Shrinkage and Warpage in the Permanent Shape of Sape-Memory Polyurethane Parts

The shape memory effect, as the most important ability of shape memory polymers, is a working property and provides the design ability to shape memory polymer features. Shrinkage and warpage are important parameters to control the dimensional accuracy of permanent and temporary shapes of an injection moulded shape memory polyurethane (SMPU) part. In this study, the effects of injection moulding parameters on the shrinkage and warpage of the permanent shape of moulded SMPU parts were experimentally investigated. The parameters of injection pressure, melt temperature, mould temperature, packing pressure, packing time, and cooling time, were chosen as the injection moulding control factors. Taguchi�s L27 orthogonal array design table was used with six injection moulding parameters and their three levels. The results showed that the part has different shrinkage ratios in three main directions, namely, the flow direction, perpendicular to the flow direction, and the direction through the thickness. The results of the analysis of variance showed that the cooling time is the most influential parameter on both the shrinkage (except in thickness) and warpage. The shrinkage in the flow direction as well as in perpendicular to the flow direction decreased with increasing the cooling time. Warpage also decreased with increasing the cooling time. Injection pressure and melt temperature were found to be effective on shrinkage in thickness. Effects of mould temperature, packing pressure, and packing time were found to be limited. A statistically significant relationship has been noticed among shrinkage, warpage, and residual stresses during the study.

Smart Lost Circulation Materials to Seal Large Fractures

Lost circulation problems may result in a significant downtime, a considerable reduction of the rate of penetration, or even well control problems. Despite advances in manufacturing lost circulation materials (LCMs), some formations, like heavily fractured carbonates, have complete losses during drilling. We develop smart LCMs using shape memory polymers (SMPs), and program them thermo-mechanically to satisfy size limitations imposed by bottomhole assemblies (BHA). Elevated downhole temperatures act as an external trigger to recover the permanent shape of LCMs, which could expand ten times larger than the temporary (programmed) dimensions for deployment. Smart LCMs are a combination of various material categories such as granular, fibrous (one-dimensional or 1-D) and planar (two-dimensional or 2-D) configurations that resume to the original shape after exposure to high temperatures. The LCMs form different structures such as flatted pellet, disc-shaped, spider-shaped, and spindled, which, respectively, presents grains, 1-D fibers, 2-D stars, and 2-D lattices after recovery. A combination of the above categories attempt to build three-dimensional (3-D) plugging capabilities across various sized fractures.

Reprogrammable Permanent Shape Memory Materials Based on Reversibly Crosslinked Epoxy/PCL Blends

Epoxy/Polycaprolactone (PCL) blends cured with a conventional diamine (4,4′-diaminodiphenylmethane, DDM) and with different amounts of a disulfide containing diamine (4, 4´-dithioaniline, DSS) were prepared through melting. The curing process was studied by FTIR and differential scanning calorimetry (DSC) and the mechanical behavior of the networks was studied by DMA. The shape memory properties and the recyclability of the materials were also analyzed. All blends showed a very high curing degree and temperature activated shape memory effect, related to the glass transition of the epoxy resin. The PCL plasticized the mixture, allowing tailoring of the epoxy glass transition. In addition, in the blends cured with DSS, as a consequence of the disulfide exchange reaction, the permanent shape could be erased and a new shape could be reprogrammed. Using this strategy, reprogrammable permanent shape memory materials were obtained.

Photothermally and magnetically controlled reconfiguration of polymer composites for soft robotics

New materials are advancing the field of soft robotics. Composite films of magnetic iron microparticles dispersed in a shape memory polymer matrix are demonstrated for reconfigurable, remotely actuated soft robots. The composite films simultaneously respond to magnetic fields and light. Temporary shapes obtained through combined magnetic actuation and photothermal heating can be locked by switching off the light and magnetic field. Subsequent illumination in the absence of the magnetic field drives recovery of the permanent shape. In cantilevers and flowers, multiple cycles of locking and unlocking are demonstrated. Scrolls show that the permanent shape of the film can be programmed, and they can be frozen in intermediate configurations. Bistable snappers can be magnetically and optically actuated, as well as biased, by controlling the permanent shape. Grabbers can pick up and release objects repeatedly. Simulations of combined photothermal heating and magnetic actuation are useful for guiding the design of new devices.