Experimental Modeling of Twin-Screw Extrusion Processes to Predict Properties of Extruded Composites

Twin-screw extrusion is used to compound fillers into a polymer matrix in order to improve the properties of the final product. The resultant properties of the composite are determined by the operating conditions used during extrusion processing. Changes in the operating conditions affect the physics of the melt flow, inducing unique composite properties. In the following work, the Residence Stress Distribution methodology has been applied to model both the stress behavior and the property response of a twin-screw compounding process as a function of the operating conditions. The compounding of a pigment into a polymer melt has been investigated to determine the effect of stress on the degree of mixing, which will affect the properties of the composite. In addition, the pharmaceutical properties resulting from the compounding of an active pharmaceutical ingredient are modeled as a function of the operating conditions, indicating the physical behavior inducing the property responses.

Structure dependencies for multiscale polymer composites using extrusion processes

Multiscale reinforcement, using carbon microfibers and multi-walled carbon nanotubes, of polymer matrix composites manufactured by twin-screw extrusion is investigated for enhanced mechanical and thermal properties with an emphasis on the use of a diverging flow in the die for fluid mechanical fiber manipulation. Using fillers at different length scales (microscale and nanoscale), synergistic combinations have been identified to produce distinct mechanical and thermal behavior. Fiber manipulation has been demonstrated experimentally and computationally, and has been shown to enhance thermal conductivity significantly. Finally, a new physics driven predictive model for thermal conductivity has been developed based on fiber orientation during flow, which is shown to successfully capture composite thermal conductivity.

Development of the ASTM E681 Standard

ASHRAE 34, based on ASTM E681, was improved by identifying and rectifying deficiencies in ASTM E681. An ASTM E681 apparatus and procedure was developed with gaseous refrigerant testing in mind. The plumbing was improved by ensuring that the pressure readings could be constantly monitored while decreasing leakage potential. An original electrical system was designed and constructed for the ignition system. Additionally, a control panel was constructed to isolate hazardous electrical elements, and facilitate the testing, while simultaneously organizing the critical plumbing and ignition components. 3D printing efficiently produced heat-resistant, nonreactive, and structurally stable lower electrode spacers, propellers, and propeller bars. The heating system was designed to ensure even temperature throughout the apparatus. The humidity system was designed to accurately condition the air. Recommendations to improve ASTM E681 are provided. The research can be built on to improve the accuracy and reproducibility of ASTM E681.