Effect of Mold Temperature on the Impact Behavior and Morphology of Injection Molded Foams Based on Polypropylene Polyethylene⁻Octene Copolymer Blends

A Design of Experiment Approach for Surface Roughness Comparisons of Foam Injection-Moulding Methods

The pursuit of polymer parts produced through foam injection moulding (FIM) that have a comparable surface roughness to conventionally processed components are of major relevance to expand the application of FIM. Within this study, 22% talc-filled copolymer polypropylene (PP) parts were produced through FIM using both a physical and chemical blowing agent. A design of experiments (DoE) was performed whereby the processing parameters of mould temperatures, injection speeds, back-pressure, melt temperature and holding time were varied to determine their effect on surface roughness, Young’s modulus and tensile strength. The results showed that mechanical performance can be improved when processing with higher mould temperatures and longer holding times. Also, it was observed that when utilising chemical foaming agents (CBA) at low-pressure, surface roughness comparable to that obtained from conventionally processed components can be achieved. This research demonstrates the potential of FIM to expand to applications whereby weight saving can be achieved without introducing surface defects, which has previously been witnessed within FIM.

Foams with Enhanced Ductility and Impact Behavior Based on Polypropylene Composites

In this work, formulations based on composites of a linear polypropylene (L-PP), a long-chain branched polypropylene (LCB-PP), a polypropylene-graft-maleic anhydride (PP-MA), a styrene-ethylene-butylene-styrene copolymer (SEBS), glass fibers (GF), and halloysite nanotubes (HNT-QM) have been foamed by using the improved compression molding route (ICM), obtaining relative densities of about 0.62. The combination of the inclusion of elastomer and rigid phases with the use of the LCB-PP led to foams with a better cellular structure, an improved ductility, and considerable values of the elastic modulus. Consequently, the produced foams presented simultaneously an excellent impact performance and a high stiffness with respect to their corresponding solid counterparts.

Crystalline Modification of Isotactic Polypropylene with a Rare Earth Nucleating Agent Based on Ultrasonic Vibration

In this paper, the crystalline modification of isotactic polypropylene (PP) with a rare earth β nucleating agent (WBG) with different ultrasound conditions was investigated by scanning electron microscopy (SEM), wide-angle X-ray diffraction (XRD), and differential scanning calorimetry (DSC). The relationship between the ultrasound conditions and the crystalline structure, as well as the mechanism for the behavior, were revealed. SEM showed that the dispersion of the nucleating agent in the PP matrix was better at shorter ultrasound distances. In addition, the higher the water cooling temperature, the better the nucleating agent was dispersed in the PP matrix. The results of XRD and DSC showed that the crystallinity and the relative content of the β-crystal were increased with nearer ultrasound distance, as well as increased in higher water cooling temperatures. In particular, under the same conditions, the crystallinity and the relative content of the β-crystal after ultrasonic treatment were much higher than those without ultrasound.

Analysis of Thermomechanical Properties of Selected Class of Recycled Thermoplastic Materials Based on Their Applications

Polypropylene and polystyrene are petroleum-based thermoplastics which are commonly used and disposed of in the environment after their service life, leading to environmental degradation. There is a need to recycle polypropylene and polystyrene, but the effect of recycling on thermo-mechanical properties is not well understood. This study aims to determine thermo-mechanical properties of the recycled polypropylene and recycled polystyrene and compare them with corresponding virgin polypropylene and newly produced polystyrene (general purpose polystyrene 1540 and high impact polystyrene 7240). The study was carried out by preparing bar-shaped samples of recycled polypropylene, recycled polystyrene, general purpose polystyrene 1540, and high impact polystyrene 7240 by compression molding using a hot press and thermally characterizing them to determine glass transition temperature and melting temperature using differential scanning calorimetry. The changes in Young’s modulus, tensile strength, hardness, and toughness due to recycling activities were determined at room temperature (24 °C), 40 °C, 60 °C, and 80 °C. The thermo-mechanical properties of recycled polystyrene (PS) were found to be comparable to those of high impact polystyrene (HIPS) 7240. The study revealed that the hardness and toughness for the recycled polymers were higher than those of corresponding virgin polymers. On the other hand, tensile strength and Young’s modulus for the recycled polymers were lower than those of the virgin polymers. Understanding the thermo-mechanical properties of the recycled polymers will contribute to more industrial applications hence increase the rate of recycling, resulting in a reduction in environmental pollution.