不同改性方式对发泡剂在铝熔体中分散性的影响

研究了4种不同改性方式对发泡剂在铝熔体中分散性的影响。结果表明：采用TiB2粉末和AlSi合金粉末混合改性发泡剂时,随着TiB2和AlSi含量的增加得到的泡沫铝样品裂纹明显减少、泡体趋向均匀,但孔隙率逐渐降低。相比较而言,混合改性法比溶胶包覆改性法制备出的泡沫铝结构均匀,裂纹要少。     

异相成核剂对聚乙烯醇热塑模压发泡的影响

以水为增塑剂兼物理发泡剂,采用热塑模压发泡方法制备了聚乙烯醇(PVA)泡沫材料,研究了成核剂含量、粒子尺寸对PVA泡沫材料泡孔结构的影响,阐述了成核剂异相成核作用与泡沫材料泡孔结构间的关系。结果表明:小粒径、含量适中的成核剂能够在PVA基体中产生较多的异相成核点,且不影响气泡的生长过程,得到孔径分布良好、发泡倍率较高的泡沫材料。     

扭转挤出技术制备再生碳纤维增强聚苯乙烯化学发泡复合材料

采用再生碳纤维（RCF）作为增强体和成核剂及扭转挤出技术制备了聚苯乙烯（PS）/RCF为主体成分的硬质泡沫,利用三维（3D）层析成像技术、电子显微镜等对泡沫材料的微观结构、泡孔形态进行了研究。结果表明,在扭转挤出过程中,聚合物熔体产生了扭转螺旋流动,使纤维充分分散并沿流动方向取向;并且改善了整个体系的混合和温度性能,使得泡孔形态整体较为均匀;此外,泡沫质量受到机头温度的影响,且当机头温度高于180 ℃时,制品表面变得凹凸不平,气体发生逃逸现象;RCF的加入,会使气泡会沿着RCF取向方向生长,但是添加过多的RCF,会影响气泡成核。     

超轻泡沫混凝土孔结构调控措施研究

泡沫混凝土是以水泥为主要胶凝材料,通过化学发泡工艺制备而成的一类轻质多孔材料.孔结构是影响泡沫混凝土性能的重要技术特征,改善超轻泡沫混凝土的性能必须从调控孔结构入手.研究了掺入消泡剂、增稠剂、硅灰、稳泡剂和纤维对超轻泡沫混凝土(120 kg/m3)孔结构特征参数的影响规律.结果 表明:掺入适量消泡剂,泡沫混凝土孔径增大、孔径分布更集中.随增稠剂掺量增加,泡沫混凝土的平均孔径和孔形状因子均减小.稳泡剂能提高料浆中气泡的稳定性和大孔比例.掺入适量的硅灰和聚丙烯纤维能降低泡沫混凝土气孔形状因子,使气孔更接近球形.推荐了超轻泡沫混凝土最优配合比,为调控超轻泡沫混凝土孔结构提供了理论基础.     

吹气发泡法制备闭孔泡沫铝发泡过程的三维数值模拟

吹气发泡法制备闭孔泡沫铝的过程实质上是搅拌流场中复杂的两相流动过程,应用计算流体力学方法分析由倾斜轴倾斜叶片引起的发泡熔池内气液两相强旋湍流流动过程. 在双流体模型基础上引入多重参考系法描述搅拌两相流场,通过分析相间相互作用及湍流模型进行封闭. 解气泡数密度函数的输运方程来分析气泡聚合和破碎引起的气泡尺寸变化. 应用体积积分的方法,计算平均及局部气含率及气泡直径. 考察了桨叶转速及气体流率对气泡直径及其分布的影响. 结果显示,气含率随桨叶转速和气体流率增加而增大;气泡直径随气体流率增加而增大,随桨叶转速增大而减小.     

细小泡孔结构木塑泡沫材料的制备及形态研究

采用带有超临界流体注入装置的单螺杆挤出发泡系统制备了微孔木塑泡沫材料.所制备的木塑泡沫材料的平均泡孔直径小于50 μm,泡孔密度大于106个/cm3.对于木塑泡沫材料,随着木纤维含量的增加,泡孔平均直径减小、泡孔密度减小、泡沫密度增加、体积膨胀率降低.     

粉末法制备聚酰亚胺泡沫塑料

以芳香二酐和二胺为单体,甲醇/四氢呋喃为溶剂,通过酯化法合成聚酯铵盐前驱体粉末、粉末法制备泡孔均匀的聚酰亚胺泡沫塑料.采用扫描电子显微镜照片、傅里叶变换红外光谱和热重分析表征泡沫材料结构及耐热性能,研究了初始加热温度、粉末粒径对泡沫密度的影响.结果表明:初始加热温度越高,泡沫密度越小.粉末粒径对泡沫密度影响较小.     

提高泡沫陶瓷比表面积的工艺研究

采用瓷石、长石、滑石等为原料,以聚氨酯泡沫体为成型体,制备了性能优良的泡沫陶瓷.实验对影响泡沫陶瓷比表面积的相关工艺因素进行了研究.实验结果表明,采用聚丙烯酰胺溶液对聚氨酯泡沫前驱体进行改性,可明显提高挂浆量.同时利用二次挂浆工艺,对素烧后的泡沫陶瓷坯体进行造孔处理,并采用明胶作为气泡稳定剂,可明显提高泡沫陶瓷的比表面积.     

Cu-NiFe_2O_4金属陶瓷的制备及性能研究

以Cu、NiO、Ni2O3和Fe2O3为原料,采用传统粉末冶金技术,冷压烧结法制备了Cu-NiFe2O4金属陶瓷惰性阳极.对制备工艺中的原料准备,压制成型,烧结过程进行了讨论.并对其导电特性及力学性能进行了研究.结果表明,金属陶瓷材料依然为陶瓷导电性所制约.     

电力封堵用缩合型硅橡胶泡沫防火材料的制备及性能

研究了不同黏度和用量的乙烯基硅油、具有不同形态的防火填料对脱氢缩合型硅橡胶泡沫材料泡孔结构及防火性能的影响,使用橡胶加工分析仪表征了硅橡胶发泡过程中的发泡速率和交联速率,同时考察了氢氧化铝、云母、硅灰石3种填料对硅橡胶泡沫材料防火性能的影响。结果表明,不加入乙烯基硅油时,硅橡胶泡沫材料的储能模量较低,泡孔以闭孔结构为主;乙烯基硅油的加入提高了硅橡胶泡沫材料的交联速率和储能模量,使之形成较多的开孔结构,同时对硅橡胶泡沫材料泡孔尺寸分布也有影响;加入片状云母容易造成泡孔的坍塌或破裂,但是经火焰烧蚀后泡孔结构和烧蚀面的完整性保持较好,所形成的完整的陶瓷化阻隔层可起到较好的防火作用,而加入氢氧化铝和硅灰石后硅橡胶泡沫材料烧蚀后开裂比较严重。     

Studies on structural foam processing II. Bubble dynamics in foam injection molding

An experimental study was carried out to gain a better understanding of the dynamic behavior of gas bubbles during the structural foam injection molding operation. For the study, a rectangular mold cavity with glass windows on both sides was constructed, which permitted us to record on a movie film the dynamic behavior of gas bubbles in the mold cavity as a molten polymer containing inert gas was injected into it. The mold was designed so that either isothermal or nonisothermal injection molding could be carried out. Materials used were polystyrene, high-density polyethylene, and polycarbonate. As chemical blowing agents, sodium bicarbonate (which generates carbon dioxide), a proprietary hydrazide and 5-phenyl tetrazole, both generating nitrogen, were used. Injection pressure, injection melt temperature, and mold temperature were varied to investigate the kinetics of bubble growth (and collapse) during the foam injection molding operation. It was found that the processing variables (e.g., the mold temperature, the injection pressure, the concentration of blowing agent) have a profound influence on the nucleation and growth rates of gas bubbles during mold filling. Some specific observations made from the present study are as follows: an increase in melt temperature, blowing agent concentration, and mold temperature brings about an increase in bubble growth but more non-uniform cell size and its distribution, whereas an increase in injection pressure (and hence injection speed) brings about a decrease in bubble growth but more uniform cell size and its distribution. Whereas almost all the theoretical studies published in the literature deal with the growth (or collapse) of a stationary single spherical gas bubble under isothermal conditions, in structural foam injection molding the shape of the bubble is not spherical because the fluid is in motion during mold filling. Moreover, a temperature gradient exists in the mold cavity and the cooling subsequent to mold filling influences bubble growth significantly. It is suggested that theoretical study be carried out on bubble growth in an imposed shear field under nonisothermal conditions.     

本征特性对聚苯乙烯及聚丙烯发泡行为的影响

以化学发泡注塑成型技术为主线,在二次开模条件下制备微发泡聚苯乙烯（PS）及微发泡聚丙烯（PP）;通过流变性、加工性分析了树脂本征特性对PS及PP发泡行为的影响。结果表明：本征特性对气泡的长大和定型过程、气体扩散具有明显的影响;熔体强度越高的材料,阻碍泡孔长大的趋势越明显,所得到的泡孔越细小而均匀;PS具有合适的熔体强度和熔体流动速率（MFR）,发泡质量较理想,泡孔直径和泡孔密度分别为41.4μm、8.7×106个/cm3;PP（K9026）熔体强度较低,而熔体流动速率过大,发泡质量明显降低,泡孔直径和泡孔密度分别为65.94μm、5.82×105个/cm3。     

聚丙烯的流变性能及发泡性能研究

采用凝胶渗透色谱仪(GPC),差示扫描量热仪(DSC)、高级流变扩展系统(ARES),熔体拉伸流变仪对等规聚丙烯(PP1)、接枝改性聚丙烯(PP2)及Borealis的高熔体强度聚丙烯(PP3)进行了测试和表征,并利用自行研制的超临界流体挤出发泡实验装置,对上述3种PP进行了超临界二氧化碳挤出发泡研究,初步探讨了聚丙烯的流变性能对聚丙烯发泡性能的影响。结果表明,带有支化结构的PP2和PP3具有较高的熔体强度和熔体弹性,能够得到泡孔均匀的挤出发泡样品,具有较好的可发泡性。     

Viscosity of glass-forming melt at the bottom of high-level waste melter-feed cold caps: Effects of temperature and incorporation of solid components

During the final stages of conversion of melter feed (glass batch) to molten glass, the glass-forming melt becomes a continuous liquid phase that encapsulates dissolving solid particles and gas bubbles that produce primary foam at the bottom of the cold cap (the reacting melter feed in an electric glass-melting furnace). The glass-forming melt viscosity plays a dominant role in primary foam formation, stability, and eventual collapse, thus affecting the rate of melting (the glass production rate per cold-cap area). We have traced the glass-forming melt viscosity during the final stages of feed-to-glass conversion as it changes in response to changing temperature and composition (resulting from dissolving solid particles). For this study, we used high-level waste melter feeds—taking advantage of the large amount of data available to us—and a variety of experimental techniques (feed expansion test, evolved gas analysis, thermogravimetric analyzer-differential scanning calorimetry, X-ray diffraction, and viscometer). Starting with a relatively low value at the moment when the melt connects, melt viscosity reached maximum within the primary foam layer and then decreased to its final melter operating temperature value. At the cold-cap bottom—the boundary between the primary foam layer and the thermal boundary layer—where physicochemical reactions of a melter feed influence the driving force of the heat transfer from the melt to the cold cap, the melt viscosity affects the rate of melting predominantly through its effect on the temperature at which primary foam is collapsing.     

Studying smoldering to flaming transition in polyurethane furniture subassemblies: Effects of fabrics,flame retardants,and material type

The transition from smoldering to flaming was studied on fabric, batting, and foam assemblies via an electric spot ignition source of similar intensity to a cigarette. The materials studied included four different fabrics (cotton, polyester, cotton/polyester blend, flame retardant cotton/polyester blend), two types of batting (cotton, polyester), and three types of polyurethane foam (nonflame retardant, flame retardant by FMVSS 302 testing, flame retardant by BS5852 testing). The results from testing found that materials highly prone to smoldering could propagate smoldering into foams and lead to ignition, whereas materials that tended to melt back from the ignition source did not. Flame retardant fabrics or foam can and do prevent the transition from smoldering to flaming provided sufficient levels of flame retardants are incorporated in the upholstery fabric or foam. The transition from smoldering to flaming of cotton fabric/nonflame retardant foam assembly was also studied using temperature measurements and evolved gas analysis. It was determined that the transition takes place when the oxygen consumption by accelerating smoldering front exceeds the oxygen supply. At this point, the solid fuel gasification becomes driven by thermal decomposition rather than by surface oxidation which leads to high enough concentrations of fuel for flaming combustion to occur.     

Visualization of bubble dynamics in foam injection molding

This article presents a visualization study on nonisothermal bubble growth and collapse in the foam injection molding process (FIM). Observation study can give more insight to the bubble growth in foaming process, especially in the challenging injection foaming process. In this study, besides the growth of bubbles, collapse of the bubbles was also observed which could provide knowledge to the final foam morphology. Cell growth vs. time was recorded and analyzed using a software‐equipped high speed camera. To investigate the cell collapse, various holding pressure was exerted on the gas‐charged molten polymer. The amount of holding pressure had noticeable effect on the rate of bubble collapse. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

A study of foam extrusion using a chemical blowing agent

An experimental study of foam extrusion was carried out to determine the effect of processing variables on the quality of the foam produced. For the study, the chemical blowing agent azodicarbonamide was used, together with an activator and a nucleating agent, to produce thermoplastic foams of low-density polyethylenes. The quality of foam was determined from photomicrographs and the tensile properties of extrudate samples. It was found that the percent elongation correlates with the foam density and that the cell structure (cell size and its distribution) correlates with the ultimate tensile properties of the foam produced. Also, an experimental study was carried out to observe the growth of gas bubbles as the polymer melt containing a blowing agent flows through a rectangular channel constructed of quartz. This experiment helped us to interpret the curved pressure profile of the polymer melt containing a blowing agent as the melt approaches the die exit, whereas the polymer without a blowing agent shows a linear pressure profile.     

Investigation of mechanical and thermo-mechanical strength of ceramic foam filters (CFFs)

During aluminium production, the molten metal will always contain varying amounts of impurities, e.g., non-metallic inclusions, and for high-quality products removing such inclusions is essential. This can be achieved by filtration using ceramic foam filters (CFFs). However, these filters are highly brittle materials subjected to strong mechanical and thermo-mechanical stresses during transport and operation, which occasionally leads to failure of the filter material. In the present study, the compression strength of five different Al₂O₃-based CFFs was measured at room temperature and elevated temperature (compressed at 730 °C), as well as while submerged in molten aluminium with varying melt compositions (pure aluminium and an aluminium-magnesium alloy). The compression strengths at room temperature were established to be in the range of 1.19–2.09 MPa depending on the filter type tested. In the case of the CFFs compressed at elevated temperature, a reduction in compression strength in the range of 9.2–58.6% was established to exist depending on filter type and heating duration, except in three of the filter/duration-combinations tested. Compression of CFF samples submerged in molten aluminium led to an even further reduction in compression strength in the range of 42.6–69.4% depending on filter type and duration of exposure. With an exposure time of only 5 min, no difference in compression strength was observed between the two aluminium melts.     

交联剂对聚乳酸流变性能及其发泡材料泡孔结构的影响

在研究交联剂对聚乳酸(PLA)流变性能影响的基础上,采用间歇发泡方法研究交联PLA发泡材料的泡孔结构。结果表明,交联剂可提高低频区PLA的损耗角正切和复数黏度以及PLA的熔体强度和拉伸黏度。交联PLA的复数黏度高,使泡孔长大初期的长大速率较低;泡孔长大后期泡孔壁被拉伸时,熔体强度和拉伸黏度的急剧提高使泡孔壁强度增加而不会被撕裂,大大减小泡孔的合并,形成较均匀且较规则的泡孔结构。交联PLA高的熔体强度可明显减少发泡时二氧化碳扩散至空气中的量,从而增加PLA发泡样品的体积膨胀率;加入0.4 phr的交联剂时,样品的体积膨胀率最大(达41)。     

Rheological aspects of thermoplastic foam extrusion

Several rheological aspects of thermoplastic foam extrusion are described by a phenomenological model of the flow in an extrusion die. The macroscopic effects of the phase change, from a homogeneous polymer melt that contains a blowing agent, to a foam, are described in terms of two dimensionless parameters. α is defined as the ratio of the pressure gradient in the melt phase to the average pressure gradient in the foam phase. Θ represents the ratio of the pressure drop in the melt phase to the pressure drop in the foam phase. The position at which the phase change initiates, the exit contribution to the Bagley ends pressure correction, and the true wall shear stress in the melt phase are related to α and Θ. The quality of the foam produced is discussed in terms of the extrusion conditions and their effect on the foaming position in the die. It is demonstrated that the ends pressure correction cannot be neglected on the basis of a long die alone. Asymptotic conditions for which the phase change has negligible effect on the melt flow rate are predicted. α is calculated from the data of Han and Villamizar, who measured the pressure distribution in the die and observed the phase change directly. The prediction of α from theory is complicated by the lack of suitable constitutive relations for the foam phase. Since Θ only requires knowledge of the pressure at which the phase change initiates, it is relatively easy to evaluate.