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In peel, tests between polycarbonate/polyethersulfone (PC/PES) blends with different compositions and thermoplastic polyurethane (TPU) films with different thicknesses a large decrease in energy release rate Gc is observed when the PC/PES blends formed a co‐continuous structure. With SEM analysis, XRD measurements, selective PC etching of failed samples, and finite element modeling of the stress distributions in the co‐continuous region this fracture behavior can be explained. It is caused by the interplay between the formation of the main crack in the process zone and the size and density of microcracks in the energy dissipation zone. While the pure components PC and PES exhibit good adhesion to the TPU, the immiscibility of PC and PES causes the steady decrease of Gc with increasing volume fraction of the minor phase. [ABSTRACT FROM AUTHOR]

In this work, the relation of injection molding parameters to the mechanical properties of various polypropylene grades is investigated to find the optimal processing parameters to minimize weld‐line effects like reduced mechanical and/or optical performance. Injection molded test specimens of five polypropylene grades with different melt flow rates were characterized for their mechanical behavior and compared with equal‐shaped specimens with a colliding weld line in the middle of the specimen. For the production of these weld‐line specimens, a special mold was used and injection molding parameters were systematically varied, tensile (ISO 527‐2) and impact (ISO 179‐1/1eU) properties were measured, and statistical analyses were performed to gain insight on the correlation between melt flow rate and weld‐line behavior. It showed that mechanical properties of specimens with weld lines can be influenced by the processing parameters, but the effect is limited. Positive correlations were found between tool temperature and tensile modulus and strength. Polypropylene grades with low melt flow indexes seem to be more susceptible to weld‐line‐induced property reductions. In a second test series similar to the pure PP investigations, glass‐fiber‐ and talc‐filled PP were used to gain insight into the weld‐line behavior of PP composites. In addition to mechanical characterization, optical and scanning electron micrographs were taken of the weld‐line areas. It was found that the reinforcing particles align along the melt flow front in the weld‐line area. As a result, the mechanical performance of weld‐line specimens is poor. Injection molding parameters were found to have only a small effect. [ABSTRACT FROM AUTHOR]

Four-dimensional (4 D) printing is a novel emerging technology, which can be defined as the ability of 3 D printed materials to change their form and functions. The term 'time' is added to 3 D printing as the fourth dimension, in which materials can respond to a stimulus after finishing the manufacturing process. 4 D printing provides more versatility in terms of size, shape, and structure after printing the construct. Complex material programmability, multi-material printing, and precise structure design are the essential requirements of 4 D printing systems. The utilization of stimuli-responsive polymers has increasingly taken the place of cell traction force-dependent methods and manual folding, offering a more advanced technique to affect a construct's adjusted shape transformation. The present review highlights the concept of 4 D printing and the responsive bioinks used in 4 D printing, such as water-responsive, pH-responsive, thermo-responsive, and light-responsive materials used in tissue regeneration. Cell traction force methods are described as well. Finally, this paper aims to introduce the limitations and future trends of 4 D printing in biomedical applications based on selected key references from the last decade. [ABSTRACT FROM AUTHOR]

Developments by Labuschagné et al. (Patent, WO 2006/123284 A2, 2006) in the manufacture of Layered Double Hydroxides (LDHs) have led to a patent describing a new effluent free synthesis method. A promising application for the LDH is as an additive for a flexible poly(vinyl chloride) (PVC) compound used for the insulation for cables used in South African underground mines. Consequently, a new formulation is required. Unfortunately formulating a PVC compound is a complex problem. The purpose of the investigation is to develop a method that can be used to find an optimum PVC formulation where the material requirements are met while also allowing for the quantitative analysis of the effect of the ingredients on the material properties. This is achieved by modeling the thermal stability, fire retardancy, and basic mechanical properties of the compound as a function of the relative proportions of the ingredients using 2nd order Scheffé polynomials. The empirical models are determined using statistical experimental design. Each model is interpreted using statistical analysis of the model terms which allows for the quantification of the effects and interactions of all the ingredients on the various response variables. The models are also used as constraints in the optimization of the PVC formulation for minimum cost. Parametric analyses are done to demonstrate how the optimization can be used to analyze the entire system taking into account the cost performance of the ingredients. Finally, it is demonstrated how the above approach requires significantly less time and labor to find an optimum formulation than the traditional approach. J. VINYL ADDIT. TECHNOL., 25:E44–E58, 2019. © 2017 Society of Plastics Engineers [ABSTRACT FROM AUTHOR]

The semicrystalline morphology of injection moldings of polyamide 11 (PA 11) prepared using mold temperatures of 25, 50, and 80°C was investigated. Regardless of the mold temperature, position‐resolved X‐ray diffraction (XRD) and polarized‐light optical microscopy (POM) revealed presence of poor/imperfect α‐crystals with an almost hexagonal arrangement of molecular stems in a nonspherulitic superstructure in the skin, and formation of α‐crystals and spherulites in the core. With increasing mold temperature, the thickness of the skin layer decreased, and the perfection of α‐crystals and the spherulite size in the core increased. The experimental observations are discussed in terms of predicted crystallization temperatures, with the prediction based on cooling‐rate simulations for the various parts of the injection moldings using Moldflow® and analysis of crystallization of the relaxed melt using fast scanning chip calorimetry, XRD, and POM. It is shown that the structure gradient in PA 11 injection moldings can be forecast without considering the effects of shear for this particular polymer. POLYM. ENG. SCI., 58:1053–1061, 2018. © 2017 Society of Plastics Engineers [ABSTRACT FROM AUTHOR]

Polymer applications range from biomedical devices and structures, packaging, or toys to automotive and industrial items. So far, biopolymers could replace commodity polymers in a variety of products, especially for biomedical applications or food packaging. One of the most used and widely studied biopolymers is poly(lactic acid) (PLA). To generate new application fields and provide a broader application of PLA, research on processing behavior is still required. This chapter covers the processing relevant behavior of PLA and processing conditions for extrusion melt spinning, injection molding, and additive manufacturing. The processing-related behavior is compared to that of commodity polymers. The aim is to provide an overview of the state of the art and some recent new developments in this research field. [ABSTRACT FROM AUTHOR]

In the field of optical components, thermoplastics are replacing more and more glass mainly because of their better freedom of design and their cost-effective processing techniques. Nevertheless, especially lenses do not have an ideal design for plastic processing, because of their varying thickness fromthe centre to the edge. These lead to great differences in shrinkage due to the different coefficients of thermal expansion of melt and solid state and, consequently, directly lead to warpage and residual stresses with state-of-the-art processing techniques. A promising solution is a new, innovative technique--compression-induced solidification (CIS)--where the melt is compressed at constant temperature until it solidifies. This results in isochronic solidification of the whole part even at high temperatures and reduces residual stresses and warpage due to the cooling of a body with homogenous shrinkage. In this paper, CIS integrated in the injection molding process is introduced, and the influence of process parameters on inner properties and dimensional accuracy of CIS polycarbonate parts are illustrated. Trials carried out indicate that an optimum level of compression pressure at the end of glass transition range and a sufficiently long period of holding time (hereinafter the adapting time) for reaching homogeneous temperatures within the melt until pressure is applied will generate parts with low residual stresses and high dimensional accuracy. [ABSTRACT FROM AUTHOR]

The article presents information on a study which examined which step of processing thermo-oxidative degradation occurs in injection molding. Two methods were utilized to study the cause and reduce thermo-oxidative degradation and its location during injection molding. A lower thermo-oxidative stress can yield a higher transparency of optical parts, less reduction of average molecular weight in microinjection molding, and a longer service life due to less consumption of stabilizers during thermo-oxidative degradation processing. An injection molding machine was encapsulated and operated under local exclusion of oxygen to examine the local thermo-oxidative stress.

This work analyzes the thermal degradation and mechanical properties of iron (Fe)-containing MgAl layered double hydroxide (LDH)-based polypropylene (PP) nanocomposite. Ternary metal (MgFeAl) LDHs were prepared using the urea hydrolysis method, and Fe was used in two different concentrations (5 and 10 mol%). Nanocomposites containing MgFeAl-LDH and PP were prepared using the melt mixing method by a small-scale compounder. Three different loadings of LDHs were used in PP (2.5, 5, and 7.5 wt%). Rheological properties were determined by rheometer, and flammability was studied using the limiting oxygen index (LOI) and UL94 (V and HB). Color parameters (L*, a*, b*) and opacity of PP nanocomposites were measured with a spectrophotometer. Mechanical properties were analyzed with a universal testing machine (UTM) and Charpy impact test. The thermal behavior of MgFeAl-LDH/PP nanocomposites was studied using differential scanning calorimeter (DSC) and thermogravimetric analysis (TGA). The morphology of LDH/PP nanocomposites was analyzed with a scanning electron microscope (SEM). A decrease in melt viscosity and increase in burning rate were observed in the case of iron (Fe)-based PP nanocomposites. A decrease in mechanical properties interpreted as increased catalytic degradation was also observed in iron (Fe)-containing PP nanocomposites. Such types of LDH/PP nanocomposites can be useful where faster degradation or faster recycling of polymer nanocomposites is required because of environmental issues. [ABSTRACT FROM AUTHOR]

Computational fluid dynamics (CFD) simulation is an important tool as it enables engineers to study different design options without a time-consuming experimental workload. However, the prediction accuracy of any CFD simulation depends upon the set boundary conditions and upon the applied rheological constitutive equation. In the present study the viscoelastic nature of an unfilled gum acrylonitrile butadiene rubber (NBR) is considered by applying the integral and time-dependent Kaye–Bernstein–Kearsley–Zapas (K-BKZ) rheological model. First, exhaustive testing is carried out in the linear viscoelastic (LVE) and non-LVE deformation range including small amplitude oscillatory shear (SAOS) as well as high pressure capillary rheometer (HPCR) tests. Next, three abrupt capillary dies and one tapered orifice die are modeled in Ansys POLYFLOW. The pressure prediction accuracy of the K-BKZ/Wagner model was found to be excellent and insensitive to the applied normal force in SAOS testing as well as to the relation of first and second normal stress differences, provided that damping parameters are fitted to steady-state rheological data. Moreover, the crucial importance of viscoelastic modeling is proven for rubber materials, as two generalized Newtonian fluid (GNF) flow models severely underestimate measured pressure data, especially in contraction flow-dominated geometries. [ABSTRACT FROM AUTHOR]

The concept of specific work of flow has been applied for the analysis of critical shearing conditions for the formation of crystal nuclei in poly (l-lactic acid) (PLLA). Systematic variation in both time and rate of shearing the melt in a parallel-plate rheometer revealed that these parameters are interconvertible regarding the shear-induced formation of crystal nuclei; that is, low shear rate can be compensated for by increasing the shear time and vice versa. This result supports the view that critical shearing conditions can be expressed by a single quantity, providing additional options for tailoring polymer processing routes when enhanced nuclei formation is desired/unwanted. Analysis of PLLA of different mass-average molar masses of 70, 90, 120, and 576 kDa confirmed improved shear-induced crystal nucleation for materials of higher molar mass, with critical specific works of flow, above which shear-induced nuclei formation occurs, of 550, 60, 25, and 5 kPa, respectively. [ABSTRACT FROM AUTHOR]

The interactive effects between additives and weld lines, which are frequent injection-moulding defects, were studied in high-density polyethylene (HDPE) and compared to weld-line-free reference samples. These materials were formulated around a D- and I-optimal experimental design, based on a quadratic Scheffé polynomial model, with up to 60 wt% calcium carbonate, masterbatched carbon black and a stabiliser package. Where reasonable and appropriate, the behaviours of the systems were modelled using statistical techniques, for a better understanding of the underlying trends. The characterisations were performed through the use of conventional tensile testing, digital image correlation (DIC) and scanning electron microscopy (SEM). A range of complex interactive effects were found during conventional tensile testing, with DIC used to better understand and explain these effects. SEM is used to better understand the failure mechanics of some of these systems through fractography, particularly regarding particle effects. A measure is introduced to quantify the deviation of the pre-yield deformation curve from the ideal elastic case. Novel analysis of DIC results is proposed, through the use of combined time-series plots and measures quantifying the extent and localisation of peak deformation. Through this, it could be found that strong shifts in the deformation mechanisms occur as a function of formulation and the presence/absence of weld lines. Primarily, changes are noted in the onset of continuous inter- and intralamellar slip and cavitation/fibrillation, seen through the onset of localised deformation and stress-whitening. [ABSTRACT FROM AUTHOR]

In the present study, melt-mixed composites based of poly (vinylidene fluoride) (PVDF) and fillers with different aspect ratios (carbon nanotubes (CNTs), carbon black (CB)) and their mixtures in composites were investigated whereby compression-molded plates were compared with melt-extruded films. The processing-related orientation of CNTs with a high aspect ratio leads to direction-dependent electrical and mechanical properties, which can be reduced by using mixed filler systems with the low aspect ratio CB. An upscaling of melt mixing from small scale to laboratory scale was carried out. From extruded materials, films were prepared down to a thickness of 50 µm by cast film extrusion under variation of the processing parameters. By combining CB and CNTs in PVDF, especially the electrical conductivity through the film could be increased compared to PVDF/CNT composites due to additional contact points in the sample thickness. The alignment of the fillers in the two directions within the films was deduced from the differences in electrical and mechanical film properties, which showed higher values in the extrusion direction than perpendicular to it. [ABSTRACT FROM AUTHOR]