Multifaceted Evaluation of Plastics: Differences due to PC/ABS Resin Compounding Ratio

Importance of the Topic

PC/ABS blends combine the heat resistance and impact strength of polycarbonate with the moldability of ABS, making them essential in automotive interiors, office equipment, and consumer electronics. Accurate determination of blend composition after molding is critical for product performance and quality control.

Objectives and Study Overview

This study evaluates the relationship between PC/ABS compounding ratios and resulting material properties. Specimens with PC:ABS ratios of 0:100, 25:75, 50:50, 75:25, and 100:0 were analyzed to predict blend composition and ensure consistency in polymer processing.

Methodology

Test specimens were produced by kneading and injection molding at defined temperatures and times for each blend ratio. Analytical methods included optical measurement of yellowness index, dynamic microhardness testing, tensile testing with noncontact extensometry, differential scanning calorimetry, infrared spectroscopy, and microscopic surface hardness mapping.

Used Instrumentation

• UV-2600i UV-Vis Spectrophotometer with ISR-2600Plus Integrating Sphere
• DUH-210 Dynamic Ultra Micro Hardness Tester
• AGX-V Autograph Precision Universal Testing Machine with TRViewX240S extensometer
• DSC-60 Plus Differential Scanning Calorimeter
• IRTracer-100 Fourier Transform Infrared Spectrophotometer with QATR-10 diamond prism
• SPM-Nanoa Scanning Probe Microscope (Nano 3D Mapping Fast mode)

Key Findings and Discussion

Optical analysis revealed decreased reflectance and increased yellowness index with higher ABS content. Microhardness peaked at 75% PC. Tensile strength and elongation increased linearly with PC ratio, while elastic modulus showed nonlinearity beyond 50–75% PC. DSC identified two glass transitions (ABS and PC) that correlated linearly with blend ratio. FTIR peak intensity at 1770 cm⁻¹ scaled with PC content, confirming composition. SPM imaging illustrated phase distributions matching nominal ratios.

Benefits and Practical Applications

Combining multiple analytical techniques provides reliable, rapid prediction of blend composition, reducing the risk of erroneous judgments in production. These methods support quality assurance in the manufacturing of PC/ABS parts for automotive, electronics, and household applications.

Future Trends and Potential Applications

Linking microscopic morphology data with mechanical performance using advanced imaging and data analytics could refine composition prediction models. Integration of inline spectroscopic monitoring and machine learning will enable real-time process control. Extending this multifaceted approach to other polymer blends and recycled materials can enhance sustainable manufacturing.

Conclusion

This multifaceted evaluation confirmed that optical, mechanical, thermal, spectroscopic, and microscopic analyses can predict PC/ABS blend composition and elucidate structure-property relationships, improving quality control and production efficiency.