Real-time Diagnosis of Micro Powder Injection Molding Using Integrated Ultrasonic Sensors

Real-time diagnostics of ceramic powder injection molding using a commercial micromolding machine was performed using ultrasound. Miniature ultrasonic sensors were integrated onto the mold insert. Melt front, solidification, temperature variation and part detachment of the feedstock inside the mold cavity were observed. It has been demonstrated that ultrasonic velocity in feedstock inside the mold cavity, the ultrasonic contact duration during which the part and mold are in contact, and holding pressure can be used to assist with optimization of injection and cooling parameters to minimize energy consumption and maximize process efficiency.

Application of activated barrier hopping theory to viscoplastic modeling of glassy polymers

An established statistical mechanical theory of amorphous polymer deformation has been incorporated as a plastic mechanism into a constitutive model and applied to a range of polymer mechanical deformations. The temperature and rate dependence of the tensile yield of PVC, as reported in early studies, has been modeled to high levels of accuracy. Tensile experiments on PET reported here are analyzed similarly and good accuracy is also achieved. The frequently observed increase in the gradient of the plot of yield stress against logarithm of strain rate is an inherent feature of the constitutive model. The form of temperature dependence of the yield that is predicted by the model is found to give an accurate representation. The constitutive model is developed in two-dimensional form and implemented as a user-defined subroutine in the finite element package ABAQUS. This analysis is applied to the tensile experiments on PET, in some of which strain is localized in the form of shear bands and necks. These deformations are modeled with partial success, though adiabatic heating of the instability causes inaccuracies for this isothermal implementation of the model. The plastic mechanism has advantages over the Eyring process, is equally tractable, and presents no particular difficulties in implementation with finite elements.

Pressure Variation during Interfacial Instability in the Coextrusion of Low Density Polyethylene Melts

Pressure variation during the coextrusion of two low density polyethylene melts was investigated. Melt streams were delivered to a die from two separate extruders to converge in a 30°° geometry to form a two layer extrudate. Melt flow in the confluent region and die land to the die exit was observed through side windows of a visualisation cell. Stream velocity ratio was varied by control of extruder screw speeds. Layer thickness ratios producing wave type interfacial instability were quantified for each melt coextruded on itself and for the combined melts. Stream pressures and screw speeds were monitored and analysed. Wave type interfacial instability was present during the processing of the melts at specific, repeatable, stream layer ratios. Increased melt elasticity appeared to promote this type of instability. Analysis of process data indicates little correlation between perturbations in extruder screw speeds and stream pressures. The analysis did however show covariance between the individual stream pressure perturbations. Interestingly there was significant correlation even when interfacial instability was not present. We conclude that naturally occurring variation in extruder screw speeds do not perturb stream pressures and, more importantly, natural perturbations in stream pressures do not promote interfacial instability.

Sensitivity of In-line Rheometry for Extrusion of Mg(OH)2 filled LDPE Compounds

In-process and off-line rheometry studies are reported for compounds based on Mg(OH)2 filled low density polyethylene, some of which were first subjected to a range of strain histories in typical compounding operations. In the study reported here, the compounds were processed using an instrumented, computer monitored single screw extruder in the IRC laboratories, fitted with in line rheometers (ILR). In initial experiments a four sensor ILR slit die was used for the in-process shear rheometry, and a Rosand RH7 twin bore capillary rheometer for off-line shear and entry pressure measurements. Off line and in-line results are compared, showing good agreement for shear. Estimates have been obtained for the sensitivity to filler loading of the off line rheometer (shear flow and entry pressure measurements), and the 4 sensor ILR (shear flow measurements), which indicate that the ILR offers similar resolution of filler level to the off line rheometer at the higher loadings, although the ILR appears to have much lower sensitivity at higher shear rates at lower loadings, an effect which appears to be related to processing effects on the rheology of the compound rather than the measurement ability of the ILR. The ILR was also able to discriminate between samples with differing processing histories. Results from a six-sensor ILR die have shown good agreement in shear flow measurements, and have added the ability to measure entry pressures, which are compared with off-line measurements.

In-process Monitoring of Micromoulding – Assessment of Process Variation

Advances in micromoulding technology are leading to complex, net-shape products having sub-milligramme masses with micro-scale surface features in a range of polymer and nanocomposite materials. For such small components subjected to the extreme stress, strain-rate and temperature gradients encountered in the micromoulding process, detailed process monitoring is desirable to highlight variations in moulding conditions and assist in creating a viable manufacturing process with acceptable quality products. This paper covers the implementation of a suite of sensors on a commercial micromoulding machine and detailed computer monitoring during processing of a polyacetal component over a range of processing conditions. The results determined that cavity pressure curve integral data provides the most sensitive factor for characterisation of a moulding process of a 0.34 mm3 (0.49 mg) product. The repeatability of the process is directly compared with that of a 15.6 mm3 (22.2 mg) product and shown to be inferior. DSC measurements of the whole products indicated little variation in average crystallinity of the products manufactured over a mould temperature range of 30 to 130 °C.

Raman spectroscopic studies of the cure of dicyclopentadiene (DCPD)

The cure of polydicyclopentadiene conducted by ring-opening metathesis polymerisation in the presence of a Grubbs catalyst was studied using non-invasive Raman spectroscopy. The spectra of the monomer precursor and polymerised product were fully characterised and all stages of polymerisation monitored. Because of the monomer's high reactivity, the cure process is adaptable to reaction injection moulding and reactive rotational moulding. The viscosity of the dicyclopentadiene undergoes a rapid change at the beginning of the polymerisation process and it is critical that the induction time of the viscosity increase is determined and controlled for successful manufacturing. The results from this work show non-invasive Raman spectroscopic monitoring to be an effective method for monitoring the degree of cure, paving the way for possible implementation of the technique as a method of real-time analysis for control and optimisation during reactive processing. Agreement is shown between Raman measurements and ultrasonic time of flight data acquired during the initial induction period of the curing process.

Vibrational spectroscopic and ultrasound analysis for in-process characterization of high-density polyethylene/polypropylene blends during melt extrusion

Spectroscopic techniques such as Raman, mid-infrared (MIR), and near-infrared (NIR) have become indispensable analytical tools for rapid chemical quality control and process monitoring. This paper presents the application of in-line Fourier transform near-infrared (FT-NIR) spectroscopy, Raman spectroscopy, and ultrasound transit time measurements for in-line monitoring of the composition of a series of high-density polyethylene (HDPE)/polypropylene (PP) blends during single-screw extrusion. Melt composition was determined by employing univariate analysis of the ultrasound transit time data and partial least squares (PLS) multivariate analysis of the data from both spectroscopic techniques. Each analytical technique was determined to be highly sensitive to changes in melt composition, allowing accurate prediction of blend content to within +/- 1% w/w (1sigma) during monitoring under fixed extrusion conditions. FT-NIR was determined to be the most sensitive of the three techniques to changes in melt composition. A four-factor PLS model of the NIR blend spectra allowed determination of melt content with a standard prediction error of +/- 0.30% w/w (1sigma). However, the NIR transmission probes employed for analysis were invasive into the melt stream, whereas the single probes adopted for Raman and ultrasound analysis were noninvasive, making these two techniques more versatile. All three measurement techniques were robust to the high temperatures and pressures experienced during melt extrusion, demonstrating each system's suitability for process monitoring and control.

Neutron-Mapping Polymer Flow: Scattering, Flow Visualization, and Molecular Theory

Flows of complex fluids need to be understood at both macroscopic and molecular scales, because it is the macroscopic response that controls the fluid behavior, but the molecular scale that ultimately gives rise to rheological and solid-state properties. Here the flow field of an entangled polymer melt through an extended contraction, typical of many polymer processes, is imaged optically and by small-angle neutron scattering. The dual-probe technique samples both the macroscopic stress field in the flow and the microscopic configuration of the polymer molecules at selected points. The results are compared with a recent "tube model" molecular theory of entangled melt flow that is able to calculate both the stress and the single-chain structure factor from first principles. The combined action of the three fundamental entangled processes of reptation, contour length fluctuation, and convective constraint release is essential to account quantitatively for the rich rheological behavior. The multiscale approach unearths a new feature: Orientation at the length scale of the entire chain decays considerably more slowly than at the smaller entanglement length.

Effect of hydroxyapatite morphology/surface area on the rheology and processability of hydroxyapatite filled polyethylene composites

The commercial success of hydroxyapatite (HA) filled polyethylene composite has generated growing interest in improving the processability of the composite. A number of synthetic procedures and post synthesis heat treatment of HA has lead to the availability of powders with widely varying morphological features. This paper addresses the effect of morphological features of HA on the rheology and processability of an injection-moulding grade HA-HDPE composite. The results showed that low surface area HA filled composite exhibited better injection processing characteristics through improved rheological responses. The effect of reducing the surface area of the filler is to require less polyethylene to wet the filler and allows more polyethylene to be involved in the flow processes. These changes reduced the temperatures and pressures required for successful processing.

Comparison of propofol and midazolam for sedation in critically ill patients

101 critically ill patients admitted to five intensive-care units were allocated randomly to receive a continuous intravenous infusion of either propofol or midazolam for sedation for up to 24 h. In addition, morphine was given to provide analgesia. The mean duration of infusion was 20.2 h (range 3.0-24.5) in the propofol group and 21.3 h (4.0-47.0) in the midazolam group and infusion rates were 1.77 mg/kg/h (range 0.40-5.00) and 0.10 mg/kg/h (0.01-0.26), respectively. The infusion rates were adjusted as necessary, and the desired level of sedation was achieved easily in most patients in both groups. There were slight falls in arterial pressure, but there were no significant differences between the groups. Heart rate was lower in patients who received propofol. Some small changes occurred in biochemical and haematological variables in both groups, but they were not clinically significant. There was no indication that either drug substantially impaired adrenal steroidogenesis. When the infusion was discontinued, there was less variability in recovery of consciousness in patients who had received propofol. In a subgroup of patients, weaning from mechanical ventilation was achieved significantly faster after discontinuation of propofol than of midazolam. Propofol proved to be a satisfactory agent for sedation of these critically ill patients and compared favourably with midazolam.