Front Cover -- Extrusion: The Definitive Processing Guide and Handbook -- Copyright -- Contents -- Preface to Second Edition -- Preface to First EditionExtrusion processes have long been a staple of the plastics manufacturing industry---so much so tha ... -- Obituary -- Part I: Single Screw Extrusion -- 1 - Extrusion Process -- 1.1 Raw Material Supply -- 1.2 Raw Material Blending and Mixing -- 1.3 Drying -- 1.4 Feeding Polymer to the Extruder -- 1.5 Extrusion -- 1.6 Secondary Operations -- 1.7 Inspection, Packaging, and Shipping -- 2 - Extruder Safety -- 2.1 Hazards Associated with an Extruder -- 2.2 Proper Training -- 2.3 Inspection and Housekeeping -- 2.4 Material Safety -- 3 - Single Screw Extruder: Equipment -- 3.1 Introduction -- 3.2 Equipment -- 3.3 Drive -- 3.4 Feed -- 3.5 Screw, Barrel, and Heaters -- 3.6 Die and Adapter -- 3.7 Controls -- 3.8 Extruder Devolatilization -- 3.9 Vertical Extruders -- References -- 4 - Plastic Behavior in the Extruder -- 4.1 Feed Zone -- 4.2 Polymer Melting or Plastication -- 4.3 Melt Conveying -- 4.4 Mixing -- 4.5 Extruder Throughput Calculations -- 4.6 Devolatilization -- 4.7 Die -- References -- 5 - Screw Design -- 5.1 Barrier Screw -- 5.2 Mixing Screw -- 5.3 Screw Wear -- 5.4 Screw Compression Ratios -- 5.5 Screw Performance [13] -- 5.6 Summary -- References -- 6 - Processing Conditions -- 6.1 Extruder Temperature Profiles -- 6.2 Extruder or Production Run Setup -- 6.3 Start-Up -- 6.4 Steady-State Operation -- 6.5 Shutdown and Product Changes -- References -- 7 - Scale-Up -- References -- 8 - Shear Rates, Pressure Drops, and Other Extruder Calculations -- 8.1 Shear Rates -- 8.2 Extruder Screw Calculations [2] -- 8.3 Different Extruder Section Output Calculations -- References -- Part II: Twin Screw Extrusion -- 9 - Twin Screw Extrusion Process -- 9.1 Raw Material Supply.

9.2 Raw Material Blending and Mixing -- 9.3 Drying and Devolatilization -- 9.4 Feeding Polymer to the Extruder -- 9.5 Extrusion -- 9.6 Secondary Operations -- 9.7 Inspection, Packaging, and Shipping -- References -- 10 - Extruder Safety -- 10.1 Hazards Associated with an Extruder -- 10.2 Personal Protective Equipment -- 10.3 Lock-Out, Tag, and Clear Procedure -- 10.4 Proper Training -- 10.5 Inspection and Housekeeping -- 10.6 Material Safety -- 11 - Twin Screw Extruder Equipment -- 11.1 Drive -- 11.2 Feed -- 11.3 Screw and Barrel Heating and Cooling -- 11.4 Die and Adapter -- 11.5 Controls -- References -- 12 - Plastic Behavior in Twin Screw Extruders -- 12.1 Feed -- 12.2 Plasticating and Melting -- 12.3 Melt Conveying -- 12.4 Mixing -- 12.5 Downstream Feeding -- 12.6 Devolatilization -- 12.7 Pumping -- 12.8 Die -- 12.9 Melt Pressure Profile -- 12.10 Residence Time -- References -- 13 - Screw Design -- 13.1 Conveying -- 13.2 Mixing Elements -- 13.3 Screw Design Applications -- Reference -- 14 - Processing Conditions -- 14.1 Extruder Temperature Profile -- 14.2 Screw Speed -- 14.3 Process Variables -- 14.4 Extruder or Production Run Setup -- 14.5 Start-Up -- 14.6 Steady-State Operation -- 14.7 Shutdown and Product Changes -- 15 - Applications -- 15.1 Compounding -- 15.2 Reactive Extrusion and Devolatilization -- 15.3 Profile and Other Twin Screw Extrusion Applications -- References -- 16 - Scale-Up -- 17 - Shear Rate, Pressure Drop, and Other Extruder Calculations -- 17.1 Shear Rates -- 17.2 Extruder Calculations -- 17.3 Other Calculations -- References -- Part III: Polymeric Materials -- 18 - Polymer Overview and Definitions -- 18.1 Overview -- 18.2 Thermoplastic versus Thermoset -- 18.3 Polymer Formation -- 18.4 Molecular Weight -- 18.5 Copolymers -- 18.6 Polymer Structures -- 19 - Polymer Structure -- 19.1 Amorphous Polymers.

19.2 Semicrystalline Polymers -- 19.3 Comparison of Semicrystalline and Amorphous Polymers -- 19.4 Crystallinity Measurement -- 19.5 Polyethylene Crystallinity -- 19.6 Polypropylene Crystallinity -- 19.7 Polystyrene Crystallinity -- 20 - Polymer Rheology -- 20.1 Definitions -- 20.2 Measurement -- 20.3 Viscosity in Extrusion -- References -- 21 - Testing Properties -- 21.1 Density and Specific Gravity -- 21.2 Melt Flow Index -- 21.3 Tensile -- 21.4 Flexural Test -- 21.5 Compressive Strength -- 21.6 Heat Deflection Temperature -- 21.7 Long-Term Heat Aging -- 21.8 Thermal Properties -- 21.9 Time-Temperature Relationship -- 21.10 Izod Impact -- 21.11 Charpy -- 21.12 Comparative Thermoplastic Properties -- 21.13 Polymer Additives -- 21.14 Drying -- 22 - Processing Recommendations for Various Resin Systems -- 22.1 Acrylonitrile Butadiene Styrene -- 22.2 Polyamide -- 22.3 Polyethylene -- 22.4 Polymethyl Methacrylate (Acrylic) -- 22.5 Polypropylene -- 22.6 Polycarbonate -- 22.7 Polystyrene -- 22.8 Polyvinyl Chloride -- 22.9 Polyester -- 22.10 Fluoropolymers -- References -- Part IV: Troubleshooting the Extrusion Process -- 23 - Problem Solving -- 24 - Five-Step Problem Solving Process -- 24.1 Problem Definition -- 24.2 Fix the Problem -- 24.3 Identify the Root Cause -- 24.4 Take Corrective Action -- 24.5 Process Monitoring -- Reference -- 25 - Design of Experiments -- 25.1 DOE Process -- 25.2 Experimental Design -- 25.3 Experiments -- References -- 26 - Quality -- 26.1 Statistical Process Control -- 26.2 Process Capability -- References -- 27 - Troubleshooting Mechanical Extrusion Problems -- 27.1 Problem 1-Extruder Screw Does Not Turn -- 27.2 Problem 2-DC Motor Will Not Start [1] -- 27.3 Problem 3-Drive Train Problems [1] -- 27.4 Problem 4-Rupture Disk Failure in the Barrel -- 27.5 Problem 5-Barrel/Screw Wear [1].

27.6 Problem 6-Screw Turns and No Material Exits the Die -- 27.7 Problem 7-Extruder Shuts Itself Off -- 27.8 Problem 8-Melt Flows Out of the Barrel Vent -- 27.9 Problem 9-Leaking Polymer at the Breaker Plate or Die -- 27.10 Problem 10-Extruder Throughput Rate is Lower than Anticipated -- 27.11 Problem 11-Temperature Overrides Set Point -- 27.12 Problem 12-Extruder Surging Caused by the Equipment -- 27.13 Problem 13-Poor or Insufficient Polymer Mixing -- 27.14 Problem 14-Throughput Variation Over Time -- References -- 28 - Troubleshooting Extrusion Product Problems -- 28.1 Problem 1-Product Surging -- 28.2 Problem 2-Variation in the Product Over Time -- 28.3 Problem 3-Random Product Variation -- 28.4 Problem 4-Streaks in the Product Caused by Poor Mixing -- 28.5 Problem 5-Variation in Product Strength -- 28.6 Problem 6-Product Degradation -- 28.7 Problem 7-Dull Streaks -- 28.8 Problem 8-Machine Direction Die Lines -- 28.9 Problem 9-Color Contamination -- 28.10 Problem 10-Holes in Extrudate -- 28.11 Problem 11-Gels -- 28.12 Problem 12-Gauge Variations -- 28.13 Problem 13-Weld Lines -- 28.14 Problem 14-Weak Film or Coating -- 28.15 Problem 15-Warpage -- 28.16 Problem 16-Sink -- Chapter 29 - Troubleshooting Sheet Extrusion -- 29.1 Mechanical Problems and Solutions -- 29.2 Product Problems and Solutions -- Chapter 30 - Troubleshooting Cast Film -- 30.1 Problem 1-Molten Web Tears Easily When Exiting the Die -- 30.2 Problem 2-Film Thickness Variation -- 30.3 Problem 3-Lines, Streaks, and Foreign Contamination -- 30.4 Problem 4-Extrudate Width is Too Narrow -- 30.5 Problem 5-Wrinkles are Formed in the Film -- 30.6 Problem 6-Roughness on Film Due to Melt Fracture -- Chapter 31 - Troubleshooting Blown Film -- 31.1 Problem 1-Bubble Instability -- 31.2 Problem 2-Gauge Variation Around the Circumference -- 31.3 Problem 3-Wrinkles.

31.4 Problem 4-Lines, Streaks, or Film Contamination -- 31.5 Problem 5-Rough Film Due to Melt Fracture -- References -- Chapter 32 - Troubleshooting Profile and Pipe -- 32.1 Problem 1-Excessive Wall Thickness or Thinness -- 32.2 Problem 2-Wavy Surface Inside the Pipe or Tubing -- 32.3 Problem 3-Weld or Knit Line Weakness -- 32.4 Problem 4-Nonuniform Resin Velocity from a Profile Die -- Part V: Auxiliary Equipment -- 34 - Drying -- 34.1 Drying Definitions and Factors Affecting Drying -- 34.2 Types of Drying Equipment -- 34.3 Purchasing a Dryer -- References -- 35 - Screen Changers -- 35.1 Breaker Plate with Screens -- 35.2 Manual Screen Changer -- 35.3 Hydraulic Screen Changer -- 35.4 Double Bolt Screen Changer -- 35.5 Ribbon-Type Screens -- 35.6 Rotary Disk Screen Changer -- References -- 36 - Gear Pumps -- 36.1 Gear Pump System -- 36.2 Drive and Control System -- 36.3 Potential Gear Pump Problems -- 36.4 Applications -- References -- 37 - Granulators -- 38 - Chillers and Heaters -- 38.1 Chillers -- 38.2 Heaters -- Reference -- Chapter 33 - Feed Systems -- 33.1 Feed System -- 33.2 Blending Systems for Single Screw Extrusion -- 33.3 Feeders -- References -- Part VI: Coextrusion -- 39 - Screw Cleaning and Purge Compounds -- 39.1 Purge -- 39.2 Mechanical Cleaning -- References -- 40 - Coextrusion Applications -- 40.1 Film -- 40.2 Sheet -- 40.3 Pipe, Tubing, and Profile -- 40.4 Wire Coating -- 40.5 Large-Part Blow Molding -- References -- 41 - Feedblocks and Dies -- 41.1 Feedblocks -- 41.2 Multimanifold Dies -- 41.3 Feedblock Combined with a Manifold Die -- 41.4 Computer-Aided Design -- References -- 42 - Polymer Selection for Coextrusion -- 42.1 Melt Viscosity Matching -- 42.2 Interfacial Instability -- References -- 43 - Troubleshooting Coextrusion -- 43.1 Problem 1-Nonuniform Cross or Transverse Direction Layer Thickness.

43.2 Problem 2-Nonuniform MD Layer Thickness.