This paper presents results from numeric simulation performed using a software specially developed to determine the crack length in samples with a weld line. The simulations results were compared with experimental results obtained by tensile testing samples molded by the injection process with several melting temperatures. The increase on the crack length in products made by the injection process may provoke a decrease on the effective rupture stress due to the decrease on the contact area or on the interpenetration. This problem might be a relevant one for structural parts since it might reduce the effective work stress. Using appropriated equations to describe: polymer cooling and rheology, the molecular inter-diffusion and interpenetration, and taking as a basis DeGennes's reptation model, it was possible to determine the inter-diffusion profile in the weld line interface and the interpenetration along the thickness. The critical interpenetration was determined on the basis of the crack length value. Finally, reducing the injection temperature the sample solidifies faster, thus decreasing the molecular inter-diffusion and the interpenetration in the weld line interface. By increasing the molecular interpenetration the maximum rupture stress of the Basf thermoplastic polymer Polystyrol 158K is also increased. The dependence between the maximum interpenetration in the middle of the sample and the critical interpenetration corresponding to the crack found by tensile testing the samples as a function of temperature variation was determined. Therefore, a software was developed able to well and coherently describe the crack dimension.
molecular diffusion; cooling time; weld line; molecular interpenetration
