Composite materials design, manufacture and evaluation

Fibre-Reinforced-Plastics are composite materials composed by thin fibres with high mechanical properties, made to work together with a cohesive plastic matrix. The huge advantages of fibre reinforced plastics over traditional materials are their high specific mechanical properties i.e. high stiffness and strength to weight ratios. This kind of composite materials is the most disruptive innovation in the structural materials field seen in recent years and the areas of potential application are still many. However, there are few aspects which limit their growth: on the one hand the information available about their properties and long term behaviour is still scarce, especially if compared with traditional materials for which there has been developed an extended database through years of use and research. On the other hand, the technologies of production are still not as developed as the ones available to form plastics, metals and other traditional materials. A third aspect is that the new properties presented by these materials e.g. their anisotropy, difficult the design of components. This thesis will provide several case-studies with advancements regarding the three limitations mentioned. In particular, the long term mechanical properties have been studied through an experimental analysis of the impact of seawater on GFRP. Regarding production methods, the pre-impregnated cured in autoclave process was considered: a rapid tooling method to produce moulds will be presented, and a study about the production of thick components. Also, two liquid composite moulding methods will be presented, with a case-study regarding a large component with sandwich structure that was produced with the Vacuum-Assisted-Resin-Infusion method, and a case-study regarding a thick con-rod beam that was produced with the Resin-Transfer-Moulding process. The final case-study will analyse the loads acting during the use of a particular sportive component, made with FRP layers and a sandwich structure, practical design rules will be provided.

Liquid crystalline phases of anisotropic, polymer functionalized nanoparticles

Diese Arbeit beschäftigt sich mit der Polymerfunktionalisierung formanisotroperrnNanopartikel wie TiO2 Nanostäbchen oder Kohlenstoff Nanoröhren. Dies dient derrnSolubilisierung und sterischen Stabilisierung in organischen Medien, da diesernionenfrei hergestellt werden können, was eine Nutzung für nanoskopische,rnelektrische Schaltkreise ermöglicht. Die Polymere wurden mittels der RAFTrn(reversible addition-fragmentation chain transfer) Polymerisation mit engenrnMolekulargewichtsverteilungen hergestellt. Im Detail wurden Ankergruppen inrnBlockcopolymere und an der Alphaposition eingeführt, welche eine Anbindung an diernNanopartikeloberfläche ermöglichen. Die Polymere wurden durch Variation derrnverschiedenen Blocklängen für eine bestmögliche Adsorption optimiert. Die sorngewonnenen Polymer funktionalisierten Nanopartikel zeigten eine gute Löslichkeit inrnorganischen Medien und zeigten zudem eine lyotropes, flüssigkristallinesrnPhasenverhalten. Dies war aufgrund der Formanisotropie zu erwarten, zeigte jedochrnebenfalls ein unerwartetes thermotropes Verhalten, welches durch die Polymerhüllernerzeugt wurde. Die Flüssigkristalle wurden eingehend mittels polarisierterrnMikroskopie und Differential Scanning Calorimetry (DSC) untersucht. Diernflüssigkristallinen Phasen aus Nanostäbchen und –röhren wurde dann zurrnOrientierung der anisotropen Nanopartikel benutzt und es konnten makroskopischrngeordnete Proben hergestellt werden. Die Polymerhülle um die Nanopartikelrnermöglichte es ebenfalls diese in Polymerfilme einzuarbeiten und sornNanopartikelverstärkte Kunststoffe herzustellen.

Inorganic-organic hybrid polymers: Solution-processible coating materials for defined surface functionalization

A new class of inorganic-organic hybrid polymers could successfully been prepared by the combination of different polymerization techniques. The access to a broad range of organic polymers incorporated into the hybrid polymer was realized using two independent approaches.rnIn the first approach a functional poly(silsesquioxane) (PSSQ) network was pre-formed, which was capable to initiate a controlled radical polymerization to graft organic vinyl-type monomers from the PSSQ precursor. As controlled radical polymerization techniques atom transfer radical polymerization (ATRP), as well as reversible addition fragmentation chain transfer (RAFT) polymerization could be used after defined tuning of the PSSQ precursor either toward a PSSQ macro-initiator or to a PSSQ macro-chain-transfer-agent. The polymerization pathway, consisting of polycondensation of trialkoxy-silanes followed by grafting-from polymerization of different monomers, allowed synthesis of various functional hybrid polymers. A controlled synthesis of the PSSQ precursors could successfully be performed using a microreactor setup; the molecular weight could be adjusted easily while the polydispersity index could be decreased well below 2.rnThe second approach aimed to incorporate differently derived organic polymers. As examples, polycarbonate and poly(ethylene glycol) were end-group-modified using trialkoxysilanes. After end-group-functionalization these organic polymers could be incorporated into a PSSQ network.rnThese different hybrid polymers showed extraordinary coating abilities. All polymers could be processed from solution by spin-coating or dip-coating. The high amount of reactive silanol moieties in the PSSQ part could be cross-linked after application by annealing at 130° for 1h. Not only cross-linking of the whole film was achieved, which resulted in mechanical interlocking with the substrate, also chemical bonds to metal or metal oxide surfaces were formed. All coating materials showed high stability and adhesion onto various underlying materials, reaching from metals (like steel or gold) and metal oxides (like glass) to plastics (like polycarbonate or polytetrafluoroethylene).rnAs the material and the synthetic pathway were very tolerant toward different functionalities, various functional monomers could be incorporated in the final coating material. The incorporation of N-isopropylacrylamide yielded in temperature-responsive surface coatings, whereas the incorporation of redox-active monomers allowed the preparation of semi-conductive coatings, capable to produce smooth hole-injection layers on transparent conductive electrodes used in optoelectronic devices.rnThe range of possible applications could be increased tremendously by incorporation of reactive monomers, capable to undergo fast and quantitative conversions by polymer-analogous reactions. For example, grafting active esters from a PSSQ precursor yielded a reactive surface coating after application onto numerous substrates. Just by dipping the coated substrate into a solution of a functionalized amine, the desired function could be immobilized at the interface as well as throughout the whole film. The obtained reactive surface coatings could be used as basis for different functional coatings for various applications. The conversion with specifically tuned amines yielded in surfaces with adjustable wetting behaviors, switchable wetting behaviors or as recognition element for surface-oriented bio-analytical devices. The combination of hybrid materials with orthogonal reactivities allowed for the first time the preparation of multi-reactive surfaces which could be functionalized sequentially with defined fractions of different groups at the interface. rnThe introduced concept to synthesis functional hybrid polymers unifies the main requirements on an ideal coating material. Strong adhesion on a wide range of underlying materials was achieved by secondary condensation of the PSSQ part, whereas the organic part allowed incorporation of various functionalities. Thus, a flexible platform to create functional and reactive surface coatings was achieved, which could be applied to different substrates. rn

Characterization of Biodegradable Polymer Nanocomposites Fabricated via Solid-State Processing

Biodegradable polymer/clay nanocomposites were prepared withpristine and organically modified montmorillonite in polylactic acid (PLA) and polycaprolactone (PCL) polymer matrices. Nanocomposites were fabricated using extrusion and SSSP to compare the effects of melt-state and solid-state processing on the morphology of the final nanocomposite. Characterization of various material properties was performed on prepared biodegradable polymer/clay nanocomposites to evaluate property enhancements from different clays and/or processing methods.

The Crystallization Kinetics of Polylactic Acid (Pla) Processed Through Solid-State/Melt Extrusion

Polylactic acid (PLA) is a bio-derived, biodegradable polymer with a number of similar mechanical properties to commodity plastics like polyethylene (PE) and polyethylene terephthalate (PETE). There has recently been a great interest in using PLA to replace these typical petroleum-derived polymers because of the developing trend to use more sustainable materials and technologies. However, PLA¿s inherent slow crystallization behavior is not compatible with prototypical polymer processing techniques such as molding and extrusion, and in turn inhibits its widespread use in industrial applications. In order to make PLA into a commercially-viable material, there is a need to process the material in such a way that its tendency to form crystals is enhanced. The industry standard for producing PLA products is via twin screw extrusion (TSE), where polymer pellets are fed into a heated extruder, mixed at a temperature above its melting temperature, and molded into a desired shape. A relatively novel processing technique called solid-state shear pulverization (SSSP) processes the polymer in the solid state so that nucleation sites can develop and fast crystallization can occur. SSSP has also been found to enhance the mechanical properties of a material, but its powder output form is undesirable in industry. A new process called solid-state/melt extrusion (SSME), developed at Bucknell University, combines the TSE and SSSP processes in one instrument. This technique has proven to produce moldable polymer products with increased mechanical strength. This thesis first investigated the effects of the TSE, SSSP, and SSME polymer processing techniques on PLA. The study seeks to determine the process that yields products with the most enhanced thermal and mechanical properties. For characterization, percent crystallinity, crystallization half time, storage modulus, softening temperature, degradation temperature and molecular weight were analyzed for all samples. Through these characterization techniques, it was observed that SSME-processed PLA had enhanced properties relative to TSE- and SSSP-processed PLA. Because of the previous findings, an optimization study for SSME-processed PLA was conducted where throughput and screw design were varied. The optimization study determined PLA processed with a low flow rate and a moderate screw design in an SSME process produced a polymer product with the largest increase in thermal properties and a high retention of polymer structure relative to TSE-, SSSP-, and all other SSME-processed PLA. It was concluded that the SSSP part of processing scissions polymer chains, creating defects within the material, while the TSE part of processing allows these defects to be mixed thoroughly throughout the sample. The study showed that a proper SSME setup allows for both the increase in nucleation sites within the polymer and sufficient mixing, which in turn leads to the development of a large amount of crystals in a short period of time.

Screening, optimization and extraction of polyhydroxyalkanoates and peptidoglycan from Bacillus megaterium

Bioplastics are polymers (such as polyesters) produced from bacterial fermentations that are biodegradable and nonhazardous. They are produced by a wide variety of bacteria and are made only when stress conditions allow, such as when nutrient levels are low, more specifically levels of nitrogen and oxygen. These stress conditions cause certain bacteria to build up excess carbon deposits as energy reserves in the form of polyhydroxyalkanoates (PHAs). PHAs can be extracted and formed into actual plastic with the same strength of conventional, synthetic-based plastics without the need to rely on foreign petroleum. The overall goal of this project was to select for a bacteria that could grow on sugars found in the lignocellulosic biomass, and get the bacteria to produce PHAs and peptidoglycan. Once this was accomplished the goal was to extract PHAs and peptidoglycan in order to make a stronger more rigid plastic, by combing them into a co-polymer. The individual goals of this project were to: (1) Select and screen bacteria that are capable of producing PHAs by utilizing the carbon/energy sources found in lignocellulosic biomass; (2) Maximize the utilization of those sugars present in woody biomass in order to produce optimal levels of PHAs. (3) Use room temperature ionic liquids (RTILs) in order to separate the cell membrane and peptidoglycan, allowing for better extraction of PHAs and more intact peptidoglycan. B. megaterium a Gram-positive PHA-producing bacterium was selected for study in this project. It was grown on a variety of different substrates in order to maximize both its growth and production of PHAs. The optimal conditions were found to be 30°C, pH 6.0 and sugar concentration of either 30g/L glucose or xylose. After optimal growth was obtained, both RTILs and enzymatic treatments were used to break the cell wall, in order to extract the PHAs, and peptidoglycan. PHAs and peptidoglycan were successfully extracted from the cell, and will be used in the future to create a new stronger co-polymer. Peptidoglycan recovery yield was 16% of the cells’ dry weight.

Three dimensional finite element simulation of polymer melting and flow in a single-screw extruder : optimization of screw channel geometry

Single-screw extrusion is one of the widely used processing methods in plastics industry, which was the third largest manufacturing industry in the United States in 2007 [5]. In order to optimize the single-screw extrusion process, tremendous efforts have been devoted for development of accurate models in the last fifty years, especially for polymer melting in screw extruders. This has led to a good qualitative understanding of the melting process; however, quantitative predictions of melting from various models often have a large error in comparison to the experimental data. Thus, even nowadays, process parameters and the geometry of the extruder channel for the single-screw extrusion are determined by trial and error. Since new polymers are developed frequently, finding the optimum parameters to extrude these polymers by trial and error is costly and time consuming. In order to reduce the time and experimental work required for optimizing the process parameters and the geometry of the extruder channel for a given polymer, the main goal of this research was to perform a coordinated experimental and numerical investigation of melting in screw extrusion. In this work, a full three-dimensional finite element simulation of the two-phase flow in the melting and metering zones of a single-screw extruder was performed by solving the conservation equations for mass, momentum, and energy. The only attempt for such a three-dimensional simulation of melting in screw extruder was more than twenty years back. However, that work had only a limited success because of the capability of computers and mathematical algorithms available at that time. The dramatic improvement of computational power and mathematical knowledge now make it possible to run full 3-D simulations of two-phase flow in single-screw extruders on a desktop PC. In order to verify the numerical predictions from the full 3-D simulations of two-phase flow in single-screw extruders, a detailed experimental study was performed. This experimental study included Maddock screw-freezing experiments, Screw Simulator experiments and material characterization experiments. Maddock screw-freezing experiments were performed in order to visualize the melting profile along the single-screw extruder channel with different screw geometry configurations. These melting profiles were compared with the simulation results. Screw Simulator experiments were performed to collect the shear stress and melting flux data for various polymers. Cone and plate viscometer experiments were performed to obtain the shear viscosity data which is needed in the simulations. An optimization code was developed to optimize two screw geometry parameters, namely, screw lead (pitch) and depth in the metering section of a single-screw extruder, such that the output rate of the extruder was maximized without exceeding the maximum temperature value specified at the exit of the extruder. This optimization code used a mesh partitioning technique in order to obtain the flow domain. The simulations in this flow domain was performed using the code developed to simulate the two-phase flow in single-screw extruders.

Dibutyltin disrupts glucocorticoid receptor function and impairs glucocorticoid-induced suppression of cytokine production

BACKGROUND: Organotins are highly toxic and widely distributed environmental chemicals. Dibutyltin (DBT) is used as stabilizer in the production of polyvinyl chloride plastics, and it is also the major metabolite formed from tributyltin (TBT) in vivo. DBT is immunotoxic, however, the responsible targets remain to be defined. Due to the importance of glucocorticoids in immune-modulation, we investigated whether DBT could interfere with glucocorticoid receptor (GR) function. METHODOLOGY: We used HEK-293 cells transiently transfected with human GR as well as rat H4IIE hepatoma cells and native human macrophages and human THP-1 macrophages expressing endogenous receptor to study organotin effects on GR function. Docking of organotins was used to investigate the binding mechanism. PRINCIPAL FINDINGS: We found that nanomolar concentrations of DBT, but not other organotins tested, inhibit ligand binding to GR and its transcriptional activity. Docking analysis indicated that DBT inhibits GR activation allosterically by inserting into a site close to the steroid-binding pocket, which disrupts a key interaction between the A-ring of the glucocorticoid and the GR. DBT inhibited glucocorticoid-induced expression of phosphoenolpyruvate carboxykinase (PEPCK) and tyrosine-aminotransferase (TAT) and abolished the glucocorticoid-mediated transrepression of TNF-alpha-induced NF-kappaB activity. Moreover, DBT abrogated the glucocorticoid-mediated suppression of interleukin-6 (IL-6) and TNF-alpha production in lipopolysaccharide (LPS)-stimulated native human macrophages and human THP-1 macrophages. CONCLUSIONS: DBT inhibits ligand binding to GR and subsequent activation of the receptor. By blocking GR activation, DBT may disturb metabolic functions and modulation of the immune system, providing an explanation for some of the toxic effects of this organotin.

Medicinal Chemistry of ureido derivatives as Antiinfectives

Ureides are compounds, which essentially incorporate urea as a substructural component either in open or cyclic form. Ureido derivatives are one of the oldest classes of bioactives, widely used as antiinfective agents. Several of these compounds, including aminoquinuride, aminocarbalide, imidurea, cloflucarban, nitrofurazone, urosulfan, viomycin are used in clinical situations. One of the ureides, the triclocarban is compulsorily used as antibacterial agent in cleansing and disinfecting solutions in hospital, household, cosmetics, toys, textile and plastics. It disables the activity of ENR, an enzyme vital for building the cell wall of the bacteria and fungus. Besides, the ureido-penicillins in clinical use there have been several ureido-lactam derivatives which have been reported to exhibit significant antibacterial activity. A urea containing dipeptide TAN-1057A isolated from Flexibacter spp. has potent bioactivity against MRSA. The metal complexes of sulphonyl ureido derivatives are effective antifungal agents by inhibiting the activity of phosphomannose isomerase, a key enzyme in the biosynthesis of yeast cell walls. There have been number of ureides including the cyclic ureas which are potent HIV protease inhibitors and display significant anti-HIV activity. The urea derivative, merimepodip that has been derived using structure based design, is potent inhibitor of IMPDH and is active against Hepatitis-C infection. This review will primarily focus on the significant work reported for this class of compounds including design, synthesis and biological activity.

Markt- und Trendanalyse Laserstrahlschmelzen 2010

Nicht nur die vielfältigen funktionsbezogenen Anforderungen von Produkten und Bauteilen, sondern vor allem die heutigen Marktbedürfnisse stellen große Herausforderungen für aktuelle Fertigungstechnologien dar. Hierbei bildet die kontinuierlich steigende Variantenvielfalt bei gleichzeitiger Senkung der Stückzahlen je Variante die differenzierten Kundenwünsche ab. Diese Entwicklungen begünstigen die Perspektiven des Laserstrahlschmelzens im Allgemeinen sowie seiner speziellen Anwendungsgebiete Rapid Prototyping, Rapid Tooling und Rapid Manufac-turing. In den Branchen der Medizintechnik und der Gummi- und Kunststoffverarbeitung ist bereits seit einiger Zeit eine dynamische Entwicklung erkennbar. Besonders in der Medizintechnik wird der immer breitere Einsatz des Laserstrahlschmelzens durch die hohe Innovationsfähigkeit des Verfahrens und ein verbesserstes Qualitäts-management vorangetrieben. Aufgrund der zunehmenden Forderungen nach individualisierten und individuellen Produkten werden bereits heute patientenangepasste Implantate mit dem Laserstrahlschmelzverfahren gefertigt. Erwarten die Marktteilnehmer eine weiterhin steigende Nachfrage nach solchen Produkten? Wie muss das Verfah-ren verbessert werden, um seine Prozessstabilität zu erhöhen? Wo liegen die zukünftigen Herausforderungen in der Strahlschmelztechnologie? Um diese und weitere Fragen zu klären hat das Fraunhofer Institut für Produkti-onsanlagen und Konstruktionstechnik (IPK) eine Markt- und Trendanalyse für das Laserstrahlschmelzen durchge-führt.

Mechanische Eigenschaften und Bruchverhalten maskengesinterter Kunststoffbauteile

Das selektive Maskensintern von Kunststoffen ermöglicht die flächige Belichtung des Bauraums, wodurch sich konstante, von der zu belichtenden Geometrie/Fläche unabhängige Zykluszeiten pro Schicht ergeben. Durch den Einsatz eines, über dem Bauraum platzierten, Infrarotstrahlerfeldes wird eine Modifikation des verarbeiteten Polyamid 12-Pulvers mit einem Absorber, hier Flammruß, notwendig. Bisher konnte gezeigt werden, dass Prototypen sowie wärmeleitfähige Kunststoffbauteile hergestellt werden können. Im Rahmen dieses Beitrags sollen die mechanischen Eigenschaften von SMS-Bauteilen betrachtet werden. Die Beeinflussung der mechanischen Kennwerte, durch variierende Materialeigenschaften sowie unterschiedliche Prozessparameter, werden ebenso wie die Richtungs-, Temperatur- und Belastungsartabhängigkeit, bei konstanten Material- und Prozessparametern, untersucht. Zur Charakterisierung des Bauteilversagens wurden Methoden wie die Lichtmikroskopie und Rasterelektronenmikroskopie eingesetzt und Bruchmechanismen abgeleitet.

Die Flüsterkette – Geräuschreduzierung an Fördersystemen

Um die in einem Kunststoffkettenfördersystem auftretenden Geräusche zu reduzieren, wurde ein spezielles Bauteil der Kette im Zweikomponenten-Spritzguss aus einem thermoplastischen Elastomer (TPE) und kettentypischen Kunststoffen gefertigt. Im Rahmen der Entwicklung wurden u. a. Voruntersuchungen zur Haftung zwischen den Werkstoffen durchgeführt. Die neu geschaffene Kette bewirkt eine Verringerung des Schalldruckpegels um 3 4 dB[A] gegenüber herkömmlichen Kunststoffketten im Fördersystem. Das ermöglicht eine Steigerung der Fördergeschwindigkeit um bis zu 30% ohne zusätzliche Lärmbelastung.

Intelligente Hochleistungsförderkette aus Kunststoff

Im folgenden Beitrag wird die Entwicklung einer metallverstärkten Kunststoffgleitkette mit integrierter Sensorik skizziert. Der Focus der Arbeit liegt unter anderem auf Untersuchungen zum Werkstoffverbundverhalten zwischen Metall und Kunststoff, der Adaptierung von Mikroelektronik in einzelne Kettenglieder, einer großserientauglichen Fertigungstechnologie für hybride Leichtbaukomponenten, sowie die Erarbeitung von Gestaltungsgrundsätzen und Logistikkonzepten für die Produktion von Leichtbaukomponenten mittels fusionierter Prozesse.

Surface quality of profile extrusion dies manufactured by Selective Laser Melting

The design of plastics profile extrusion dies becomes increasingly more complex so that conventional manufacture processes reach their limit in the die manufacture. A feasible manufacture of arbitrarily designed dies is only possible by additive manufacturing. An especially promising process is hereby the Selective Laser Melting with which metal parts with series identical mechanical properties can be produced without the need for part specific tooling or downstream sintering processes. Disadvantegeous is, however, the relatively rough surface of additively manufactured parts. Against this background, the manufacturing of an profile extrusion die by Selective Laser Melting and the plastics profile surface quality, that can be achieved with such dies, is investigated. For this purpose, profiles are extruded both with an additively manufactured die and a conventionally milled sample of the same die geometry. In case of the additively manufactured die a concept for the surface finishing of the flow channel is required, which can be applied to arbitrarily shaped geometries. Therefore, two different reworking processes are applied only to the die land of the flow channel. The comparison of the surface roughnesses shows that the additively manufactured die with a polished die land delivers the same surface quality as the conventional die.

Scintillation crystal including a rare earth halide, and a radiation detection apparatus including the scintillation crystal.

A scintillation crystal can include Ln(1-y)REyX3, wherein Ln represents a rare earth element, RE represents a different rare earth element, y has a value at 0-1, and X represents a halogen. In an embodiment, the scintillation crystal is doped with a Group 1 element, a Group 2 element, or a mixt. thereof, and the scintillation crystal is formed from a melt having a concn. of such elements or mixt. thereof of at least ∼0.02%. In another embodiment, the scintillation crystal can have unexpectedly improved proportionality and unexpectedly improved energy resoln. properties. In a further embodiment, a radiation detection app. can include the scintillation crystal, a photosensor, and an electronics device. Such a radiation detection app. can be useful in a variety of applications.