Freeform fabrication of functional aluminium prototypes using powder metallurgy

Freeform fabrication methods allow the direct formation of parts built layer by layer, under the control of a CAD drawing. Most of these methods form parts in thermoplastic or thermoset polymers, but there would be many applications for freeform fabrication of fully functional metal or ceramic parts. We describe here the freeforming of sinterable aluminium alloys. In addition, the building approach allows different materials to be positioned within a monolithic part for an optimal combination of properties. This is illustrated here with the formation of an aluminium gear with a metal-matrix composite wear surface. (C) 1999 Kluwer Academic Publishers.

Effect of temperature and a crosslinking promoter on the gamma-radiolysis of a perfluoroelastomer

Methods of promoting the radiation-induced cross linking of poly(tetrafluoro-ethylene-co-perfluoromethyl vinyl ether) (TFE/PMVE) have been investigated. Greater control of the crosslinking and chain-scission reactions was achieved by varying the radiolysis temperature. This was attributed to temperature affecting the mobilities of reactive species such as polymeric free radicals. These reactive species are precursors to radiation-induced cross links and chain-ends. Analysis of the sol/gel behaviour, tensile properties and FTIR indicated that the optimum temperature for the radiation crosslinking of TFE/PMVE, at a dose of 150 kGy, was 263 K. This temperature was 10 K below the glass transition temperature. Incorporation of 1 wt% triallyl isocyanurate (TAIC) greatly amplified the radiation crosslinking of TFE/PMVE, The dose for gelation was decreased by 70%, and the additive imparted superior mechanical properties compared to the neat irradiated TFE/PMVE. Electron spin resonance (ESR) measurements showed higher radical yields at 77 K with the 1 wt% TAIC, indicating that the crosslinking promoter was acting as a radical trap. (C) 1999 Society of Chemical Industry.

New methods for the assessment of in vitro and in vivo stress cracking in biomedical polyurethanes

This article describes a new test method for the assessment of the severity of environmental stress cracking of biomedical polyurethanes in a manner that minimizes the degree of subjectivity involved. The effect of applied strain and acetone pre-treatment on degradation of Pellethane 2363 80A and Pellethane 2363 55D polyurethanes under in vitro and in vivo conditions is studied. The results are presented using a magnification-weighted image rating system that allows the semi-quantitative rating of degradation based on distribution and severity of surface damage. Devices for applying controlled strain to both flat sheet and tubing samples are described. The new rating system consistently discriminated between. the effects of acetone pre-treatments, strain and exposure times in both in vitro and in vivo experiments. As expected, P80A underwent considerable stress cracking compared with P55D. P80A produced similar stress crack ratings in both in vivo and in vitro experiments, however P55D performed worse under in vitro conditions compared with in vivo. This result indicated that care must be taken when interpreting in vitro results in the absence of in vivo data. (C) 2001 Elsevier Science Ltd. All rights reserved.

A cellulose liquid crystal motor: a steam engine of the second kind

The salient feature of liquid crystal elastomers and networks is strong coupling between orientational order and mechanical strain. Orientational order can be changed by a wide variety of stimuli, including the presence of moisture. Changes in the orientation of constituents give rise to stresses and strains, which result in changes in sample shape. We have utilized this effect to build soft cellulose-based motor driven by humidity. The motor consists of a circular loop of cellulose film, which passes over two wheels. When humid air is present near one of the wheels on one side of the film, with drier air elsewhere, rotation of the wheels results. As the wheels rotate, the humid film dries. The motor runs so long as the difference in humidity is maintained. Our cellulose liquid crystal motor thus extracts mechanical work from a difference in humidity.

First Curl, Then Wrinkle

The excellent properties of elastomers are exploited to trigger wrinkling instabilities in curved shells. Micro- and nano-fibres are produced by electrospinning and UV irradiated: each fibre consists of a soft core and a stiff outer half-shell. Upon solvent de-swelling, the fibres curl because the shell and the core have different natural lengths. Wrinkling only starts after the fibre has attained a well-defined helical shape. A simple analytical model is proposed to find the curling curvature and wrinkle wavelength, as well as the transition between the “curling” and “wrinkling” regimes. This new instability resembles that found in the tendrils of climbing plants as they dry and lignify.

Mechanical characterization of polyhydroxyalkanoate and poly (lactic acid) blends

In this work, the mechanical behavior of polyhyroxyalkanoate (PHA)/poly(lactic acid) (PLA) blends is investigated in a wide range of compositions. The mechanical properties can be optimized by varying the PHA contents of the blend. The flexural and tensile properties were estimated by different models: the rule of mixtures, Kerner–Uemura–Takayanagi (KUT) model, Nicolai–Narkis model and Béla–Pukánsky model. This study was aimed at investigating the adhesion between the two material phases. The results anticipate a good adhesion between both phases. Nevertheless, for low levels of incorporation of PHA (up to 30%), where PLA is expectantly the matrix, the experimental data seem to deviate from the perfect adhesion models, suggesting a decrease in the adhesion between both polymeric phases when PHA is the disperse phase. For the tensile modulus, a linear relationship is found, following the rules of mixtures (or a KUT model with perfect adhesion between phases) denoting a good adhesion between the phases over the composition range. The incorporation of PHA in the blend leads to a decrease in the flexural modulus but, at the same time, increases the tensile modulus. The impact energy of the blends varies more than 157% over the entire composition. For blends with PHA weight fraction lower than 50%, the impact strength of the blend is higher than the pure base polymers. The highest synergetic effect is found when the PLA is the matrix and the PHA is the disperse phase for the blend PHA/PLA of 30/70. The second maximum is found for the inverse composition of 70/30. PLA has a heat-deflection temperature (HDT) substantially lower than PHA. For the blends, the HDT increases with the increment in the percentage of the incorporation of PHA. With up to 50% PHA (PLA as matrix), the HDT is practically constant and equal to PLA value. Above this point (PHA matrix), the HDT of the polymer blends increases linearly with the percentage of addition of PHA.

Processing of continuous fibre reinforced thermoplastics

Towpregs based on different fibres and thermoplastic matrices were processed for highly demanding and more commercial applications by different composite processing technologies. In the technologies used, compression moulding and pultrusion, the final composite pr ocessing parameters were studied in order to obtain composites with adequate properties at industrial compatible production rates. The produced towpregs were tested to verify its polymer content and degree of impregnation. The obtained results have shown t hat the coating line enabled to produce, with efficiency and industrial scale speed rates, thermoplastic matrix towpregs that may be used to manufacture composites for advanced and larger volume commercial markets.

Experimental study on polyester based concretes filled with glass fibre reinforced plastic recyclates – a contribution to composite materials sustainability

The development and applications of thermoset polymeric composites, namely fibre reinforced plastics (FRP), have shifted in the last decades more and more into the mass market [1]. Despite of all advantages associated to FRP based products, the increasing production and consume also lead to an increasing amount of FRP wastes, either end-of-lifecycle products, or scrap and by-products generated by the manufacturing process itself. Whereas thermoplastic FRPs can be easily recycled, by remelting and remoulding, recyclability of thermosetting FRPs constitutes a more difficult task due to cross-linked nature of resin matrix. To date, most of the thermoset based FRP waste is being incinerated or landfilled, leading to negative environmental impacts and supplementary added costs to FRP producers and suppliers. This actual framework is putting increasing pressure on the industry to address the options available for FRP waste management, being an important driver for applied research undertaken cost efficient recycling methods. [1-2]. In spite of this, research on recycling solutions for thermoset composites is still at an elementary stage. Thermal and/or chemical recycling processes, with partial fibre recovering, have been investigated mostly for carbon fibre reinforced plastics (CFRP) due to inherent value of carbon fibre reinforcement; whereas for glass fibre reinforced plastics (GFRP), mechanical recycling, by means of milling and grinding processes, has been considered a more viable recycling method [1-2]. Though, at the moment, few solutions in the reuse of mechanically-recycled GFRP composites into valueadded products are being explored. Aiming filling this gap, in this study, a new waste management solution for thermoset GFRP based products was assessed. The mechanical recycling approach, with reduction of GFRP waste to powdered and fibrous materials was applied, and the potential added value of obtained recyclates was experimentally investigated as raw material for polyester based mortars. The use of a cementless concrete as host material for GFRP recyclates, instead of a conventional Portland cement based concrete, presents an important asset in avoiding the eventual incompatibility problems arisen from alkalis silica reaction between glass fibres and cementious binder matrix. Additionally, due to hermetic nature of resin binder, polymer based concretes present greater ability for incorporating recycled waste products [3]. Under this scope, different GFRP waste admixed polymer mortar (PM) formulations were analyzed varying the size grading and content of GFRP powder and fibre mix waste. Added value of potential recycling solution was assessed by means of flexural and compressive loading capacities of modified mortars with regard to waste-free polymer mortars.

A cellulosic liquid crystal pool for cellulose nanocrystals: structure and molecular dynamics at high shear rates

Cellulose and its derivatives, such as hydroxypropylcellulose (HPC) have been studied for a long time but they are still not well understood particularly in liquid crystalline solutions. These systems can be at the origin of networks with properties similar to liquid crystalline (LC) elastomers. The films produced from LC solutions can be manipulated by the action of moisture allowing for instance the development of a soft motor (Geng et al., 2013) driven by humidity. Cellulose nanocrystals (CNC), which combine cellulose properties with the specific characteristics of nanoscale materials, have been mainly studied for their potential as a reinforcing agent. Suspensions of CNC can also self-order originating a liquid-crystalline chiral nematic phases. Considering the liquid crystalline features that both LC-HPC and CNC can acquire, we prepared LC-HPC/CNC solutions with different CNC contents (1,2 and 5 wt.%). The effect of the CNC into the LC-HPC matrix was determined by coupling rheology and NMR spectroscopy - Rheo-NMR a technique tailored to analyse orientational order in sheared systems. (C) 2015 Elsevier Ltd. All rights reserved.

A Study on Microstructure Characteristics of TEPs-modified Adhesives

Thermally expandable particles (TEPs) were developed by Dow Chemical Co in the early 1970´s [1] and were further developed by others [2, 3]. They are particles made up of a thermoplastic shell filled with liquid hydrocarbon. On heating them, two transformations will occur. One is the softening of shell material and the other is the gasification of the hydrocarbon liquid inside it. As a consequence, the shell will expand as the gas inside it will push the softened shell from inside out causing it to grow in size [4]. When fully expanded, the growth in volume of the particle can be from 50 to 100 times [3]. Owing to this unique behaviour, TEPs are used by the industry in a wide variety of applications mainly for weight reduction and appearance improvement for thermoplastics, inks, and coatings. In adhesive bonding, TEPs have been used for recycling purposes. Moreover, TEPs might be used to modify structural adhesives for other new purposes, such as: to increase the joint strength by creating an adhesive functionally modified along the overlap of the joint by gradual heating and/or to heal the adhesive in case of damage.

Estudo da Produção de Towpregs e Transformação por Pultrusão

Durante as últimas décadas, os materiais compósitos têm substituído com sucesso os materiais tradicionais em muitas aplicações de engenharia, muito devido às excelentes propriedades que se conseguem obter com a combinação de materiais diferentes. Nos compósitos reforçados com fibras longas ou contínuas tem-se verificado, ao longo dos últimos anos, um aumento do uso de matrizes termoplásticas, fruto de várias vantagens associadas, como o facto de serem bastante mais ecológicas, comparativamente às termoendurecíveis. No entanto, este aumento está muito dependente do desenvolvimento de novas tecnologias de processamento, pois a elevada viscosidade dos termoplásticos, comparativamente aos termoendurecíveis, dificulta significativamente o processo. Muitos equipamentos de produção de termoplásticos são resultado de adaptações de equipamentos de produção de termoendurecíveis, onde normalmente é necessário adicionar fornos de pré-aquecimento. Neste trabalho, pretendeu-se produzir pré-impregnados de fibras contínuas com matriz termoplástica, por deposição a seco de polímero em pó sobre fibras de reforço (denominados por towpreg) para, posteriormente, serem transformados por pultrusão e caracterizados. As matérias-primas utilizadas foram: Polipropileno (PP) como matriz termoplástica e fibra de carbono como reforço. Por forma a melhorar as propriedades finais do compósito, foram otimizadas as condições de processamento na produção dos towpregs, estudando-se a influência da variação dos parâmetros de processamento no teor de polímero presente nestes, tendo como objetivo teores mássicos de polímero superiores a 30%. A condição ótima e a influência dos parâmetros de processamento foram obtidas com o auxílio do Método de Taguchi. Os perfis produzidos por pultrusão foram sujeitos a ensaios de flexão, de forma a obter as suas propriedades quando sujeitos a esse tipo de esforço. Foram também realizados ensaios de calcinação de forma a obter as frações mássicas de fibra e polímero presentes no compósito final. Sabidas as frações mássicas, converteramse em frações volúmicas e obtiveram-se as propriedades teoricamente esperadas através da Lei das Misturas e compararam-se com as obtidas experimentalmente. As propriedades obtidas foram também comparadas com as de outros compósitos pultrudidos.

Food waste valorization through the production of polyhydroxyalkanoates by mixed microbial cultures

Dissertação para obtenção do Grau de Mestre em Engenharia Química e Bioquímica

Produtos têxteis inteligentes incorporando filamentos compósitos com nanotubos de carbono

Programa Doutoral em Engenharia Têxtil.

Using OpenFOAM to aid the design of complex profile extrusion dies

[Extrat] Thermoplastic profiles are very attractive due to their inherent design freedom. However, the usual methodologies employed to design extrusion forming tools, based on experimental based trial–and–error procedures, are highly dependent on the designer’s experience and lead to high resources consumption. Despite of the relatively low cost of the raw materials employed on the production of this type of profiles, the resources involved in the die design process significantly increase their cost. These difficulties are even more evident when a complex geometry profile has to be produced and there is no previous experience with similar geometries. Therefore, novel design approaches are required, in order to reduce the required resources and guarantee a good performance for the produced profile. (...)

Impact performance prediction of injection-molded talc-filled polypropylene through thermomechanical environment assessment

Due to the fact that different injection molding conditions tailor the mechanical response of the thermoplastic material, such effect must be considered earlier in the product development process. The existing approaches implemented in different commercial software solutions are very limited in their capabilities to estimate the influence of processing conditions on the mechanical properties. Thus, the accuracy of predictive simulations could be improved. In this study, we demonstrate how to establish straightforward processing-impact property relationships of talc-filled injection-molded polypropylene disc-shaped parts by assessing the thermomechanical environment (TME). To investigate the relationship between impact properties and the key operative variables (flow rate, melt and mold temperature, and holding pressure), the design of experiments approach was applied to systematically vary the TME of molded samples. The TME is characterized on computer flow simulation outputsanddefined bytwo thermomechanical indices (TMI): the cooling index (CI; associated to the core features) and the thermo-stress index (TSI; related to the skin features). The TMI methodology coupled to an integrated simulation program has been developed as a tool to predict the impact response. The dynamic impact properties (peak force, peak energy, and puncture energy) were evaluated using instrumented falling weight impact tests and were all found to be similarly affected by the imposed TME. The most important molding parameters affecting the impact properties were found to be the processing temperatures (melt andmold). CI revealed greater importance for the impact response than TSI. The developed integrative tool provided truthful predictions for the envisaged impact properties.