Geometry dependence of the elongation behavior of a polypropylene melt through a micro die

A series of rheological experiments was performed for a polypropylene (PP) melt to explore its elongation behavior through a capillary die. Using an advanced twin-bore capillary rheometer with dies measuring 1.0, 0.5, and 0.25 mm in diameter, the experiments were performed at 210, 220, and 230 °C. The results indicated that the temperature of the PP melt had a significant effect on its extensional viscosity. The different decreases in the extensional viscosity values in the tested dies revealed the geometry dependence of the extensional viscosity. In the case of PP in the 0.25 mm die at 210 °C, the extensional viscosity values under different extensional strain rates were much higher than those in the other dies. Only in the 1.0 mm die did the relationship between the extensional viscosity of PP and its temperature obey the Arrhenius equation due to the larger die size which related to a slight size effect on its elongation behavior. The calculated deviations of the extensional viscosity in the tested dies demonstrated that the increasing pressure applied to the PP melt in the micro channel was related to the geometry dependence of the elongation behavior of the PP melt. The change in the extensional viscosity eventually relied on the interaction of the die geometry, the temperature, and the extensional stress of the PP melt.     

Rheological Study on Polypropylene/Cycloolefin Copolymer Blends

Summary: Polypropylene, cycloolefin copolymer and their blends were characterized by means of melt flow analysis and capillary rheometry at temperatures between 190 and 230 °C in order to shed more light on COC fiber formation obtained in injection molding process. Melt viscosity and its activation energy as functions of blend composition show negative deviation from the expected additivity (Negative Deviating Blends). The COC/PP viscosity ratio increases with shear rate, but decreases with temperature. High temperature, low viscosity ratio and high shear rate seem to be favorable for fiber formation. Glass transition (from the reversible heat flow curve of modulated DSC) of dumbbell specimens produced by injection molding at 230 °C with COC minor component was 2–4 °C higher than that of grinded pellets obtained from mixing at 190 °C.     

Melt flow behavior of polypropylene composites filled with multi-walled carbon nanotubes during extrusion

Polypropylene (PP) composites filled with multi-walled carbon nanotubes (MWCNTs) were prepared using a twin-screw extruder. The melt flow properties of the composites were measured with a capillary rheometer in a temperature range from 180 to 230 °C and at various apparent shear rates varying from 100 to 4000 s⁻¹. The results showed that the melt shear stress increased almost linearly while the melt shear viscosity decreased almost linearly with increasing shear rates in a bi-logarithmic coordinate system. The melt shear flow followed the power law relationship and the dependence of the melt shear viscosity on temperature obeyed the Arrhenius equation. The relationship between the melt shear viscosity and the MWCNT weight fraction was roughly linear under the investigated range of temperature or shear rate.     

Rheological properties of styrene–butadiene rubber filled with electron beam modified surface treated dual phase fillers

The rheological properties of styrene–butadiene rubber (SBR) loaded with dual phase filler were measured using Monsanto Processability Tester (MPT) at three different temperatures (100°C, 110°C and 130°C) and four different shear rates (61.3, 306.3, 613, and 1004.5 s⁻¹). The effect of electron beam modification of dual phase filler in absence and presence of trimethylol propane triacrylate (TMPTA) or triethoxysilylpropyltetrasulphide (Si-69) on melt flow properties of SBR was also studied. The viscosity of all the systems decreases with shear rate indicating their pseudoplastic or shear thinning nature. The higher shear viscosity for the SBR loaded with the electron beam modified filler is explained in terms of variation in structure of the filler upon electron beam irradiation. Die swell of the modified filler loaded SBR is slightly higher than that of the unmodified filler loaded rubber, which is explained by calculating normal stress difference for the systems. Activation energy of the modified filler loaded SBR systems is also slightly higher than that of the control filler loaded SBR system.     

Melt elongation flow behaviour of LDPE/LLDPE blends

The extensional rheological properties of low density polyethylene (LDPE)/linear low density polyethylene (LLDPE) blend melts were measured using a melt spinning technique under temperatures ranging from 160 to 200 °C and die extrusion velocities varying from 9 to 36 mm/s. The results showed that the melt elongation stress decreased with a rise of temperature while it increased with increasing extensional strain rate and the LDPE weight fraction. The dependence of the melt elongation viscosity on temperature roughly obeyed the Arrhenius equation, it increased with increasing extensional strain rate and the LDPE weight fraction when the extensional strain rate was lower than 0.5 s⁻¹, and it reached a maximum when the extensional strain rate was about 0.5 s⁻¹, which can be attributed to the stress hardening effect.     

A study on the micro‐injection molding of multi‐cavity ultra‐thin parts

In this study, we report the micro‐injection molding of ultra‐thin parts (100, 250, and 500 µm). The results show that the flow resistance increases as the cavity becomes thinner. The melt front is not symmetric when filling a four‐cavity ultra‐thin part and filling the eight‐cavity mold under a low temperature. If we increase the mold temperature or cavity thickness, the melt front becomes symmetric. Finally, we construct the operation windows of molding for three kinds of plastics (PS, PMMA, PC) and provide a molding range based on mold temperature and injections speed. Meanwhile, the relationship between the thickness and the operation windows are also investigated. The thinner the cavity is, the smaller the operation window is. We need to increase the injection speed significantly for molding the ultra‐thin parts with micro‐features on both surfaces which are 60 µm in thickness. Furthermore, we succeed in molding 30 µm ultra‐thin parts in this experiment. Copyright © 2009 John Wiley & Sons, Ltd.     

Fabrication of needle-type micro SOFCs for micro power devices

We report the world smallest tubular solid oxide fuel cell – needle-type micro SOFCs applicable to micro power devices. The anode-supported cell was prepared using cost effective, conventional extrusion and dip-coating techniques. The diameter of the needle-type cell is 0.4 mm, consisting of NiO-Gd doped Ceria (GDC) for anode (under 100 μm thick), GDC for electrolyte (8 μm thick), and (La, Sr) (Co, Fe)O₃ – GDC for cathode. The cell performances of 80, 160 and 300 mW cm⁻² at 450 °C, 500 °C, and 550 °C, respectively, were obtained using a simple current collection method with wet H₂ fuel. Impedance analysis indicated that the SOFC has a potential to be improved by optimizing the current collection method. Bundle concept using the SOFCs with the packing density of 100 cells in 1 cm³ was also proposed.     

Shear-induced non-isothermal crystallization of poly(butylene adipate-co-terephthalate)

The influence of shear on non-isothermal crystallization of commercial poly(butylene adipate-co-terephthalate) (PBAT) was investigated. PBAT melt was sheared at 130 and 150 °C at rates of 10–100/s, and then cooled. The crystallization was followed by a light depolarization technique, whereas the crystallized specimens were analyzed by DSC, 2D-SAXS, 2D-WAXS, PLM and SALS. Shear flow shifted crystallization to higher temperature, and the effect was augmented by lower temperature of shearing as well as by higher shear rate and strain. Crystallization peak rate temperature of PBAT, sheared at 130 °C for 5 min at 100/s, increased by up to 12 °C. However, no evidence of crystal orientation due to shear was found, indicating that the shear induced the point-like nucleation. Only a small increase of melting peak temperatures, by up to 2–5 °C, was observed for the specimens sheared at the highest rates (≥50/s).     

Determination of the Rheological Properties of Polypropylene Filled with Colemanite

Colemanite (Ca₂B₆O₁₁.H₂O) in powder form was filled to polypropylene (PP) at concentrations of 5, 7.5, 11.25, 16.875, and 25.312 wt%, and filled PP granules were obtained. To prevent oxidation, an antioxidant (Songnox 1010) was added to the colemanite‐filled polypropylene mixture at a ratio of 0.2 wt%. The rheological properties of the resulting composite material were determined using a Melt Flow Index testing device, at four separate pressure settings (298.2, 524, 689.5, and 987.4 kPa) and four separate temperature settings (190°C, 200°C, 210°C, and 220°C). The viscosity, shear rate, shear stress, and power law index (n) values of the colemanite‐filled PP were measured as part of the testing conducted. The study determined that viscosity values increased by approximately 60% in response to increasing colemanite content in the resulting filled material, while shear rate values decreased by 62%. The viscosity values were found to decrease with increasing temperature and pressure values, while shear rate values were found to increase. Additionally, Power Law Index value was found to vary between 0.561 and 0.687, with an average value of 0.608 based on the colemanite content used. Copyright © 2017 John Wiley & Sons, Ltd.     

Effect of Interfacial Failure on the Viscosity of High-density Polyethylene

The effect of a processing agent (Dynamar) on the viscosity and surface properties of high-density polyethylene (HDPE) has been studied. A capillary rheometer was used to measure the viscosity of HDPE compounds containing various concentrations of Dynamar as a function of time at constant apparent shear rates. The shear rates used are 250 and 500 sec⁻¹. The addition of a small amount of Dynamar leads to a marked reduction in viscosity. The viscosity decreases dramatically initially, then levels off to an equilibrium. The rate of the viscosity reduction and the equilibrium viscosity value depend upon the Dynamar concentration and the shear rate. This phenomenon can be explained by the migration of Dynamar from the bulk to the interface of HDPE melt and die wall, resulting in the formation of a lubrication layer. X-ray photoelectron spectroscopy and scanning secondary ion mass spectrometry analyses of the extrudates from a slit die reveal a low concentration of Dynamar at the surface. Adhesive failure at the Dynamar and HPDE interface is attributed to a reduction in viscosity. © 1997 John Wiley & Sons, Ltd.     

Unique rheological behavior of rubber based nanocomposites

Montmorillonite clay (N) based nanocomposites were prepared using three different grades of acrylonitrile butadiene rubber (NBR) (19%, 34%, and 50% acrylonitrile contents), styrene butadiene rubber (SBR), and polybutadiene rubber (BR). Rheological study was carried out on these nanocomposites at three different temperatures (110 °C, 120 °C, and 130 °C) over a range of shear rates for comparison. The results showed that the shear viscosity decreased with increasing shear rate and incorporation of the unmodified (N) and the modified (OC) fillers up to a certain loading, when the results were compared with the gum rubber. This effect became more prominent with increasing polarity of the rubber. The die swell, on the other hand, decreased with loading of N and OC. With increasing filler volume fraction, the die swell further decreased. Decrease of viscosity with concomitant decrease of die swell is unique in such systems. Consecutive runs of the same sample over different shear rates increased the viscosity. The results were explained with the help of X‐Ray Diffraction (XRD) data and Transmission Electron Microscopy (TEM).© 2005 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 1854–1864, 2005     

Fiber spinning from the nematic melt. VI. Flow instabilities in the 30:70 copolyester of hydroxybenzoic acid and 2-hydroxy-6-naphthoic acid

The rheological behavior and fiber spinning are investigated for the Celanese liquid crystal copolyester 30 mol% p-hydroxybenzoic acid and 70 mol% 2-hydroxy-6-naphthoic acid (designated as 30HBA/70HNA) with inherent viscosity 7.8 dL/g. Shear thinning viscosity, and yield stress are observed at low shear stress, which probably results from the existence of crystallites in the melt. The crystal-nematic melting point of the copolymer, as measured by differential scanning calorimetry, is around 309°C. Extrudates are collected at four different temperatures ranging from 315 to 345°C. Melt fracture and die swell are observed above 335°C at low shear stress. A wide-angle x-ray diffraction (WAXS) study of an annealed sample indicates that the abnormal phenomenon may be due to crystallites arising from blocky units of HNA. Fiber spinning is performed at high shear rate at 325 and 335°C. Flow is stable under these conditions. The spin draw ratio is the ratio of take-up velocity to the velocity of extrudate existing from the capillary. The initial modulus reaches a maximum at a fairly low spin draw ratio. Instron and wide-angle x-ray (WAXS) studies show that the mechanical properties and orientation are poor for the fiber spun near the crystal-nematic melting point. Also, thermal history is found to affect the rheological behavior. Heat treatment offibers, particularly those which are well oriented, brings an improvement of mechanical properties.     

Proposing a nano-approach to modify viscosity behavior of SAE 5W50 as light road vehicles lubricant

In this paper, viscosity of MWCNT (%50)–TiO₂ (%50)/5W50 is investigated in temperature range of 5–55 °C, solid volume fractions of 0.05%, 0.1%, 0.25%, 0.5%, 0.75% and 1%, and shear rate range of 666.5–10,664 (s^?1). Experimental results showed non-Newtonian behavior of enriched nano-engine oil. Nano-engine oil viscosity reduction (compared to 5W50 base oil) in some specific temperatures and solid volume fractions is one of the unique and interesting results of this research. Maximum viscosity reduction (??11%) occurred in 15 °C and solid volume fraction of 0.05%, and maximum viscosity enhancement (+?17%) was observed in 25 °C and solid volume fraction of 1%. The main goal of present study is to control viscosity increase of nanofluid after adding nanoparticles to the oil. Modeling and prediction of results were achieved via RSM and ANN methods.

     

Preparation and properties of cellulose/PE-co-AA blends

Cellulose/polyethylene-co-acrylic acid blends (cellulose concentration 0–50 wt.%) was prepared via mixing their alkaline solutions. The formed suspension was precipitated and dried, where after the morphology as well the thermal and mechanical properties of the blends were characterized by Differential Scanning Calorimetry (DSC), Scanning Electron Microscopy (SEM), and Dynamic Mechanical Analyses (DMA). In addition, the melt properties of the blend were studied by rotational rheometer following some injection molding trials as well. The polymers were found to be dispersed homogenously in the blend and the crystallization temperature of the PE-co-AA phase was increased ～6 °C due to the nucleation ability of the cellulose phase. The size of the discontinuous cellulose phase was 5 μm at the most while at higher cellulose concentrations (30–50 wt.%) the polymers formed co-continuous morphology in the blend. This change in the morphology was observed also in their melt properties which showed that the blend reached so called percolation point at ～20 wt.% of cellulose. Finally, the blends were found to be injection moldable over the whole composition range, if only the injection molding became more challenging (i.e. higher mold temperatures and longer mold cooling times were required) after the percholation point.     

Vibration-induced change of crystal structure in isotactic polypropylene and its improved mechanical properties

In order to understand the formation of different crystal structures and improve the mechanical properties of isotactic polypropylene (iPP), melt vibration technology, which generally includes shear vibration and hydrostatic pressure vibration, was used to induce the change of crystal structure of iPP. iPP forms α crystal structure in traditional injection molding. Through melt vibration, crystal orientated and its size became smaller, and a change of crystal structure of iPP from α form to β form and γ form was achieved. Therefore, the mechanical properties of iPP were improved. At high melting temperature (230 °C), only β form can be induced. At low melting temperature (190 °C), either β form or γ form can be induced, depending on the combination of frequency and vibration pressure. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 42: 2385–2390, 2004     

Melt flow behavior in capillary extrusion of nanometer calcium carbonate filled PCL bio-composites

Nanosized calcium carbonate (nano-CaCO₃) filled polycaprolactone (PCL) bio-composites were prepared by using a twin-screw extruder. The melt flow behavior of the composites, including the entry pressure drop, melt shear flow curves and melt shear viscosity, were measured through a capillary rheometer operated in a temperature range of 170∼200 °C and shear rates varying from 50 to 10³ s⁻¹. The entry pressure drop showed a non-linear increase with increasing shear stress when the filler weight fraction was less than 3%, while it decreased slightly with an increase of shear stress at a filler weight fraction of 4%. The melt shear flow roughly followed a power law, while the effect of temperature on the melt shear viscosity was estimated by using the Arrhenius equation. Moreover, the influence of the nano-CaCO₃ on the melt shear viscosity of the PCL composite was not significant at low filler levels.     

Rheological,morphological, thermal,and mechanical properties of blends of vectra A950 and poly(trimethylene terephthalate): A study on a high-viscosity-ratio system

Poly(trimethylene terephthalate) (PTT) and a liquid crystalline polymer, Vectra A950 (VA), were melt-blended and subjected to capillary rheometry. Effects of VA content, shear rate and temperature on viscosity and flow activation energy (E_a) were investigated. Partial fibrillation was found even though the viscosity ratio was greater than one, leading to the formation of in-situ composites. Thermal and thermogravimetric analysis of the blends suggested that they were immiscible and their thermal stabilities were enhanced. From tensile tests, the incorporation of VA improved tensile modulus, slightly decreased tensile strength, and drastically lowered elongation at break, compared to neat PTT. It was found that the blend with the best VA dispersion can be achieved at the minimum VA content (10 wt%) and lowest processing temperature (250 °C). Not only did this blend exhibit improved mechanical properties comparable to those of blends processed at temperatures closer to the crystalline-to-nematic transition of VA (～280 °C), it also shows enhanced processibility through the reduction of both melt viscosity and E_a.     

Rheology of molten polystyrene with dissolved supercritical and near-critical gases

The viscosities of polystyrene melts containing three different dissolved gases, carbon dioxide, and the refrigerants R134a (1,1,1,2-tetrafluoroethane) and R152a (1,1-difluoroethane) are investigated at pressures up to 20 MPa. These pressures reach near-critical and supercritical conditions for the three gas components, and produce polymer–gas solutions containing up to 10 wt % gas. The measurements are performed in a sealed high-pressure capillary rheometer at 150 and 175°C, and at shear rates ranging from 1–2,000 s⁻¹. Very large reductions in melt viscosity are observed at high gas loading; at 150°C, 10 wt % R152a reduces the Newtonian viscosity by nearly three orders of magnitude relative to pure polystyrene. The viscosity data for all three polystyrene–gas systems follows ideal viscoelastic scaling, whereby the set of viscosity curves for a polymer-gas system can be scaled to a master curve of reduced viscosity vs. reduced shear rate identical to the viscosity curve for the pure polymer. The viscoelastic scaling factors representing the effect of dissolved gas content on rheological behavior are found to follow roughly the same variation with composition for all three polystyrene gas systems. © 1999 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 37: 2771–2781, 1999     

Surface structures and electrochemical characteristics of surface-modified carbon anodes for lithium ion battery

Petroleum coke and those heat-treated at 1860 °C, 2100 °C, 2300 °C 2600 °C and 2800 °C (abbreviated as PC, PC1860, PC2100, PC2300, PC2600 and PC2800) were fluorinated by elemental fluorine of 3 × 10⁴ Pa at 200 °C and 300 °C for 2 min. Natural graphite powder samples with average particle sizes of 5 μm, 10 μm and 15 μm (abbreviated as NG5μm, NG10μm and NG15μm) were also fluorinated by ClF₃ of 3 × 10⁴ Pa at 200 °C and 300 °C for 2 min. Transmission electron microscopic (TEM) observation revealed that closed edge of PC2800 was destroyed and opened by surface fluorination, which increased the first coulombic efficiencies of PC2300, PC2600 and PC2800 by 12.1–18.2% at 60 mA/g and by 13.3–25.8% at 150 mA/g in 1 mol/dm³ LiClO₄–ethylene carbonate (EC)/diethyl carbonate (DEC) (1:1 in volume). Light fluorination of NG10μm and NG15μm increased the first coulombic efficiencies by 22.1–28.4% at 150 mA/g in 1 mol/dm³ LiClO₄–EC/DEC/PC (PC: propylene carbonate, 1:1:1 in volume).     

Melt rheology and morphology of thermoplastic elastomers from polyethylene/nitrile‐rubber blends: The effect of blend ratio,reactive compatibilization,and dynamic vulcanization

A study of the melt‐rheological behavior of thermoplastic elastomers from high‐density polyethylene and acrylonitrile butadiene rubber (NBR) blends was carried out in a capillary rheometer. The effect of the blend ratio and shear rate on the melt viscosity reveals that the viscosity decreases with the shear rate but increases with NBR content. Compatibilization by maleic anhydride modified polyethylene has no significant effect on the blend viscosity, but a finer dispersion of the rubber is obtained, as is evident from scanning electron micrographs. The melt‐elasticity parameters, such as the die swell, principal normal stress difference, recoverable shear strain, and elastic shear modulus of the blends, were also evaluated. The effect of annealing on the morphology of the extrudate reveals that annealing in the extruder barrel results in the coalescence of rubber particles in the case of the incompatible blends, whereas the tendency toward agglomeration is somewhat suppressed in the compatibilized blends. © 2000 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 38: 1104–1122, 2000