Combinatorial materials research applied to the development of new surface coatings: II. Process capability analysis of the coating formulation workflow

A combinatorial process has been developed for the high throughput production and evaluation of surface coatings. The workflow designed for the production of arrays of liquid coatings involves the robotic transfer of aliquots of solutions of raw materials to an array of glass vials and mixing of the coatings using an unconventional magnetic stirring process. An investigation of the capability of the workflow to accurately and repeatedly prepare coating arrays was conducted as a function of solution viscosity and aliquot size. In addition, mixing capability was evaluated as a function of solution viscosity, total solution volume, and mechanism of stirring. Overall, the results of the study indicated that adequate accuracy and repeatability of the coating preparation process can be achieved as long as raw material solutions are designed such that viscosity is below about 250 cP and aliquot sizes are above about 75 μl. With regard to mixing capability, total solution volume was found to have a profound affect as did the stirring mechanism.     

Modelling a circulating fluidized bed riser reactor with gas—solids downflow at the wall

A predictive model was developed for the fully developed zone of a circulating fluidized bed (CFB) riser reactor operating in the fast fluidization regime that overcomes limitations of existing models. The model accounts for the upward flow of gas and solids in the core and downward flow of the two phases in the annulus. Additionally, a numerical solution methodology for the simulation of a riser reactor employing the hydrodynamic model was devised. A simulation was performed using the fast, main Claus reaction to demonstrate the effects of backmixing in the fast fluidization regime. It was found that the molar flow rates of the reactants leaving a fast fluidized CFB riser reactor were significantly higher than those leaving an identical reactor operating in the pneumatic transport regime.     

The non-Fickian diffusion of deterrents into a nitrocellulose-based propellant

The diffusion of solutions of ethyl centralite (EC), dibutylphthalate (DBP), and dinitrotoluene (DNT) into a nitrocellulose (NC) propellant is investigated. DBP and EC penetrate the propellant in a way consistent with Case II diffusion. The diffusion of DNT solutions is Fickian. The apparent activation energy for Case II diffusion is 62 kJ/mol for DBP and 66 kJ/mol for EC. Changes to coating solvent polarity have little effect on DNT and DBP penetration and merely alter the rate, not the mechanism, of EC diffusion into the propellant.     

Frying Performance of No-<Emphasis Type="Italic">trans</Emphasis>, Low-Linolenic Acid Soybean Oils

Two extruded-expelled physically refined soybean oils with reduced contents of linolenic acid, ultra-low- linolenic acid (ULL, 1.5%) and low-linolenic acid (LL, 2.6%), and a extruded-expelled physically refined control oil (control, 5.3% linolenic acid) were evaluated by frying French fries in a commercial-like setting for 6 h day⁻¹ during 23 days. The oils became darker, increased in yellow color at the beginning, and became redder and less green throughout the process. Free fatty acids levels were not different among the oils until day 14, after which, ULL was different from the control for the remainder of frying. The conjugated dienoic acid values were greatest in the control. Generally, ULL and LL oils had lower percentages of polar compounds than did the control, providing a frying life 2 days longer than the control and ~30% increase in frying time. A trained sensory panel evaluated the French fries on days 2, 5, and 6. Buttery and potato flavors decreased, and rancid and painty flavors increased over frying time for all products. Rancid flavor was highest in the fries from the control oil. Overall, the ULL and LL oils performed better than did the control oil and ULL tended to perform better than the LL.     

Study of the polymerization of 1-octadecene with different rnetallocene catalysts

Summary 1-Octadecene (C18) was polymerized by using different metallocene catalysts. The rac-Et(Ind)₂ZrC1₂/MAO (I) and rac-Me₂Si(Ind)₂ZrC1₂/MAO (III) presented the highest activity as compared with ra-Et(2-Me-Ind)₂ZrCl₂/MAO (II) and Ph₂C(Flu)(Cp)ZrC1₂/MAO (IV) catalysts. Catalyst IV produced polymers with highest molecular weights. The microstructure of the polymers was determined by ¹³C-NMR spectroscopy. Catalyst systems I, II and III produced isotactic polymers while catalyst IV produced polymers with mainly syndiotactic structures but with large amount of stereoregular error. Received: 21 June 2002/Revised version: 4 November 2002/ Accepted: 4 November 2002     

Numerical Analysis of the Constrained Blister Test

The constrained blister test is investigated through finite element analysis to determine the applicabilities and the limitations of the new technique. Numerical results confirm that the strain energy release rate asymptotically approaches a constant value. These results also show that the test technique and the approximate solution for strain energy release rate are applicable for some practical cases.     

Elucidation of the miniemulsion stabilization mechanism and polymerization kinetics

Styrene/hexadecane miniemulsions were polymerized at 50°C using a redox initiator. The miniemulsions and their corresponding latexes were characterized in terms of size, polymerization rate, and surface properties. The resulting data were analyzed to elucidate the miniemulsion stabilization and polymerization mechanisms. It was found that the free surfactant concentration exceeded the critical micelle concentration when large amounts of surfactant (60 mM sodium lauryl sulfate) were used, resulting in simultaneous micellar and droplet nucleation. Most surfactant was on the surface of the droplets (85%) or particles (95%). The fractional surface coverage was proportional to the surfactant concentration to the 0.55 power. Using a particle diameter equation, the number of particles was calculated to be proportional to the surfactant concentration to the 1.35 power. Through direct particle size measurements, a power of 1.38 was confirmed. The rate of polymerization was determined by reaction calorimetry to be proportional to the number of particles to the 0.59 power, in contrast to classical Smith–Ewart kinetics for conventional emulsions (1.0 power). The average number of radicals per particle was estimated from the rate and number data, and varied with the particle diameter to the 0.97 power. The observed kinetic dependencies were validated through an extension of Smith–Ewart theory. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 90: 3987–3993, 2003     

Rheology and Consolidation of Colloidal Alumina-Coated Silicon Nitride Suspensions

In an attempt to improve the colloidal processing of Si₃N₄ ceramics, we studied the rheology and consolidation of colloidal suspensions of Si₃N₄ particles (average particle size 0.7 μm) with small Al₂O₃ particles (average particle size 20 nm). It was found that at pH >7, the viscosity of the mixtures increased and then decreased with an increasing concentration of Al₂O₃. λpotential measurements, optical micrographs, and visible light absorptance measurement suggest that such viscosity behavior is due to clustering of Si₃N₄ particles bridged by the small Al₂O₃ particles. This is also supported by the Derjaquin-Landau-Verwey-Overbeek (DLVO) potential calculations that show the barrier height in the DLVO potential between Al₂O₃ and Si₃N₄ is small. The small barrier height under current experimental conditions stems from the small size of the Al₂O₃ particles. The small barrier height allows the thermal motion of the two kinds of particles to overcome the barrier and attach to each other. The adsorption of small Al₂O₃ particles on Si₃N₄ can occur even when both Al₂O₃ and Si₃N₄ carry the same sign of charges. The adsorption of Al₂O₃ on Si₃N₄ also increases the density of consolidated compacts.     

Microstructure and morphology of amine-cured epoxy coatings before and after outdoor exposures—An AFM study

Atomic force microscopy (AFM) has been used to study the morphology and microstructure of an amine-cured epoxy before and after outdoor exposure. Measurements were made from samples prepared in an essentially CO₂-free, H₂O-free glove box and from samples prepared in ambient conditions. For those prepared in a CO₂-free glove box, AFM imaging was conducted on (1) an unexposed air/coating surface, (2) an unexposed coating bulk, (3) an unexposed coating/substrate interface, and (4) a field exposed air/coating surface. For samples prepared in ambient conditions, only the unexposed air/coating surface was investigated. The same regions of the exposed samples were scanned periodically by the AFM to monitor changes in the surface morphology of the coating as UV exposure progressed. Small angle neutron scattering and Fourier transform infrared spectroscopy (FTIR) studies were performed to verify the microstructure and to follow chemical changes during outdoor exposure, respectively. The results have shown that amine blushing, which occurs only under ambient conditions, had a significant effect on the surface morphology and microstructure of the epoxy. The surface morphology of the samples prepared under CO₂-free, dry conditions was generally smooth and homogeneous. However, the interface and the bulk samples clearly revealed a two-phase structure consisting of bright nodular domains and dark interstitial regions, indicating an inhomogeneous microstructure. Such heterogeneous structure of the bulk was in good agreement with results obtained by small angle neutron scattering of unexposed samples and by AFM phase imaging of the degraded sample surface. The relationship between submicrometer physical changes and molecular chemical degradation is discussed. Presented at the 82nd Annual Meeting of the Federation of Societies for Coatings Technology, October 27–29, 2004, in Chicago, IL.     

Analysis of solvent extracts of bituminous coal macerals by chromatography, 1H n.m.r. and field-desorption mass spectrometry

Analysis of the carbon disulphide extracts of nine samples of UK coal-maceral concentrates by ¹H highresolution n.m.r. spectroscopy, gas-liquid chromatography and field-desorption mass spectrometry indicates the presence of components with a wide molecular weight range extending up to 1200 amu; these are attributed to n-alkanes up to ≈C₅₀ and highly condensed polynuclear aromatic compounds.