Optimization of Filler Compositions of Electrically Conductive Polypropylene Composites for the Manufacturing of Bipolar Plates

In this research, polypropylene (PP)-graphite composites were prepared using the melt mixing technique in a twin-screw extruder. Graphite, multi-walled carbon nanotubes (MWCNT), carbon black (CB), and expanded graphite (EG) were added to the PP in binary, ternary, and quaternary formations. The graphite was used as a primary filler, and MWCNT, CB, and EG were added to the PP-graphite composites as secondary fillers at different compositions. The secondary filler compositions were considered the control input factors of the optimization study. A full factorial design of the L-27 Orthogonal Array (OA) was used as a Design of Experiment (DOE). The through-plane electrical conductivity and flexural strength were considered the output responses. The experimental data were interpreted via Analysis of Variance (ANOVA) to evaluate the significance of each secondary filler. Furthermore, statistical modeling was performed using response surface methodology (RSM) to predict the properties of the composites as a function of filler composition. The empirical model for the filler formulation demonstrated an average accuracy of 83.9% and 93.4% for predicting the values of electrical conductivity and flexural strength, respectively. This comprehensive experimental study offers potential guidelines for producing electrically conductive thermoplastic composites for the manufacturing of bipolar fuel cell plates.

Development, processing and characterization of Polycaprolactone/Nano-Hydroxyapatite/Chitin-Nano-Whisker nanocomposite filaments for additive manufacturing of bone tissue scaffolds

This paper focuses on utilizing the Fused Deposition Modeling (FDM) to manufacture Polycaprolactone/Nano-Hydroxyapatite/Chitin-Nano-Whisker nanocomposite scaffolds and their subsequent characterization for biomedical applications. FDM nanocomposite filaments were manufactured in multiple nanocomposite formulations of Polycaprolactone/Nano-Hydroxyapatite (nHA), Polycaprolactone/Chitin-Nano-Whisker (CNW), and Polycaprolactone/nHA/CNW using a green method. The FDM processing conditions were optimized using Taguchi orthogonal array method. The mechanical, biodegradation, and biocompatibility properties of the bone tissue scaffolds were assessed. A preosteoblast mouse bone cell line was used for cell proliferation and attachment assays. The results indicated that CNW content in the filaments slightly increases the mechanical properties of the 3D printed parts, and the nanocomposite with 3% CNW content exhibited significant improvement in the cell proliferation and attachment properties of the scaffolds. The nHA content considerably improved the mechanical properties of the scaffolds. The nHA and CNW nanofillers increased the biodegradation rate of PCL. In general, considering all types of responses, a green manufactured nanocomposite of PCL/nHA/CNW can significantly increase the biological and mechanical properties of the 3D printed products for bone tissue scaffolds.

Enhancing the accuracy and efficiency of characterizing polymeric cellular structures using 3D-based computed tomography

Characterizing the morphology of polymeric foams is crucial for determining their practical applicability. The internal cellular structure of polymeric foams is typically analyzed by 2 D imaging techniques, such as Scanning Electron Microscopy (SEM) and optical microscopy. The problem with these techniques is that their tests are tedious, destructive, and the accuracy of the obtained results is questionable. The objective of this paper is to establish and experimentally verify an efficient 3- dimensional (3 D) Microcomputed-tomography based methodology for reliably estimating and characterizing each of the phases commonly present in multiple types of polymeric foam samples, such as the open, the closed, and the solid phase. A comparative study was carried out between morphology data obtained from 2-dimensional (2 D) analysis and those obtained from 3 D analysis to investigate the reliability of the 2 D analysis results. In this context, the experimental results revealed that by using a 2 D method the open porosity was underestimated at the expense of closed porosity, which in turn was overestimated, while the total porosity was not impacted. Also, visualization of the internal structure of polymer foams by using Micro-CT provides details about the 3 D space which cannot be obtained from SEM images. The analysis of foamed specimen demonstrated that the polymeric foam phases extracted from Micro-CT images were in agreement with the experimentally measured values of total porosity of the samples. In an effort to reduce computational requirements, the effects of reducing data size on the accuracy of results has also been studied by averaging image pixels in 3 D space and the results were compared for multiple types of foam structures. This method reduced the processing time considerably, and yielded comparable porosity values. However, the number of detected pores were lowered due to the inability of this method to detect very small cells after 3 D averaging of image pixels.

Morphological Analysis of Foamed HDPE/LLDPE Blends by X-ray Micro-Tomography: Effect of Blending, Mixing Intensity and Foaming Temperature

Non-invasive x-ray micro-computed tomography was employed for thorough quantitative and qualitative analysis of the cellular structure of foams made of linear low density polyethylene (LLDPE), high density polyethylene (HDPE) and their blends. Special emphasis was given to the differences between the results of 3D and 2D analyses, to evaluate the possible errors while studying the morphology using conventional 2D techniques (e.g. SEM). Blends with the weight compositions of 90%LLDPE/10%HDPE and 75%LLDPE/25%HDPE were produced at different rotor speeds of 10, 60 and 120 rpm and batch foaming was examined over a wide range of temperature. The void fraction values from 2D and 3D analysis were found to agree well with those obtained with the Archimedes method. Results showed more uniform cell size distribution for blends mixed at the lower spectrum of screw rotational speed. Among the blends with higher void fraction values and relatively uniform cellular structure, higher average cell size (3–30%) and cell population density (1.25–2.5 times) were noticed in 3D analysis compared with 2D data. The micro-CT images at different cross sections revealed anisotropic cell growth and more elongated cells along the thickness of the specimen. It was also observed that, with increase in foaming temperature, cell shrink prevailed over cell coalescence in the samples with lower viscosity (prepared at low rpm of 10), while for those with higher viscosity (prepared at an rpm of 60) cell coalescence was more dominant.

Manufacture of Integral Skin PP Foam Composites in Rotational Molding

The feasibility of applying the single-charge rotational foam molding processing principle to the fabrication of integral skin polypropylene (PP) foams comprising a PP solid skin and a PP foamed core is investigated in this study. A systematic process interruption and sample evaluation approach was used to quantify the experimental results and explore possibilities for improving the process control strategies to ultimately achieve a desired homogeneity and thickness uniformity of the solid PP skin layer that would be fully encapsulating the PP foamed core of a desired cell population density and average cell size. The experimental results revealed that this is quite a challenging task, not only because of the well-known intrinsically poor foaming nature of PP due to its low melt strength at elevated temperatures, but also because, in single-charge rotational molding, the processing parameters are often conflicting with each other and therefore, have to be optimized within a very narrow processing window. However, simultaneous, single-charge, quality PP integral skin and foamed PP core formation in rotational foam molding is feasible. Optimizing the heating profile, heating rate, heating time, and the mold rotational speed as well as careful selection of PP resins (or resin blends), chemical blowing agents (CBA), and their composition formulations is strongly recommended.

Fundamental Study of CBA-blown Bubble Growth and Collapse Under Atmospheric Pressure

This article focuses on gaining a fundamental understanding of the bubble growth and collapse phenomena in a chemical blowing agent (CBA)based foaming process under atmospheric pressure. The behavior of CBA-blown bubbles exposed to various processing conditions is observed using a hot-stage optical microscope-based image processing system. A mathematical model that accounts for the effects of diffusion, surface tension, viscosity, and elasticity has been employed. It has been found that the processing temperature, diffusivity, and gas bulk concentration have dominant effects on the life span of CBA-blown bubbles.

Single-Step Rotational Foam Molding of Skin-Surrounded Polyethylene Foams

This paper demonstrates howthe rotational foam molding process can be employed for the manufacture of plastic articles that have a distinct layer of nonfoamed skin surrounding a foamed core or layer. It is focused on the singlestep processing principle, the main feature of which is the simultaneous introduction of both the foamable and nonfoamable resin into the cavity of the mold at the beginning of the cycle. Although this advanced concept eliminates the need for process interruptions and the use of drop boxes or plastic bags, it requires an appropriate processing strategy that would assure that the execution of the adhesion of the nonfoamable thermoplastic resin to the internal surface of the mold always takes place prior to the activation of the foamable resin.

A Novel System Design for Continuous Processing of Plastic/Wood-Fiber Composite Foams with Improved Cell Morphology

It is believed that the moisture that is inherently present in nondried wood-fibers adversely affects the cell morphology of plastic/wood-fiber composite foams processed in extrusion. Based on this hypothesis, achieving a continuous extrusion-based production of fine-celled plastic/wood-fiber composite foams witha desirable quality would be strongly conditioned by the efficiency of the system designed for uninterrupted wood-fiber moisture elimination. This paper presents an innovative approachin addressing this problem by implementing the well-known cascade devolatilizing system in a chemical blowing agent (CBA) based production of plastic/wood-fiber composite foams. It comprises a moisture-evaporation tandem extrusion system equipped witha vent at the interconnection of the two extruders to serve for purging the moisture in the atmosphere. In order to check the performance of the newly developed system, an experimental study has been carried out for comparing the cell morphology and the volume expansion ratios of the foams obtained by processing identically formulated foamable plastic/wood-fiber composite mixtures using simultaneously the cascade devolatilizing tandem extrusion system and a corresponding single extruder withno vent. The experimental results revealed that the foams produced by using the cascade devolatilizing tandem system exhibited significantly improved cell morphologies and surface quality.

Manufacturability of Fine-Celled Cellular Structures in Rotational Foam Molding

Any closed-cell polyolefin foam production tends to achieve the highest possible cell size distribution uniformity, cell size reduction, and cell density augmentation. However, the control of the cell size of rotationally foam-molded cellular structures formed on the base of a chemical blowing agent (CBA) might be often aggravated by some inherent limitations that are unique to the rotational molding process, which results in coarser-celled final cellular structures. Although a fine-celled morphology (cell size<100 [mm] and cell density > 106 [cells/cm3]) in rotationally molded foams has been closely approached, it has not been actually achieved yet, nor has it been ever clarified whether it is actually achievable in rotational foam molding or not. This study attempts to provide an answer to this fundamental question by focusing on the understanding of the mechanisms governing the formation, growth, shrinkage, and collapse of CBA-blown bubbles in nonpressurized polymer melts originating from extrusion melt compounded foamable resins in a pellet form.