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Conference Proceedings

CBT AS A NOVEL MATRIX MATERIAL AND ITS PROCESSING TECHNIQUES FOR COMPOSITES
Gabor Balogh, November 2011

Cyclic butylene terephthalate (CBT) is a novel thermoplastic matrix material for composites. Besides its low viscosity (0,02 Pas) and superior mechanical properties CBT has some other advantages over conventional matrix materials. During its polymerization no by-product is being made and it is easy to recycle. But processing of CBT is complicated and may results in a brittle material. Polycaprolactone (PCL) as an additive for CBT will also be introduced to increase toughness. In this paper the proper amount of PCL is determined to obtain a ductile material and a method is described how to fabricate prepregs and composites.

EFFECT OF MISALIGNMENTS OF A POLYETHYLENE CIRCULAR NOTCHED BAR SPECIMEN ON THE ASYMMETRIC FATIGUE CRACK GROWTH BEHAVIOR
Ilhyun Kim | Youngjian Zhao | Byoung-Ho Choi, November 2011

In this study, the effect of various misalignments of the circular notched bar (CNB) specimens on the fatigue crack propagation behavior of pipe grade polyethylene is investigated by three dimensional numerical analyses. The effect of the asymmetric crack growth of the misaligned CNB specimens on the lifetime to failure is also addressed. Two types of misalignments of the CNB specimen, i.e., (a) a concentric misalignments (Case I) and (b) an angular misalignments (Case II), are considered using finite element analysis. It is observed that as the misalignments increase, the asymmetric crack growth is accelerated so that the time to reach the critical SIF decreases. Therefore, it can be understood that the lifetime to failure of CNB specimens can vary noticeably once the CNB specimen is misaligned initially. Considering results from this study, the fatigue crack growth behavior including the estimation of the lifetime of CNB specimens should addressed by considering the misalignment effects.

CHAIN EXTENSION OF RECYCLED POLYAMIDES : HOW TO INCREASE THE AMOUNT OF RECYCLED PA IN THE AUTOMOTIVE INDUSTRY
Elodie Gaouyat, November 2011

The present work attempts to implement reactive compatibilisation of blends of recycled engineering plastics, more particularly the case of recycled PA66 contaminated by recycled PA6. Low molecular weight, high Tg Styrene-Maleic Anhydride copolymers were tested as chain extenders / compatibilizers. It appeared that the addition of 2% by weight of SMA to an incompatible system of recycled PA6 and PA66 improved both ductility and impact performance by factors of at least 10 and 1.5 respectively. Moreover, high Tg SMA improved performances at elevated temperature, partly due to its ability to effectively crosslink but also because of its inherent heat resistance.

ULTRAMID® ENDURE – STAYS COOL EVEN WHEN IT IS HOT
Manoranjan Prusty | Martin Baumert | Martin Völker | Tobias Nachtigaeller | Susanne Gruber | Dietmar See | Wolfgang Seib | Harald Kroeger | Walter Rau | Hans-peter Beringer | Willy Bert Hoven Nievelstein, November 2011

New Ultramid® Endure from BASF is the first of its kind PA66 based polymer which has excellent heat ageing resistance,welding strength after heat ageing and good processing properties. Ultramid® Endure can withstand continuous use over 3000 hours at 220°C and temperature peaks upto 240°C. The excellent heat ageing properties of Ultramid® Endure allows it to be used for applications such as resonator, charge air lines etc.

TRANSPORT PARAMETERS OF DEACTIVATED POLY-(ORTHOAMINOPHENOL) FILM ELECTRODES
Ricardo Tucceri, November 2011

Poly(o-aminophenol) (POAP) films were deactivated and then reactivated, and dependences of the different charge-transport and charge-transfer parameters on the degree of deactivation (c) were obtained by employing Electrochemical Impedance Spectroscopy. These dependences were extracted when the polymer contacts an electroactive solution and a mediation reaction occurs at the polymerelectrolyte interface. While some parameters, such as interfacial metal-film and film-solution resistances (Rmf, Refs, Rifs), the high-frequency capacitance (CH) and the redox capacitance (Cp) exhibit a continuous variation without hysteresis between deactivation and reactivation processes within the whole c range, others, such as electron and ion diffusion coefficients (De, Di), show hysteresis between consecutive deactivation and reactivation processes. On the basis of these findings it was considered that while some parameters of the polymer only depend on the amount of redox active sites, others (De and Di) depend on both the quantity and distribution of redox active sites.

Designing Lexan* Copolymers for Future Markets
André J.P. van Zyl | Robert D. van de Grampel | Theo L. Hoeks, November 2011

With the progression of technology, increasing pressure is put on engineering plastics companies to fulfill strict design criteria of equipment manufacturers. Therefore novel materials are needed to address specific needs. The most common method to manipulate material performance is by either blending or an additive approach. Although relatively cost-effective and requiring low technological input, these methods are not always desired due to the potential incompatibility of blends and/or nonpermanence of additives. In this paper a copolycarbonate approach will be discussed to address specific consumer needs. More specifically the tailoring of properties from a molecular perspective will be discussed and examples showed of how copolycarbonates can be used to capture novel markets.

FILLER RE-AGGREGATION AND NETWORK FORMATION TIME SCALE IN EXTRUDED HIGH DENSITY POLYETHYLENE / MULTI-WALLED CARBON NANOTUBE COMPOSITES
Frank Yepez Castillo | Brian P. Grady | Daniel E. Resasco, November 2011

Multi-walled carbon nanotube/high density polyethylene composites with varying amounts of carbon nanotubes were processed in an extruder fitted with a low-shear adaptor. This equipment allowed annealing of the melt for various amounts of time under low shear before it was passed through a slit die. The effect this treatment had on the electrical and mechanical properties of the composites was investigated. Results obtained from extruded samples were compared to the mechanical and electrical properties of samples that had been mixed in a micro-compounder and compression molded. Differences in the crystallinity and the orientation of extruded samples were also assessed.

RELIABILITY ANALYSIS OF PB TUBING IN COLD WATER DISTRIBUTION SYSTEM
Zhenwen Zhou | Alexander Chudnovsky, November 2011

A number of water utilities in various states of USA have reported a persistent premature failure of polybutylene (PB) tubing in water distribution system. Failure analysis of PB system and a methodology of reliability analysis of PB tubing in potable water application are presented in this paper. The reliability analysis allows predicting future failures. Thus, the proposed methodology is validated by comparison of failure prediction with actually reported field failures in selected water districts from Maryland, Georgia and Ohio. The proposed methodology also allows a rational replacement planning by considering the effect of preventive replacement program on the reduction of emergence replacements. Understanding of main PB failure mechanisms in potable water application important for proper interpretation statistics is also discussed.

PENT AND ITS APPLICATION IN PIPE LIFETIME PREDICTION
Haiying Zhang | Zhenwen Zhou | Alexander Chudnovsky, November 2011

A new method of evaluating the polyethylene (PE) pipe lifetime in brittle failure has been recently proposed. It consists of an extrapolation of the failure time in the Pennsylvania notch test to arbitrary PE pipes at various loads and temperatures. This paper presents a detailed review of the theoretical and experimental basis of the new lifetime prediction method and discusses its limitations. An experimental examination of the proposed method applied to a commercial high-density PE is reported. The results suggest that the proposed method overestimate the lifetime at room temperature by 30 ~ 40 times. It is inadequate for extrapolation of brittle fracture time of PE from 80°C to room temperature. Such limitation is related to the changes in failure mechanism and kinetics of crack growth taking place at some intermediate temperature. An alternative method for PE pipes lifetime prediction based on a combination of testing and modeling is discussed.

COLD DRAWING AND ITS ROLE IN FRACTURE OF POLYOLEFIN PIPES
Alexander Chudnovsky | Zhenwen Zhou | Haiying Zhang | Kalyan Sehanobish, November 2011

There are three major modes of polyolefin pipes failure: ductile, stress driven brittle and degradation assisted brittle fractures. The ductile failure results from material instability on macro-scale. It appears as a ballooning resulting from large-scale strain localization (stretching and thinning) similar to that observed in cold drawing in uniaxial tension (necking). The brittle fracture is manifested in cracking with no large deformation on macro-scale. However, there is a localized crazing in front of the crack, which consists of micro fibers and membranes. It also results from cold drawing, but on micro-scale. This paper presents analysis of cold drawing as time dependent phase transition referred to as “delayed necking”. The connections between ductile and brittle polyolefin pipes failure from one side and delayed necking on another are discussed.

ENHANCING BIOPOLYMERS WITH HIGH PERFORMANCE NATURAL TALC PRODUCTS
Caroline Abler | Jérôme Crépin-Leblond | Frédéric Jouffret | Saied H. Kochesfahani, November 2011

The effect of talcs on PolyLactic Acid (PLA) performance has been studied with a focus on properties of fully crystallized PLA. The results show that talc could be used as an effective nucleation agent to improve mechanical properties of PLA including stiffness, heat deflection temperature and impact strength. It is also shown in two PLA formulations that Luzenac High Aspect Ratio talc (HAR®) in combination with plasticizers and impact modifiers could further improve crystallization speed and impact properties through modifying the amorphous phase of PolyLactic Acid.

USE OF DIGITAL IMAGE CORRELATION AND INVERSE MODELING TO DETERMINE RESIDUAL STRESS IN AXISYMMETRIC POLYMER COMPONENTS
Frode Grytten | Mariusz Blochowiak | Einar L. Hinrichsen | Terje Tofteberg | Magnus Bengtsson | Susanne Nilsson, November 2011

This paper presents a new method to determine residual stress profiles in cables and other axisymmetric objects using digital image correlation and inverse modeling. 3D digital image correlation with two cameras and stereo-vision was used to determine full-field displacements resulting from cutting a slit in a disk made from cable insulation. These displacements were compared to predicted displacements in a finite element analysis of the cutting. Differences between nodal displacements and the corresponding measured displacements were used to construct a cost function which was iteratively minimized by changing the residual stress field used as initial condition in the finite element simulation.

KEY ISSUES IN MICROFABRICATION, THERMAL BONDING AND SURFACE MODIFICATION OF CYCLIC OLEFIN COPOLYMER (COC/TOPAS®) MICROFLUIDIC DEVICES
C.Y. Yue | S. Roy | R.K. Jena | Z.Y. Wang | Y.C. Lam, November 2011

Cyclic olefin copolymers (COC/TOPAS) are commonly employed for making microfluidic devices. Several issues need to be addressed before this can be realized. A reliable technique for micro-replicating COC is required. Good sealing and high bond strength between COC inter-layers without destroying channel integrity is necessary. The intrinsically hydrophobic surface has to be rendered hydrophilic to facilitate flow and electrophoretic separation. Here we report the production of high fidelity microdevices by hot-embossing. Thermal seals with high bond strengths for bonding below the glass transition temperature Tg, photografting using suitable hydrophilic monomers to give good surface wettability and hemocompatibility are outlined.

Optimization of Nanocomposites Injection Molding by design of Experiments
Fabian Rios | Samuel Kenig | Amos Ophir, November 2011

Design of experiments (DOE) is a systematic method based on designed experimental rums used to evaluate the effects of selected variables on the final product properties. The method is especially useful when materials are expensive and/or scarce and only small quantities are available for experimentation, such as with carbon nanotubes (CNT). The effects of injection molding on the properties of Polycarbonate and Polybutylene Terephthalate multi-wall CNT composites were studied using DOE. Results demonstrated that although only a small number of experimental runs were used, a significant effect of the injection molding parameters on the properties of the nanocomposites was detected.

PHYSICOCHEMICAL PROPERTIES OF PLASMA POLYMERIZED ACRYLIC ACID, ε-CAPROLACTONE AND LACTIC ACID FILMS
Aitor Larrañaga | Susana Petisco | Raul Villanueva | Jagoba J. Iturri | Sergio Moya | Emilio Meaurio | Jose-Ramon Sarasua, November 2011

The physicochemical properties of plasma polymerized films were investigated by means of X-Ray photoelectron spectroscopy (XPS), Fourier Transform infrared spectrophotometry (FTIR), ellipsometry and Water Contact Angle. Three different monomers (acrylic acid, ε-caprolactone and lactic acid) were polymerized in a Plasma Polymerization System for different times (7, 15 and 30 min) and power conditions (80 and 120 W). While plasma polymerized acrylic acid and ε-caprolactone shared a strong similarity with the conventional polymers, lactic acid did not bear any resemblance to the conventional polymer.

PVC – Moving Up to the Next Level
Stuart Patrick, November 2011

The papers from the most recent IOM3 conference, PVC 2011, are used as the basis for this paper. The PVC market is reviewed on the basis of Europe’s environmental challenges with management options being reshaped by global megatrends. The cost competitiveness of PVC products, energy saving from using PVC products and increasing recognition of our sustainable development progress can only serve our industry well into the future. The Voluntary Commitments of the past ten years (Vinyl 2010) and the next ten years (VinylPlus) are reviewed. Examples of educational initiatives in the UK to improve perceptions are also highlighted.

MECHANICAL AND THERMAL PROPERTIES OF SUPERCRITICAL CARBON DIOXIDE PROCESSED EPOXY SILICONE BLENDS
S. K. Joshi | M. G. H. Zaidi | A. Tiwari | P. L. Sah | S. Alam, November 2011

Mechanical and thermal properties of epoxy have been modified through blending of diglycidylether of bisphenol A (0.1 mol) with polydimethylsiloxane (PDMS) at concentration ranging 1.0 to 3.0 phr of resin at 1400 psi and 90±10C for 1hr in supercritical carbon dioxide (scCO2), followed by curing with triethylenetetramine (10 phr) at 40±10C.The formation of synthesized epoxy silicone blends (ESBs) has been ascertained through ultraviolet –visible (Uv-vis), Fourier transformed infrared (FT-IR), X-ray diffraction (XRD) spectra and microscopy. With PDMS concentration, the compressive, tensile strength, Rockwell hardness (R scale), fringe values and crystallinity of ESBs were decreased with simultaneous increase in their impact strength, resistance against wear and thermal stability. Key words: Supercritical carbon dioxide, Polymer blends, Spectra, Morphology, Mechanical and thermal properties.

COMPLEX INVESTIGATION OF INJECTION MOULD FILLING
Andras Szucs | Károly Belina, November 2011

 Thin wall injection moulding is a difficult process. High viscosity polymeric material is injected into a mould by high speed and high pressure. A special instrumented injection mould was designed for the investigation of the cavity filling of injection mould. Rheological measurement can be carried out with different wall thickness slit die inserts. The pressure can be measured during the filling, the packing and the cooling stages as well. The pressure drop during the filling can be used for determination the flow properties of the material. The measured cavity pressure of the injection cycle is proper for the validation if thin wall injection moulding simulation. The filling of the dies was simulated by Moldex3D software. 

SYNTHESIS OF POLYPYRROLE / POLYTHIOPHENE COPOLYMERS IN SUPERCRITICAL CARBON DIOXIDE
M.G.H.Zaidi | A.Thakur | T. Agarwal | G.B.Pant | S. Alam | R. Singh, November 2011

Chemical oxidative copolymerization of pyrrole with thiophene was conducted using ferric chloride initiator at 90 °C, 1200 psi over 24 hours in supercritical carbon dioxide (scCO2). Polymerizations were conducted with different concentration ratios of pyrrole to thiophene 1:0, 0:1, 1:1 and 1:2 in a 100 mL high-pressure batch reactor. Polymerization yield which was up to 56.7 % in homopolymerizations was found to decrease in copolymerizations at molar ratio of pyrrole to thiophene 1:1 .The polymers were characterized by ultraviolet visible (Uv-vis), Fourier transformed infrared (FT-IR) spectra, elemental analysis, gel permeation chromatography (GPC), simultaneous thermogravimetricdifferential thermal analysis-differential thermogravimetry (TG-DTA-DTG), electrical conductivity and atomic force microscopy (AFM). Key words: Supercritical carbon dioxide, Polymerization, Polypyrrole, Polythiophene, Copolymers, Characterization.

Evaluation of tribological behavior of amorphous and crystalline thermoplastic compounds under high pressure, velocity and temperature conditions
Reema Sinha | Sangita Nandi | Arun Sikder | Radha Kamalakaran | Susanta Mitra | Ed Kung, November 2011

In the present study, the friction and wear properties of two high temperature resistant polymers, an amorphous polyetherimide (PEI) and a crystalline polyetheretherketone (PEEK), have been investigated at specific combinations of high pressure, velocity and temperature against smooth steel counterparts. The effects of internal lubricant, polytetrafluoroethylene (PTFE) and PTFE with short fiber reinforcements (carbon fiber) are outlined. The tests were performed on a thrustwasher testing machine under dry sliding conditions. Different analytical techniques were employed to study the correlation between the transfer layer and wear properties. Lubricated and lubricated-reinforced compounds showed excellent wear properties compared to pristine resins throughout all PV conditions.










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