scholarly journals Lightweight High-Performance Polymer Composite for Automotive Applications

Polymers ◽  
2019 ◽  
Vol 11 (2) ◽  
pp. 326 ◽  
Author(s):  
Valentina Volpe ◽  
Sofia Lanzillo ◽  
Giovanni Affinita ◽  
Beniamino Villacci ◽  
Innocenzo Macchiarolo ◽  
...  
Keyword(s):  
Glass Fiber ◽  
Automotive Industry ◽  
High Performance ◽  
Injection Pressure ◽  
Dimensional Accuracy ◽  
Processing Parameters ◽  
Injection Molding Process ◽  
Polyamide 66 ◽  
Molding Process ◽  
And Performance

The automotive industry needs to produce plastic products with high dimensional accuracy and reduced weight, and this need drives the research toward less conventional industrial processes. The material that was adopted in this work is a glass-fiber-reinforced polyamide 66 (PA66), a material of great interest for the automotive industry because of its excellent properties, although being limited in application because of its relatively high cost. In order to reduce the cost of the produced parts, still preserving the main properties of the material, the possibility of applying microcellular injection molding process was explored in this work. In particular, the influence of the main processing parameters on morphology and performance of PA66 + 30% glass-fiber foamed parts was investigated. An analysis of variance (ANOVA) was employed to identify the significant factors that influence the morphology of the molded parts. According to ANOVA results, in order to obtain homogeneous foamed parts with good mechanical properties, an injection temperature of 300 °C, a high gas injection pressure, and a large thickness of the parts should be adopted.

Numerical and Experimental Study on the Injection Moulding of a Thin-Wall Complex Part

2008 ◽  
Author(s):  
Catalin Fetecau ◽  
Ion Postolache ◽  
Felicia Stan
Keyword(s):  
Injection Molding ◽  
Injection Pressure ◽  
Mold Temperature ◽  
Processing Parameters ◽  
Injection Molding Process ◽  
Thin Wall ◽  
Molding Process ◽  
Complex Part ◽  
Filling Time ◽  
Wall Injection

The research presented in this paper involves numerical and experimental efforts to investigate the relative thin-wall injection molding process in order to obtain high dimensional quality complex parts. To better understand the effects of various processing parameters (the filling time, injection pressure, the melting temperature, the mold temperature) on the injection molding of a thin-wall complex part, the molding experiments are regenerated into the computer model using the Moldflow Plastics Insight (MPI) 6.1 software. The computer visualization of the filling phase allows accurate prediction of the location of the flow front, welding lines and air traps. Furthermore, in order to optimize the injection molding process, the effects of the geometry of the runner system on the filling and packing phases are also investigated. It is shown that computational modeling could be used to help the process and mold designer to produce accurate parts.

Effect of Injection Molding Process on Electrical Conductivity and Mechanical Property of Nanoparticle Filled Polymer Composites

2012 ◽  
Vol 486 ◽  
pp. 34-38
Author(s):  
Jing Chao Zou ◽  
Ai Yun Jiang ◽  
Bao Feng Zhang ◽  
Hai Hong Wu ◽  
Ya Jun Zhou
Keyword(s):  
Mechanical Properties ◽  
Mechanical Property ◽  
Electrical Conductivity ◽  
Polymer Composites ◽  
Testing Machine ◽  
Injection Pressure ◽  
Processing Parameters ◽  
Injection Molding Process ◽  
Molding Process ◽  
Filled Polymer

Authors investigated the relationship among processing parameters, microstructures, electrical conductivity and mechanical property of injection molded nanoparticle filled polymer composites at present study. Standard tensile specimens were injected under different injecting pressures and packing pressures. The molded specimens were removing five layers from the surface to observe the microstructures at different positions of the moldings. The electrical properties were measured with a two-terminal standard resistor under DC condition at room temperature, and the mechanical properties of the moldings were measured by INSTRON 5580 Universal testing machine. The results showed that filled nanoparticles may form the best conductive path under the higher packing pressure matched with higher injection pressure. The mechanical properties of the molding depend on not only the concentration of the nanofiller, but processing conditions as well.

scholarly journals High-Performance of a Thick-Walled Polyamide Composite Produced by Microcellular Injection Molding

Materials ◽  
2021 ◽  
Vol 14 (15) ◽  
pp. 4199
Author(s):  
Dariusz Sykutera ◽  
Piotr Czyżewski ◽  
Piotr Szewczykowski
Keyword(s):  
Injection Molding ◽  
High Performance ◽  
Flow Direction ◽  
Cell Diameter ◽  
Injection Molding Process ◽  
Polyamide 66 ◽  
Molding Process ◽  
Sem Images ◽  
Microcellular Injection Molding ◽  
Sink Mark

Lightweight moldings obtained by microcellular injection molding (MIM) are of great significance for saving materials and reducing energy consumption. For thick-walled parts, the standard injection molding process brings some defects, including a sink mark, warpage, and high shrinkage. Polyamide 66 (PA66)/glass fiber (GF) thick-walled moldings were prepared by MuCell® technology. The influences of moldings thickness (6 and 8.4 mm) and applied nitrogen pressure (16 and 20 MPa) on the morphology and mechanical properties were studied. Finally, the microcellular structure with a small cell diameter of about 30 μm was confirmed. Despite a significant time reduction of the holding phase (to 0.3 s), high-performance PA66 GF30 foamed moldings without sink marks and warpage were obtained. The excellent strength properties and favorable impact resistance while reducing the weight of thick-walled moldings were achieved. The main reason for the good results of polyamide composite was the orientation of the fibers in the flow direction and the large number of small nitrogen cells in the core and transition zone. The structure gradient was analysed and confirmed with scanning electron microscopy (SEM) images, X-ray micro computed tomography (micro CT) and finite element method (FEM) simulation.

Determination of Optimal Microminiature Powder Injection Molding Parameters by Taguchi Approach

2011 ◽  
Vol 189-193 ◽  
pp. 2997-3000
Author(s):  
Haw Pei Li ◽  
Norhamidi Muhamad
Keyword(s):  
Stainless Steel ◽  
Injection Molding ◽  
High Performance ◽  
Injection Pressure ◽  
Steel Powder ◽  
Powder Injection Molding ◽  
Powder Injection ◽  
Injection Molding Process ◽  
Taguchi Approach ◽  
Molding Process

The global manufacturing trend is now focusing towards miniaturization. Microminiature Powder Injection Molding (μPIM) is a viable technology to fabricate complex and high performance miniaturized components. The μPIM technique was used to produce the near-net shape micro components in this study. Fine stainless steel powder with particle size of 5μm was mixed with a ternary water-based binder system. Micro dumbbells with the largest dimension of 9mm were replicated. In order to obtain successful and well molded micro dumbbells, the Design of Experiments (DOE) technique was applied to investigate the optimal parameters in injection molding process. Injection parameters such as injection pressure (A), injection temperature (B), powder loading (C), mold temperature (D), injection time (E) and holding time (F) were optimized by using stainless steel feedstocks. Taguchi approach is chosen and the results were evaluated with signal-to-noise (SN) ratio and analysis of variance (ANOVA). The results show that the feedstocks could be replicated by using μPIM method with the application of Taguchi approach.

scholarly journals Constant Temperature Approach for the Assessment of Injection Molding Parameter Influence on the Fatigue Behavior of Short Glass Fiber Reinforced Polyamide 6

Polymers ◽  
2021 ◽  
Vol 13 (10) ◽  
pp. 1569
Author(s):  
Selim Mrzljak ◽  
Alexander Delp ◽  
André Schlink ◽  
Jan-Christoph Zarges ◽  
Daniel Hülsbusch ◽  
...  
Keyword(s):  
Injection Molding ◽  
Glass Fiber ◽  
Process Parameters ◽  
Fatigue Properties ◽  
Injection Molding Process ◽  
Molding Process ◽  
Short Glass Fiber ◽  
Glass Fiber Reinforced ◽  
Molding Parameter ◽  
Short Glass

Short glass fiber reinforced plastics (SGFRP) offer superior mechanical properties compared to polymers, while still also enabling almost unlimited geometric variations of components at large-scale production. PA6-GF30 represents one of the most used SGFRP for series components, but the impact of injection molding process parameters on the fatigue properties is still insufficiently investigated. In this study, various injection molding parameter configurations were investigated on PA6-GF30. To take the significant frequency dependency into account, tension–tension fatigue tests were performed using multiple amplitude tests, considering surface temperature-adjusted frequency to limit self-heating. The frequency adjustment leads to shorter testing durations as well as up to 20% higher lifetime under fatigue loading. A higher melt temperature and volume flow rate during injection molding lead to an increase of 16% regarding fatigue life. In situ Xray microtomography analysis revealed that this result was attributed to a stronger fiber alignment with larger fiber lengths in the flow direction. Using digital volume correlation, differences of up to 100% in local strain values at the same stress level for different injection molding process parameters were identified. The results prove that the injection molding parameters have a high influence on the fatigue properties and thus offer a large optimization potential, e.g., with regard to the component design.

scholarly journals Study on Stability of a Novel Binder System Based on Palm Stearin in Metal Injection Moulding Application

2007 ◽  
Vol 4 (2) ◽  
pp. 1
Author(s):  
Muhammad Hussain Ismail ◽  
Norhamidi Muhamad ◽  
Aidah Jumahat ◽  
Istikamah Subuki ◽  
Mohd Afian Omar
Keyword(s):  
Injection Molding ◽  
Flow Characteristics ◽  
Injection Pressure ◽  
Palm Stearin ◽  
Steel Powder ◽  
Metal Injection Molding ◽  
Injection Molding Process ◽  
Binder System ◽  
Molding Process ◽  
Flow Activation Energy

Metal Injection Molding (MIM) is a wellestablished technology for manufacturing a variety of complex and small precision parts. In this paper, fundamental rheological characteristics of MIM feedstock using palm stearin are theoretically analyzed and presented. The feedstock consisted of gas atomized 316L stainless steel powder at three different particle size distributions and the binder system of palm stearin (PS) and polyethylene (PE). The powder loading used was 60vol % for all samples (monosize 16 µm, monosize 45 µm, and bimodal 16 µm + 45 µm) and the binder system of 40vol %(PS/PE = 40/60). The viscosity of MIM feedstock at different temperatures and shear rates was measured and evaluated. Results showed that, the feedstock containing palm stearin exhibited suitable rheological properties by increasing the fluidity of feedstock in MIM process. The rheological results also showed a pseudoplastic flow characteristics, which poses higher value of shear sensitivity (n) and lower value of flow activation energy (E), that are both favourable for injection molding process. The green parts were successfully injected and exhibited adequate strength for handling by optimizing the injection pressure and temperature.

Powder Injection Molding of Ti-6Al-4V Alloy for Defect-Free High Performance Titanium Parts with Low Carbon/Oxygen Contents

2018 ◽  
Vol 770 ◽  
pp. 189-194
Author(s):  
Dong Guo Lin ◽  
Jae Man Park ◽  
Tae Gon Kang ◽  
Seong Taek Chung ◽  
Young Sam Kwon ◽  
...  
Keyword(s):  
Injection Molding ◽  
Alloy Powder ◽  
High Performance ◽  
Physical And Mechanical Properties ◽  
Powder Injection Molding ◽  
Powder Injection ◽  
Solid Loading ◽  
Injection Molding Process ◽  
Low Carbon ◽  
Molding Process

In this work, powder injection molding (PIM) of Ti-6Al-4V alloy powder has been studied. Defect-free high performance Ti-6Al-4V parts with low carbon/oxygen contents have been successfully prepared by PIM. A pre-alloyed Ti-6Al-4V alloy powder and wax-polymer binder system have been mixed together to prepare the feedstock. In mixing stage, the solid loading percentage and mixing conditions have been optimized. Rheological and thermal debinding behaviors of prepared feedstock have been characterized and numerically expressed based on rheometry and thermal gravity experimental results. In addition, the injection molding process of Ti-6Al-4V parts has been numerically analyzed to optimize the injection molding conditions. Consequently, the defect-free Ti-6Al-4V parts with low carbon and oxygen contents have been successfully fabricated by PIM, which exhibits excellent physical and mechanical properties.

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