Optimization of degree of sphericity of primary phase during cooling slope casting of A356 Al alloy: Taguchi method and regression analysis

The present work presents the results of experimental investigation of semi-solid rheocasting of A356 Al alloy using a cooling slope. The experiments have been carried out following Taguchi method of parameter design (orthogonal array of L-9 experiments). Four key process variables (slope angle, pouring temperature, wall temperature, and length of travel of the melt) at three different levels have been considered for the present experimentation. Regression analysis and analysis of variance (ANOVA) has also been performed to develop a mathematical model for degree of sphericity evolution of primary alpha-Al phase and to find the significance and percentage contribution of each process variable towards the final outcome of degree of sphericity, respectively. The best processing condition has been identified for optimum degree of sphericity (0.83) as A(3), B-3, C-2, D-1 i.e., slope angle of 60 degrees, pouring temperature of 650 degrees C, wall temperature 60 degrees C, and 500 mm length of travel of the melt, based on mean response and signal to noise ratio (SNR). ANOVA results shows that the length of travel has maximum impact on degree of sphericity evolution. The predicted sphericity obtained from the developed regression model and the values obtained experimentally are found to be in good agreement with each other. The sphericity values obtained from confirmation experiment, performed at 95% confidence level, ensures that the optimum result is correct and also the confirmation experiment values are within permissible limits. (c) 2014 Elsevier Ltd. All rights reserved.

Shear induced crystallization in different polymorphic forms of PVDF induced by surface functionalized MWNTs in PVDF/PMMA blends

Shear induced crystallization in PVDF/PMMA blends, especially at higher fractions of PMMA, can be quite interesting in understanding the structure-property correlation and processing of these blends. In a recent submission (Phys. Chem. Chem. Phys., 2014, 16, 2693-2704), we clearly demonstrated, using dielectric spectroscopy, that the origin of segmental relaxations concerning the crystalline segments of PVDF in PVDF/PMMA blends in the presence of MWNTs (multiwalled nanotubes) was strongly contingent on the size of the crystallite. We now understand that the fraction of PMMA in the blends governs the origin of polymorphism in PVDF. This motivated us to systematically study the effect of shear on the crystallization behavior of PVDF especially in blends with different polymorphic forms of PVDF. Two model blends were selected; one with a mixture of alpha and beta crystals and the other predominantly rich in alpha crystals. Initially, physical ageing, at different oscillation frequencies (1 rad s(-1) and 0.1 rad s(-1)), was monitored by melt rheology and subsequently, the effect of steady shear was probed in situ without changing the history of the samples. Intriguingly, the rate of crystallization was observed to be significantly higher for higher oscillation frequencies, which essentially suggest that shear has induced crystallization in the blends. More interestingly, the effect of steady shear was more pronounced in the blends rich in alpha crystals (bigger crystallites as observed from SAXS) and at lower oscillation frequencies.

Polymer-grafted multiwall carbon nanotubes functionalized by nitrene chemistry: effect on cooperativity and phase miscibility

The demixing of polystyrene (PS) and poly(vinyl methylether) (PVME) was systematically investigated in the presence of surface functionalized multiwall carbon nanotubes (MWNTs) by melt rheology. As PS-PVME blends are weakly interacting blends, the contribution of conformational entropy increases, resulting in thermo-rheological complexity wherein the concentration fluctuation persists even beyond the critical demixing temperature. These phenomenal changes were followed here in the presence of MWNTs with different surface functional groups. Polystyrene was synthesised by atom transfer radical polymerization and was immobilized onto carboxyl acid functionalized multiwall carbon nanotubes (COOH-MWNTs) via nitrene chemistry in order to improve the phase miscibility in PS-PVME blends. Interestingly, blends with 0.25 wt% polystyrene grafted multiwall carbon nanotubes (PS-g-MWNTs) delayed the spinodal decomposition temperature in the blends by similar to 33 degrees C with respect to both control blends and those with COOH-MWNTs. While the localization of COOH-MWNTs in PVME was explained from a thermodynamic point of view, the localization of PS-g-MWNTs was understood to result from favorable PS-PVME contact and the degree of surface coverage of PS on the surface of MWNTs. The length of the cooperative rearranging region (xi) decreased in presence of PS-g-MWNTs, suggesting confinement effects on large scale motions and enhanced interchain concentration fluctuation.

Polyolefin based antibacterial membranes derived from PE/PEO blends compatibilized with amine terminated graphene oxide and maleated PE

In this study, various strategies like amine terminated GO (GO-NH2), in situ formed polyethylene grafted GO (PE-g-GO) and their combinations with maleated PE (maleic anhydride grafted PE) were adopted to reactively compatibilize blends of low density polyethylene (LDPE) and polyethylene oxide (PEO). These blends were further explored to design porous, antibacterial membranes for separation technology and the flux and the resistance across the membranes were studied systematically. It was observed that GO-NH2 led to uniform dispersion of PEO in a PE matrix and further resulted in a significant improvement in the mechanical properties of the blends when combined with maleated PE. The efficiency of various compatibilizers was further studied by monitoring the evolution of morphology as a function of the annealing time. It was observed that besides rendering uniform dispersion of PEO in PE and improving the mechanical properties, GO-NH2 further suppresses the coalescence in the blends. As the melt viscosities of the phases differ significantly, there is a gradient in the morphology as also manifested from scanning acoustic microscopy. Hence, the membranes were designed by systematically reducing the thickness of the as-pressed samples to expose the core as the active area for flux calculations. Selected membranes were also tested for their antibacterial properties by inoculating E. coli culture with the membranes and imaging at different time scales. This study opens new avenues to develop PE based cost effective anti-microbial membranes for water purification.

Effect of shrinkage induced flow on binary alloy dendrite growth: An equivalent undercooling model

This paper presents a theoretical model for studying the effects of shrinkage induced flow on the growth rate of binary alloy dendrites. An equivalent undercooling of the melt is defined in terms of ratio of the phase densities to represent the change in dendrite growth rate due to variation in solutal and thermal transport resulting from shrinkage induced flow. Subsequently, results for dendrite growth rate predicted by the equivalent undercooling model is compared with the corresponding predictions obtained using an enthalpy based numerical method for dendrite growth with shrinkage. The agreement is found to be good. Published by Elsevier Ltd.

Polyolefin based antibacterial membranes derived from PE/PEO blends compatibilized with amine terminated graphene oxide and maleated PE

In this study, various strategies like amine terminated GO (GO-NH2), in situ formed polyethylene grafted GO (PE-g-GO) and their combinations with maleated PE (maleic anhydride grafted PE) were adopted to reactively compatibilize blends of low density polyethylene (LDPE) and polyethylene oxide (PEO). These blends were further explored to design porous, antibacterial membranes for separation technology and the flux and the resistance across the membranes were studied systematically. It was observed that GO-NH2 led to uniform dispersion of PEO in a PE matrix and further resulted in a significant improvement in the mechanical properties of the blends when combined with maleated PE. The efficiency of various compatibilizers was further studied by monitoring the evolution of morphology as a function of the annealing time. It was observed that besides rendering uniform dispersion of PEO in PE and improving the mechanical properties, GO-NH2 further suppresses the coalescence in the blends. As the melt viscosities of the phases differ significantly, there is a gradient in the morphology as also manifested from scanning acoustic microscopy. Hence, the membranes were designed by systematically reducing the thickness of the as-pressed samples to expose the core as the active area for flux calculations. Selected membranes were also tested for their antibacterial properties by inoculating E. coli culture with the membranes and imaging at different time scales. This study opens new avenues to develop PE based cost effective anti-microbial membranes for water purification.

Combinatorial Approach to Develop Tailored Biodegradable Poly(xylitol dicarboxylate) Polyesters

The objective of this work was to develop a versatile strategy for preparing biodegradable polymers with tunable properties for biomedical applications. A family of xylitol-based cross-linked polyesters was synthesized by melt condensation. The effect of systematic variation of chain length of the diacid, stoichiometric ratio, and postpolymerization curing time on the physicochemical properties was characterized. The degradation rate decreased as the chain length of the diacid increased. The polyesters synthesized by this approach possess a diverse spectrum of degradation (ranging from similar to 4 to 100% degradation in 7 days), mechanical strength (from 0.5 to similar to 15 MPa) and controlled release properties. The degradation was a first-order process and the rate constant of degradation decreased linearly as the hydrophobicity of the polyester increased. In controlled release studies, the order of diffusion increased with chain length and curing time. The polymers were found to be cytocompatible and are thus suitable for possible use as biodegradable polymers. This work demonstrates that this particular combinatorial approach to polymer synthesis can be used to prepare biomaterials with independently tunable properties.

Thermally Induced Demixing in an LCST Mixture in the Presence of Densely Grafted Nanoparticles: Tuning the Graft Chain Length To Induce Thermodynamic Miscibility

The demixing in an LCST mixture of PS/PVME (polystyrene/poly(vinyl methyl ether)) was probed here by melt rheology in the presence of gold nanoparticles which were densely coated with varying graft lengths of PS. The graft density for the gold nanoparticles coated with 3 kDa PS was ca. Sigma = 1.7 chains/nm(2), and that for 53 kDa PS was ca. Sigma = 1.2 chains/nm(2). The evolution of morphology, as the blends transit through the metastable and the unstable envelopes of the phase diagram, and the localization of the gold nanoparticles upon demixing were monitored using in situ hot-stage AFM and confocal Raman imaging. Interestingly, gold nanoparticles coated with 3 kDa polystyrene (PS(3 kDa)-g-nAu) were localized in the PVME phase, whereas gold nanoparticles coated with 53 kDa polystyrene (PS(53 kDa)-g-nAu) were localized in the PS phase of the blend. While the localization of PS(3 kDa)-g-nAu in the PVME phase can be expected to be of entropic origin due to expulsion from the PS phase as R-g,R-matrix chains > R-g,R-grafted chains (where R-g is the radius of gyration of the polymer chain), the localization of PS(53 kDa)-g-nAu in the PS phase is believed to be facilitated by favorable melt/graft interactions. The latter nanoparticles also delayed the demixing by 12 degrees C with respect to the neat mixture. The observed changes were addressed in context to enthalpic interactions between the grafted PS and the free PS, the entropic losses (deformational entropic losses on blending, translational entropic loss of the free PS, and the conformational entropic loss of the grafted PS), and the interface of the grafted and the free chains.

Electromagnetic shielding materials and coatings derived from gelation of multiwall carbon nanotubes in an LCST mixture

Thermally induced demixing in an LCST mixture, polystyrene (PS)/polyvinyl methyl ether] (PVME), was used as a template to design materials with high electrical conductivity. This was facilitated by gelation of multiwall carbon nanotubes (MWNTs) in a given phase of the blends. The MWNTs were mixed in the miscible blends and the thermodynamic driven demixing further resulted in selective localization in the PVME phase of the blends. This was further confirmed by atomic force microscopy (AFM). The time dependent gelation of MWNTs at shallow quench depth, evaluated using isochronal temperature sweep by rheology, was studied by monitoring the melt electrical conductivity of the samples in situ by an LCR meter coupled to a rheometer. By varying the composition in the mixture, several intricate shapes like gaskets and also coatings capable of attenuating the EM radiation in the microwave frequency can be derived. For instance, the PVME rich mixtures can be molded in the form of a gasket, O-ring and other intricate shapes while the PS rich mixtures can be coated onto an insulating polymer to enhance the shielding effectiveness (SE) for EM radiation. The SE of the various materials was analyzed using a vector network analyzer in both the X-band (8.2 to 12 GHz) and the K-u-band (12 to 18 GHz) frequency. The improved SE upon gelation of MWNTs in the demixed blends is well evident by comparing the SE before and after demixing. A reflection loss of -35 dB was observed in the blends with 2 wt% MWNTs. Further, by coating a layer of ca. 0.15 mm of PS/PVME/MWNT, a SE of -15 dB at 18 GHz could be obtained.

Polyester derived from recycled poly(ethylene terephthalate) waste for regenerative medicine

Despite advances in regenerative medicine, the cost of such therapies is beyond the reach of many patients globally in part due to the use of expensive biomedical polymers. Large volumes of poly(ethylene terephthalate) (PET) in municipal waste is a potential source of low cost polymers. A novel polyester was prepared by a catalyst-free, melt polycondensation reaction of bis(hydroxyethylene) terephthalate derived from PET post-consumer waste with other multi-functional monomers from renewable sources such as citric acid, sebacic acid and D-mannitol. The mechanical properties and degradation rate of the polyester can be tuned by varying the composition and the post-polymerization time. The polyester was found to be elastomeric, showed excellent cytocompatibility in vitro and elicited minimal immune response in vivo. Three-dimensional porous scaffolds facilitated osteogenic differentiation and mineralization. This class of polyester derived from low cost, recycled waste and renewable sources is a promising candidate for use in regenerative medicine.

Electromagnetic interference shielding through MWNT grafted Fe3O4 nanoparticles in PC/SAN blends

In this study, multiwall carbon nanotubes (MWNTs) were chemically grafted onto dopamine anchored iron oxide (Fe3O4) nanoparticles via diazotization reaction to design electromagnetic (EM) shielding materials based on PC (polycarbonate)/SAN poly (styrene-co-acrylonitrile)] blends. A two step mixing protocol was adopted to selectively localize the nanoparticles in a given phase of the blends. In the first step, MWNT-g-Fe3O4 nanoparticles were solution blended with PC, followed by dilution with SAN during melt mixing in the subsequent step. This strategy, besides improving the quality of dispersion of MWNTs in the blends, facilitated enhanced EM interference shielding effectiveness (SE). Both, the MWNTs and the modified MWNTs, selectively localized in the PC phase and led to high electrical conductivity, in striking contrast to PC filled MWNT composites. The SE was measured on toroidal samples over a broad range of frequencies; X-band (8.2-12 GHz) and K-u-band (12-18 GHz). It was observed that the shielding mechanism mostly involved reflection in the blends with MWNTs, whereas absorption dominated in the case of blends with MWNT-g-Fe3O4. To realize the efficacy of this strategy, a few compositions were prepared by physical mixing MWNTs with Fe3O4 nanoparticles. Intriguingly, blends with MWNT-g-Fe3O4 nanoparticles manifested enhanced microwave absorption over physically mixed nanoparticles. An SE of -32.5 dB was observed (at 18 GHz) for MWNT (3 wt%)-g-Fe3O4 (3 vol%) in PC/SAN blends.

Controlling the cross-section of waveguides inscribed on bulk chalcogenide glasses using fast laser

Waveguides have been fabricated on melt-quenched, bulk chalcogenide glasses using the femto-second laser inscription technique at low repetition rates in the single scan regime. The inscribed waveguides have been characterized by butt-coupling method and the diameter of the waveguide calculated using the mode-field image of the waveguide. The waveguide cross-section symmetry is analyzed using the heat diffusion model by relating the energy and translation speed of the laser. The net-fluence and symmetry of the waveguides are correlated based on the theoretical values and experimental results of guiding cross-section.

Study of Microstructure Evolution during Semi-Solid Processing of an In-Situ Al Alloy Composite

In the present work, effect of pouring temperature (650 degrees C, 655 degrees C, and 660 degrees C) on semi-solid microstructure evolution of in-situ magnesium silicide (Mg2Si) reinforced aluminum (Al) alloy composite has been studied. The shear force exerted by the cooling slope during gravity driven flow of the melt facilitates the formation of near spherical primary Mg2Si and primary Al grains. Shear driven melt flow along the cooling slope and grain fragmentation have been identified as the responsible mechanisms for refinement of primary Mg2Si and Al grains with improved sphericity. Results show that, while flowing down the cooling slope, morphology of primary Mg2Si and primary Al transformed gradually from coarse dendritic to mixture of near spherical particles, rosettes, and degenerated dendrites. In terms of minimum grain size and maximum sphericity, 650 degrees C has been identified as the ideal pouring temperature for the cooling slope semi-solid processing of present Al alloy composite. Formation of spheroidal grains with homogeneous distribution of reinforcing phase (Mg2Si) improves the isotropic property of the said composite, which is desirable in most of the engineering applications.

Enzymatically degradable EMI shielding materials derived from PCL based nanocomposites

In this study, two different types of multiwall carbon nanotubes (MWNTs) namely pristine (p-MWNTs) and amine functionalized (a-MWNTs) were melt-mixed with polycaprolactone (PCL) to develop biodegradable electromagnetic interference (EMI) shielding materials. The bulk electrical conductivity of the nanocomposites was assessed using broadband dielectric spectroscopy and the structural properties were evaluated using dynamic mechanical thermal analysis (DMTA). Both the electrical conductivity and the structural properties improved after the addition of MWNTs and were observed to be proportional to the increasing fractions in the nanocomposites. The shielding effectiveness of the nanocomposites was studied using a vector network analyzer (VNA) in a broad range of frequencies, X-band (8 to 12 GHz) and K-u-band (12 to 18 GHz) on toroidal samples. The shielding effectiveness significantly improved on addition of MWNTs, more in the case of p-MWNTs than in a-MWNTs. For instance, at a given fraction of MWNTs (3 wt%), PCL with p-MWNTs and a-MWNTs showed a shielding effectiveness of -32 dB and -29 dB, respectively. Moreover, it was observed that reflection was the primary mechanism of shielding at lower fractions of MWNTs, while absorption dominated at higher fractions in the composites. As one of the rationales of this work was to develop biodegradable EMI shielding materials to address the challenges concerning electronic waste, the effect of different MWNTs on the biodegradability of PCL composites was assessed through enzymatic degradation. The enzymatic degradation of the samples cut from the hot pressed films by bacterial lipase was investigated. It was noted that a-MWNTs exhibited almost similar degradation rate as the control PCL sample; however, p-MWNTs showed a slower degradation rate. This study demonstrates the potential use of PCL-MWNT composites as flexible, light weight and eco-friendly EMI shielding materials.

Influence of plate length and plate cooling rate on solidification and microstructure of A356 alloy produced by oblique plate

A356 alloy melt solidifies partially when it flows down on an oblique plate cooled from bottom by counter flowing water. Columnar dendrites are continuously formed on the plate wall. Because of the forced convection, these dendrites are sheared off into equiaxed/fragmented grains and then washed away continuously by producing semisolid slurry at plate exit. Plate cooling rate provides required extent/amount of solidification whereas plate length enables necessary shear for producing semisolid slurry of desired quality. Slurry obtained is solidified in metal mould to produce semisolid-cast billets of desired microstructure. Furthermore, semisolid-cast billets are also heat-treated to improve surface quality. Microstructures of both semisolid-cast and heat-treated billets are compared. The effects of plate length and plate cooling rate on solidification and microstructure of billets produced by using oblique plate are illustrated. Three different plate lengths (200 mm, 250 mm, 300 mm) associated with three different heat transfer coefficients (1000, 2000 and 2500 W/(m(2).K)) are involved. Plate length of 250 mm with heat transfer coefficient of 2000 W/(m(2).K) gives fine and globular microstructures and is the optimum as there is absolutely no possibility of sticking of slurry to plate wall.