Ludwig Cardon

Processing of Polysulfone to Free Flowing Powder by Mechanical Milling and Spray Drying Techniques for Use in Selective Laser Sintering

Polysulfone (PSU) has been processed into powder form by ball milling, rotor milling, and spray drying technique in an attempt to produce new materials for Selective Laser Sintering purposes. Both rotor milling and spray drying were adept to make spherical particles that can be used for this aim. Processing PSU pellets by rotor milling in a three-step process resulted in particles of 51.8 μm mean diameter, whereas spray drying could only manage a mean diameter of 26.1 μm. The resulting powders were characterized using Differential Scanning Calorimetry (DSC), Gel Permeation Chromatography (GPC) and X-ray Diffraction measurements (XRD). DSC measurements revealed an influence of all processing techniques on the thermal behavior of the material. Glass transitions remained unaffected by spray drying and rotor milling, yet a clear shift was observed for ball milling, along with a large endothermic peak in the high temperature region. This was ascribed to the imparting of an orientation into the polymer chains due to the processing method and was confirmed by XRD measurements. Of all processed powder samples, the ball milled sample was unable to dissolve for GPC measurements, suggesting degradation by chain scission and subsequent crosslinking. Spray drying and rotor milling did not cause significant degradation.

Shaping ceramics through indirect selective laser sintering

Purpose n n n n nThe purpose of this paper is to compare different powder metallurgy (PM) processes to produce ceramic parts through additive manufacturing (AM). This creates the potential to rapidly shape ceramic parts with an almost unlimited shape freedom. In this paper, alumina (Al2O3) parts are produced, as Al2O3 is currently the most commonly used ceramic material for technical applications. n n n n nDesign/methodology/approach n n n n nVariants of the following PM route, with indirect selective laser sintering (indirect SLS) as the AM shaping step, are explored to produce ceramic parts: powder synthesis, indirect SLS, binder removal and furnace sintering and alternative densification steps. n n n n nFindings n n n n nFreeform-shaped Al2O3 parts with densities up to approximately 90 per cent are obtained. n n n n nResearch limitations/implications n n n n nThe resulting Al2O3 parts contain inter-agglomerate pores. To produce higher-quality ceramic parts through indirect SLS, these pores should be avoided or eliminated. n n n n nOriginality/value n n n n nThe research is innovative in many ways. First, composite powders are produced using different powder production methods, such as temperature-induced phase separation and dispersion polymerization. Second, four different binder materials are investigated: polyamide (nylon-12), polystyrene, polypropylene and a carnauba wax – low-density polyethylene combination. Further, to produce ceramic parts with increased density, the following densification techniques are investigated as additional steps of the PM process: laser remelting, isostatic pressing and infiltration.

The Effect of Injection Molding Temperature on the Morphology and Mechanical Properties of PP/PET Blends and Microfibrillar Composites

Within this research the effect of injection molding temperature on polypropylene (PP)/poly(ethylene terephthalate) (PET) blends and microfibrillar composites was investigated. Injection molding blends (IMBs) and microfibrillar composites (MFCs) of PP/PET have been prepared in a weight ratio 70/30. The samples were processed at three different injection molding temperatures (Tim) (210, 230, 280 °C) and subjected to extensive characterization. The observations from the fracture surfaces of MFCs showed that PET fibers can be achieved by three step processing. The results indicated that Tim has a big influence on morphology of IMBs and MFCs. With increasing the Tim, distinctive variations in particle and fiber diameters were noticed. The differences in mechanical performances were obtained by flexural and impact tests. Establishing relationships between the processing parameters, properties, and morphology of composites is of key importance for the valorization of MFC polymers.

Optimisation of the Adhesion of Polypropylene-Based Materials during Extrusion-Based Additive Manufacturing

Polypropylene (PP) parts produced by means of extrusion-based additive manufacturing, also known as fused filament fabrication, are prone to detaching from the build platform due to their strong tendency to shrink and warp. Apart from incorporating high volume fractions of fillers, one approach to mitigate this issue is to improve the adhesion between the first deposited layer and the build platform. However, a major challenge for PP is the lack of adhesion on standard platform materials, as well as a high risk of welding on PP-based platform materials. This study reports the material selection of build platform alternatives based on contact angle measurements. The adhesion forces, investigated by shear-off measurements, between PP-based filaments and the most promising platform material, an ultra-high-molecular-weight polyethylene (UHMW-PE), were optimised by a thorough parametric study. Higher adhesion forces were measured by increasing the platform and extrusion temperatures, increasing the flow rate and decreasing the thickness of the first layer. Apart from changes in printer settings, an increased surface roughness of the UHMW-PE platform led to a sufficient, weld-free adhesion for large-area parts of PP-based filaments, due to improved wetting, mechanical interlockings, and an increased surface area between the two materials in contact.

Processing of Syndiotactic Polystyrene to Microspheres for Part Manufacturing through Selective Laser Sintering

Syndiotactic polystyrene pellets were processed into powder form using mechanical (ball milling, rotor milling) and physicochemical (spray drying) techniques with the intention of using it as feed material for selective laser sintering. New materials are an important component in broadening the application window for selective laser sintering but must meet strict requirements to be used. Particles obtained were characterized in size and shape using SEM imaging, analyzed by software, and compared to the product obtained by conventional ball milling. Rotor milling and spray drying proved capable of making spherical powders, yet only rotor milling achieved particles with a mean diameter within the desired range of 45–97 µm. Subsequently, the obtained powders were examined for the effect each processing technique imparts on the intrinsic properties of the material. Differential scanning calorimetry analysis revealed amorphization for all methods and a reduction in crystallinity after processing, however, the reduction in crystallinity was acceptably low for the spray-dried and rotor-milled powders. Ball milling displayed an exceptional reduction in crystallinity, suggesting severe degradation. As a final test, the rotor-milled powder was subjected to single-layer test and displayed good coalescence and smooth morphology, albeit with a large amount of warpage.

Development of crystalline morphology and its relationship with mechanical properties of PP/PET microfibrillar composites containing POE and POE-g-MA

The main goal of this research is to study the development of crystalline morphology and compare it to various mechanical properties of microfibrillar composites (MFCs) based on polypropylene (PP) and poly(ethylene terephthalate) (PET), by adding a functional compatibilizer and a non-functional rubber in two different steps in the processing sequence. The MFCs were prepared at a weight ratio of 80/20 PP/PET by twin screw extrusion followed by cold drawing and injection moulding. The non-functionalized polyolefin-based elastomer (POE) and the functional compatibilizer (i.e., POE grafted with maleic anhydride (POE-g-MA)) were added in a fixed weight percentage at two stages: during extrusion or during injection moulding. The morphology observations showed differences in crystalline structure, and the PP spherulite size was reduced in all MFCs due to the presence of PET fibrils. Their relationship with the mechanical performances of the composite was studied by tensile and impact tests. Adding the functional compatibilizer during extrusions showed better mechanical properties compared to MFCs. Overall, a clear relationship was identified between processing, structure and properties.

Can the melt flow index be used to predict the success of fused deposition modelling of commercial poly(lactic acid) filaments into 3D printed materials

ABSTRACT The melt flow index (MFI) of seven commercial poly(lactic acid) (PLA) grades is investigated in view of 3D printing quality. A threshold value of 10u2005g (10 min)−1 (2.16u2005kg; ISO 1133) is put forward for a successful printing (190–220°C), enabling a fast and practical screening of PLA materials. It is however shown that a sole focus on MFI is insufficient, as the plasticiser type and crystallinity also play a role after the polymer melt deposition. The latter is supported by scanning electron micromorphology and differential scanning calorimetry measurements. In particular, blending with poly(hydroxyl butyrate) (PHB; 20u2005m%) allows to control both MFI and crystallinity without the need for annealing.

Long-term stability of cellulose acetate butyrate thin films for nuclear certified reference materials

Characterization of cellulose acetate butyrate (CAB) thin films with 17, 35 and 52 wt% butyryl is carried out to select the most suitable matrix material for the U and Pu containing large-sized dried spike reference material. The virgin CAB samples were aged by vibrations, heat, humidity, UV light and X-rays. Characterization was done by thermo-analytical techniques, gel permeation chromatography, mechanical tests and via Rayleigh and Compton scattering. The results show that CAB with lower butyryl content can withstand higher operational temperatures and has greater mechanical strength while CAB with higher butyryl content seems to be more resistant to radiation.

3D Printing on Textiles: Testing of Adhesion

3D printing on textiles is a possible future application for mass customization of textile products. In this paper nwe investigate three test methods to quantify the adhesion of 3D printed PLA parts to a textile substrate. The first nproposed test method is a perpendicular tensile test, the second is a shear test, and the third is a peel test. These nthree tests are used to characterise the adhesion of a 3D printed shape on six different textile substrates. The test nmethods are compared and it is shown how they can help in standardizing the research of 3D printing on textiles.

Facile and low-cost route for sensitive stretchable sensors by controlling kinetic and thermodynamic conductive network regulating strategies

Highly sensitive conductive polymer composites (CPCs) are designed employing a facile and low-cost extrusion manufacturing process for both low- and high-strain sensing in the field of, for example, structural health/damage monitoring and human body movement tracking. Focus is on the morphology control for extrusion-processed carbon black (CB)-filled CPCs, utilizing binary and ternary composites based on thermoplastic polyurethane (TPU) and olefin block copolymer (OBC). The relevance of the correct CB amount, kinetic control through a variation of the compounding sequence, and thermodynamic control induced by annealing is highlighted, considering a wide range of experimental (e.g., static and dynamic resistance/scanning electron microscopy/rheological measurements) and theoretical analyses. High CB mass fractions (20 m %) are needed for OBC (or TPU)-CB binary composites but only lead to an intermediate sensitivity as their conductive network is fully packed and therefore difficult to be truly destructed. Annealing is needed to enable a monotonic increase of the relative resistance with respect to strain. With ternary composites, a much higher sensitivity with a clearer monotonic increase results, provided that a low CB mass fraction (10-16 m %) is used and annealing is applied. In particular, with CB first dispersed in OBC and annealing, a less compact, hence, brittle conductive network (10-12 m % CB) is obtained, allowing high-performance sensing.