Polymers/Organic Materials Aging Overview Robert Bernstein Sandia National Laboratories Organic Materials Department Albuquerque, NM rbernst@sandia.gov 505-284-3690 179th Technical Meeting Rubber Division April 18-20, 2011 Akron, Ohio Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company, for the United States Department of Energy’s National Nuclear Security Administration under contract DE-AC04-94AL85000. 1 Organic Materials Problems; Organic Materials Aging and Degradation Nuclear Power Plant Cable Insulation O-rings Shorting Plugs 13 CH2 CH CH2 CH CH3 CH3 n n 13 CH2 CH CH2 CH 13 CH3 CH3 n Labeled Polymers n Textiles 2 Temperature ‘Accelerated Aging’ Reaction Coordinate 3 General Approach/Goals Macroscopic level Molecular Level Physical property Sealing Force Chemical Property Compression Set Tensile Strength Permeation Elongation Additives Dimensional changes Goals • Prediction of physical properties vs. time • Predict remaining lifetime of field materials • Develop condition monitoring method 4 Deception! Conclusions derived from initial high temperature, short duration (even out to 1 year) accelerated aging can be misleading. Chemistry / mechanisms must be understood. Results must be critically analyzed to identify and understand mechanism changes 5 Thermal-oxidative Aging: Nylon Average % tensile strength remaining 100 90 80 70 60 138 °C 138 °C 2nd Spool 124 °C 124 °C 2nd Run 124 °C 2nd Spool 109 °C 99 °C 95° C 95 °C 2nd Run 80 °C 64 °C 48 °C 37 °C 50 40 30 20 10 0 1 10 100 1000 Time in days at temperature Bernstein, R.; Gillen, K. T. Polymer Degradation and Stability, Nylon 6.6 accelerating aging studies: II. Longterm thermal-oxidative and hydrolysis results 2010, 95, 1471-1479. 2000 days ~ 5.5 years 6 7 Arrhenius Equation Arrhenius equation: k =Ae-Ea/RT Old Chemist expression: increase rate by 10 °C will double the rate 8 Time Warp Back to High School…. …..but only briefly…. 9 Equation of a Line y=mx + b what you want y-intercept what you know slope 10 Function of a Line y intercept =b y=mx + b slope =m y x 11 Arrhenius Equation Activation Energy k =Ae-Ea/RT rate Gas constant Temperature (Kelvin) Pre-exponential factor e Empirical equation 12 Arrhenius Equation k =Ae-Ea/RT ln(k) = ln(A) – Ea/RT ln(k) =– Ea/RT + ln(A) ln(k) =–( Ea/R)(1/T) + ln(A) 13 Function of a Line y intercept =b y=mx + b slope =m y x 14 Function of a Line y intercept =ln(A) ln(k) =–( Ea/R)(1/T) + ln(A) slope = -Ea/R ln(k) 1/T 15 Arrhenius Equation Arrhenius equation: k =Ae-Ea/RT ln(k) =–( Ea/R)(1/T) + ln(A) k = anything Plot log(aT) vs 1/T linear if Arrhenius What is Ea? 16 Ea Energy reactants products Reaction coordinate ---Imagine a marble--- 17 Ea Energy reactants products Reaction coordinate 18 Ea Intermediates/Transition states Ea Energy reactants products Reaction coordinate 19 Are Diamonds forever? Kinetics vs. Thermodynamics Energy Diamond Graphite Reaction coordinate 20 (really the same thing) 21 Ea Intermediates/Transition states Ea Energy Diamond Graphite Reaction coordinate 22 Arrhenius Equation k =Ae-Ea/RT Critical assumption is that Ea is CONSTANT Assume Ass-u-me 23 Time-Temperature Superposition Does mechanism change as a function of temperature? If same mechanism: • same shape (log graph) • should be constant acceleration (multiple) 1. Pick a reference temperature 2. Multiply the time at each temperature by the constant that gives the best overlap with the reference temperature data 3. Define that multiple as ‘aT’ (aT = 1 for ref. temp.) 4. Find aT for each temperature Plot log(aT) vs 1/T linear if Arrhenius Gillen, K. T.; Celina, M.; Clough, R. L.; Wise, J. Trends in Polymer Science, Extrapolation of Accelerated Aging Data -Arrhenius or Erroneous? 1997, 5, 250-257. Arrhenius equation: Empirical equation k =Ae-Ea/RT ln(k) = ln(A) – Ea/RT 24 Thermal-oxidative Aging: Nylon Average % tensile strength remaining 100 90 80 70 60 138 °C 138 °C 2nd Spool 124 °C 124 °C 2nd Run 124 °C 2nd Spool 109 °C 99 °C 95° C 95 °C 2nd Run 80 °C 64 °C 48 °C 37 °C 50 40 30 20 10 0 1 10 100 1000 Time in days at temperature Bernstein, R.; Gillen, K. T. Polymer Degradation and Stability, Nylon 6.6 accelerating aging studies: II. Longterm thermal-oxidative and hydrolysis results 2010, 95, 1471-1479. 2000 days ~ 5.5 years 25 Thermal-oxidative Aging: Nylon Shifted Data Average % tensile strength remaining 100 90 80 70 60 138 °C 138 °C 2nd Spool 124 °C 124 °C 2nd Run 124 °C 2nd Spool 109 °C 99 °C 95 °C 95 °C 2nd Run 80 °C 64 °C 48 °C 37 °C 50 40 30 20 10 Shift Factor 8.5 9.0 3.25 2.75 3.0 1.0 0.45 0.75 0.65 0.25 0.20 0.12 0.08 0 1 10 100 1000 Shifted time to 109 °C, days Bernstein, R.; Gillen, K. T. Polymer Degradation and Stability, Nylon 6.6 accelerating aging studies: II. Long-term thermal-oxidative and hydrolysis results 2010, 95, 1471-1479. 26 Shift factor, aT Thermal-oxidative Aging: Nylon Shift Factor Graph 10 10 1 1 0.1 0.1 0.01 0.01 ~23 °C 0.001 0.001 0.0001 0.0001 2.4 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4 3.5 1000/T, 1/K Bernstein, R.; Gillen, K. T. Polymer Degradation and Stability, Nylon 6.6 accelerating aging studies: II. Long-term thermal-oxidative and hydrolysis results 2010, 95, 1471-1479. 27 Thermal Exposure Thermal-Oxidation Polymer + O2 Oxidized Polymer Quantify amount of oxygen consumed •Simple in theory •Difficult in practice •Amazingly sensitive 28 Schematic of Oxuptake Initial Pressure of O2 O2 O2 O2 O2 O2 O2 O2 O2 Final Pressure of O2 D O2 O2 Polymer O2 + Time Oxidized Polymer O2 O2 29 Oxygen Consumption Shift Factor, aT Normalized Measured Property Enhanced Extrapolation ‘Good’ O XX O X XO O X X X Measured Property O Oxygen Consumption X O O O O 1/Temperature, K-1 High Temp Low Temp 30 31 Shift Factor, aT Normalized Measured Property Enhanced Extrapolation: ‘Bad’ O XX O X XO O X X X Measured Property O Oxygen Consumption O X O O O O 1/Temperature, K-1 High Temp Low Temp 32 DLO, Need to Know Diffusion Limited Oxidation (DLO) effects if oxygen dissolved in material used up faster by reaction than it can be replenished by diffusion from surrounding air atmosphere Race between: the oxygen consumption rate versus the oxygen diffusion rate Therefore we need estimates of: 1. O2 permeability versus aging temperature 2. O2 consumption versus aging temperature 33 Diffusion-Limited Oxidation (DLO) O2 O2 O2 O2 O2 O2 O2 rxn rate > diffusion rate Heterogeneous O2 O2 O2 O2 O2 rxn rate < diffusion rate Homogeneous 34 Modulus Profiling Measure of Inverse tensile compliance Closely related to tensile modulus Modulus vs. Shore A 100 M o d u lu s, M P a Indentation technique ca. 50mm resolution 10 1 20 30 40 Excellent to examine ‘geneity’ of aging (heteo- or homo-) (DLO issues) 50 60 70 S h o re A h a rd n e ss 80 90 100 35 Schematic of Modulus Profile Experiment Probe tip, sample and mass Mass is applied in two steps Gillen, K. T.; Clough, R. L.; Quintana, C. A. Polym. Degrad. Stab., Modulus profiling of polymers 1987, 17, 31-47 36 Modulus Profiler 37 Modulus Profiler Sample 38 Homogeneous Aging Aging of a nitrile rubber at temperatures ranging from 65°C to 125°C Modulus profiles of samples aged at 65°C indicate the presence of homogeneous aging 735 days 497 days 350 days 226 days 0 days o 65 C 0 20 40 60 P, % Wise, J.; Gillen, K. T.; Clough, R. L. Polymer Degradation and Stability, An ultrasensitive technique for testing the Arrhenius extrapolation assumption for thermally aged elastomers 1995, 49, 403-418. 80 100 BNM O D65 39 Heterogeneous Aging Modulus profiles for samples aged at 95°C show that diffusion-limited oxidation (DLO) is becoming important; at 125°C, DLO effects are very significant 176 days 1000 127 days 1000 84 days 18 days 36 days 14 days 0 days 7 days 4 days 100 M o d u lu s, M P a 100 -1 D , MPa 0 days 10 10 o o 95 C 125 C 1 1 0 20 40 60 P, % 80 100 BNM O D95 0 20 40 60 P, % Wise, J.; Gillen, K. T.; Clough, R. L. Polymer Degradation and Stability, An ultrasensitive technique for testing the Arrhenius extrapolation assumption for thermally aged elastomers 1995, 49, 403-418. 80 100 BNM O D125 40 Nylon: Tensile versus Oxygen Consumption 10 Shift factor, aT 10 10 10 10 10 10 1 10 0 10 -1 10 -2 10 ~23°C -3 -4 10 10 Tensile Strength Shift Factor Oxygen Consumption Shift Factor -5 10 2.4 2.6 2.8 3.0 1000/T, 1/K 3.2 3.4 1 0 -1 -2 -3 -4 -5 Thermal-oxidative tensile: Prediction vs. Experimental Arrhenius Predictions 64 °C Thermal-oxidative 41 Arrhenius predictions severely off target suggest change in mechanism/nonArrhenius behavior Initial data Predicted: 92% at ca. 3700 days Observe: 92% at ca. 835 days Oxygen consumption suggests no change in thermal-oxidative mechanism Possible explanation involving mechanism change? 42 Nylon Structure H 2N NH2 1,6 -Hexanediamine H N + O O N H H N O n O OH HO O Adipic Acid H2O Nylon 6.6 43 Humidity Aging Schematic H2O H2O O2 H2O O2 H2O O2 H2O O2 O2 H2O O2 O2 H2O H2O O2 O2 O2 H2O O2 H 2O H2O Time, D O2 H2O O2 H2O O2 H2O O2 44 Humidity Aging Hardware 45 Organic Materials Aging and Degradation Specifics -o-rings General path –most organic materials This talk –details not important (all published) 46 O-ring Published Documentation Bernstein, R.; Gillen, K. T. Polymer Degradation and Stability, Predicting the Lifetime of Fluorosilicone O-rings 2009, 94, 2107-2133. Bernstein, R.; Gillen, K. T. "Fluorosilicone and Silicone O-Ring Aging Study," SAND2007-6781, Sandia National Laboratories, 2007. Chavez, S. L.; Domeier, L. A. "Laboratory Component Test Program (LCTP), Stockpile O-Rings," BB1A3964, 2004. Gillen, K. T.; Bernstein, R.; Wilson, M. H. Polymer Degradation and Stability, Predicting and Confirming the Lifetime of O-rings 2005, 87, 257-270. Gillen, K. T.; Celina, M.; Bernstein, R. In Polymer Degradation and Stability Validation of Improved Methods for Predicting Long-Term Elastomeric Seal Lifetimes from Compression Stress-Relaxation and Oxygen Consumption Techniques, 2003; Vol. 82, pp 25-35. 47 O-rings Background Used as environmental seals or other seals O-RING CROSS-SECTIONS Most systems filled with inert gas to protect interior components from oxidation & hydrolysis UNAGED 15 yr in field Previously: No technique to measure equilibrium sealing force No technique to rapidly achieve equilibrium compression set No correlation 48 CSR Jigs Gap of jig can be adjusted to any desired size O-ring pieces cut to allow air circulation Measurement of force involves very slow and slight compression until electrical contact is broken between the top and bottom plates Jigs can be placed in ovens, thus providing isothermal measurements 49 Compression Stress Relaxation (CSR) Shawbury-Wallace Compression Stress Relaxometer (CSR) MK II Commercial Instrument Measure of Force -O-ring sealing force Can Adjust Gap Size to Approximate Actual Compression in System (Wallace Test Equipment, Cryodon, England) 50 Accelerated aging 1) Physical force decay -Equilibrium values achieved –starting point -Ability to get field returned o-ring force –ending point 2) Chemical force decay Prediction of force changes as a function of aging Why we do isothermal measurements… 9 8 7 ~2 hrs F/L, N/cm 6 5 4 3 2 1 0 -4 10 -3 10 -2 10 -1 10 0 10 1 10 2 10 o Time after removal from 110 C oven, days Sealing force per unit length versus time out of a 110 °C oven for two CSR jigs containing Butyl-A o-ring segments that had aged under 25% compression until the force degraded by ~42% (top curve) and ~72% (bottom curve), respectively. Gillen, K. T.; Celina, M.; Bernstein, R. In Polymer Degradation and Stability Validation of Improved Methods for Predicting Long-Term Elastomeric Seal Lifetimes from Compression StressRelaxation and Oxygen Consumption Techniques, 2003; Vol. 82, pp 25-35. 51 52 All Jigs at Temperatures -Fluorosilicone 100 90 80 70 % F/Fo 60 50 Jig #3 138 °C Jig #4 138 °C Jig #5 138 °C Jig #1 138 °C Jig #5 124 °C Jig #6 124 °C Jig #8 124 °C Jig #14 109 °C Jig #15 109 °C Jig #4 80 °C Jig #7 80 °C 40 30 20 10 0 0.1 1 10 100 1000 Time, Days Bernstein, R.; Gillen, K. T. "Fluorosilicone and Silicone O-Ring Aging Study," SAND2007-6781, Sandia National Laboratories, 2007. Bernstein, R.; Gillen, K. T. Polymer Degradation and Stability, Predicting the Lifetime of Fluorosilicone O-rings 2009, 94, 2107-2133. 53 Time-Temperature Superposition Does mechanism change as a function of temperature? If same mechanism: • same shape (log graph) • should be constant acceleration (multiple) 1. Pick a reference temperature 2. Multiply the time at each temperature by the constant that gives the best overlap with the reference temperature data 3. Define that multiple as ‘aT’ (aT = 1 for ref. temp.) 4. Find aT for each temperature Plot log(aT) vs 1/T linear if Arrhenius Gillen, K. T.; Celina, M.; Clough, R. L.; Wise, J. Trends in Polymer Science, Extrapolation of Accelerated Aging Data -Arrhenius or Erroneous? 1997, 5, 250-257. Arrhenius equation: Empirical equation k =Ae-Ea/RT ln(k) = ln(A) – Ea/RT 54 Time-Temperature Superposition 100 90 80 70 % F/Fo 60 50 40 30 20 10 Shift Factor 7 5 3.5 6 2 3 2.5 1 0.9 0.5 0.4 S Jig #3 138 °C S Jig #4 138 °C S Jig #5 138 °C S Jig #1 138 °C S Jig #5 124 °C S Jig #6 124 °C S Jig #8 124 °C S Jig #14 109 °C S Jig #15 109 °C S Jig #4 80 °C S Jig #7 80 °C 0 0.1 1 10 100 Shifted time to 109 °C, Days 1000 55 Shift factor, aT Shift Factor Plot 10 10 1 1 0.1 0.1 0.01 0.01 ~80 °C 0.001 0.001 ~23 °C 0.0001 2.4 2.5 2.6 2.7 2.8 2.9 3.0 1000/T, 1/K 3.1 3.2 3.3 3.4 0.0001 3.5 Temperature ‘Accelerated Aging’ Reaction Coordinate 56 57 Shift factor, aT Shift Factor Plot 10 10 1 1 23 °C aT =0.065 0.1 0.1 0.01 0.01 23 °C aT = 0.011 ~80 °C 0.001 0.001 23 °C aT = 0.000926 ~23 °C 0.0001 2.4 2.5 2.6 2.7 2.8 2.9 3.0 1000/T, 1/K 3.1 3.2 3.3 3.4 0.0001 3.5 58 Shifted Data with RT ‘Prediction’ w/o 80 C data Predicted Time at 23 °C, Years 1 10 100 1000 100 90 80 70 % F/Fo 60 50 40 30 20 10 0 0.1 1 10 100 Shifted time to 109 °C, Days 1000 59 Shift factor, aT Shift Factor Plot 10 10 1 1 23 °C aT =0.065 0.1 0.1 0.01 0.01 23 °C aT = 0.011 ~80 °C 0.001 0.001 23 °C aT = 0.000926 ~23 °C 0.0001 2.4 2.5 2.6 2.7 2.8 2.9 3.0 1000/T, 1/K 3.1 3.2 3.3 3.4 0.0001 3.5 Shifted Data with RT ‘Prediction’ All data Predicted Time at 23 °C, Years 0.1 1 10 100 100 90 80 70 % F/Fo 60 50 40 30 20 10 0 0.1 1 10 100 Shifted time to 109 °C, Days 1000 60 61 Shift factor, aT Shift Factor Plot 10 10 1 1 23 °C aT =0.065 0.1 0.1 0.01 0.01 23 °C aT = 0.011 ~80 °C 0.001 0.001 23 °C aT = 0.000926 ~23 °C 0.0001 2.4 2.5 2.6 2.7 2.8 2.9 3.0 1000/T, 1/K 3.1 3.2 3.3 3.4 0.0001 3.5 62 Shifted Data with RT ‘Prediction’ 109 and 80 only Predicted Time at 23 °C, Years 0.01 0.1 1 10 100 100 90 80 70 % F/Fo 60 50 40 30 20 10 0 0.1 1 10 100 Shifted time to 109 °C, Days 1000 63 Shift Factor Plot 10 10 ~50% in ~ 20 years Shift factor, aT 1 1 23 °C aT =0.065 0.1 0.1 ~50% in ~ 100 years 0.01 0.01 23 °C aT = 0.011 ~80 °C 0.001 0.001 23 °C aT = 0.000926 ~50% in ~ 1000 years ~23 °C 0.0001 2.4 2.5 2.6 2.7 2.8 2.9 3.0 1000/T, 1/K 3.1 3.2 3.3 3.4 0.0001 3.5 64 O-ring Sealing force arguably most important parameter Correlation between equilibrium values sealing force compression set Difficult to measure slow and laborious Easy to measure quick and simple O-RING CROSS-SECTIONS UNAGED 15 yr in field 65 Force versus Compression Set Data -Fluorosilicone 100 % Force Remaining at Temperature 90 80 70 60 50 40 30 20 10 0 0 20 40 60 80 100 % Equilibrium Compression set -Corrected for Temperature Field Data* 66 * not quite the whole story, but good enough for this conversation! 100 J1 Compression set (~1 day), % 90 J2 J8 80 best prediction 70 hi-T prediction 60 50 40 30 20 10 0 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 Aging Aging time, time, years years W69set2 Compression set measurements of three fluorosilicone o-rings taken on surveillance units approximately 1 day after removal from the unit. The solid curve and the dashed curve assume a linear relationship between set and force decay. Bernstein, R.; Gillen, K. T. Polymer Degradation and Stability, Predicting the Lifetime of Fluorosilicone O-rings 2009, 94, 2107-2133 67 Other Compression Set Data XE-5601 SILICONE (E. A. Salazar data) 100 Different Silicone Different Program Different PI 10,000-hour Compression Set, % 40% initial strain at 80 25C 66C 100C 60 121C 149C 40 20 0 1 10 100 Aging time, hrs 1000 10000 Sil-set2 Gillen, K. T. "Silicone seal analysis," Internal Memo, SNL, 2001. Compression Set 68 100 o 10,000-hour Compression Set, % T, C, 80 60 a Filled circles show 40 yr British data for"temperate conditions" T 25 1 66 3.1 100 21 121 55 149 320 Data Analyzed by Gillen Added in 40 year RT data from another source 40 20 0 -3 10 -2 10 -1 10 0 10 1 10 Aging time, years at 25C 2 10 Silsh2 Gillen, K. T. "Silicone seal analysis," Internal Memo, SNL, 2001. 69 Arrhenius Plot for Compression Set 10 3 10,000 hour recovery data 2 Shift factor a T 10 10 10 1 0 2.2 2.4 2.6 2.8 1000/T, K 3.0 3.2 3.4 -1 Sil-Arr2 Arrhenius plot of the shift factors for silicone compression set which leads to an aging room temperature prediction for compression set Gillen, K. T. "Silicone seal analysis," Internal Memo, SNL, 2001. 70 Force versus Compression Set Data Predicted Time at Room Temperature, Years 0.01 100 0.1 1 10 100 0 80 20 70 % F/Fo 60 40 50 40 60 30 20 10 0 80 Force Compression Set 100 Compression set, % 90 71 Force versus Compression Set Data Predicted Time at Room Temperature, Years 0.01 100 0.1 1 10 100 0 80 20 70 % F/Fo 60 40 50 40 60 30 20 10 0 80 Compression set, % 90 Force Compression Set 100 Correlation between current Silicone Force data and Compression set data obtained from three different sources (and different sizes!) Fluorosilicone versus Silicone!! Displays confidence in generalized predictions about silicone o-rings state of health (CS easy to measure) under oxidative environments* 72 10 0 .9 9 0 .8 8 0 .7 7 0 .6 6 0 .5 5 0 .4 4 F /F 0 1 .0 la b -a g e d B u ty l-A 0 .3 F , N /cm Butyl Force vs. Compression set; lab and field aged 3 la b -a g e d B u ty l-B 2 0 .2 la b -a g e d B u ty l-C 0 .1 1 fie ld -a g e d B u tyl-B 0 0 .0 0 20 40 60 80 100 C o m p re ssio n se t, % Equilibrium values of compression set plotted versus F/F0 for laboratoryaged o-rings for three butyl materials plus field results for Butyl-B plotted assuming that F0 = 10 N/cm. Gillen, K. T.; Bernstein, R.; Wilson, M. H. Polymer Degradation and Stability, Predicting and Confirming the Lifetime of O-Rings 2005, 87, 257-270. 73 Heavily Filled Silicone 100 % Force Remaining at Temperature 90 80 70 60 50 40 30 20 10 0 0 20 40 60 80 100 % Equilibrium Compression set -Corrected for Temperature Conducting o-rings compression set versus force remaining 74 Progression of Stress Relaxation due to Chemical Aging Time = 0 Time = .5sec Time =.8sec Time = 1sec SIGYY -191 psi=133 N/cm2 -89 psi= 61 N/cm2 Time = 30 years Time = 56 year Time 90 years Slide Courtesy of David Lo 13 psi= 9 N/cm2 Take home messages… 1) Be aware of mechanism changes 2) Understand chemistry/be careful with the details –DLO, O2 vs. H2O etc 1) Find something to measure 2) Do things at many temp (as far apart as possible) 3) Do things for very very long time 4) Validate against real world 5) It would be nice to know your performance requirements 75 Lots of help… Dora Derzon, Brad Hance, Don Bradley, Roger Assink, James Hochrein, Steven Thornberg, David Lo, Kathy Alam, Laura Martin, John Schroeder, Patti Sawyer, Mark Stavig, and Ken Gillen 76 Questions… 77