Processing of cenosphere/HDPE syntactic foams using an industrial scale polymer injection molding machine
Processing of cenosphere/HDPE syntactic foams using an industrial scale polymer injection molding machine
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DOI：
10.1016/j.matdes.2015.12.052
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发表时间：
2016-02-15
影响因子：
8.4
通讯作者：
Ramakrishna, Seeram
中科院分区：
文献类型：
--
作者：
Kumar, B. R. Bharath;Doddamani, Mrityunjay;Ramakrishna, Seeram
快速生产高质量组件是工业应用中降低成本的关键。目前的工作是使用工业规模注塑机制造复合泡沫、空心颗粒填充轻质复合材料的首次尝试。以高密度聚乙烯（HDPE）为基体材料，粉煤灰微珠为填料。开发含有空心珠的复合泡沫塑料具有双重目的，即有益地利用工业废粉煤灰和降低组件的成本。注射成型过程中使用的压力和温度经过优化，可最大程度地减少空心微珠的破裂并实现空心微珠与 HDPE 的完全混合。优化的参数用于制造含有 20、40 和 60 wt% 空心微珠的复合泡沫塑料。随着空珠含量的增加，密度和强度降低，模量增加。成分的表面改性导致强度随着填料含量的增加而增加。由于直接测量漂珠性质的固有困难，基于微分方案的理论模型用于通过进行参数研究来估计漂珠的性质。通过铸造多个工业部件证明了使用优化注塑工艺的潜力。 (C) 2015 Elsevier Ltd. 保留所有权利。
Rapid production of high quality components is the key to cost reduction in industrial applications. The present work is the first attempt of manufacturing syntactic foams, hollow particle filled lightweight composites, using an industrial scale injection molding machine. High density polyethylene (HDPE) is used as the matrix material and fly ash cenospheres are used as the filler. Development of syntactic foams with cenospheres serves dual purpose of beneficial utilization of industrial waste fly ash and reduction in the cost of the component. The pressure and temperature used in the injection molding process are optimized to minimize fracture of cenospheres and obtain complete mixing of cenospheres with HDPE. The optimized parameters are used for manufacturing syntactic foams with 20, 40 and 60 wt% cenospheres. With increasing cenosphere content, density and strength reduce and modulus increases. Surface modification of constituents results in rise in strength with increasing filler content. A theoretical model based on a differential scheme is used to estimate the properties of cenospheres by conducting parametric studies because of inherent difficulties in direct measurement of cenosphere properties. The potential for using the optimized injection molding process is demonstrated by casting several industrial components. (C) 2015 Elsevier Ltd. All rights reserved.