Flow of polymeric melts in short tubes

In an attempt to further understand the flow of polymeric melts through gates in injection molding, the present investigation deals with measurement of pressure drops during isothermal extrusion of fiber-filled and unfilled polystyrene, polypropylene, and polycarbonate melts in short tubes with sudden contraction at high shear rates typical of injection molding. Flow curves for these materials have been determined over a wide range of shear rates at various temperatures by using a capillary rheometer and extruder. Measurements indicate that rheological properties of fiber-filled melts after injection molding differ from those of fresh samples. Moreover, it has been found that decreasing the tube length increases the slope of the curve for pressure drop vs. Volumetric flow rate. Extra pressure losses due to end effects have been determined which show that at high shear rates these losses can reach levels as high as 100 bar, with the effect being higher for the fiber-filled melts. By using a viscoelastic consitutive equation, the extra pressure losses have been separated into entrance and exit losses. Model parameters required for this calculation have been determined from viscosity-shear rate curves for the melts. For various polymers, master curves useful for industrial applications have been constructed for the extra pressure losses.     

Self‐reinforced polypropylene/LCP extruded strands and their moldings

Polypropylenes (PP) of various molecular weights were mixed with a thermotropic liquid crystal polymer (LCP) and strands were prepared by extrusion and stretching. The strands were subsequently pelletized and then injection molded at temperatures below the melting point of LCP. The mechanical properties and the morphology of the strands and injection‐molded specimens were investigated as a function of draw ratio, LCP concentration, and PP molecular weight. The results for strands show that an increase in the draw ratio, LCP concentration and matrix molecular weight in general enhance the modulus and tensile strength. However, the tensile properties of injection‐molded specimens are found to be reduced compared with those of the original strands, in particular at high LCP concentration. The morphology of LCP changes from spherical or ellipsoidal droplets to elongated fibrils in the strands as the draw ratio increases, but this aligned LCP fibrillar morphology was not transferred to the injection‐molded specimens because of the disorientation of fibrils during injection molding. Compatibilization of PP/LCP blends was also studied by using various polymers. Maleic anhydride and acrylic acid modified PPs improved the tensile properties modestly, but maleic anhydride modified EPDM reduced the tensile properties.     

Continuous ultrasonic devulcanization of unfilled butyl rubber

The devulcanization of resin‐cured unfilled butyl rubber with a grooved‐barrel ultrasonic reactor under various processing conditions was carried out. The experiments indicated that, because of the lower unsaturation and good thermal stability of butyl rubber, its devulcanization could be successfully accomplished only under severe ultrasonic‐treatment conditions. Gel permeation chromatography measurements were carried out for the virgin gum and sol part of devulcanized samples to study the changes in the rubber network during the devulcanization process. The obtained data showed a significant molecular weight reduction and a broadening of the molecular weight distribution upon devulcanization, which indicated that the devulcanization and degradation of butyl rubber occurred simultaneously. The rheological properties showed that devulcanized butyl rubber was more elastic than the virgin gum. The vulcanizates of the devulcanized butyl rubber showed mechanical properties comparable to those of the virgin vulcanizate. The thermal behaviors of the virgin and devulcanized butyl rubber were different and were correlated to the double‐bond content. The structural characteristics of the devulcanized butyl rubber were simulated with the Dobson–Gordon theory of rubber network statistics. A fairly good agreement between the experimental data and theoretical prediction was achieved. The simulation of devulcanized butyl rubber indicated that the rate of crosslink rupture was much higher than that of the main chain. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 94: 1316–1325, 2004     

Effect of Austenitizing Temperature on Pearlite Transformation of a Medium-Carbon Steel

Metallurgist - Pearlite transformation is a necessary step in the production of ultra-high strength wires and nanostructured bainitic steels. The initial austenite grain size has an important...     

Effect of Cu addition on microstructure and impact toughness in the simulated coarse-grained heat-affected zone of high-strength low-alloy steels

The effects of Cu content on microstructure and impact toughness in the simulated coarse-grained heat-affected zone (CGHAZ) of high-strength low-alloy steels were investigated. It has been observed that the microstructure in the simulated CGHAZ of Cu-free steel is dominated by a small proportion of acicular ferrite and predominantly bainite with martensite–austenite constituent. Whereas, in the 0.45 and 1.01% Cu-containing steels, the acicular ferrite increased significantly due to the effective nucleation on intragranular inclusions with outer layer of MnS and CuS. The formation of acicular ferrite is attributed to superior high heat-affected zone impact toughness in the 0.45% Cu-containing steel. Furthermore, the increasing martensite–austenite constituent and ε-Cu precipitates in the simulated CGHAZ of 1.01% Cu-containing steel caused degradation in impact toughness.     

Properties of polyetherimide/graphite composites prepared using ultrasonic twin‐screw extrusion

The dispersion of various graphites in polymers is a challenging problem limiting their potential use. To solve this problem, an ultrasound assisted twin‐screw extruder was developed and utilized to compound polyetherimide (PEI) with untreated nature graphite (UG), modified graphite (MG) and expanded graphite (EG) at concentrations up to 10 wt %. The effect of ultrasonic amplitude on rheological, mechanical and electrical properties of the PEI composites was investigated. Ultrasonic treatment of PEI/UG composites showed little effect on these properties. In contrast, ultrasonic treatment of PEI/MG and PEI/EG composites led to an increase of the storage (G′), loss (G″) moduli and complex viscosity and to a decrease of the damping characteristics. In particular, the PEI/5 wt %EG composite ultrasonically treated at an amplitude of 10 μm showed a 45% higher complex viscosity than the untreated composite at a frequency of 0.5 rad/s. Also, the PEI/5 wt % EG composite treated at an amplitude of 10 μm showed a reduction in the electrical volume resistivity by almost three orders of magnitude leading to a lower percolation threshold. The untreated and treated PEI/UG and PEI/MG composites did not show any percolation within all graphite concentrations studied, due to large size of particles of UG and MG and their strong agglomeration. The ultrasonic treatment showed slight effect on mechanical properties of all these composites. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 41397.     

Birefringence in injection‐compression molding of amorphous polymers: Simulation and experiment

The influence of the processing variables on the residual birefringence was analyzed for polystyrene and polycarbonate disks obtained by injection‐compression molding under various processing conditions. The processing variables studied were melt and mold temperatures, compression stroke, and switchover time. The modeling of flow‐induced residual stresses and birefringence of amorphous polymers in injection‐compression molded center‐gated disks was carried out using a numerical scheme based on a hybrid finite element/finite difference/control volume method. A nonlinear viscoelastic constitutive equation and stress‐optical rule were used to model frozen‐in flow stresses in moldings. The filling, compression, packing, and cooling stages were considered. Thermally‐induced residual birefringence was calculated using the linear viscoelastic and photoviscoelastic constitutive equations combined with the first‐order rate equation for volume relaxation and the master curves for the Young's relaxation modulus and strain‐optical coefficient functions. The residual birefringence in injection‐compression moldings was measured. The effects of various processing conditions on the measured and simulated birefringence distribution Δn and average transverse birefringence <n_rr?n_θθ> were elucidated. Comparison of the birefringence in disks manufactured by the injection molding and injection‐compression molding was made. The predicted and measured birefringence is found to be in fair agreement. POLYM. ENG. SCI., 2013. © 2013 Society of Plastics Engineers