The SPE Library contains thousands of papers, presentations, journal briefs and recorded webinars from the best minds in the Plastics Industry. Spanning almost two decades, this collection of published research and development work in polymer science and plastics technology is a wealth of knowledge and information for anyone involved in plastics.
Long fibre reinforced thermoplastics have excellent mechanical properties and stiffness-weight ratio which is of particular interest to the automotive industry. The new Inline-Compounding processes for long fibre materials offer users more flexibility as they are able to both compound and process such materials in accordance with their own formulation and also use ready-made compounds. The following process combinations are possible: E-LFT; In-Line-Compounding and Direct Extrusion to Profile or Plate D-LFT; In-Line-Compounding and Compression Moulding S-LFT; In-Line-Compounding and Injection Moulding
The principal challenge in applying composite materials to automotive vehicles is to provide structural
performance that allows for significant weight reductions over conventional materials such as steel. However the automotive market is quite different from the proven aerospace composite arena. Aircraft parts are typically
produced in low volumes with few requiring very complex surface shaping. The automotive industry by contrast produces a variety of products comprising hundreds of basic structural forms. Dramatic changes in fiber orientation can occur inducing large thickness changes loss of laminate stack-up symmetry and balance. All of these issues can have a considerable effect on the behavior of the final part. This paper describes how the FiberSIM suite of software tools supports the entire composite engineering process by using a unique material simulation technology that predicts how composite material conform to complex surfaces. Engineers can quickly visualize ply shapes and fiber orientations and identify manufacturing problems during the design phase. Designers can also create and automatically update drawings and related manufacturing data directly from the master CAD model thus reducing opportunities for errors and delays on the manufacturing floor. Practical case studies from automotive highlight how composite engineering can be improved and risk can be reduced by the use of these new integrated simulation-driven tools.
Techniques to simulate resin infusion using classical RTM simulation software are investigated. The difference in the filling behavior between “rigid” and “flexible” molds is evaluated and explained. A model describing the
evolution of permeability with pressure is developed for flexible moulds. This model takes into account the changes in thickness of the cavity following deformations of the mold cover as well as the compressibility of the reinforcement. The model is validated by comparison of numerical simulations for a complex automobile part
manufactured by resin infusion with actual test results obtained at the factory
Reinforced reaction injection molding (RRIM) has reemerged as an important method in automotive exterior applications. Presently composite applications demand higher productivity and improved part performance. Stability at higher heat to endure E-coat oven bake improvements in fillers yielding easier processing at high loading improved toughness at high modulus and higher productivity have already been realized with RRIM in Europe and NAFTA. Now the kinetics of one new material Bayflex 190 is such that reaction is essentially complete at demold. In the past RRIM molded parts were required to be baked at 120oC and above to complete chemical reactions attain complete physical properties and de-gas parts prior to painting. In current E-coat applications postcure of 190oC is typical. Elimination of postcure means significant savings in energy increased productivity decreased handling and lower capital expense. Bayflex 190 polyurea attains virtually all properties at demold. After molding parts can be washed and primed directly. Dynamic mechanical analysis shows that further heating to 200oC anneals and strengthens the composite. Several very sensitive analytical methods have been employed to characterize the degree of cure at demold. Differential scanning calorimetry (DSC) shows no exothermic chemical reaction up to 200oC. Thermal gravimetric analysis (TGA) shows no CO2 loss from unreacted isocyanates. And Fourier transform infrared spectroscopy (FTIR) scans indicate no free isocyanate in freshly molded samples. Parts painted in production exhibit no defects associated with elimination of postcure.
The durability of a SRIM Urethane composite are evaluated and the results are used to develop a design guide to aid in the use of this material. Test methods for static fatigue creep and impact testing are described in detail. The Oak Ridge National Laboratory developed these methods for durability testing. The raw test data from an earlier study are summarized and generalized in the form of design equations. The scope and limitations of these design equations are discussed. This material evaluation and data summary process provides a means for designing for durability using an E-glass reinforced SRIM Urethane composite.
Contemporary vehicles utilize a mix of materials in their construction consisting of metals plastics and composites. These materials must possess suitable surface properties to achieve desired performance when these parts are adhesively bonding or painted for field service. Surface preparation methods now in place oftentimes use solvents or caustics an increasingly unacceptable approach in an era of mounting environmental regulations. New methods of surface preparation are called for that are environmentally benign and economically feasible while meeting the stringent quality standards of the automotive industry. The use of energetic ultraviolet light is emerging as a promising technology to compete with the old methods of surface preparation. This paper reports the utility of using energetic UV light to generate appropriate surface chemical composition on plastics composites and metals for subsequent painting or adhesive bonding operations. UV treatments have the potential to replace the old methods of treating assorted materials used in the automotive industry in an environmentally responsible and cost-effective manner.
It is commonly accepted that bonding polypropylene to itself or other adherends is difficult and the options available for cost-effective bonding using adhesives are very limited. The aim of the presentation will be to describe a new range of heat-activated adhesives recently developed in our research laboratories and their applications. These adhesives which are now commercially available offer numerous advantages for the rapid manufacture of composite materials in addition to promoting new or improved assembly methods in a wide range of market sectors. e.g. automobile aerospace construction textiles footwear and packaging to mention but a few. The main focus of the presentation will be to outline various ways in which the film strand or pellet forms of the new adhesives may be used to solve a variety of industrial problems. The range of materials to which polypropylene can be successfully bonded (e.g. to itself to many metals and to a range of other materials notably cellulosics) will be outlined together with their associated manufacturing methodologies
such as hot compression lasers and induction heating. An indication of the mechanical bond strengths which
can be achieved at various temperatures will also be outlined.
Composite plate materials for use as bipolar plates in a fuel cell stack must meet certain performance criteria namely high surface and through-plane electrical conductivity very low gas permeability and chemical resistance to both coolants and reactants. In addition to these performance criteria it is necessary from a cost viewpoint that the bipolar plates are easy to manufacture. One category of materials being used for bipolar plates are carbon composites where carbon additives are mixed with a thermoset resin for net-shape compression molding of bipolar plates. A study of the corrosion resistance (via electrochemical testing) helium permeation stack performance and electrical conductivity of a variety of composite materials designed for bipolar plate applications will be presented.
At present membrane electrode assembly performance levels and stack operating conditions of PEM fuel cells a plate area specific resistance of less than approximately 20 mohm cm2 and a plate thickness of less than 2 mm are required to meet the vehicular volumetric power density target (> 2 kW/l). It is however difficult to meet these aggressive requirements and simultaneously obtain good mechanical properties when using polymeric plate materials. Polymers become brittle and break frequently at the high conductive filler loadings (e.g. > 50 v/o graphite) required for high conductivity. This study investigates a potential approach for obtaining high plate conductivity at low conductive filler loadings thus enabling high volumes of thin and ductile plates to be manufactured at low scrap rates.
This paper presents the results of a 3D FEM analysis of some layer spreading experiments performed on flat die with a coextrusion feed-block. The complete feed-block and die assembly was simulated using a commercially available 3D FEM software package and a path-line analysis was used to determine the interface position and the degree the of layer spreading. The results obtained were in good agreement with the experimental data. The simulation also provided a better insight into the flow development within these types of systems.
Microwaves provide rapid, selective and volumetric heating in processing polymers and polymer composites. A variable frequency mode-switching method was studied to uniformly bond two polymer composites with an epoxy-based adhesive. Results were compared with thermal process. For one substrate, microwave method reduced the bonding time and enhanced the bonding strength significantly. For the other substrate, microwaves reduced the bonding time and achieved equal bonding strength as that in thermal process.
The global market for liquid mixed metal stabilizers is migrating toward heavy-metal-free products. Historically, these systems have not been performance and cost competitive. High efficiency calcium-zinc stabilizers have the potential to replace heavy-metal-based products. The intrinsic value of non-phenolic lubricating calcium intermediates and calcium-zinc stabilizers are discussed within the following report.
AFM was used to study the morphology of ultrathin poly[styrene -b- butadiene -b-styrene] copolymer (SBS) films deposited on polystyrene brushes. The grafting density and molecular weight of the grafted polymer layers were varied to reveal the relationship between the parameters of the brush interface and the structure of the film. We found a strong effect of the underlying brushes on the formation of the SBS films.
Large diameter high density polyethylene (HDPE) pipe, typically with diameters greater than 300 mm (12 inches) often have very different failure modes than smaller diameter pipe of the same materials. Heavier wall thicknesses, sometimes greater than 50 mm (two inches), are more susceptible to oxidation during manufacture. The aqueous media transported in such pipes may also oxidize the pipe wall. Such pipes are also often more susceptible to excessive deformation by soil settlement. In this paper, failures in three different large diameter HDPE systems will be investigated.
Walter G. McDonough, Gale A. Holmes, Joy P. Dunkers, May 2002
Multi-fiber model composites are being used in studies into the nucleation of failure in composites. Results have revealed that the nucleation of critical flaws in unidirectional fibrous composites may rely on the time-dependent redistribution of stress by the viscoelastic matrix. Although their role in flaw nucleation is not clearly understood, shear deformation bands have been detected between fiber breaks. Furthermore, interfacial phenomena have been detected in the matrix by Optical Coherence Tomography.
The flow of plastics pellets between the first flights of a single screw can lead to conveying problems. As a result, the throughput varies or not enough material reaches the following screw sections. In order to gain a better insight in the correlations that exist between pellet properties, barrel and screw geometry, a physico-analytical model is worked out. On the basis of this model, the pellet flow behavior can be analyzed relatively accurately.
K. Jayaraman, P. Papworth, Chichang Shu, M.D. Wolkowicz, May 2002
Tiger striping in injection molded bars made of thermoplastic olefin (TPO) blends has been examined by a detailed analysis of the disperse phase morphology. This is evaluated in flow mark regions and out of flow mark regions on the part surface and near the wall, and also just behind the flow front but away from the wall. The results point to a way to control the rheology of the components for avoiding or delaying the onset of flow lines.
In this paper, polystyrene and polylactide were blended at a composition of 50/50 to form a co-continuous morphology. The influence of annealing on the final morphologies of the blend is investigated using SEM and Mercury Intrusion Porosimetry. It is demonstrated that a series of co-continuous networks with pore sizes ranging from 1 to 80 microns and higher have been achieved by varying the annealing conditions. A mechanism of coalescence is discussed in order to account for the said morphologies.
C.-K. Jen, Z. Sun, M . Kobayashi, M . Sayer, C.-K. Shih, May 2002
Ultrasonic stand-alone and film-type high temperature sensors and system have been used to measure in-line the barrel and screw wear during low-density polyethylene extrusion. These sensors are nonintrusive and non-destructive. For the screw wear measurement the system is equipped with fast data acquisition. Measurement accuracy of better than 50 ?m can be achieved.
This paper provides an overview of the application of extrusion simulation towards process analysis and screw design. The paper discusses some of what is possible today with computer aided screw design; what can be obtained from simulation results, what the limitations are, and shows a couple of examples of how to apply simulation towards design.
Kim McLoughlin Senior Research Engineer, Global Materials Science Braskem
A Resin Supplier’s Perspective on Partnerships for the Circular Economy
About the Speaker
Kim drives technology programs at Braskem to develop advanced polyolefins with improved recyclability and sustainability. As Principal Investigator on a REMADE-funded collaboration, Kim leads a diverse industry-academic team that is developing a process to recycle elastomers as secondary feedstock. Kim has a PhD in Chemical Engineering from Cornell. She is an inventor on more than 25 patents and applications for novel polyolefin technologies. Kim is on the Board of Directors of SPE’s Thermoplastic Materials & Foams Division, where she has served as Education Chair and Councilor.
A Resin Supplier’s Perspective on Partnerships for the Circular Economy
About the Speaker
Gamini has a BS and PhD from Purdue University in Materials Engineering and Sustainability. He joined Penn State as a Post Doctorate Scholar in 2020 prior to his professorship appointment. He works closely with PA plastics manufacturers to implement sustainability programs in their plants.
A Resin Supplier’s Perspective on Partnerships for the Circular Economy
About the Speaker
Tom Giovannetti holds a Degree in Mechanical Engineering from The University of Tulsa and for the last 26 years has worked for Chevron Phillips Chemical Company. Tom started his plastics career by designing various injection molded products for the chemical industry including explosion proof plugs and receptacles, panel boards and detonation arrestors for 24 inch pipelines. Tom also holds a patent for design of a polyphenylene sulfide sleeve in a nylon coolant cross-over of an air intake manifold and is a Certified Plastic Technologist through the Society of Plastic Engineers. Tom serves on the Oklahoma Section Board as Councilor, is also the past president of the local Oklahoma SPE Section, and as well serves on the SPE Injection Molding Division board.
Joseph Lawrence, Ph.D. Senior Director and Research Professor University of Toledo
A Resin Supplier’s Perspective on Partnerships for the Circular Economy
About the Speaker
Dr. Joseph Lawrence is a Research Professor and Senior Director of the Polymer Institute and the Center for Materials and Sensor Characterization at the University of Toledo. He is a Chemical Engineer by training and after working in the process industry, he has been engaged in polymers and composites research for 18+ years. In the Polymer Institute he leads research on renewably sourced polymers, plastics recycling, and additive manufacturing. He is also the lead investigator of the Polyesters and Barrier Materials Research Consortium funded by industry. Dr. Lawrence has advised 20 graduate students, mentored 8 staff scientists and several undergraduate students. He is a peer reviewer in several journals, has authored 30+ peer-reviewed publications and serves on the board of the Injection Molding Division of SPE.
Matt Hammernik Northeast Account Manager Hasco America
A Resin Supplier’s Perspective on Partnerships for the Circular Economy
About the Speaker
Matt Hammernik serves as Hasco America’s Northeast Area Account Manager covering the states Michigan, Ohio, Indiana, and Kentucky. He started with Hasco America at the beginning of March 2022. Matt started in the Injection Mold Industry roughly 10 years ago as an estimator quoting injection mold base steel, components and machining. He advanced into outside sales and has been serving molders, mold builders and mold makers for about 7 years.
84 countries and 85.6k+ stakeholders strong, SPE
unites
plastics professionals worldwide – helping them succeed and strengthening their skills
through
networking, events, training, and knowledge sharing.
No matter where you work in the plastics industry
value
chain-whether you're a scientist, engineer, technical personnel or a senior executive-nor
what your
background is, education, gender, culture or age-we are here to serve you.
Our members needs are our passion. We work hard so
that we
can ensure that everyone has the tools necessary to meet her or his personal & professional
goals.
Need help from SPE Headquarters?
SPE HQ provides a range of services to Chapters. If you are a chapter and need HQ services (i.e.,
event registration - full list of HQ services can be found here), please fill out and submit the HQ services request form found
here: www.4spe.org/HQservices.
IMPORTANT! If you are simply looking to post your
event on SPE's calendar, please click the "Submit an Event" button below. All events
submitted for inclusion in the SPE calendar are subject to approval.
Going to a SPE event?
If you are going to a SPE event and need a Visa invitation letter, please submit your request for a Visa Invitation letter.
SPE Members receive discounted rates on all event registrations. Not a member of SPE? Join today!
How to reference articles from the SPE Library:
Any article that is cited in another manuscript or other work is required to use the correct reference style. Below is an example of the reference style for SPE articles:
Brown, H. L. and Jones, D. H. 2016, May.
"Insert title of paper here in quotes,"
ANTEC 2016 - Indianapolis, Indiana, USA May 23-25, 2016. [On-line].
Society of Plastics Engineers, ISBN: 123-0-1234567-8-9, pp. 000-000.
Available: www.4spe.org.
Note: if there are more than three authors you may use the first author's name and et al. EG Brown, H. L. et al.
