Volume 36, Issue 4

New extensional mixing elements (EME) for twin-screw extrusion were applied to compound glass fibers (GF), carbon fibers (CF) or polyethylene terephthalate fibers (PETF) reinforced polymer composites with polymer matrix of polypropylene (PP) or polyethylene oxide (PEO) and the resulting fiber degradation upon processing was evaluated and compared with compounding via shear flow-dominated kneading blocks (KB). Composites structures were characterized in terms of fiber length and distribution, and cumulative length ratio, at five locations along the mixing zone. Although significant fiber breakage was achieved for both configurations, it was markedly lower in composites processed using the EME, because whereas the high shear stress kneading motion in the KB degrades fibers significantly, fiber breakup is significantly minimized by the alignment induced by the EME prior to flow in the high-stress regions.

Polyethylene terephthalate (PET) films were prepared by cast extrusion using a twin-screw extruder with a severe screw profile. The effect of an organically modified montmorillonite on thermal, mechanical, optical, and barrier properties of the PET films were investigated. Morphological characterization of the nanocomposite films was performed by employing wide angle X-ray diffraction (WAXD), scanning electron microscopy (SEM), and transmission electron microscopy (TEM) followed by image analysis. The results unfold a mixed morphology for the nanocomposite films with more than 95% exfoliated and intercalated silicate layer structures, depending on the screw rotation speed. The remarkable dispersion of the organoclay particles at the nano-level is discussed in terms of solubility parameter and favorable interactions between PET macromolecules and organic modifier of the nanoclay. The crystal content of the nanocomposite films and their cold and hot crystallization temperatures confirmed the role of silicate nanolayers as a heterogeneous nucleating agent. While all nanocomposite films exhibit higher haze values in comparison to the neat PET samples, incorporation of 2 wt% nanoclay brought about 25% increase in tensile modulus and barrier properties. A range of screw rotation speeds with optimized properties in terms of haze, morphology, thermal, mechanical, and barrier properties is suggested.

To improve the thermal stability, ZF-GO (graphene oxide (GO) modified by zinc ferrite (ZF)) is prepared. In view of the anti-dripping function of ZF-GO and flame retardant effect of ammonium polyphosphate (APP), the influence of ZF-GO, APP, mixture of ZF-GO and APP on combustion performance, thermal stability and mechanical properties of polylactic acid (PLA) is investigated. Results show that the modification of GO by ZF significantly improves the residue of ZFGO by 34.7%. The char-forming capability and unique network structure of ZF-GO prevent the melt dripping of PLA. Although APP can increase the limiting oxygen index of PLA, there is still melt dripping. The combination of ZF-GO and APP improves the residual yield of 94PLA/3ZF-GO/3APP by 4.3 times relative to pure PLA, and the UL-94 level reaches V-0. The two additives show synergistic char-forming effect, and there is both physical carbonization and chemical carbonization. The incorporated fillers can decrease the total heat release (THR) of PLA composites. Specifically, the THR and peak value of heat release rate of 94PLA/3ZF-GO/3APP decrease by 21.2% and 53.9%, respectively. For the PLA/ZF-GO/APP system, plenty of residues and the anti-dripping network structure are key factors to get good flame retardancy. Addition of ZFGO and APP reduces the tensile strength, but the tensile elongation of the modified PLA composites is improved. 94PLA/ 3ZF-GO/3APP shows good integrated performance.

This study evaluated the mixing effect of simple uniaxial extensional flow for the dispersion of multiwalled carbon nanotubes (MWCNTs) into polypropylene (PP) as a nonpolar matrix. An only converging flow allowed for a high strain rate and was suitable for the compounding process. The extensional flow was characterized from the entrance pressure drop (ΔP 0 ) at the converging section. Thus, in this study, capillary extrusion was employed to generate uniaxial extensional flow. Based on the hypothesis that the dispersion of nanofillers depends on the magnitude of flow-induced stress, ΔP 0 , which related to extensional stress, was measured directly during capillary extrusion by using an orifice die. The influences of the mass flow rate and the hole diameter in the orifice die, which affected ΔP 0 , on the extrusion of PP nanocomposites with an MWCNT loading of 1.0 wt.% were studied. The extruded samples were collected, and the dispersion state was evaluated based on the melt viscoelastic properties, volume resistivity, and morphological observations by optical microscopy (OM) and transmission electron microscopy (TEM). The agglomeration area of the MWCNTs decreased with higher ΔP 0 (higher mass flow rate and smaller hole diameter), which increased the uniformity of the dispersion. Moreover, the influence of the length-to-diameter (L/D) ratio of the hole in the capillary die on the dispersion state of the MWCNTs was investigated. A higher L/D ratio of the capillary die did not improve the dispersion state, although shear and extensional stresses were provided.

This study presents the pulsed heating strategy as an advancement of the current state of the art in industry towards the theoretically fastest method of heating a thermoplastic sheet. Experimental temperature measurements are combined with an explicit finite difference numerical model to describe the pulsed heating method and indicate its added value in IR heating of thermoplastic sheets. Different process settings are evaluated and indicate the effect of the applied heat flux and the time interval t OFF during pulsed heating. When switched off, the residual heating of the heater elements is able to partially compensate for the convective heat losses at the surface of the sheet. This results in a more uniform temperature distribution through thickness without slowing down the overall heating process. The study shows that this effect is lost when the time interval in which the heater element is switched off, increases. Applying pulsed heating opens up a large processing window to control the through-thickness temperature difference. When the total amount of applied thermal energy is taken into account, pulsed heating is able to increase the overall heating rate and simultaneously keep the temperature difference through thickness limited.

Auxetic structures are popular, since they have many applications in defense, textile and sport industries. The advantages of providing comfort and protection to people for the impact energy increase the usability of auxetic structures in these areas. Within the scope of this study, two structures were designed as honeycomb and auxtetic structures with lateral displacements in opposite directions. The auxetic and honeycomb structures were modeled in Ansys software by keeping the boundaries of these two structures close to each other. Structural and modal analysis were applied to these structures and the auxetic structure gave better results in terms of the tensile strength.

In the melt blowing process, the molten polymers extruded from nozzles are elongated by high-velocity and high-temperature air flow. In this study, with the aim of stabilizing the melt blowing process for producing nonwoven webs with fine diameter fibers, the effect of the control of polymer rheology by the introduction of either low melt flow rate (MFR) polypropylene (PP) or long chain branched PP (LCB-PP) to regular high MFR PP was investigated. Introduction of low MFR PP into regular PP increased shear viscosity and fibers of larger diameter were produced in the melt blowing process, while introduction of low MFR LCB-PP suppressed the elongational viscosity reduction with the increase of strain rate, and eventually spinning was stabilized. It was found that the blending of an optimum amount of LCB-PP to regular PP caused the stabilization of the melt blowing process. As a result, the formation of nonwoven webs consisting of fine fibers of rather uniform diameter distribution could be achieved.

Rule of mixtures (RoMs) of composite materials is continuously modified according to different component materials and their composition forms to play the role of theoretical verification and evaluation. This paper studied the regular relationship between the bonding surface and mechanical performance of the composites. The three bonding surface designs were made into PLA/EP test samples by 3D printing technology. The tensile and bending properties of the composite materials were proved to be stronger than the average of those of their component materials. The mechanical properties show regular changes with the bonding surface and structural design. The bonding surface between components is an important reference information that cannot be ignored for the performance prediction and adjustment of laminated composite materials.

Ethylene-butene copolymer (EBC)/carbon-fiber (CF) composites can be utilized as an electromechanical material due to their ability to change electric resistance with mechanical strain. The electro-mechanical properties and thermal conductivity of ethylene butene copolymer (EBC) composites with carbon fibers were studied. Carbon fibers were introduced to EBC with various concentrations (5 to 25 wt%). The results showed that carbon fibers’ addition to EBC improves the electric conductivity up to 10 times. Increasing the load up to 2.9 MPa will raise the electric resistance change by 4 500% for a 25% fiber sample. It is also noted that the EBC/CF composites’ electric resistance underwent a dramatic increase in raising the strain. For example, the resistance change was around 13 times higher at 15% strain compared to 5% strain. The thermal conductivity tests showed that the addition of carbon fibers increases the thermal conductivity by 40%, from 0.19 to 0.27 Wm –1 K –1 .

The underlying process for the production of textile reinforced thermoplastics is the impregnation of dry textile reinforcements with a thermoplastic matrix. The process parameters such as temperature, time and pressure of the impregnation are mainly determined by the permeability of the reinforcement. This results from a complex interaction of hydrodynamic compaction and relaxation behavior caused by textile and process parameters. The foundation for the description and optimization of impregnation progresses is therefore the determination of the pressure-dependent permeability of fibre textiles. Previous experimental investigations have shown that the dynamic compaction behavior during the impregnation of fibre reinforcements with thermoplastics or thermosets can be successfully characterized. However, for most cases, an analytical representation has not been possible due to the complexity of the process. Although it may be possible to reproduce this behavior by numerical calculations, the results need to be confirmed by experiments. This paper lays the analytical foundation for building a scaled model system, based on the theory of similarity, to observe, measure, and evaluate the dynamic compaction behavior of textile reinforcements under controlled process conditions.

When selecting a melt-filtration system, the initial pressure drop is a critical parameter. We used heuristic optimization algorithms to develop general analytical equations for estimating the dimensionless pressure loss of square and Dutch woven screens in polymer processing and recycling. We present a mathematical description – without the need for further numerical methods – of the dimensionless pressure loss of non-Newtonian polymer melt-flows through woven screens. Applying the theory of similarity, we first simplified, and then transformed into dimensionless form, the governing equations. By varying the characteristic independent dimensionless influencing parameters, we created a comprehensive parameter set. For each design point, the nonlinear governing equations were solved numerically. We subsequently applied symbolic regression based on genetic programming to develop models for the dimensionless pressure drop. Finally, we validated our models against experiments using both virgin and slightly contaminated in-house and post-industrial recycling materials. Our regression models predict the experimental data accurately, yielding a mean relative error of MRE = 13.7%. Our modeling approach, the accuracy of which we have proven, allows fast and stable prediction of the initial pressure drop of polymer-melt flows through square woven and Dutch weave screens, rendering further numerical simulations unnecessary.

This study employed solid hot stretching technology to produce successfully specifically oriented polylactic acid (PLA) while investigating the impact of orientation structure on its photo-oxidation aging properties. After orientation, the molecular weight and mechanical properties retention rate of PLA were improved, and the crystallinity (X c ) increased in conjunction with prolonged aging time, while the molecular orientation failed to modify the mechanism responsible for PLA deterioration. Furthermore, an examination regarding the way in which the photo-oxidation stability of PLA was enhanced, demonstrated that the increased X c and structural orientation were beneficial for delaying the photo-oxidation aging of PLA.

Injection compression molding (ICM) is a hybrid injection molding process for manufacturing polymer products with high precision and surface accuracy. In this study, a 3D flow simulation was employed for ICM and injection molding (IM) processes. Initially, the process parameters of IM and ICM were discussed based on the numerical simulations. The IM and ICM processes were compared via numerical simulation by using CAE tools of Moldflow software. The effect of process parameters of mold surface temperature, melting temperature, compression force and injection time on clamping force and pressure at the injection location of molded 3D BJ998MO Polypropylene (MFI 100) part was investigated by Taguchi analysis. In conclusion, it was found that the ICM has a relatively lower filling pressure than ICM, which results in reduced clamping force for producing a 3D thin-walled polymeric part.