Polymer-melt interactions during casting formation in the lost foam process

Synthesis and expansion characteristics of expandable styrene/methyl methacrylate copolymer beads: The effects of monomer composition and cell structure modifying aid

Parts cast of metals such as iron, using expandable polystyrene foams, may have an unacceptable amount of surface defects, such as lustrous carbon. The use of foams made of styrene/methyl methacrylate copolymers can improve the quality of foam molds and metal parts made using such molds. In this work, expandable copolymers were synthesized by suspension copolymerization of styrene and methyl methacrylate in the presence of blowing agents (pentane isomers). When the surrounding temperature was high enough to vaporize the blowing agent and soften the polymer shell, the beads were expanded. The effects of monomer composition and cell structure modifying aid (polyethylene wax) on the particle size, average molecular weight and molecular weight distribution of synthesized copolymer, pentane content and expansion properties (density, residual pentane of pre-expanded particles and cell structure) were investigated. The results showed that monomer composition had a significant effect on the copolymerization kinetic and the copolymer molecular weight. In addition, cell structure, cell size and cell size distribution of the pre-expanded particles were strongly influenced by cell structure modifying aid concentration. The effects of comonomer composition and copolymer particle size on pentane content of expandable particles were also studied.