
required.
A
Nominal flow rate is as supplied by the manufacturer of the material. Maximum allowable tolerance = 630 % per individual lot.
B
Test specimens are unannealed Test Method D638, Type I tensile bars and shall be tested at 50 mm/min when the material is one that shows a breaking strain greater
than 10 %, or at 5 mm/min when the material breaks at a strain equal to or less than 10 %.
C
MPa 3 145 = psi.
D
Test specimens are the center of the unannealed Test Method D638,, Type I tensile bars with a nominal 3.2 by 12.7-mm cross section. Span is a nominal 50 mm. Rate
of crosshead is 1.3 mm/min using Method I. Report 1 % secant based on strain.
E
Test specimens are nominal 3.2 mm in width and are at the center section of unannealed Test Method D638, Type I tensile bar.
F
J/m = ft·lbf/in. 3 53.38.
G
Test specimens are nominal 3.2 by 12.7-mm cross section and shall be unannealed.
H
Minimum values are based on testing the material by Test Method D648, Method A (test span 101.6 mm).

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D4101 – 10a
TABLE A Detail RequirementsA of Polypropylene Not Called Out by Tables B, C, G, and T
Designation or
Property 0 1 2 3 4 5 6 7 8 9
Order No.
B
1 Tensile stress at yield, Unspecified 20 35 50 65 80 95 110 125 Specify
Test Method D638, min, MPaC valueD
2 Flexural modulus (1 % secant),E Unspecified 1000 2000 3000 4000 5000 6000 7000 8000 Specify
Test Methods D790 (A), min, MPaC valueD
3 Izod impact resistanceF at 23°C, Unspecified 15 30 45 60 90 135 190 250 Specify
Test Method D256, min, J/mG valueD
4 Deflection temperature at 455 kPa,H Unspecified 80 95 110 130 150 170 90 210 Specify
Test Method D648, min, °C valueD
5 To be determined Unspecified ... ... ... ... ... ... ... ... ...
A
It is recognized that detailed test values, particularly Izod impact, may not predict nor even correlate with performance of parts molded of these materials.
B
Test specimens are unannealed Test Method D638, Type I tensile bars and shall be tested at 50 mm/min when the material is one that shows a breaking strain greater
than 10 %, or at 5 mm/min when the material breaks at a strain equal to or less than 10 %.
C
MPa 3 145 = psi or kPa 3 0.145 = psi.
D
If a specific value is required, it must appear on the drawing or contract, or both.
E
Test specimens are nominal 3.2 by 12.7-mm cross section and are at the center of unannealed Test Method D638, Type I tensile bar. Span is a nominal 50 mm. Rate
of crosshead is 1.3 mm/min using Method I. Report 1 % secant based on strain.
F
Test specimens are nominal 3.2 mm in thickness and are at the center section of Test Method D638, Type I tensile bar.
G
J/m 3 (1.873 3 10−2) = ft · lb/in. or J/m = ft · lb/in. 3 53.38.
H
Test specimens are nominal 3.2 by 12.7-mm cross section and shall be unannealed.

TABLE B Detail RequirementsA of Unfilled and Unreinforced Polypropylene

Designation
Property 0 1 2 3 4 5 6 7 8 9
or Order No.
B
1 Tensile stress at yield, Test Method D638, Unspecified 5 10 15 20 25 30 35 40 Specify
min, MPaC valueD
2 Flexural modulus (1 % secant),E Test Unspecified 100 250 500 750 1000 1250 1500 1750 Specify
Methods D790, (A), min, MPaC valueD
3 Izod impact resistanceF at 23°C, Unspecified 10 50 100 200 300 400 500 700 Specify
Test Method D256, min, J/mG valueD
4 Deflection temperature at 455 kPa,H Test Method Unspecified 50 60 70 80 90 100 110 120 Specify
D648, min, °C valueD
5 Flow rate,I Test Method D1238, Condition Unspecified #0.3 >0.3-1.0 >1.0-3.0 >3.0-10 >10-20 >20-40 >40-100 >100 Specify
230/2.16, g/10 min valueD
A
It is recognized that detailed test values, particularly Izod impact, may not predict nor even correlate with performance of parts molded of these materials.
B
Test specimens are unannealed Test Method D638, Type I tensile bars and shall be tested at 50 mm/min when the material is one that shows a breaking strain greater
than 10 %, or at 5 mm/min when the material breaks at a strain equal to or less than 10 %.
C
MPa 3 145 = psi or kPa 3 0.145 = psi.
D
If a specific value is required, it must appear on the drawing or contract, or both.
E
Test specimens are nominal 3.2 by 12.7-mm cross section and are at the center of unannealed Test Method D638, Type I tensile bar. Span is a nominal 50 mm. Rate
of crosshead is 1.3 mm/min using Method I. Report 1 % secant based on strain.
F
Test specimens are nominal 3.2 mm in thickness and are at the center section of Test Method D638, Type I tensile bar.
G
J/m 3 (1.873 3 10−2) = ft · lb/in. or J/m = ft · lb/in. 3 53.38.
H
Test specimens are nominal 3.2 by 12.7-mm cross section and shall be unannealed.
I
Nominal flow rate is as supplied by the manufacturer of the material. Allowable tolerance 630 % per individual lot.

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D4101 – 10a
TABLE C Detail RequirementsA of Calcium Carbonate Filled Polypropylene
Designation
or Order Property 0 1 2 3 4 5 6 7 8 9
Number
1 Tensile Stress at YieldB Unspecified 10 14 17 21 24 27 31 34 Specify ValueD
Test Method D638, min, MPaC
2 Flexural Modulus (1 % secant)E Unspecified 800 1100 1400 1700 1900 2200 2500 2700 Specify ValueD
Test Method D790 (A), min,
MPaC
3 Izod impact resistanceF at +23°C Unspecified 15 35 55 75 90 110 135 255 Specify ValueD
Test Method D256, min, J/mG
4 Deflection Temperature at 455 Unspecified 75 80 85 90 95 100 105 110 Specify ValueD
kPaH
Test Method D648, min, °C
5 To be determined Unspecified ... ... ... ... ... ... ... ... Specify ValueD
A
It is recognized that detailed test values, particularly Izod impact, may not predict nor even correlate with performance of molded parts.
B
Test specimens are unannealed Test Method D638, Type I tensile bars and shall be tested at 50 mm/min when the material is one that shows a breaking strain greater
than 10 %, or at 5 mm/min when the material breaks at a strain equal to or less than 10 %.
C
MPa 3 145 = psi or kPa 3 0.145 = psi.
D
If a specific value is required, it must appear on the drawing or contract, or both.
E
Test specimens are nominal 3.2 by 12.7-mm cross section and are at the center of unannealed Test Method D638, Type I tensile bar. Span is a nominal 50 mm. Rate
of crosshead is 1.3 mm/min using Method I. Report 1 % secant modulus based on strain.
F
Test specimens are a nominal 3.2 mm in thickness and are cut from the center of a Test Method D638, Type I tensile bar.
G
J/m 3 (1.873 3 10-2) = ft- lb/in. or J/m = ft-lb/in. 3 53.38.
H
Test specimens are nominal 3.2 by 12.7-mm cross section and shall be unannealed.

TABLE G Detail RequirementsA of Glass Reinforced Polypropylene

Designation
or Order Property 0 1 2 3 4 5 6 7 8 9
Number
1 Tensile Stress at YieldB Unspecified 24 32 40 48 57 65 74 82 Specify ValueD
Test Method D638, min, MPaC
2 Flexural Modulus (1 % secant)E Unspecified 1000 1900 2800 3700 4600 5500 6400 7300 Specify ValueD
Test Method D790 (A), min,
MPaC
3 Izod impact resistanceF at +23°C Unspecified 15 35 55 80 100 130 150 170 Specify ValueD
Test Method D256, min, J/mG
4 Deflection Temperature at 455 Unspecified 80 90 100 110 120 130 140 150 Specify ValueD
kPaH
Test Method D648, min, °C
5 To be determined Unspecified ... ... ... ... ... ... ... ... Specify ValueD
A
It is recognized that detailed test values, particularly Izod impact, may not predict nor even correlate with performance of molded parts.
B
Test specimens are unannealed Test Method D638, Type I tensile bars and shall be tested at 50 mm/min when the material is one that shows a breaking strain greater
than 10 %, or at 5 mm/min when the material breaks at a strain equal to or less than 10 %.
C
MPa 3 145 = psi or kPa 3 0.145 = psi.
D
If a specific value is required, it must appear on the drawing or contract, or both.
E
Test specimens are nominal 3.2 by 12.7-mm cross section and are at the center of unannealed Test Method D638 Type I tensile bar. Span is a nominal 50 mm. Rate
of crosshead is 1.3 mm/min using Method I. Report 1 % secant modulus based on strain.
F
Test specimens are a nominal 3.2 mm in thickness and are cut from center section of Test Method D638, Type I tensile bar.
G
J/m 3 (1.873 3 10-2) = ft- lb/in. or J/m = ft-lb/in. 3 53.38.
H
Test specimens are a nominal 3.2 by 12.7 mm cross section and shall be unannealed.

TABLE H Detail RequirementsA of Unfilled and Unreinforced Polypropylene Copolymers

Designation
or Order Property 0 1 2 3 4 5 6 7 8 9
Number
1 Flexural Modulus (1 % secant)B Unspecified 100 300 600 900 1200 1500 1800 2100 Specify ValueD
Test Method D790 (A), min,
MPaC
2 Izod impact resistanceE at 23°C Unspecified 20 40 70 120 180 260 400 Non Specify ValueD
Test Method D256, min, J/mF BreakG
3 Multiaxial Impact Ductile-Brittle Unspecified <10 <0 <-10 <-20 <-30 <-40 <-50 <-60 Specify ValueD
Transition Temperature, °CH
A
It is recognized that detailed test values, particularly Izod impact, may not predict nor even correlate with performance of parts molded of these materials.
B
Test specimens are nominal 3.2 by 12.7-mm cross section and are at the center of unannealed Test Method D638, Type I tensile bar. Span is a nominal 50 mm. Rate
of crosshead is 1.3 mm/min using Method I. Report 1 % secant modulus based on strain.
C
MPa 3 145 = psi or kPa 3 0.145 = psi.
D
If a specific value is required, it must appear on the drawing or contract, or both.
E
Test specimens are nominal 3.2 mm in thickness and are cut from center section of unannealed Test Method D638, Type I tensile bar.
F
J/m 3 (1.873 3 10–2) = ft • lb/in. or J/m = ft • lb/in. 3 53.38.
G
Izod impact resistance, non-break failure mode, no value reported
H
Plate with thickness 3.2 6 0.2 mm.

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D4101 – 10a
TABLE T Detail RequirementsA of Talc Filled Polypropylene
Designation
or Order Property 0 1 2 3 4 5 6 7 8 9
Number
1 Tensile stress at YieldB Unspecified 12 16 20 24 28 32 36 40 Specify
Test Method D638, min, MPaC ValueD
2 Flexural Modulus (1 % secant)E Unspecified 650 1000 1350 1700 2050 2400 2750 3100 Specify
Test Method D790 (A), min, MPaC ValueD
3 Izod impact resistanceF at +23°C Unspecified 15 35 55 75 95 115 135 155 Specify
Test Method D256, min, J/mG ValueD
4 Deflection Temperature at 455 kPaH Unspecified 70 80 90 100 110 120 130 140 Specify
Test Method D648, min, °C ValueD
5 To be determined Unspecified ... ... ... ... ... ... ... ... Specify
ValueD
A
It is recognized that detailed test values, particularly Izod impact, may not predict nor even correlate with performance of molded parts.
B
Test specimens are unannealed Test Method D638, Type I tensile bars and shall be tested at 50 mm/min when the material is one that shows a breaking strain greater
than 10 %, or at 5 mm/min when the material breaks at a strain equal to or less than 10 %.
C
MPa 3 145 = psi or kPa 3 0.145 = psi.
D
If a specific value is required, it must appear on the drawing or contract, or both.
E
Test specimens are nominal 3.2 by 12.7 mm cross section and are at the center of unannealed Test Method D638, Type I tensile bar. Span is a nominal 50 mm. Rate
of crosshead is 1.3 mm/min using Method I. Report 1 % secant modulus based on strain.
F
Test specimens are a nominal 3.2 mm in thickness and are at the center of a Test Method D638, Type I tensile bar.
G
J/m 3 (1.873 3 10-2) = ft- lb/in. or J/m = ft-lb/in. 3 53.38.
H
Test specimens are nominal 3.2 by 12.7 mm cross section and shall be unannealed.

TABLE 1 Melt Temperature Requirements for Molding

Flow Rate, g/10 min Melt Temperature, °C
1.0–1.5 250
1.6–2.5 240
2.6–4.0 230
4.1–6.5 220
6.6–10.5 210
10.6–17.5 200
17.6-30.0 190

SUPPLEMENTARY REQUIREMENTS

The following supplementary items may become part of this specification, when applicable, as
agreed upon between the user and the supplier.

S1. Approval S3.2 In the event such tests are to be designated as require-
S1.1 Material submitted by a new supplier must be ap- ments to be tested by the supplier, this must appear on the part
proved by the user. Material or test specimens submitted by the drawing or purchase contract, or both.
supplier and intended for evaluation shall be accompanied by S4. Quality Assurance Provisions for Government/
the supplier’s laboratory test report. Military Procurement
S2. New Sources S4.1 Selection of Acceptable Quality Level (AQL) and of
S2.1 The user may elect to temporarily accept shipment on Inspection Level (IL) shall be made with consideration of the
the supplier’s certification. specific use requirements. This is discussed in Sections 7 and
8 of Practice D1898, with reference to MIL-STD-105 . In the
S3. Infrared Spectrophotometry or Thermal Analysis, or absence of contrary requirements, the following values shall
Both apply:
S3.1 At the option of the user, infrared or thermal analysis, Testing (Polymer, Unfabricated) IL AQL
or both, may be conducted on material/parts supplied to this S−1A ...
__________
specification. The curves established for initial approval shall A
Samples shall be drawn from the required number of units and pooled for
constitute the reference standard and shall be kept on file at the preparation of molded samples for property evaluation.
user’s laboratory. All samples shall produce curves that corre-
spond to the reference standard within agreed upon tolerances S5. Government/Military Packaging
when tested under the same conditions as those specified on the S5.1 (Text of this section will be the same as presently being
master set of curves. balloted by Subcommittee D20.94.)

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D4101 – 10a
APPENDIXES

(Nonmandatory Information)

X1. ADDITIONAL TEST METHODS AND CONDITIONS

X1.1 Table X1.1 specifies the other test methods and

conditions, other than the five standard test methods, that can
be used to characterize polypropylene.

TABLE X1.1 Test Methods and ConditionsA

Suffix from Test Conditions

Standard Test
Specimen Type Processing D4000 or and Supplementary
Number Property Units
Dimensions, mm Method D4101, Instructions
Method
Section 5
1. Rheological properties
1.1 Melt flow rate D1238 Granules or powder g/10 min VC2 Test temperature 230°C, 2.16
kg load
1.2 Melt rheology D3835 Granules or powder Pa-s Test temperatures 190, 210, and
230°C
2. Mechanical properties
2.1 Tensile stress at yield D638 Type I, thickness = 3.2 Injection MPa KY Test at 50 mm/min when the
material is one that shows a
breaking strain greater than
10 %, or at 5 mm/min when
the material breaks at a strain
equal to or less than 10 %
2.2 Tensile elongation at yield % LY
2.3 Tensile modulus MPa Speed of 5 mm/min with Class
B-2 or better extensometer
2.4 Tensile creep modulus D2990 Type I, thickness = 3.2 Injection MPa At room temperature and at
least two elevated
temperatures for 1000 h at
three stress levels
2.5 Flexural modulus D790 Center of Type I bar, 63.5 Injection MPa UC 1 % secant, 50 mm span, 1.3
by 12.7 by 3.2 mm/min speed 5 6 0.1 mm
radius support rods and
loading nose at yield if yield
occurs at less than 5 % strain,
otherwise report value at 5 %
2.6 Flexural strength MPa NA
2.7 Flexural creep modulus D2990 Center of Type I bar, 63.5 Injection MPa At room temperature and at
by 12.7 by 3.2 least two elevated
temperatures for 1000 h at
three stress levels
2.8 Compressive strength D695 12.7 by 12.7 by 25.4 prism Injection MPa QA Speed 1.3 mm/min (strain rate
or 12.7 mm diameter by 0.05 mm/mm/min)
25.4 mm long right
cylinder
2.9 Compressive modulus 12.7 by 12.7 by 50.8 prism MPa Slenderness ratio 11 to 16 to 1,
or 12.7 mm diameter by speed 1.3 mm/min (strain rate
50.8 mm long right 0.025 mm/mm/min)
cylinder
2.10 Compressive creep D2990 12.7 by 12.7 prism or 12.7 Injection At room temperature and at
modulus mm diameter length least two elevated
(must be sufficient to temperatures for 100 h at
meet slenderness ratio three stress levels
or 11 to 15)
2.11 Shear strength D732 50 disk or 50 by 50 by 50 square Injection MPa Speed 1.3 mm/min
with thickness of 3.2
2.12 Shear modulus D5279 76 by 13 by 3.2 Injection Pa −150°C to Tg+20°C or
Tm+10°C @ 1 Hz
Pa SM
2.13 Izod impact resistance D256 Center of Type I bar, 57.2 by 12.7 Injection J/m PA Use a 2.7 J pendulum for all
by 3.2 materials, unless at 2.7 J non-
break behavior is observed.
2.14 Charpy impact D6110 127 by 12.7 by 3.2 Injection J/m PB
resistance
2.15 Cantilever beam impact D4812 Center of Type I bar, 63.5 by 12.7 J/m
by 3.2
2.16 Tensile impact D1822 Type S, thickness = 3.2 Injection kJ/m2
resistance

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D4101 – 10a

TABLE X1.1 Continued

Suffix from Test Conditions
Standard Test
Specimen Type Processing D4000 or and Supplementary
Number Property Units
Dimensions, mm Method D4101, Instructions
Method
Section 5
2.17 Gardner D5420 Minimum 50 by 50 by 3.2 Injection J PG3 Geometry GC at +23°C, or
impact square or 50 diameter –30°C, or both
by 3.2 diskB
2.18 Puncture D3763 Minimum 100 Injection J Test speed 2.2 m/s. Report
properties by 100 by 3.2 energy at peak load and total
square or 100 energy at 50 % of the peak
diameter by 3.2 load. Primary test temperature
+23°C. If the temperature at
which the material transitions
from ductile to brittle failure is
required, recommended test
temperatures for initial
evaluation are +0°C, -15°C,
-30°C and -40°C.
2.19 Rockwell D785 Minimum 25 by 25 square Injection HRR Rockwell R scale (thickness of
hardness by 6 or 25 diameter disk compression specimen may be achieved
by 6 thick by plying specimens or
thinner specimens may be
used if hardness is shown not
to be changed)
2.20 Shore A or D hardness D2240 Minimum 25 by 25 square Injection Shore A Shore A or D scale (thickness of
by 6 or 25 diameter disk com- or D specimen may be achieved
by 6 thick pression by plying specimens or
thinner specimens may be
used if hardness is shown not
to be changed). Values at 1 s.

3. Thermal properties
3.1 Melting temperature D2117 Any material form °C CE Fisher-Johns
D3418 CD DSC/DTA
3.2 Heat deflection temperature D648 127 by 13 by 3.2 Injection °C YA Unannealed specimen, 1820
kPa stress.
YD Unannealed specimen, 455 kPa
stress.
3.3 Vicat softening temperature D1525 Minimum 12 by 12 by 3 square or Injection °C CB Rate A, 50°C/h
12 diameter disk
3.4 Coefficient of linear thermal D696 Between 50 and 120 length, other Injection µm/(m·°C) Dilatometer, between −30° and
expansion dimensions depend on test +30°C (use E228 for
apparatus temperatures other than −30
and +30°C)
E831 Between 2 and 10 length and less Injection µm/(m·°C) Report over ranges from −30 to
than 10 lateral dimension 0°C, 0 to +30°C, and +30 to
+60°C
3.5 Thermal conductivity C177 Depends on test apparatus Injection cal/s/
cm2/°C/cm
3.6 Brittleness temperature D746 Length minimum 20 + minimum 5 Injection °C PL Procedure A
in clamp by 6.35 by 1.91
3.7 Flammability D635 127 by 12.7 by 3.2 Injection mm/min FA
D2863 127 by 6.5 by 3.2 Injection % FB
D3801 127 by 12.7 by 3.2 Injection s FC Generate rating based on
burning time and glow time
MVSS-302 355 by 102 by 1.25 Injection mm/min
4. Electrical properties
4.1 Volume resistivity D257 100 by 100 by 3.2 square or Compression Ohm·cm EG Electrification for 60 s with
100 diameter disk by 3.2 applied voltage of 500 V
4.2 Dielectric strength D149 100 by 100 by 3.2 square or Compression kV/mm EA Method A—short time
100 diameter disk by 3.2
ED Method B—step by step
4.3 Dielectric constant D150 100 by 100 by 3.2 square or Compression ED Test at 1 MHz
100 diameter disk by 3.2
4.4 Dissipation factor EE
4.5 Arc resistance D495 Dependent on test apparatus, Compression s EF
thickness 3.2

5. Optical
5.1 Yellowness indexA E313 Minimum 63.5 by 63.5 by 3.2 or Injection Yl Reflectance with specular light
minimum 63.5 diameter disk by included
3.2
5.2 Yellowness index D6290 Pellets YI Reflectance, specular light
excluded, Illuminant C, 2°
observer calculate YI with
E313 equation

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D4101 – 10a

TABLE X1.1 Continued

Suffix from Test Conditions
Standard Test
Specimen Type Processing D4000 or and Supplementary
Number Property Units
Dimensions, mm Method D4101, Instructions
Method
Section 5
5.3 Gloss D523 150 by 75 by 3.2 Injection At 45 and 60°

6.
6.1 Natural weathering D1435 Type I tensile bar for physical Injection W7 Angle of exposure 45°, report
testing and minimum 65.5 by exposure time, % retention of
63.5 square or 63.5 diameter physical properties and total
disk by 3.2 for color change. solar radiant energy. See
Third Alphanumeric Suffixes
for evaluations of exposure
and failure criteria.C
SAE J1976 Type I tensile bar for physical Injection W8 Angle of exposure 5°, report
testing and minimum 65.5 by exposure time, % retention of
63.5 square or 63.5 diameter physical properties and total
disk by 3.2 for color change. solar radiant energy. See
Third Alphanumeric Suffixes
for evaluations and failure
criteria.C
6.2 Accelerated weathering D2565 same as for 6.1 Injection W1 Xenon-arc test as described in
First Digit 1. Exposure for 720
h.D See Third Digit
Alphanumeric for evaluations
of exposure and failure
criteria.C
D4329 same as for 6.1 Injection W2 Fluorescent UV/condensation
test as described in First Digit
2.D See Third Alphanumeric
Suffixes for evaluations of
exposure and failure criteria.C
SAE J1885 same as for 6.1 Injection W4 Xenon-arc test as described in
First Digit 4. Radiant
exposure of 1240.8 kJ/
(m2.nm) at 340 nm.D See
Third Alphanumeric Suffixes
for evaluations of exposure
and failure criteria.C
SAE J1960 same as for 6.1 Injection W3 Xenon-arc test as described in
First Digit 3. Radiant
exposure of 2500 kJ/(m2.nm)
at 340 nm.D See Third
Alphanumeric Suffixes for
evaluations of exposure and
failure criteria.C
D4364 same as for 6.1 Injection W5, UV radiant exposure below 385
W6 nm of 1000 MJ/m2
(approximately 3 years).D
Specify whether First Digit is
5 or 6. See Third
Alphanumeric Suffixes for
evaluations of exposure and
failure criteria.C
6.3 Oven aging D3012 50 by 10 by 1.0 Compression Days SA Test temperature = 150°C
or Injection
7. Other
7.1 Water absorption D570 50.8 by 3.2 disk Injection % 24 h immersion at ambient
temperature
7.2 Water absorption D570 50.8 by 3.2 disk Injection % Long-term immersion to
saturation
7.3 Chemical resistance D543 50.8 by 3.2 thick disk or Type I Injection % Disk for weight and dimensional
bar, 3.2 thickness changes
Injection % Type I for mechanical properties
retention, 7 day immersion
7.4 Density D792 37 by 12.7 by 3.2 Injection kg/m3 GC
D1505 Pellet or section of molded or kg/m3 GD
extruded sample
7.5 Ash D5630 Granules or pellets %
A
The measurement of yellowness index of molded flat specimens for comparison between other laboratories is not as reproducible as with pellets due to the difference
in molding techniques to make the specimen; the additional heat history applied to the material; differences in design of the colorant measurement systems; the level of
specimen transparence, translucence, or opaqueness; and the color of the background backing up the specimen.
B
The Gardner impact resistance of a material is dependent on the size and shape of the specimen, gating of the mold, and the material flow pattern in the mold during
injection molding. When the impact failure mode is ductile the specimen dimensions do not make a significant difference, but when the impact failure mode is brittle, larger
specimens of the same thickness will yield higher impact results. In cases of non-agreement, customer and supplier shall agree on specimen and dimensions used.
C
Failure shall be when the material loses tensile strength or Izod impact properties. If color change is critical, DE cannot exceed 3.0.

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D4101 – 10a
D
The minimum exposure time shall be that necessary to produce a statistically significant change in the property measured, that is, tensile strength, impact resistance
or color, in the least stable material being evaluated.

X2. TABLE PP REQUIREMENTS FOR UNREINFORCED POLYPROPYLENE GROUPS 02 AND 03 (NATURAL COLOR
ONLY)

X2.1 Table X2.1 is the former Table PP for the line call out previously classified with these groupings may continue to be
of random copolymers (Group 2) and copolymers and impact used. All new materials shall be called out with the Group 5
modified materials (Group 03). Groups 02 and 03 have been classification.
replaced by Group 05 in the main document. A material

TABLE X2.1 PP Requirements for Unreinforced Polypropylene (Natural Color Only)

Flexural
ModulusD Izod Deflection
Tensile
Nominal Flow B (1 % Impact,E Temperature
Stress at
Rate,A Test Density, max Secant), Resistance at 455-KPa
Yield, Test
Method D1238, Test Methods Test at 23°C, Stress,G
Group Description Class Description Grade Description Method
Condition D1505 or Methods Test Test
D638,
230/2.16, D792, kg/m3 D790, Method Method
min,C
g/10 min Procedure A, D256, min, D648H, min,
F
MPa
min,C J/m °C
MPa
02 Random 1 General purpose 1 ... . . . 910 24 1000 30 78
copolymer 2 ... . . . 910 24 800 30 67
3 ... . . . 910 22 700 30 67
4 ... . . . 910 20 600 40 62
5 ... . . . 910 17 500 45 62
6 ... . . . 910 16 400 50 60
7 ... . . . 910 15 350 50 60
0 Other
2 Nucleated 1 ... . . . 915 26 975 35 87
2 ... . . . 915 24 675 40 77
3 ... . . . 915 22 575 40 73
4 ... . . . 915 21 375 50 67
0 Other
0 Other 0 Other
03 Copolymers 1 Low impact 1 ... . . . 905 26 1000 10 80
or impact 2 ... . . . 905 21 850 10 65
modified 3 ... . . . 905 23 850 30 70
4 ... . . . 905 18 650 30 65
5 ... . . . 905 17 450 30 60
6 ... . . . 905 24 800 50 75
7 ... . . . 905 22 750 50 70
8 ... . . . 905 20 750 50 70
9 ... . . . 905 18 650 50 65
0 Other
2 Moderate impact 1 ... . . . 905 27 1000 60 85
2 ... . . . 905 25 850 70 80
3 ... . . . 905 23 850 70 75
4 ... . . . 905 21 750 70 70
5 ... . . . 905 19 550 70 70
6 ... . . . 905 19 550 70 60
7 ... . . . 905 22 700 90 75
8 ... . . . 905 17 650 90 65
9 ... . . . 905 15 550 90 60
0 Other
3 Medium impact 1 ... . . . 905 25 1000 100 75
2 ... . . . 905 23 900 120 70
3 ... . . . 905 19 700 120 65
4 ... . . . 905 17 500 120 60
5 ... . . . 905 17 600 150 65
6 ... . . . 905 25 850 200 70
7 ... . . . 905 20 850 200 70
8 ... . . . 905 20 700 200 70
9 ... . . . 905 16 500 200 60
0 Other
4 High impact 1 ... . . . 905 24 800 300 80
2 ... . . . 905 21 800 300 75
3 ... . . . 905 21 550 300 70
4 ... . . . 905 17 500 300 65
5 ... . . . 905 15 450 300 60
6 ... . . . 905 16 500 400 65

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D4101 – 10a

TABLE X2.1 Continued

Flexural
ModulusD Izod Deflection
Tensile
Nominal Flow (1 % Impact,E Temperature
A StressB at
Rate, Test Density, max Secant), Resistance at 455-KPa
Yield, Test
Method D1238, Test Methods Test at 23°C, Stress,G
Group Description Class Description Grade Description Method
Condition D1505 or Methods Test Test
D638,
230/2.16, D792, kg/m3 D790, Method Method
min,C
g/10 min Procedure A, D256, min,F D648H, min,
MPa
min,C J/m °C
MPa
7 ... ... 905 24 750 600 70
8 ... ... 905 20 700 600 65
9 ... ... 905 19 500 600 60
0 Other
5 Nucleated 1 ... . . . 905 29 1000 10 77
2 ... . . . 905 27 1300 30 95
3 ... . . . 905 23 950 30 90
4 ... . . . 905 21 850 30 85
5 ... . . . 905 23 1050 50 85
6 .... . . . 905 19 800 50 85
7 ... . . . 905 26 1150 80 85
8 ... . . . 905 22 850 80 80
9 ... . . . 905 19 550 100 80
0 Other
0 Other 0 Other
A
Nominal flow rate is as supplied by the manufacturer of the material. Maximum allowable tolerance = 630 % per individual lot.
B
Test specimens are unannealed Test Method D638, Type I tensile bars and shall be tested at 50 mm/min when the material is one that shows a breaking strain greater
than 10 %, or at 5 mm/min when the material breaks at a strain equal to or less than 10 %.
C
MPa 3 145 = psi.
D
Test specimens are the center of the unannealed Test Method D638,, Type I tensile bars with a nominal 3.2 by 12.7-mm cross section. Span is a nominal 50 mm. Rate
of crosshead is 1.3 mm/min using Method I. Report 1 % secant based on strain.
E
Test specimens are nominal 3.2 mm in width and are at the center section of unannealed Test Method D638, Type I tensile bar.
F
J/m = ft·lbf/in. 3 53.38.
G
Test specimens are nominal 3.2 by 12.7-mm cross section and shall be unannealed.
H
Minimum values are based on testing the material by Test Method D648, Method A (test span 101.6 mm).

SUMMARY OF CHANGES

Committee D20 has identified the location of selected changes to this standard since the last issue (D4101 - 10)
that may impact the use of this standard. (November 1, 2010)

(1) Added new Note 12 regarding runner size effects on

measured properties.

Committee D20 has identified the location of selected changes to this standard since the last issue (D4101 - 09)
that may impact the use of this standard. (April 1, 2010)

(1) Revised 13.1.7.

Committee D20 has identified the location of selected changes to this standard since the last issue (D4101 - 08)
that may impact the use of this standard. (September 1, 2009)

(1) Revised Footnote E in Tables A, B, C, G, and T. (2) Revised Footnote B in Table H.

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D4101 – 10a
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