Thermal stability and degradation kinetics of feedstocks for powder injection moulding – A new way to determine optimal solid loading?

Design of Sustainable Aluminium-Based Feedstocks for Composite Extrusion Modelling (CEM)

Additive manufacturing (AM) has become one of the most promising manufacturing techniques in recent years due to the geometric design freedom that this technology offers. The main objective of this study is to explore Composite Extrusion Modelling (CEM) with aluminium as an alternative processing route for aluminium alloys. This process allows for working with pellets that are deposited directly, layer by layer. The aim of the technique is to obtain aluminium alloy samples for industrial applications with high precision, without defects, and which are processed in an environmentally friendly manner. For this purpose, an initial and preliminary study using powder injection moulding (PIM), necessary for the production of samples, has been carried out. The first challenge was the design of a sustainable aluminium-based feedstock. The powder injection moulding technique was used as a first approach to optimise the properties of the feedstock through a combination of water-soluble polymer, polyethyleneglycol (PEG), and cellulose acetate butyrate (CAB) wich produces low CO2 emissions. To do this, a microstructural characterisation was carried out and the critical solid loading and rheological properties of the feedstocks were studied. Furthermore, the debinding conditions and sintering parameters were adjusted in order to obtain samples with the required density for the following processes and with high geometrical accuracy. In the same way, the printing parameters were optimised for proper material deposition.

Thermal Stability of Allyl-Functional Phthalonitriles-Containing Benzoxazine/Bismaleimide Copolymers and Their Improved Mechanical Properties

Copolymerization is the typical method to obtain the high-performance resin composites, due to its universality and regulation performance. It can be employed among various resin matrices with active groups to obtain the desired structures, and subsequently, the outstanding properties. In this work, the copolymerization between the allyl-functional phthalonitrile-containing benzoxazine resin (DABA-Ph) and 4,4'-bis(Maleimidodiphenyl)methane (BMI) were monitored. The interactions among the active groups including allyl moieties, maleimide, benzoxazine rings and nitrile groups were investigated. Differential scanning calorimetry (DSC) and dynamic rheological analysis (DRA) were used to study the curing behaviors and the processing properties. The possible curing processes were proposed and confirmed by Fourier transform infrared spectroscopy (FTIR). Then, glass fiber-reinforced DABA-Ph/BMI composites were designed, and their thermal-mechanical properties were studied. Results indicated that all the composites exhibited outstanding flexural strength, flexural modulus, and high glass-transition temperatures (Tg > 450 °C). The thermal stability of the composites was studied by thermogravimetry (TGA) and evaluated by the integral program decomposition temperature (IPDT). it is believed that the excellent thermal mechanical properties and outstanding Tg as well as good thermal stability would enable the reinforced copolymer-based laminates to be applied in wider fields.