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Annealing is the heating a molded plastic part to just below its glass transition temperature Annealing is used to reduce inherent stresses that may be introduced during the molding and cooling processes Annealing High stress levels generally make molded plastic parts more susceptible to stress cracking Stress reduction can provide an extra measure of safety from aggressive chemical environments that may come in contact with the molded part. Applications such as medical devices, automotive lenses, and institutional / commercial food ware are areas where stress-cracking failures can be critical.

Annealing is not a cure-all!

First consider proper mold design, processing parameters, resin selection, application requirements and your resin supplier!

M Three different types of annealing processes are typically used in the plastics industry:

Batch Hot Oven Annealing

Annealing

(CFHA) Conveyorized Forced Hot Air Annealing (IR) Infrared Annealing

Batch Annealing consists of placing parts, usually on racks, in a hot air convection oven that is set at a certain temperature for a specific time period Annealing cycles can take from thirty minutes to as long as 2 hours or more at temperatures ranging from 230F to 270F Annealing Long cycles are sometimes necessary due to restricted airflow caused by parts being packed on top of or placed very close to one another Parts closest to the airflow see hotter temperatures for a longer period of time. This can lead to inconsistent annealing throughout the population of parts in the oven.

Batch Hot Air Annealing

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IR Infrared annealing is a process that is best suited for in-line implementation. It is a continuous annealing process much like CFHA. However, unlike CFHA, heat is generated in the molded part by absorption of electromagnetic energy transmitted from IR emitters. Direct energy absorption by the molded part generates the required heat for annealing. This method is a very fast and efficient way of generating heat. Comparatively, the hot air annealing methods generate part heat by first heating the surrounding air which in turn heats the molded part. Typical in-line IR annealing cycles range from about 60 seconds to as long as six minutes, depending on the size and wall thickness of the part.

M Typically implemented as an in-line annealing process with cycle times ranging from 60 seconds to 5 minutes

Although IR annealing is generally the fastest of the three methods, it also has a few drawbacks. Off-line implementation is possible, but not generally recommended. Also, part orientation sometimes is critical for successful IR annealing.

Recommendations
In-line implementation only! Use a robot to place parts on the conveyor belt Cycle time must be consistent part to part Parts should reach the IR oven within 30 seconds after de-molding Oven parameters generally change with various part geometry's

Conveyorized Forced Hot Air

CFHA Annealing uses forced hot air set at a certain velocity and temperature as the heat source. Unlike the batch process, this process is conveyorized and is well suited for implementation as an in-line annealing process. Parts can be set on the conveyor belt immediately after molding which works especially well with robotic part pickers. This method allows for each part to be heated identically, which yields consistent annealing results. Typical annealing times using CFHA can range from as little as four minutes to as long as fifteen minutes or more with temperatures ranging from 250F to 275F, depending on part design, size, and thickness. This process can also be implemented as an offline process where parts could be annealed some time after molding if necessary.

M Conveyorized Forced Hot Air Annealing can be implemented as an in-line or off-line annealing process with cycle times ranging from approximately 7 minutes to 1 hour.

Annealing Methods for Reducing Stress in Molded Plastic Parts M

Advantages Small oven footprint Short annealing cycles In-line processing Disadvantages Difficult part geometry's and thick parts may be challenging Smaller processing windows

Advantages Larger processing window In-line or off-line processing Difficult part geometrys ok Disadvantages Larger oven footprint Longer annealing cycles

Bayer Corporation recommends annealing only after mold design and processing parameters are optimized!

Injection molded thermoplastic parts generally develop both compressive and tensile stresses during molding and subsequent cooling. High residual stresses in the form of surface tensile stresses are generally responsible for premature part failure.

ENVIRONMENTAL STRESS CRACKING (ESC)

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What is it?
Localized cleaving of portions of intermingled molecular chains in an area of concentrated stress

Exposure to Stress Cracking Agent

Localized high stress area

Stress Crack (refracting light)

Although it is a destructive test, solvent stress testing is recommended. M Solvent Stress Testing Area @ Bayer Corporation All testing is done in a ventilated laboratory hood!

One way to estimate internal tensile stresses at or near the surface of polycarbonate parts is to use an immersion test with TnP (toluene and n-propyl alcohol) solutions. Propylene Carbonate is another test solvent that may be used to determine stress levels as low as 400 psi. After immersion, crazes or cracks will appear in areas where the higher tensile stress levels are concentrated.

Annealing Equipment
Batch
P.O. Box 1320 Minneapolis, MN 55440 1-800-328-5476

Despatch Industries Inc.

CFHA Despatch Industries

Despatch Industries Inc. P.O. Box 1320 Minneapolis, MN 55440 1-800-328-5476

IR Hennecke Machinery
Mayview Rd, & Park Dr. Lawrence, PA 15055 412-777-2000