Testing and analysis methods at KAP The extensive possibilities of our laboratories

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Microscopy

Microscopy laboratory of the KAP DF.Fotografie

In plastics analysis, microscopic methods offer target-oriented investigation options both in the context of research and development activities and in the areas of failure analysis and quality assurance.

These include, among others:

  • Determination of material and material properties
  • Identification of processing errors to evaluate component quality
  • Fractographic investigations
  • 3D-visualised surface quantifications
  • Polarisation microscopic description of internal component stresses and orientations
  • Evaluation of structural component features
  • Quantification of the size and distribution of fillers and reinforcing materials, pores and multiphase systems
  • Volume-based component measurements and structural investigations

IKV has a comprehensive range of microscopic preparation and analysis methods that cover the entire spectrum of techniques relevant to plastics analysis. These make it possible to obtain meaningful results quickly and reliably. Careful sample preparation plays a central role in this. Through its daily involvement in public research projects and the processing of numerous industrial issues, IKV has built up a broad knowledge base that supports the rapid production of valid and meaningful test results.

Microscopic methods and equipment

  • Light macroscopy
  • Light microscopy
  • Scanning electron microscopy
  • Energy-dispersive X-ray spectroscopy
  • Transmission electron microscopy
  • Atomic force microscopy
  • Laser confocal microscopy
  • µ-computed tomography (µ-CT)
  • Microscope heating and heating-shear stages
  • Preparation equipment

Spectroscopy

ESCA – Electron spectroscopy for chemical analysis (ESCA) DF.Fotografie

The precise identification of a material is the basis for subsequent work steps and procedures in many practical areas and applications. Plastics as well as numerous other organic and inorganic substances can be identified using the following methods as indispensable tools for structure elucidation:

  • Fourier transform infrared spectroscopy (FT-IR) is a generally non-destructive standard method for the material characterisation of (semi-)organic substances and thus also of plastics, coatings and contaminations.
  • Energy-dispersive X-ray structure analysis (EDX) is suitable for characterising inorganic substances such as fillers. This method of near-surface elemental analysis (for elements with atomic number ≥ 6) can be carried out both at specific points and over defined areas.
  • Using electron spectroscopy for chemical analysis (ESCA), also known as X-ray photoelectron spectroscopy (XPS), an elemental analysis of the surface is carried out, which detects elements from atomic number 3 and examines the first few nanometers of the sample.

The following tasks can typically be pursued with spectroscopic methods:

  • Material identification
  • Quality control
  • Aging condition / oxidative damage
  • Identification of impurities or contamination
  • Acquisition of reaction kinetics
  • Surface analysis including barrier and protective layers
  • Trace analysis of metal compounds such as metal oxides including their distribution

Spectroscopy methods and equipment

  • Fourier transform infrared spectroscopy (FT-IR)
  • Electron spectroscopy for chemical analysis (ESCA or XPS)
  • Energy dispersive X-ray spectroscopy (EDX)
  • Coupling with thermal analysis in the form of TGA/DSC/FT-IR/MS

Mechanical testing

Part of the mechanical testing laboratory at KAP. DF.Fotografie

Mechanical testing is an important tool for product testing and quality assurance. To characterise the mechanical properties of construction materials, testing methods such as the tensile test, the notched bar impact test and the hardness test are fundamental and frequently used methods. The use of universal testing machines enables both standard-compliant testing processes and individualised component testing.

The test methods in the short-term test include:

  • Tensile, compression and bending tests
  • Torsion tests, shear tests
  • Crack widening tests, tear propagation tests
  • Adhesion test
  • Friction test
  • Compression set determination

Additional parameters influencing the plastic, such as climate and media influences, are already taken into account when designing the test and preparing the test specimens. The mechanical tests are often preceded by work in the areas of sample preparation, ageing using UV radiation and/or conditioning in climatic chambers. Furthermore, other laboratory areas are optimally equipped for a variety of long-term or dynamic tests. In all laboratory areas, tests are carried out on thermoplastics and thermosets as well as on fiber composites with extensive experience.

Methods and equipment for mechanical testing

  • Specimen production
  • Sample conditioning
  • UV and climate chamber
  • Universal testing machines for short-term testing (incl. climate and media influence)
  • Dynamic testing machines (fatigue tests)
  • Long-term test benches
  • High-speed tear and puncture testing machine
  • Drop tower
  • Flapping pendulum
  • Abrasion test
  • Rebound test

Thermal analysis

Blick in das Physiklabor des KAP.
The thermal analysis team works in the physics laboratory. Thermal analysis is used to determine many properties that are important for the processing and use of plastic products. DF.Fotografie

The diverse and informative methods of thermal analysis help to identify complex relationships between the processing, structure and properties of plastics. Thermal analysis methods can be used to identify and characterise polymers and detect processing influences and material damage.
Thermal analysis is used to determine many properties that are important for the processing and use of plastic products. These include:

  • Melting temperature, melting enthalpy
  • Solidification temperature
  • Glass transition temperature
  • Crosslinking states for thermosets and elastomers
  • Qualitative and quantitative description of thermal and thermo-oxidative degradation processes
  • Determination of filler and reinforcing material content
  • Expansion coefficients
  • Residual stresses
  • Temperature-dependent modulus of elasticity under different loads

The methods are used for different materials: thermoplastics, thermosets, elastomers, resin and adhesive systems, foodstuffs, pharmaceuticals, building materials and many more.

Methods and equipment for thermal analysis

  • Differential scanning calorimetry (DSC)
  • Thermogravimetric analysis (TGA) with coupling options with FT-IR and MS
  • Thermo-mechanical analysis (TMA)
  • Dynamic mechanical analysis (DMA)

Rheometric analysis

Rheometric methods can be used to measure the extent of deformation of a material or liquid when a force is applied to it.

Knowledge of the flow behavior of plastic melts, rubber or silicone compounds and also the viscosity of resin systems is essential in order to be able to design the manufacturing processes in a targeted manner. In addition to the amount of viscosity, its elastic and viscous components can also be determined. This option provides important information, for example, about the extent to which a plastic melt reacts to a temperature increase under shear. As the viscosity of a plastic is the result of many detailed properties such as molecular weight distribution, degree of branching and additives, rheometric methods can also provide comparative evidence of batch fluctuations.

  • The following properties can be described using rheometric investigations:
  • Viscosity as a function of temperature, shear rate and pressure
  • Elastic and ideal viscosity components of the viscosity
  • Structural viscosity
  • Determination of Carreau parameters
  • Storage and loss moduli as a function of temperature and shear rate
  • Change in a molecular structure (e.g. through degradation or cross-linking)
  • Change in additivation
  • Gel point or the pot life of a resin system

Oscillatory measurements in particular offer many possibilities for material characterisation. Preliminary tests are required to find a suitable individual operating point for the interaction system of rheometer and material.

Methods and equipment for rheometry

  • Capillary rheometer
  • Rotational rheometer
  • Melt index device
  • Mooney viscometer
  • Rubber Process Analyser

Practical examples

Insights into projects from various industries

Construction industry

Practical examples: Construction

Plastics are indispensable in the construction industry, whether in seals, pipes or insulation materials. Our practical examples from this sector show how targeted damage analyses have enabled material defects to be identified and rectified at an early stage. In this way, we contribute to the longevity and safety of buildings.
Installing electronic circuit board

Practical examples: Electrics and electronics

Plastics in electronic components have to withstand the highest loads. Our examples from the electronics industry show how we use careful analysis to help prevent failures and ensure the safety and functionality of complex devices and systems.
Bisschiene aus der Dentalmedizin

Practical examples: Medical technology

Reliability of plastic products in medical technology: case studies show how precise material testing can eliminate potential risks and ensure safety standards.

Practical examples

Examples from the day-to-day work of the audit and analysis department illustrate the approach and diverse consulting options that KAP offers its clients. These insights show how tailor-made solutions are developed to meet the specific requirements of each industry.

View practical examples

Mitarbeiter des KAP im Beratungsgespräch mit Kunden am Flipchart.© DF.Fotografie