MME (19-23) March 23, 2023

POLYMER PROCESSING

Process Selection of
Selection for Polymer
Manufacturing Product

Material
Process
Selection
Selection
Justification and its
Properties

Probable Parameters
for
Defects
Processing

• Abdullah Khan (02)

Submitted by:
• Hadia Ahsan (10)

Submitted to: • Sir Ahmad Usman

MME (19-23) March 23, 2023

Assignment 01
1. Selection of Polymer Product
Wires and cables used in containment dome of nuclear power plant. The containment vessel is a vital safety feature
in a nuclear reactor that functions as the third defense line against the spread of radioactive substances into the
surrounding area, following the nuclear fuel cladding and pressure shell. The wires and cables within the enclosure
are exposed to a complicated nuclear reaction environment for a prolonged period, which causes the accumulation
of detrimental impacts from elements such as radiation and temperature. These can further make materials suffer
from oxidation, decomposition and other chemical reactions, as well as embrittlement, hardening, cracking and other
physical changes (Levet et al., 2017). These damages to insulation and mechanical performance will impede the safe
and stable operation of nuclear power plant (Ding et al., 2021).

Figure 1: Model of Westinghouse-led IRIS primary

reactor system and compact containment vessel. Figure 2: PEEK Tubes and Wires

2. Material Selection and its Properties

Poly Ether-Ether-Ketone (PEEK) is best suited material for such application. As a typical representative of high-
performance engineering plastic, PEEK exhibits very excellent thermal stability, fatigue resistance and radiation
resistance. It also has good mechanical properties, chemical resistance, flame resistance, peel resistance (A complete
guide to peek material & properties 2022). So, it is widely used as insulation material in high-temperature engineering
environments. PEEK cables and wires are used in structure of nuclear reactor containment vessel (Kurtz, 2011).

Figure 1: PEEK- A High Performance Plastic Figure 4: Chemical Structural Formula of PEEK

3. Process Selection for Manufacturing and its Justification

The extrusion process is the best suited polymer processing method for manufacturing PEEK tubing for this
application. Extrusion involves melting and forcing the polymer through a die to create a continuous shape, such as a
tube (4 processing methods for Peek - Advanced EMC Technologies: High performance polymer seals & bearings 2018).
MME (19-23) March 23, 2023

Extrusion is generally considered the preferred method for manufacturing PEEK tubes and rods compared to injection
molding, for the following reasons:

▪ Material properties: PEEK is a high-performance engineering polymer that requires careful processing to
achieve the desired mechanical and thermal properties. The extrusion process allows for better control over
the orientation and crystallinity of the polymer, resulting in higher strength and stiffness properties compared
to injection molding.
▪ Cross-sectional shape: Extrusion is better suited for producing tubes and rods with a uniform cross-sectional
shape, as it allows for continuous processing of the material without the need for separate molds. Injection
molding, on the other hand, requires a separate mold for each individual part, which can be time-consuming
and expensive.
▪ Wall thickness: Extrusion is better suited for producing tubes and rods with consistent wall thickness
throughout the length of the part. Injection molding, on the other hand, can result in variations in wall
thickness due to the nature of the process.
▪ Cost-effectiveness: Extrusion is generally a more cost-effective process than injection molding for producing
large quantities of tubes and rods, as it requires less tooling and setup time.

4. Parameters for Processing

Some critical parameters and controls for the extrusion process of PEEK tubing are:

i. Temperature control: PEEK has a high melting temperature of around 343°C (649°F), so it is crucial to control
the temperature of the extruder barrel, die, and mandrel to ensure that the PEEK material is melted uniformly
and maintained at the correct temperature throughout the extrusion process.
ii. Screw speed: The screw speed determines the rate at which the PEEK material is transported through the
extruder barrel. Typically, a screw speed of 10-20 rpm is recommended for PEEK extrusion.
iii. Die design: The die is responsible for shaping the molten PEEK material into the desired tube shape. The die
design should be optimized to ensure that the PEEK material flows smoothly and evenly, without any
interruptions or defects.
iv. Cooling rate: Once the PEEK material has been extruded, it needs to be cooled quickly to maintain its shape
and prevent deformation. The cooling rate can be controlled by adjusting the temperature of the cooling
medium, such as air or water.
v. Line speed: The line speed determines the rate at which the PEEK tubing is pulled through the extruder. The
line speed should be carefully controlled to ensure that the tubing is extruded at a consistent diameter and
thickness.
vi. Tension control: The tension on the PEEK tubing as it is being pulled through the extruder can affect the final
dimensions and mechanical properties of the tubing. The tension should be carefully monitored and
controlled to ensure that the tubing is not stretched or deformed.
vii. Quality control: Regular quality checks should be performed during the extrusion process to ensure that the
PEEK tubing meets the required specifications for diameter, thickness, and mechanical properties. This can be
done using a range of techniques, such as measuring the diameter and wall thickness of the tubing, performing
visual inspections for defects, and testing the mechanical properties of the tubing using equipment such as a
tensile tester.

Note that the specific values for these parameters may vary depending on the specific extruder and PEEK material
being used, as well as the desired properties of the final tubing product.
MME (19-23) March 23, 2023

5. Probable Defects
Here are some common defects that can occur in products during manufacturing processes, along with their causes
and remedies:

i. Porosity: Small air pockets or voids within the material

▪ Causes: Incomplete filling of mold, incorrect material temperature, trapped gases
▪ Remedies: Increase injection pressure, increase injection speed, adjust material temperature
ii. Flash: Excess material that extends from the parting line of the mold
▪ Causes: Excessive injection pressure, incorrect clamping force, worn or damaged mold
▪ Remedies: Reduce injection pressure, adjust clamping force, repair or replace mold
iii. Sink marks: Indentations or depressions in the surface of the part
▪ Causes: Incomplete filling of mold, variation in wall thickness, incorrect material temperature
▪ Remedies: Increase injection pressure, adjust material temperature, modify mold design
iv. Weld lines: Visible lines or marks where the material flows together during molding
▪ Causes: Multiple injection points, material flow front collision, inadequate packing pressure
▪ Remedies: Adjust mold design to reduce multiple injection points, optimize packing pressure, adjust
material temperature
v. Warpage: Deformation or distortion of the part, causing it to be non-uniform
▪ Causes: Non-uniform cooling, inadequate clamping force, incorrect ejection timing
▪ Remedies: Optimize cooling rate, adjust clamping force, modify ejection timing

By identifying and addressing these common defects, manufacturers can produce high-quality products with minimal
waste or rework (Whelan & Dunning, 1988).

References

1. Levet, A., Colombani, J., & Duponchel, L. (2017). Studying radiolytic ageing of Nuclear Power Plant Electric cables with
FTIR spectroscopy. Talanta, 172, 139–146. https://doi.org/10.1016/j.talanta.2017.05.046

2. Ding, R., Xu, L., Li, J., Liao, J., Wang, J., Wang, Z., & Ma, H. (2021). Investigation and life expectancy prediction on
poly(ether-ether-ketone) cables for thermo-oxidative aging in Containment Dome of Nuclear Power Plant. Polymer
Testing, 103, 107362. https://doi.org/10.1016/j.polymertesting.2021.107362

3. A complete guide to peek material & properties. WayKen. (2022, August 23). Retrieved March 23, 2023, from
https://waykenrm.com/blogs/peek-material-and-properties/

4. Admin. (2018, May 2). 4 processing methods for Peek - Advanced EMC Technologies: High performance polymer seals
& bearings. Advanced EMC Technologies | High Performance Polymer Seals & Bearings. Retrieved March 23, 2023,
from https://advanced-emc.com/4-processing-methods-for-peek

5. Kurtz, S. M. (2011). Peek Biomaterials Handbook. William Andrew.

6. Whelan, T., & Dunning, D. (1988). The Dynisco extrusion processors handbook. Dynisco Inc.