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Compression Molding (compression + molding)
Selected AbstractsSeparation, size reduction, and processing of XLPE from electrical transmission and distribution cablePOLYMER ENGINEERING & SCIENCE, Issue 4 2000C. C. White The recycling of power transmission cable insulated with crosslinked PE (XLPE) was investigated by using different methods of separation and reprocessing. Separation was attempted by thermo-chemical, thermo-mechanical and microwave-mechanical means, the latter being the most successful. A mechanism encompassing all of these was formulated. Compression molding, extrusion, and injection molding with and without preheating of the material were also investigated. It was found that by preheating the XLPE and injection molding under high injection pressure, the neat XLPE could be formed into shapes with tensile strengths equal to that of the original insulation. In view of available observations, possible mechanisms for the flow and reconsolidation of XLPE crumb are proposed and discussed. [source] Effect of Ti addition on magnetic properties of TbCu7 -type Sm-Fe-Co-Mn system nitridesELECTRONICS & COMMUNICATIONS IN JAPAN, Issue 7 2008Hiroshi Yamamoto Abstract To support the development of high-performance isotropic bonded magnets, experiments were carried out to investigate the effect of Ti addition on the magnetic properties of Sm-Fe-Co-Mn system nitride compounds with TbCu7 -type structure. Sm10(Fe0.9Co0.1)89.5,xMn0.5Tix (x=0 to 1.0) alloy ribbons were prepared by the single-roller rapid-quenching method. The effects of alloy composition and of heat treatment and nitriding conditions on the magnetic properties were examined. The optimum preparation conditions of the compounds were as follows. Composition: {Sm10(F0.9Co0.1)89Mn0.5Ti0.5}86.8N13.2; roller speed: 50 m/s; heat treatment: 700°C×60 min in high-purity Ar gas; nitriding conditions: 420°C×15 h in high-purity N2 gas. Typical magnetic properties of the obtained compound powders were Jr = 0.97 T, HcJ = 730.8 kA/m,(BH)max = 140.0 kJ/m3 (17.6 MGOe), Tc=500°C. XRD, TEM photographs, and recoil loops of the hysteresis curve demonstrated that this sample had the characteristics of an exchange spring magnet. The value of (BH)max for the isotropic compression molding bonded magnet prepared from the {Sm10(F0.9Co0.1)89Mn0.5Ti0.5}86.8N13.2 powder was 94.8 kJ/m3 (11.9 MGOe) at a bonded magnet density of 6.07 Mg/m3. The reversible temperature coefficient of Jr was ,(Jr)=,0.04%/°C and the temperature coefficient of HcJ in the range from 25°C to 125°C obtained by linear extrapolation was ,(HcJ)=,0.40%/°C. © 2008 Wiley Periodicals, Inc. Electron Comm Jpn, 91(7): 25,31, 2008; Published online in Wiley InterScience (www.interscience.wiley.com). DOI 10.1002/ecj.10124 [source] A preliminary study on bladder-assisted rotomolding of thermoplastic polymer compositesADVANCES IN POLYMER TECHNOLOGY, Issue 1 2007A. Salomi Abstract In this preliminary work, a new process is examined for manufacturing hollow parts from continuous fiber-reinforced thermoplastic polymer. The new process combines the basic idea of bag forming (or bladder-assisted forming) with the rotation of the mold for the processing of thermoplastic matrix composites. A pressurized membrane is used to compact the composite on the inner wall of a mold, which is placed inside a forced convection oven. The mold is removed from the oven for the cooling stage. The process was initially developed by using a thermoplastic pre-preg obtained using yarns of commingled E-glass fibers with isotactic polypropylene (iPP). A preliminary characterization of the thermoplastic composite showed that the material can be consolidated with pressures as low as 0.01 MPa, which is readily achievable with the process of this study. The design of the mold and membrane was carried out on the basis of both structural analysis of the aluminum shell and thermal analysis of the mold. The mold thickness is of great importance with respect to both the maximum pressure allowed in the process and the overall cycle time. Molding was performed on stacks of three and six layers of yarn, varying the applied pressure between 0.01 and 0.05 MPa and maximum temperature of the internal air between 185°C and 215°C. The composite shells obtained under different processing conditions were characterized in terms of physical and mechanical properties. Mechanical properties comparable with those obtained by compression molding and vacuum bagging were obtained. The maximum values obtained are 12.1 GPa and 290 MPa for the flexural modulus and the flexural strength, respectively. Furthermore, the results obtained show that mechanical properties improve with increasing the pressure during the cycle and with the maximum temperature used in the process. © 2007 Wiley Periodicals, Inc. Adv Polym Techn 26:21,32, 2007; Published online in Wiley InterScience (www.interscience.wiley.com). DOI 10.1002/adv.20085 [source] Microstructure and physical properties of open-cell polyolefin foamsJOURNAL OF APPLIED POLYMER SCIENCE, Issue 2 2009M. A. Rodriguez-Perez Abstract The cellular structure, physical properties, and structure,property relationships of novel open-cell polyolefin foams produced by compression molding and based on blends of an ethylene/vinyl acetate copolymer and a low-density polyethylene have been studied and compared with those of closed-cell polyolefin foams of similar chemical compositions and densities and with those of open-cell polyurethane foams. Properties such as the elastic modulus, collapse stress, energy absorbed in mechanical tests, thermal expansion, dynamic mechanical response, and acoustic absorption have been measured. The experimental results show that the cellular structure of the analyzed materials has interconnected cells due to the presence of large and small holes in the cell walls, and this structure is clearly different from the typical structure of open-cell polyurethane foams. The open-cell polyolefin foams under study, in comparison with closed-cell foams of similar densities and chemical compositions, are good acoustic absorbers; they have a significant loss factor and lower compressive strength and thermal stability. The physical reasons for this macroscopic behavior are analyzed. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009 [source] Surface damage analysis of retrieved highly crosslinked polyethylene tibial components after short-term implantation,JOURNAL OF BIOMEDICAL MATERIALS RESEARCH, Issue 1 2008B. M. Willie Abstract The use of highly crosslinked polyethylene (PE) in the knee remains controversial, because of reduced fatigue fracture properties of the material. The current study investigated postmelt surface damage as well as potential contributors to this damage in retrieved highly crosslinked PE tibial components, after short-term in vivo durations. Retrieved conventional PE tibial components were examined for comparison, as well as unused time zero highly crosslinked and conventional PE tibial components for inherent manufacturing surface characterization. Predominant surface damage modes on highly crosslinked PE components were machine mark loss and abrasion, while conventional PE components primarily had machine mark loss, abrasion, and delamination. In vivo duration, PE thickness, and conformity of the design were significant predictors of surface damage on retrieved conventional PE components. Donor weight and the conformity of the design were significant predictors of surface damage on retrieved highly crosslinked PE components. This retrieval data on highly crosslinked PE tibial components suggest that in vivo wear occurred, observed as postmelt surface damage. The highly crosslinked Durasul material examined in this retrieval study appeared to outperform the conventional PE components made from 4150 resin, ram-extruded and ,-sterilized in air, but not the conventional components made from 1020 resin, compression molding and , sterilization in nitrogen. Early retrieval data of highly crosslinked PE tibial components are important to serve as a benchmark to be compared with future longer-term retrieval studies investigating whether surface damage translates to clinically relevant particulate wear debris generation and PE clinical performance. © 2007 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater, 2008 [source] Study of prelocalized graphite/styrene acrylonitrile conducting composites for device applicationsPHYSICA STATUS SOLIDI (A) APPLICATIONS AND MATERIALS SCIENCE, Issue 2 2006V. K. Sachdev Abstract Conductive polymer composites were prepared by compression molding of prelocalized graphite on to styrene acrylonitrile (SAN) particles. The electrical conductivity is found to be strongly dependent on the graphite content. Three different series were prepared for different processing and material parameters. A low percolation threshold has been noticed when only 1 wt% of graphite is incorporated. Resistivity as low as ,14 , cm has been achieved in a composite with SAN resin particles of 180,212 µm size and graphite 10,20 µm at 90 °C, 105 MPa and 15 min. An electrically conducting network of graphite channels has been observed using scanning electron microscopy. V,I characteristic reveals that at a lower percentage of graphite the increase in current with increase in electric field is due to the hopping/tunneling of electrons, while for higher percentages of graphite ohmic behavior similar to metals has been observed. The data has been analyzed using percolation model. The value of the exponent t that determines the increase in electrical conductivity above the percolation threshold is found to be close to the values given in the literature. The theoretically calculated values of conductivity are found to be in satisfactory agreement with the experimental ones. (© 2006 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim) [source] The research on the mechanical and tribological properties of carbon fiber and carbon nanotube-filled PEEK compositePOLYMER COMPOSITES, Issue 8 2010Jian Li The main objective of this article is to develop high wear resistance carbon fiber reinforced polyether ether ketone composite with addition of multiwall carbon nanotube (MWCNT). These compounds were well mixed in a Haake batch mixer, and compounded polymers were fabricated into sheets of known thickness by compression molding. Samples were tested for wear resistance with respect to different concentration of fillers. The wear resistance properties of these samples depend on filler aspect ratio. Wear resistance of composite with 20 wt% of CF increases when MWCNT was introduced. The worn surface features have been examined using scanning electron microscope. Photomicrographs of the worn surfaces revealed higher wear resistance with the addition of carbon nanotube. Also, better interfacial adhesion between carbon and vinyl ester in carbon-reinforced vinyl ester composite was observed. POLYM. COMPOS., 31:1315,1320, 2010. © 2009 Society of Plastics Engineers [source] In situ reinforcement of poly(butylene terephthalate) and butyl rubber by liquid crystalline polymerPOLYMER COMPOSITES, Issue 5 2009S. Kumar Ternary in situ butyl rubber (IIR)/poly(butylene terephthalate) (PBT) and liquid crystalline polymer (LCP) blends were prepared by compression molding. The LCP used was a versatile Vectra A950, and the matrix material was IIR/PBT 50/50 by weight. Morphological, thermal, and mechanical properties of blends were investigated using scanning electron microscopy (SEM), atomic force microscopy (AFM), differential scanning calorimetry, and thermogravimetric analysis (TGA). Microscopy study (SEM) showed that formation of fibers is increasing with the increasing amount of LCP A950. Microscopic examination of the fractured surface confirmed the presence of a polymer coating on LCP fibrils. This can be attributed to some interactions including both chemical and physical one. The increased compatibility in polymer blends, consisting of IIR/PBT, by the presence of LCP A950 may be explained by the adsorption phenomena of the polymer chains onto the LCP fibrils. SEM and AFM images provided the evidence of the interaction between IIR/PBT and the LCP. Dynamic mechanical analyses (DMA) and TGA measurements showed that the composites possessed a remarkably higher modulus and heat stability than the unfilled system. Storage modulus for the ternary blend containing 50 wt% of LCP exhibits about 94% increment compared with binary blend of IIR/PBT. From the above results, it is suggested that the LCP A950 can act as reinforcement agent in the blends. Moreover, the fine dispersion of LCP was observed with no extensional forces applied during mixing, indicating the importance of interfacial adhesion for the fibril formation. POLYM. COMPOS., 2009. © 2008 Society of Plastics Engineers [source] PANI,LDPE composites: Effect of blending conditionsPOLYMER COMPOSITES, Issue 1 2009M. Cote A composite based on polyaniline (PANI) and low density polyethylene (LDPE) with electrical conductivity was developed. Polyaniline was polymerized by chemical oxidation and doped with dodecyl-benzene-sulfonic acid (DBSA). PANI,LDPE composites were prepared via melt blending and the films were obtained by compression molding. The influence of three variables of the blending (temperature, [PANI], rotor speed) on conductivity, microstructure and mechanical properties of the composites was studied by means of statistical tools and a 23 experimental design. The results show that the PANI concentration is the most influential variable, which mainly affects the conductivity and the elongation at break of the composites. These changes are related to the microstructure of the composites. Statistically, the other variables don't show significant influence on conductivity and mechanical properties in the studied range. POLYM. COMPOS., 2009. © 2008 Society of Plastics Engineers. [source] Electrical and mechanical properties of multi-walled carbon nanotubes reinforced PMMA and PS compositesPOLYMER COMPOSITES, Issue 7 2008R.B. Mathur The use of multi-walled carbon nanotubes (MWCNT) as reinforcing material for thermoplastic polymer matrices, polymethyl methacrylate (PMMA), and polystyrene (PS) has been studied. MWCNT were synthesized by chemical vapor deposition (CVD) technique using ferrocene-toluene mixture. As-prepared nanotubes were ultrasonically dispersed in toluene and subsequently dispersed in PMMA and PS. Thin polymer composite films were fabricated by solvent casting. The effect of nanotube content on the electrical and mechanical properties of the nanocomposites was investigated. An improvement in electrical conductivity from insulating to conducting with increasing MWCNT content was observed. The carbon nanotube network showed a classical percolating network behavior with a low percolation threshold. Electromagnetic interference (EMI) shielding effectiveness value of about 18 dB was obtained in the frequency range 8.0,12 GHz (X-band), for a 10 vol% CNT loading. An improved composite fabrication process using casting followed by compression molding and use of functionalized MWCNT resulted in increased composites strength. POLYM. COMPOS., 2008. © 2008 Society of Plastics Engineers [source] An acoustic emission study on the fracture behavior of continuous glass fiber/polypropylene composites based on commingled yarnPOLYMER COMPOSITES, Issue 7 2008Yantao Wang The fracture behavior of continuous glass fiber reinforced polypropylene composites made of commingled yarn in the form of biaxial (±±45°) noncrimp warp-knitted fabric, twill woven fabric, and swirl mat, respectively, was investigated by virtue of single edge notched tensile (SEN-T) specimens. These composite laminates were manufactured by compression molding and cooled at two different rates (1°C/min and 10°C/min) during the last processing phase of the laminates. The failure mechanisms were studied by acoustic emission (AE) analysis. AE amplitude ranges corresponding to the individual failure modes have been identified. For biaxial noncrimp fabric reinforced materials, the failure mechanisms involved in the fracture procedure are governed by the interface related failure events. Higher cooling rate, which is accompanied by better fiber/matrix adhesion, results in not only the increase in the relative proportion of high-amplitude failure events, but also the occurrence of a large quantity of fiber fracture events. For woven fabric and mat reinforced composites, fiber-dominated failure mechanisms result in the higher fracture toughness when compared with biaxial noncrimp fabric composites. Under this circumstance, the change in cooling rate only results in the difference in the relative frequency of the individual failure modes. In addition, it is found out that the initiation fracture toughness of SEN-T specimens can be easily assessed by marking the load value which corresponds to the first point of AE signals emitted stably in AE events-displacement curves. POLYM. COMPOS., 2008. © 2008 Society of Plastics Engineers [source] Mechanism of fiber,matrix separation in ribbed compression molded parts,POLYMER COMPOSITES, Issue 4 2007Alejandro Londoño-Hurtado This paper presents a model that predicts fiber,matrix separation in ribbed sections of compression molded parts. The model combines a mechanical analysis of compression molding with some experimentally measured variables. It is shown that with a higher closing speed, the viscosity of the material will increase and fiber,matrix separation can be reduced. Specific applications for this method are compression molding of sheet molding compounds and glass mat-reinforced thermoplastics. POLYM. COMPOS., 28:451,457, 2007. © 2007 Society of Plastics Engineers [source] Development of renewable resource,based cellulose acetate bioplastic: Effect of process engineering on the performance of cellulosic plasticsPOLYMER ENGINEERING & SCIENCE, Issue 5 2003A. K. Mohanty This paper deals with the development of a cellulose acetate biopolymer. Plasticization of this biopolymer under varying processing conditions to make it a suitable matrix polymer for bio-composite applications was studied. In particular, cellulose acetate was plasticized with varying concentrations of an eco-friendly triethyl citrate (TEC) plasticizer, unlike a conventional, petroleum-derived phthalate plasticizer. Three types of processing were used to fabricate plasticized cellulose acetate parts: compression molding, extrusion followed by compression molding, and extrusion followed by injection molding. The processing mode affected the physicomechanical and thermal properties of the cellulosic plastic. Compression molded samples exhibited the highest impact strength, tending towards the impact strength of a thermoplastic olefin (TPO), while samples that were extruded and then injection molded exhibited the highest tensile strength and modulus values. Increasing the plasticizer content in the cellulosic plastic formulation improved the impact strength and strain to failure while decreasing the tensile strength and modulus values. The coefficient of thermal expansion (CTE) of the cellulose acetate increased with increasing amounts of plasticizer. Plasticized cellulose acetate was found to be processable at 170,180°C, approximately 50°C below the melting point of neat cellulose acetate. [source] Influence of chemical composition on the rheological behavior of condensation reaction resinsPOLYMER ENGINEERING & SCIENCE, Issue 2 2003M. Doyle In this paper, the chemorheological and dynamic mechanical behavior of melamine-formaldehyde (MF) resins of four different formaldehyde/melamine (F/M) molar ratios (1.25, 1.5 1.75 and 2.00) are investigated. MF resins polymerize via a polycondensation reaction involving formation of up to 10 wt% of H2O on cure. This typically results in rapid and extensive foaming of the resin when it is cured under atmospheric pressure. Experimental adaptation for the foaming behavior of MF resins is used to gather rheological information concerning the curing kinetics and the mechanical response of neat MF resins of different molar ratios. Likewise, the procedures developed allow curing of the resins under atmospheric pressure, hence allowing volatile evacuation as occurs during venting procedures (commonly used during compression molding of MF molding compounds) or as a result of absorption by hydrophilic fillers or substrates. The results show that increased moisture content in the B-stage leads to faster reaction rates and greater foaming. Gelation and vitrification times are identified for each molar ratio, and are found to increase with decreasing molar ratio. The dynamic mechanical behavior of carefully molded neat MF samples of different molar ratios is studied using DMTA. Tg is found to be 200°C for the resin with the lowest formaldehyde content (F/M = 1.25), and around 230°C for the other resins. The storage shear modulus above Tg is studied, and the results show that the crosslink density increases with increasing molar ratio. [source] Structure of reactively extruded rigid PVC/PMMA blendsPOLYMERS FOR ADVANCED TECHNOLOGIES, Issue 6 2005Y. Haba Abstract A novel route for producing polymer blends by reactive extrusion is described, starting from poly (vinyl chloride)/methyl methacrylate (PVC/MMA) dry blend and successive polymerization of MMA in an extruder. Small angle X-ray scattering (SAXS) measurements were applied to study the monomer's mode of penetration into the PVC particles and to characterize the supermolecular structure of the reactive poly(vinyl chloride)/poly(methyl methacrylate) (PVC/PMMA) blends obtained, as compared to the corresponding physical blends of similar composition. These measurements indicate that the monomer molecules can easily penetrate into the PVC sub-primary particles, separating the PVC chains. Moreover, the increased mobility of the PVC chains enables formation of an ordered lamellar structure, with an average d -spacing of 4.1,nm. The same characteristic lamellar structure is further detected upon compression molding or extrusion of PVC and PVC/PMMA blends. In this case the mobility of the PVC chains is enabled through thermal energy. Dynamic mechanical thermal analysis (DMTA) and SAXS measurements of reactive and physical PVC/PMMA blends indicate that miscibility occurs between the PVC and PMMA chains. The studied reactive PVC/PMMA blends are found to be miscible, while the physical PVC/PMMA blends are only partially miscible. It can be suggested that the miscible PMMA chains weaken dipole,dipole interactions between the PVC chains, leading to high mobility and resulting in an increased PVC crystallinity degree and decreased PVC glass transition temperature (Tg). These phenomena are shown in the physical PVC/PMMA blends and further emphasized in the reactive PVC/PMMA blends. Copyright © 2005 John Wiley & Sons, Ltd. [source] Gel point prediction of metal-filled castor oil-based polyurethanes system,POLYMERS FOR ADVANCED TECHNOLOGIES, Issue 10-12 2002Anil Srivastava Abstract Prediction of gel point conversion and network formation is of great importance in polycondensation during synthesis as well as processing. It enables one to estimate the safe conversions for reactor operation without gelation and the cycle time during processing, and plays an important role in controlling the molding parameters used for reinforced reaction injection molding (RRIM), reaction injection molding (RIM) and compression molding. Theories of gelation have been extensively published in the literature and supported by experimental data for various polycondensation systems. However, most such studies relate to unfilled systems. In this work, metal-filled polyurethanes have been synthesized in bulk by reacting toluene di-isocyanate with castor oil and its polyols possessing different hydroxyl values. Metallic aluminum powder (10,40% by weight) was dispersed thoroughly in castor oil and its polyols before reacting at different temperatures (30,60,°C) in a moisture-free, inert environment. The gel point conversions were measured experimentally and an empirical model from the experimental data has been developed to predict the gelation behavior. The proposed model could be of immense importance in the paints, adhesives and lacquers industries, which use castor oil in bulk. From these experiments it was concluded that: (i) fine metal powder gives a rise in viscosity; (ii) metal fillers not only restrict the molecular motion due to the increase in viscosity, but also lower the conversion; (iii) the vegetable oil and its polyols have a number of bulky groups, which also impart the delay tendency in gel time; (iv) there is a change in gelation dynamics at 50,°C , this is due to the change in reactivity of di-isocyanates; (v) the presence of metal filler does not initiate the intermolecular condensation; (vi) there is a gap between theoretical and experimental gel point owing to the unequal reactivity of the secondary alcohol position; (vii) there is an inverse relationship of gel time with the reaction temperature and hydroxyl value of polyols. An empirical model based on process parameters, i.e., hydroxyl value, temperature, shape factor and filler concentration, has been derived and found to be adequate for the metal-filled system. The correlation coefficient on the data is on the lower side in some cases because the following were not taken into account: (i) the first-order kinetics followed by the reaction in the second half while it is tending towards gelation; (ii) the error in observing the gel point viscosity; (iii) errors in assuming the spherical shape of aluminum metal powder; (iv) errors due to failure to maintain the constant speed in agitation. Copyright © 2003 John Wiley & Sons, Ltd. [source] | ||||||||||