Performance of a parallel viscoelastic-viscoplastic model for a microcellular thermoplastic foam on wide temperature range

This paper is concerned with the experimental testing and the constitutive modelling of a thermoplastic microcellular polyethylene-terephthalate (MC-PET) foam on the temperature range of 21–210 °C in order to investigate the temperature-dependent performance of the applied parallel viscoelastic-viscoplastic material model. By means of carefully designed uniaxial mechanical tests in temperature chamber, the viscous, elastic and yielding behaviours of the investigated material are identified, which are then applied for selecting suitable viscoelastic-viscoplastic constitutive models. The material characterization process is conducted using finite-element-based fitting method, including also the analysis of the applied numerical optimization algorithm. The fitting results are used to analyse the parameter sensitivity and to propose closed-form analytical relations for the temperature dependency of the material parameters. Finally, the utilisation of the analytical temperature functions for speeding up the parameter-fitting process is also demonstrated.     

Device for non-disruptive taking of melt samples from a compounding process and direct injection molding

A concept for taking a sample from a polymer melt stream plus the direct processing of this melt to specimen is presented. Therefore, a melt sampling and direct injection molding (MSIM) device was developed. Process parameters were studied and the set-up was implemented successfully. Using the MSIM device, different thermoplastics were processed and provided specimen characterized. The mechanical material properties from samples of the MSIM process show a good consistency compared with data from conventional processes. The MSIM device can be used in production processes for quality control, e.g. color or mechanical properties, as well as in the field of research and development to reduce development cycles.     

A technique for in situ X-ray computed tomography of deformation-induced cavitation in thermoplastics

Deformation-induced cavitation influences the mechanical response of polymeric materials, but acquiring in situ measurements of the spatial evolution of cavities has typically necessitated the use of synchrotron radiation sources. The objective of this study is to develop and demonstrate a method allowing for in situ measurements of deformation-induced cavitation in axisymmetric polymer specimens, using a home-laboratory X-ray computed tomography setup. The method is demonstrated by assessing deformation-induced cavitation of mineral-filled PVC in a repeated loading-unloading experiment. A temporal resolution of about 3 s is obtained by exploiting the axisymmetry of notched round tensile specimens. The evolution of relative density was captured throughout the experiment, revealing an interplay between void nucleation and void growth. Combined with surface deformation measurements obtained by digital image correlation, the present technique yields data suitable for calibration and validation of material models.     

MICROMOLDING ON CURVED SURFACES WITH THERMOPLASTICS

Microstructures were produced on curved surfaces and micro-protrusions by using direct micromolding with fourthermoplastic polymers. This method is simpler and more convenient than micromolding with liquid prepolymer or using theμTM method. By repeated molding, crossed structures were produced with a stamp prepared only with lines. The processingvariables including the softening temperature of the polymers and heating time were discussed. The result shows that theoptimal molding temperature is preferably slightly higher than the melting temperature of the thermoplastic polymers, atwhich polymers are in the critical states of being melted. This method can be applied to many polymers except those with high softening temperatures or high rate of shrinkage upon temperature change.     

Flow analysis of the weld line formation during injection mold filling of thermoplastics

To study the weld line formation of colliding flow fronts the filling of a mold cavity was simulated. The thermo-rheological findings were used to investigate the sources of weld line weakness. In this way critical areas of the interface in regard to the lack of interdiffusion and the inappropriate molecular orientation were found to be placed near the surface of the finished parts. The main source for the weld line weakness seems to be the V-notch that arises due to the poorly bonded region near the surface in combination with the large shrinkage as a result of extremely high molecular orientations induced at the end of the filling. Furthermore, the empirical knowledge was confirmed that weld lines are rather more sensitive to the local flow situation than the global processing conditions. Melt and mold temperatures can be considered to be the most important factors which influence the weld line strength.In part presented at the 6th European Conference on Rheology, Erlangen, 2002     

Effects of irradiation conditions on the weathering of engineering thermoplastics

The nature of the light source and its intensity can be important variables in accelerated weathering of aromatic engineering thermoplastics. Activation spectra show that BPA polycarbonate (PC) and its blends are very sensitive to UV with wavelengths <300 nm, as is well-known in the literature, but other resins gave unremarkable results. Xenon arc weathering experiments performed under identical conditions, but with different filter combinations did not show consistent rate enhancements. For 48 samples across a range of aromatic engineering thermoplastics, conditions using borosilicate inner and outer filters were 1.7× harsher than the CIRA/soda lime filter combination. However, the range was 1.0-2.5 and the standard deviation was approximately 0.35 making the correlation 1.7 ± 0.7 at 95% confidence level for any given sample. The quartz/borosilicate combination used in SAE J1960 was 2.3× harsher than CIRA/soda lime conditions, but the standard deviation was 1.1 making the correlation 2.3 ± 2.2 at the 95% confidence level for any given sample. The effects of irradiance level and the dark cycle were determined in order to establish the legitimacy of accelerated testing methods. Linear increases in degradation with increased irradiance were observed for PC, poly(butylene terephthalate), and blends of PC with other polymers. Some non-linearity was found for styrene acrylonitrile copolymer (SAN), and extreme non-linearity was found for ABS. No effect was found from a light/dark cycle other than the rate reductions expected from the lower dose rate. Thus, for accelerated weathering of engineering thermoplastics, the best possible match for sunlight is required, but increasing the intensity and decreasing or eliminating the dark period are permissible for most aromatic thermoplastic resins.     

Lamination-based rapid prototyping of microfluidic devices using flexible thermoplastic substrates

Transposing highly sensitive DNA separation methods (such as DNA sequencing with high read length or the detection of point mutations) to microchip format without loss of resolution requires fabrication of relatively long (approx. 10 cm) microchannels along with sharp injection bands. Conventional soft lithography methods, such as mold casting or hot-embossing in a press, are not convenient for fabricating long channels. We have developed a lamination-based replication technique for rapid fabrication of sealed microfluidic devices with a 10 cm long, linear separation channel. These devices are fabricated in thin cyclo-olefin copolymer (COC) plastic substrates, thus making the device flexible and capable of assuming a range of 3-D configurations. Due to the good optical properties of COC, this new family of devices combines multiple advantages of planar microfluidics and fused-silica capillaries.     

Investigation of infill-patterns on mechanical response of 3D printed poly-lactic-acid

This paper presents the effect of infill patterns (IPs) on the mechanical response of 3D printed specimens by conducting the low-velocity impact test (LVI) and compression test. The poly-lactic acid (PLA, purity 98 wt% >) material has selected and printed using fused deposition modeling (FDM, speed 20 mm/s, layer height 0.2 mm, no of layers 30, extruded at 200 °C) with four different IPs: triangle, grid, quarter cubic, and tri-hexagon. The LVI test on velocity-time, energy-time and force-displacement, and the compression responses have examined and presented in this study. The LVI test was carried out to determine the penetration energy level, energy absorption capacity (toughness), stiffness, and strength of PLA porous parts (60% infill density) for implant/tissue/recyclable product applications. The results have shown that the triangular pattern has produced the highest absorbed energy in LVI test (penetration energy 7.5 J, and stiffness 668.82 N/mm) due to more sheared/contact layers’ perpendicular to impactor (hemispherical insert); while the grid pattern exhibited the highest compressive strength (72 MPa) due to more layers aligned along the compressive loading direction The SEM fracture surface image of Triangular IP has produced effective raster and layer bonding, less number of voids, more amount of circular beach markings, and absence of ratchet lines leading to possess improved mechanical properties.     

Catalytic efficiency of some novel nanostructured heterogeneous solid catalysts in pyrolysis of HDPE

In the present study, the catalytic conversion of high density polyethylene (HDPE) to useful products has been investigated in the presence of BaTiO₃ based catalysts in a micro steel reactor at 350 °C and 30 min reaction time. The catalysts, including BaTiO₃, Pb/BaTiO₃, Co/BaTiO₃ and Pb–Co/BaTiO₃ were prepared in the laboratory by reactive calcination method and characterized by Scanning Electron Microscopy (SEM), Energy Dispersive X-rays (EDX), Surface Area Analyzer (SAA) and X-rays Diffractometry (XRD). The product yields (over all yields and yields of liquid, gas and coke/residue) as a function of individual catalyst concentration was studied. The result indicated a promising effect of the catalysts used on conversion to liquid products and their composition in term of carbon range (C₆ – >C₃₀) & hydrocarbon group types (paraffin's, olefins, naphthenics, and aromatics). Among the catalysts used, Pb–Co/BaTiO₃ gave the maximum yield of liquid products (86%) when used in 1 wt % loading. The same catalyst gave the average yield (20–25%) of different range hydrocarbons i.e. C₆–C₁₂, C₁₃–C₁₆, C₁₇–C₂₀ and C₂₀–C₃₀. Inversely, the un-doped BaTiO_3, favored the formation of C₆–C₁₂ and C₁₃–C₁₆ range hydrocarbons, whereas Pb doped BaTiO₃ and Co doped BaTiO₃ enhanced the yield of C₁₃–C₁₆, and C₂₀–C₃₀ range hydrocarbons. Regarding the hydrocarbon group types, all catalysts significantly increased the formation of paraffins and reduced olefins and naphthenes.     

Open-tubular nanoelectrochromatography (OT-NEC): gel-free separation of single stranded DNAs (ssDNAs) in thermoplastic nanochannels

Electrophoresis or electrochromatography carried out in nanometer columns (width and depth) offers some attractive benefits compared to microscale columns. These advantages include unique separation mechanisms that are scale dependent, fast separation times, and simpler workflow due to the lack of a need for column packing and/or wall coatings to create a stationary phase. We report the use of thermoplastics, in this case PMMA, as the substrate for separating single-stranded DNAs (ssDNAs). Electrophoresis nanochannels were created in PMMA using nanoimprint lithography (NIL), which can produce devices at lower cost and in a higher production mode compared to the fabrication techniques required for glass devices. The nanochannel column in PMMA was successful in separating ssDNAs in free solution that was not possible using microchip electrophoresis in PMMA. The separation could be performed in <1 s with resolution >1.5 when carried out using at an electric field strength of 280 V/cm and an effective column length of 60 μm (100 nm × 100 nm, depth and width). The ssDNAs transport through the PMMA column was driven electrokinetically under the influence of an EOF. The results indicated that the separation was dominated by chromatographic effects using an open tubular nano-electrochromatography (OT-NEC) mode of separation. Interesting to these separations was that no column packing was required nor a wall coating to create the stationary phase; the separation was affected using the native polymer that was UV/O₃ activated and an aqueous buffer mobile phase.