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Sample records for shot injection molding

  1. Interface conditions of two-shot molded parts

    SciTech Connect

    Kisslinger, Thomas; Bruckmoser, Katharina Resch, Katharina; Lucyshyn, Thomas E-mail: guenter.langecker@unileoben.ac.at; Langecker, Guenter Ruediger E-mail: guenter.langecker@unileoben.ac.at; Holzer, Clemens

    2014-05-15

    The focus of this work is on interfaces of two-shot molded parts. It is well known that e.g. material combination, process parameters and contact area structures show significant effects on the bond strength of multi-component injection molded parts. To get information about the bond strength at various process parameter settings and material combinations a test mold with core back technology was used to produce two-component injection molded tensile test specimens. At the core back process the different materials are injected consecutively, so each component runs through the whole injection molding cycle (two-shot process). Due to this consecutive injection molding processes, a cold interface is generated. This is defined as overmolding of a second melt to a solidified polymer preform. Strong interest lies in the way the interface conditions change during the adhesion formation between the individual components. Hence the interface conditions were investigated by computed tomography and Raman spectroscopy. By analyzing these conditions the understanding of the adhesion development during the multi-component injection molding was improved.

  2. INJECTION-MOLDING APPARATUS

    DOEpatents

    Lobell, G.M.

    1958-02-11

    This patent is drawn to an injection molding apparatus for producing a tube closed at one end wherein the normally unsupported end of the core located in the cavity during the injection of the molten material to fill the space between the core and cavity wall, which supporting means is automatically removed from operation during the forming of the closed end of the tube. This support means is a plug extending through the end of the core into a recess in the bottom of the cavity where the closed end of the tube is to be formed. The plug is spring pressed into said recess and is forced out of the recess by a slidable bushing at the top of the cavity which is moved against the force of the spring by the molten material when it fills the uppormost open end portion of the cavity, thereby permitting the closed end of the tube to be formed.

  3. Low-pressure injection molding

    SciTech Connect

    Mangels, J.A. )

    1994-05-01

    Ceramic injection molding experienced a revival in the 1970s and 1980s with the application of ceramics for gas turbine components. Concurrently, techniques were being developed for the injection molding of powdered metal compositions into complex shaped articles. The impetus for the development of injection molding as a ceramic fabrication process lay in the potential to produce complex-shaped components to near-net shape. In the ceramic injection molding process, ceramic powders are processed to obtain the desired particle size, distribution and morphology and blended to obtain a homogeneous distribution. These powders are then mixed with the organic binders, generally in a heated, highshear mixer at temperatures above the melting point of the organic binders. The injection molding mix is pelletized, cooled and fed into an injection molding machine. The molding mix is reheated to a fluid state and injected under high pressure (7--70 MPa) into a die cavity. The molded part is removed from the tooling after the molding mix has solidified in the die. The organic binders are then removed from the component at temperatures up to 400 C, generally by some combination of wicking and thermal decomposition. Finally, the component is sintered to obtain its final ceramic properties, using conventional ceramic processes.

  4. Ceramic injection molding material analysis, modeling and injection molding simulation

    NASA Astrophysics Data System (ADS)

    Drummer, D.; Messingschlager, S.

    2014-05-01

    In comparison to unfilled polymers, a ceramic feedstocks has a very high viscosity, a very high heat conductivity and a different pvT-behavior. So far standard simulation tools for plastic injection molding are capable of simulating unfilled or fiber filled compounds with their typical low viscosity and heat conductivity etc. but not for very high ceramic powder filled polymers. This article shows an approach of preparing and adding ceramic feedstocks to standard injection molding tools. Two different feedstocks are used.

  5. Injection Molding of Plastics from Agricultural Materials

    SciTech Connect

    Bhattacharya, M.; Ruan, R.

    2001-02-22

    The objective of this research was to conduct a systematic study to relate injection molding parameters to properties of blends of starch and synthetic polymer. From this study, we wished to develop a thorough understanding of the injection molding process and gain significant insight into designing molds and aiding in developing products cheaply and efficiently.

  6. Injection molding ceramics to high green densities

    NASA Technical Reports Server (NTRS)

    Mangels, J. A.; Williams, R. M.

    1983-01-01

    The injection molding behavior of a concentrated suspension of Si powder in wax was studied. It was found that the injection molding behavior was a function of the processing techniques used to generate the powder. Dry ball-milled powders had the best molding behavior, while air classified and impact-milled powders demonstrated poorer injection moldability. The relative viscosity of these molding batches was studied as a function of powder properties: distribution shape, surface area, packing density, and particle morphology. The experimental behavior, in all cases, followed existing theories. The relative viscosity of an injection molding composition composed of dry ball-milled powders could be expressed using Farris' relation.

  7. Porous media heat transfer for injection molding

    DOEpatents

    Beer, Neil Reginald

    2016-05-31

    The cooling of injection molded plastic is targeted. Coolant flows into a porous medium disposed within an injection molding component via a porous medium inlet. The porous medium is thermally coupled to a mold cavity configured to receive injected liquid plastic. The porous medium beneficially allows for an increased rate of heat transfer from the injected liquid plastic to the coolant and provides additional structural support over a hollow cooling well. When the temperature of the injected liquid plastic falls below a solidifying temperature threshold, the molded component is ejected and collected.

  8. Planning an Injection Mold Design Training Program.

    ERIC Educational Resources Information Center

    Allyn, Edward P.

    With the increased use of plastics worldwide the shortage of trained personnel in moldmaking and design for plastic injection molds is becoming critical. Local schools and community colleges should provide courses in mold design and mold making, since most workers presently learn while working under experienced designers on the job. Following this…

  9. Two-component co-injection and transfer molding and gas-assisted injection molding of polymers: Simulation and experiment

    NASA Astrophysics Data System (ADS)

    Li, Chengtao

    Two-component molding is a novel process for manufacturing polymer products with a sandwich structure or a hollow structure. Typically, two different materials are injected or transferred into a mold sequentially or simultaneously. The skin is generally a prime polymer with required surface and bulk properties for intended use. The core can be solid, foam or gas. Obtaining a uniform encapsulated structure is difficult and there are no science-based rules for optimization of process setup. Thus, a physical model and process simulations have been developed based on the kinematics and dynamics of a moving interface, and Hele-Shaw approximation. The model has incorporated temperature and shear rate dependences of viscosity of both skin and core component into the transient interface evolution. Based on the developed model, simulations have been carried out to study flow rate controlled simultaneous co-injection molding of thermoplastics, pressure-controlled sequential transfer molding of rubber compounds, and gas-assisted injection molding (GAIM). The simulation results were compared with the experimental data, and in general, good agreement was found between the predicted and experimentally measured interface distribution in moldings. For simultaneous co-injection molding, it is found that material pairs with a broad range of viscosities may be utilized. Breakthrough phenomena are mainly determined by the volume of melt of initial single phase injection and rheological properties of material combinations. When the core has a lower viscosity than the skin, or the volume of initial injection of skin melt is smaller, breakthrough is very likely. However, the breakthrough can be eliminated by controlling injection rate of the skin and core melts. For sequential transfer molding, it is found that the rubber distribution in moldings are dominated by the rheological properties of components and the volume fraction transferred, but independent of the gate pressure. When the

  10. Particle Image Velocimetry During Injection Molding

    NASA Astrophysics Data System (ADS)

    Bress, Thomas; Dowling, David

    2012-11-01

    Injection molding involves the unsteady non-isothermal flow of a non-Newtonian polymer melt. An optical-access mold has been used to perform particle image velocimetry (PIV) on molten polystyrene during injection molding. Velocimetry data of the mold-filling flow will be presented. Statistical assessments of the velocimetry data and scaled residuals of the continuity equation suggest that PIV can be conducted in molten plastics with an uncertainty of +/-2 percent. Simulations are often used to model polymer flow during injection molding to design molds and select processing parameters but it is difficult to determine the accuracy of these simulations due to a lack of in-mold velocimetry and melt-front progression data. Moldflow was used to simulate the filling of the optical-access mold, and these simulated results are compared to the appropriately-averaged time-varying velocity field measurements. Simulated results for melt-front progression are also compared with the experimentally observed flow fronts. The ratio of the experimentally measured average velocity magnitudes to the simulation magnitudes was found on average to be 0.99 with a standard deviation of 0.25, and the difference in velocity orientations was found to be 0.9 degree with a standard deviation of 3.2 degrees. formerly at the University of Michigan.

  11. Rapid control of mold temperature during injection molding process

    NASA Astrophysics Data System (ADS)

    Liparoti, Sara; Hunag, Tsang Min; Sorrentino, Andrea; Titomanlio, Giuseppe; Cakmak, Mukerrem

    2015-05-01

    The control of mold surface temperature is an important factor that determines surface morphology and its dimension in thickness direction. It can also affect the frozen molecular orientation and the mold surface replicability in injection molded products. In this work, thin thermally active films were used to quickly control the mold surface temperature. In particular, an active high electrical conductivity carbon black loaded polyimide composites sandwiched between two insulating thin polymeric layers was used to condition the mold surface. By controlling the heating time, it was possible to control precisely the temporal variation of the mold temperature surface during the entire cycle. The surface heating rate was about 40°C/s and upon contact with the polymer the surface temperature decreased back to 40°C within about 5 s; the overall cycle time increased only slightly. The effect on cross section sample morphology of samples of iPP were analyzed and discussed on the basis of the recorded temperature evolution.

  12. Rapid control of mold temperature during injection molding process

    SciTech Connect

    Liparoti, Sara; Titomanlio, Giuseppe; Hunag, Tsang Min; Cakmak, Mukerrem; Sorrentino, Andrea

    2015-05-22

    The control of mold surface temperature is an important factor that determines surface morphology and its dimension in thickness direction. It can also affect the frozen molecular orientation and the mold surface replicability in injection molded products. In this work, thin thermally active films were used to quickly control the mold surface temperature. In particular, an active high electrical conductivity carbon black loaded polyimide composites sandwiched between two insulating thin polymeric layers was used to condition the mold surface. By controlling the heating time, it was possible to control precisely the temporal variation of the mold temperature surface during the entire cycle. The surface heating rate was about 40°C/s and upon contact with the polymer the surface temperature decreased back to 40°C within about 5 s; the overall cycle time increased only slightly. The effect on cross section sample morphology of samples of iPP were analyzed and discussed on the basis of the recorded temperature evolution.

  13. Powder Injection Molding of Titanium Components

    SciTech Connect

    Simmons, Kevin L.; Nyberg, Eric A.; Weil, K. Scott; Miller, Megan R.

    2005-01-01

    Powder injection molding (PIM) is a well-established, cost-effective method of fabricating small-to-moderate size metal components. Derived from plastic injection molding and employing a mixture of metal powder and plastic binder, the process has been used with great success in manufacturing a wide variety of metal products, including those made from stainless steel, nickel-based superalloys, and copper alloys. Less progress has been achieved with titanium and other refractory metal alloys because of problems with alloy impurities that are directly attributable to the injection molding process. Specifically, carbon, oxygen, and nitrogen are left behind during binder removal and become incorporated into the chemistry and microstructure of the material during densification. Even at low concentration, these impurities can cause severe degradation in the mechanical properties of titanium and its alloys. We have developed a unique blend of PIM constituents where only a small volume fraction of binder (~5 – 10 vol%) is required for injection molding; the remainder of the mixture consists of the metal powder and binder solvent. Because of the nature of decomposition in the binder system and the relatively small amount used, the binder is eliminated almost completely from the pre-sintered component during the initial stage of a two-step heat treatment process. Results will be presented on the first phase of this research, in which the binder, injection molding, de-binding and sintering schedule were developed. Additional data on the mechanical and physical properties of the material produced will be discussed.

  14. Dynamic Feed Control For Injection Molding

    DOEpatents

    Kazmer, David O.

    1996-09-17

    The invention provides methods and apparatus in which mold material flows through a gate into a mold cavity that defines the shape of a desired part. An adjustable valve is provided that is operable to change dynamically the effective size of the gate to control the flow of mold material through the gate. The valve is adjustable while the mold material is flowing through the gate into the mold cavity. A sensor is provided for sensing a process condition while the part is being molded. During molding, the valve is adjusted based at least in part on information from the sensor. In the preferred embodiment, the adjustable valve is controlled by a digital computer, which includes circuitry for acquiring data from the sensor, processing circuitry for computing a desired position of the valve based on the data from the sensor and a control data file containing target process conditions, and control circuitry for generating signals to control a valve driver to adjust the position of the valve. More complex embodiments include a plurality of gates, sensors, and controllable valves. Each valve is individually controllable so that process conditions corresponding to each gate can be adjusted independently. This allows for great flexibility in the control of injection molding to produce complex, high-quality parts.

  15. The research of UV curing injection molding

    NASA Astrophysics Data System (ADS)

    Xie, Pengcheng; Chang, Le; Song, Le; Cai, Tianze; Ding, Yumei; Yang, Weimin

    2015-05-01

    The micro-injection molding technology and the UV (ultraviolet) curing technique are combined to bring about a new plastic forming method, UV curing injection molding. The mean weight of micro-product is an important process characteristic for UV curing injection molding as well as the surface quality of micro-features is another important process characteristic for this new plastic forming method. This research investigates three effects of processing factors on the mass-change rate of micro-product and the surface quality of micro-features. In every particular, the following two factors are considered: UV material system temperature and the packing pressure. The study revealed that as usual, the micro-products gain weight with the imported increasing UV material system temperature and the improved packing pressure. Meanwhile, the increasing packing pressure also improves the surface quality, yet, warming the UV system temperature up has no effect on the quality of the product.

  16. Nanostructuring steel for injection molding tools

    NASA Astrophysics Data System (ADS)

    Al-Azawi, A.; Smistrup, K.; Kristensen, A.

    2014-05-01

    The production of nanostructured plastic items by injection molding with ridges down to 400 nm in width, which is the smallest line width replicated from nanostructured steel shims, is presented. Here we detail a micro-fabrication method where electron beam lithography, nano-imprint lithography and ion beam etching are combined to nanostructure the planar surface of a steel wafer. Injection molded plastic parts with enhanced surface properties, like anti-reflective, superhydrophobic and structural colors can be achieved by micro- and nanostructuring the surface of the steel molds. We investigate the minimum line width that can be realized by our fabrication method and the influence of etching angle on the structure profile during the ion beam etching process. Trenches down to 400 nm in width have been successfully fabricated into a 316 type electro-polished steel wafer. Afterward a plastic replica has been produced by injection molding with good structure transfer fidelity. Thus we have demonstrated that by utilizing well-established fabrication techniques, nanostructured steel shims that are used in injection molding, a technique that allows low cost mass fabrication of plastic items, are produced.

  17. Analysis of cavity pressure and warpage of polyoxymethylene thin walled injection molded parts: Experiments and simulations

    NASA Astrophysics Data System (ADS)

    Guerrier, P.; Tosello, G.; Hattel, J. H.

    2015-05-01

    Process analysis and simulations on molding experiments of 3D thin shell parts have been conducted. Moldings were carried out with polyoxymethylene (POM). The moldings were performed with cavity pressure sensors in order to compare experimental process results with simulations. The warpage was characterized by measuring distances using a tactile coordinate measuring machine (CMM). Molding simulations have been executed taking into account actual processing conditions. Various aspects have been considered in the simulation: machine barrel geometry, injection speed profiles, cavity injection pressure, melt and mold temperatures, material rheological and pvT characterization. Factors investigated for comparisons were: injection pressure profile, short shots length, flow pattern, and warpage. A reliable molding experimental database was obtained, accurate simulations were conducted and a number of conclusions concerning improvements to simulation accuracy are presented regarding: pvT data, mesh, short shots, cavity pressure for process control validation as well as molding machine geometry modelling. Eventually, a methodology for improved molding simulations of cavity injection pressure, filling pattern and warpage was established.

  18. Effects of polymer melt compressibility on mold filling in micro-injection molding

    NASA Astrophysics Data System (ADS)

    Nguyen, Q. M. P.; Chen, X.; Lam, Y. C.; Yue, C. Y.

    2011-09-01

    In conventional injection molding, the molten polymer in the filling stage is generally assumed to be incompressible. However, this assumption may not be valid in micro-injection molding, since high injection pressure is normally required to avoid short shots. This paper presents both numerical and experimental investigations on the effects of polymer melt compressibility on mold filling into a micro-thickness impression. The study was conducted on six different part thicknesses ranging from 920 to 370 µm. A high-flow COC TOPAS 5013L-10 polymer was chosen as the TOPAS family has recently attracted significant interest for its use in microfluidic applications. A combined finite element/finite difference/control volume approach was adopted to simulate the compressible flow. The shear viscosity of a polymer melt was characterized by the Cross-WLF model, while the melt compressibility was modeled with a double-domain Tait equation. The results obtained indicated that the compressibility of the polymer melt has significant effects on impression pressure and density distribution in the fully filled part with thickness smaller than 620 µm and that the effects become more pronounced with a decrease in part thickness.

  19. Injection molding and debinding of micro gears fabricated by micro powder injection molding

    NASA Astrophysics Data System (ADS)

    Ni, Xin-lei; Yin, Hai-qing; Liu, Lin; Yi, Shan-jie; Qu, Xuan-hui

    2013-01-01

    Micro powder injection molding (μPIM) was investigated for possible mass production of micro-components at relatively low cost. However, scaling down to such a level produces challenges in injection molding and debinding. Micro gears were fabricated by μPIM from in-house feedstock. The effect of injection speed and injection pressure on the replication of the micro gear cavity was investigated. Solvent debinding and thermal debinding processes were discussed. The results show that micro gears can be successfully fabricated under the injection pressure of 70 MPa and the 60% injection speed. Either too low or too high injection speed can cause incomplete filling of micro gears. The same is the case with too low injection pressure. Too high injection pressure can bring cracks. Solvent debinding of micro gears was performed in a mixture of petroleum ether and ethanol. Subsequently, micro gears were successfully debound by a multistep heating schedule.

  20. Research in manufacturing of micro-structured injection molded polymer parts

    NASA Astrophysics Data System (ADS)

    Lucyshyn, Thomas; Struklec, Tobias; Burgsteiner, Martin; Graninger, Georg; Holzer, Clemens

    2015-12-01

    An overview of current research results is given for the topic of injection molding of micro-structured polymer parts regarding filling behavior and demolding process of micro-structures as well as the production of micro-structures on curved surfaces. In order to better understand how micro-structures are formed during the filling stage of injection molding, a study was performed on a test part with micro-channels placed parallely and perpendicularly to flow direction. Short shots with a highly fluent Polypropylene grade were injection molded with the melt front stopping in the structure fields. The melt and mold temperature, the injection rate as well as the use of a variotherm heating system were varied in a systematic Design of Experiments. The shape of the flow front was investigated with the optical measurement system Alicona InfiniteFocus. The data gained was analyzed with Matlab scripts and provided the needed distance to completely fill the structures as a reference value. The next topic covers the demolding step, which is a crucial process step in injection molding of micro-structured parts as the successfully replicated structures often get destroyed in the following demolding step. In order to evaluate the influence of the four aspects polymer, mold surface (coatings), structure (geometry and placement) and process settings on the demolding behavior, an injection mold with integrated measurement system was built, which makes it possible to measure the demolding force respectively a demolding energy under process conditions. These values can be used to quantitatively compare the impact of the above mentioned influencing factors on demolding. Finally, a concept to produce micro-structures on curved surfaces with injection molding is shown: A flat metal premaster structure is used to produce an elastomeric polymer (dimethylsiloxane) master in a casting process. This master is fixed in a conventional injection mold and a thermoplastic polymer is replicated

  1. Molecular orientation distributions during injection molding of liquid crystalline polymers: Ex situ investigation of partially filled moldings

    SciTech Connect

    Fang, Jun; Burghardt, Wesley R.; Bubeck, Robert A.

    2013-01-10

    The development of molecular orientation in thermotropic liquid crystalline polymers (TLCPs) during injection molding has been investigated using two-dimensional wide-angle X-ray scattering coordinated with numerical computations employing the Larson-Doi polydomain model. Orientation distributions were measured in 'short shot' moldings to characterize structural evolution prior to completion of mold filling, in both thin and thick rectangular plaques. Distinct orientation patterns are observed near the filling front. In particular, strong extension at the melt front results in nearly transverse molecular alignment. Far away from the flow front shear competes with extension to produce complex spatial distributions of orientation. The relative influence of shear is stronger in the thin plaque, producing orientation along the filling direction. Exploiting an analogy between the Larson-Doi model and a fiber orientation model, we test the ability of process simulation tools to predict TLCP orientation distributions during molding. Substantial discrepancies between model predictions and experimental measurements are found near the flow front in partially filled short shots, attributed to the limits of the Hele-Shaw approximation used in the computations. Much of the flow front effect is however 'washed out' by subsequent shear flow as mold filling progresses, leading to improved agreement between experiment and corresponding numerical predictions.

  2. Thermal monitoring of the thermoplastic injection molding process with FBGs

    NASA Astrophysics Data System (ADS)

    Alberto, Nélia J.; Nogueira, Rogério N.; Neto, Victor F.

    2014-08-01

    Injection molding is an important polymer processing method for manufacturing plastic components. In this work, the thermal monitoring of the thermoplastic injection molding is presented, since temperature is a critical parameter that influences the process features. A set of fiber Bragg gratings were multiplexed, aiming a two dimensional monitoring of the mold. The results allowed to identify the different stages of the thermoplastic molding cycle. Additionally, the data provide information about the heat transfer phenomena, an important issue for the thermoplastic injection sector, and thus for an endless number of applications that employ this type of materials.

  3. Comparison of injection molding and injection/compression molding for the replication of microstructure

    NASA Astrophysics Data System (ADS)

    Hong, Seokkwan; Hwang, Jeongho; Kang, Jeongjin; Yoon, Kyunghwan

    2015-11-01

    Because of increasing interest in the functional surfaces including micro- or nano-patterns, the mass production of such surfaces has been actively researched. Both conventional injection molding (CIM) and injection/compression molding (ICM) of micro-patterns were investigated in the present study. The molding subject is a multi-scale structure that consists of a macro-scale thin plate and micro-scale patterns formed regularly on its surface. The transcription ratios of micro pattern made by CIM and ICM for different flow length were experimentally measured, and the origin of the obtained results was identified through numerical analysis. It was found that the cavity pressure and polymer temperature are the most important factors for micro-pattern filling; in particular, the polymer temperature is the key factor determining the transcription ratio. It was also found that the difference in CIM and ICM micro-pattern transcription ratios originates from the differences in the cavity pressure history if other molding conditions are the same.

  4. Optomechanical details in injection-molded assemblies

    NASA Astrophysics Data System (ADS)

    Hebert, Raymond T.

    1995-12-01

    With the advent of low-cost electro-optic components such as LEDs, laser diodes and CCD imaging devices, the cost and performance demands now fall upon the optical subsystems in order to achieve realistic marketing targets for many emerging commercial and consumer products. One of the many benefits of injection-molded plastic optics is the diversity of features that are available to the design team. Once designed and incorporated into the tooling, many features are virtually free in high-volume production. These features can include mechanical details as well as optical functions. Registration features can be included for precisely positioning optical elements to one another or to other assemblies such as printed circuit boards or housings. Snaps, compression features, spring-loading elements, standoffs, self-tapping screws or ultrasonically weldable features can greatly facilitate ease of assembly.

  5. Hydrogen silsesquioxane mold coatings for improved replication of nanopatterns by injection molding

    NASA Astrophysics Data System (ADS)

    Hobæk, Thor Christian; Matschuk, Maria; Kafka, Jan; Pranov, Henrik J.; Larsen, Niels B.

    2015-03-01

    We demonstrate the replication of nanosized pillars in polymer (cyclic olefin copolymer) by injection molding using nanostructured thermally cured hydrogen silsesquioxane (HSQ) ceramic coatings on stainless steel mold inserts with mold nanostructures produced by a simple embossing process. At isothermal mold conditions, the average pillar height increases by up to 100% and a more uniform height distribution is observed compared to a traditional metal mold insert. Thermal heat transfer simulations predict that the HSQ film retards the cooling of the polymer melt during the initial stages of replication, thus allowing more time to fill the nanoscale cavities compared to standard metal molds. A monolayer of a fluorinated silane (heptadecafluorotrichlorosilane) deposited on the mold surface reduces the mold/polymer interfacial energy to support demolding of the polymer replica. The mechanical stability of thermally cured HSQ makes it a promising material for nanopattern replication on an industrial scale without the need for slow and energy intensive variotherm processes.

  6. Injection molding of ceramics using a polyacetal based binder system

    SciTech Connect

    Ebenhoech, J.S.

    1996-06-01

    Among the production routes to small complex ceramic parts, powder injection molding is the most attractive alternative. It combines near net shape capability with good surface finish and is easy to automate. With the development of the catalytic debinding process for polyacetal binders, the main impediments for the acceptance of ceramic injection molding as a mass production method can be overcome. The use of this system ensures short molding cycle times, high green strength and fast debinding without deformation. Ready to mold compounds are commercially available for various oxide and non-oxide ceramic materials as well as the equipment needed for this process.

  7. Study on heat flux from resin to mold in injection molding process

    SciTech Connect

    Nishiwaki, Nobuhiko; Hori, Sankei

    1999-07-01

    Recently, an injection molding of thermoplastic is widely used in many industries, because this manufacturing method is very suitable for mass production. For injection molding processes, a number of software packages for simulating an injection molding process have been developed. It is assumed in these software packages that the heat transfer coefficient between the resin and the mold surface is constant at the filling or cooling stages. In general, when melted resin flows into the mold, heat is generated in the flowing resin because of the high viscosity at the filling stage. Moreover at the cooling stage, a separation of the molded part from the mold surface generally occurs because of shrinkage of the molded material. Therefore, the heat transfer coefficient has not been accurately obtained yet at these stages. In this paper, the temperature near the surface of the mold cavity has been experimentally measured, so the heat flux that flows from the resin to the mold has been able to be analytically estimated by an inverse conduction method. On the other hand, the separating behavior of the resin from the mold surface has been measured using an ultrasonic transducer attached to the outer surface of the stationary mold. The heat flux that flows from the resin to the mold has been analytically estimated. The apparent heat transfer coefficient can be obtained from the heat flux and the representative temperature difference, which is measured by an ultrasonic technique. It was discovered that the heat flux and the apparent heat transfer coefficient are hardly influenced by the separation.

  8. Effects of mold geometry on fiber orientation of powder injection molded metal matrix composites

    SciTech Connect

    Ahmad, Faiz Aslam, Muhammad Altaf, Khurram Shirazi, Irfan

    2015-07-22

    Fiber orientations in metal matrix composites have significant effect on improving tensile properties. Control of fiber orientations in metal injection molded metal composites is a difficult task. In this study, two mold cavities of dimensions 6x6x90 mm and 10x20x180 mm were used for comparison of fiber orientation in injection molded metal composites test parts. In both mold cavities, convergent and divergent flows were developed by modifying the sprue dimensions. Scanning electron microscope (SEM) was used to examine the fiber orientations within the test samples. The results showed highly aligned fiber in injection molded test bars developed from the convergent melt flow. Random orientation of fibers was noted in the composites test bars produced from divergent melt flow.

  9. Fabrication of sinterable silicon nitride by injection molding

    NASA Technical Reports Server (NTRS)

    Quackenbush, C. L.; French, K.; Neil, J. T.

    1982-01-01

    Transformation of structural ceramics from the laboratory to production requires development of near net shape fabrication techniques which minimize finish grinding. One potential technique for producing large quantities of complex-shaped parts at a low cost, and microstructure of sintered silicon nitride fabricated by injection molding is discussed and compared to data generated from isostatically dry-pressed material. Binder selection methodology, compounding of ceramic and binder components, injection molding techniques, and problems in binder removal are discussed. Strength, oxidation resistance, and microstructure of sintered silicon nitride fabricated by injection molding is discussed and compared to data generated from isostatically dry-pressed material.

  10. Injection molding simulation with variothermal mold temperature control of highly filled polyphenylene sulfide

    NASA Astrophysics Data System (ADS)

    Birkholz, A.; Tschiersky, M.; Wortberg, J.

    2015-05-01

    For the installation of a fuel cell stack to convert chemical energy into electricity it is common to apply bipolar plates to separate and distribute reaction gases and cooling agents. For reducing manufacturing costs of bipolar plates a fully automated injection molding process is examined. The high performance thermoplastic matrix material, polyphenylene sulfide (PPS), defies against the chemical setting and the operation temperature up to 200 °C. To adjust also high electrical and thermal conductivity, PPS is highly filled with various carbon fillers up to an amount of 65 percentage by volume. In the first step two different structural plates (one-sided) with three different gate heights and molds are designed according to the characteristics of a bipolar plate. To cope with the approach that this plate should be producible on standard injection molding machines with variothermal mold temperature control, injection molding simulation is used. Additionally, the simulation should allow to formulate a quality prediction model, which is transferrable to bipolar plates. Obviously, the basis for a precise simulation output is an accurate description of the material properties and behavior of the highly filled compound. This, the design of the structural plate and mold and the optimization via simulation is presented, as well. The influence of the injection molding process parameters, e.g. injection time, cycle times, packing pressure, mold temperature, and melt temperature on the form filling have been simulated to determine optimal process conditions. With the aid of the simulation and the variothermal mold temperature control it was possible to reduce the required melt temperature below the decomposition temperature of PPS. Thereby, hazardous decomposition products as hydrogen sulfide are obviated. Thus, the health of the processor, the longevity of the injection molding machine as well as the material and product properties can be protected.

  11. Local mechanical properties of LFT injection molded parts: Numerical simulations versus experiments

    NASA Astrophysics Data System (ADS)

    Desplentere, F.; Soete, K.; Bonte, H.; Debrabandere, E.

    2014-05-01

    In predictive engineering for polymer processes, the proper prediction of material microstructure from known processing conditions and constituent material properties is a critical step forward properly predicting bulk properties in the finished composite. Operating within the context of long-fiber thermoplastics (LFT, length < 15mm) this investigation concentrates on the prediction of the local mechanical properties of an injection molded part. To realize this, the Autodesk Simulation Moldflow Insight 2014 software has been used. In this software, a fiber breakage algorithm for the polymer flow inside the mold is available. Using well known micro mechanic formulas allow to combine the local fiber length with the local orientation into local mechanical properties. Different experiments were performed using a commercially available glass fiber filled compound to compare the measured data with the numerical simulation results. In this investigation, tensile tests and 3 point bending tests are considered. To characterize the fiber length distribution of the polymer melt entering the mold (necessary for the numerical simulations), air shots were performed. For those air shots, similar homogenization conditions were used as during the injection molding tests. The fiber length distribution is characterized using automated optical method on samples for which the matrix material is burned away. Using the appropriate settings for the different experiments, good predictions of the local mechanical properties are obtained.

  12. Smart plastic functionalization by nanoimprint and injection molding

    NASA Astrophysics Data System (ADS)

    Zalkovskij, Maksim; Thamdrup, Lasse H.; Smistrup, Kristian; Andén, Thomas; Johansson, Alicia C.; Mikkelsen, Niels Jørgen; Madsen, Morten Hannibal; Garnæs, Jørgen; Kristiansen, Tommy Tungelund; Diemer, Mads; Døssing, Michael; Minzari, Daniel; Tang, Peter Torben; Kristensen, Anders; Taboryski, Rafael; Essendrop, Søren; Nielsen, Theodor; Bilenberg, Brian

    2015-03-01

    In this paper, we present a route for making smart functionalized plastic parts by injection molding with sub-micrometer surface structures. The method is based on combining planar processes well known and established within silicon micro and sub-micro fabrication with proven high resolution and high fidelity with truly freeform injection molding inserts. The link between the planar processes and the freeform shaped injection molding inserts is enabled by the use of nanoimprint with flexible molds for the pattern definition combined with unidirectional sputter etching for transferring the pattern. With this approach, we demonstrate the transfer of down to 140 nm wide holes on large areas with good structure fidelity on an injection molding steel insert. The durability of the sub-micrometer structures on the inserts have been investigated by running two production series of 102,000 and 73,000 injection molded parts, respectively, on two different inserts and inspecting the inserts before and after the production series and the molded parts during the production series.

  13. Research on machine vision system of monitoring injection molding processing

    NASA Astrophysics Data System (ADS)

    Bai, Fan; Zheng, Huifeng; Wang, Yuebing; Wang, Cheng; Liao, Si'an

    2016-01-01

    With the wide development of injection molding process, the embedded monitoring system based on machine vision has been developed to automatically monitoring abnormality of injection molding processing. First, the construction of hardware system and embedded software system were designed. Then camera calibration was carried on to establish the accurate model of the camera to correct distortion. Next the segmentation algorithm was applied to extract the monitored objects of the injection molding process system. The realization procedure of system included the initialization, process monitoring and product detail detection. Finally the experiment results were analyzed including the detection rate of kinds of the abnormality. The system could realize the multi-zone monitoring and product detail detection of injection molding process with high accuracy and good stability.

  14. Mathematical modeling of the process of filling a mold during injection molding of ceramic products

    NASA Astrophysics Data System (ADS)

    Kulkov, S. N.; Korobenkov, M. V.; Bragin, N. A.

    2015-10-01

    Using the software package Fluent it have been predicted of the filling of a mold in injection molding of ceramic products is of great importance, because the strength of the final product is directly related to the presence of voids in the molding, making possible early prediction of inaccuracies in the mold prior to manufacturing. The calculations were performed in the formulation of mathematical modeling of hydrodynamic turbulent process of filling a predetermined volume of a viscous liquid. The model used to determine the filling forms evaluated the influence of density and viscosity of the feedstock, and the injection pressure on the mold filling process to predict the formation of voids in the area caused by the shape defect geometry.

  15. Residual stresses in injection molded products

    NASA Astrophysics Data System (ADS)

    Jansen, K. M. B.

    2015-12-01

    During the molding process residual stresses are formed due to thermal contraction during cooling as well as the local pressure history during solidification. In this paper a simple analytical model is reviewed which relates residual stresses, product shrinkage as well as warpage to the temperature and pressure histories during molding. Precise excimer laser layer removal measurements were performed to verify the predicted residual stress distributions. In addition, detailed shrinkage and warpage measurements on a large series of polymers and for different molding conditions were performed and are shown to compare well with the model predictions.

  16. Residual orientation in micro-injection molded parts

    SciTech Connect

    Healy, John; Edward, Graham H.; Knott, Robert B.

    2008-06-30

    The residual orientation following micro-injection molding of small rectangular plates with linear polyethylene has been examined using small-angle neutron scattering, and small- and wide-angle X-ray scattering. The effect of changing the molding conditions has been examined, and the residual chain orientation has been compared to the residual orientation of the crystallites as a function of position in the sample. This study has found that, for micromoldings, the orientation of the crystallites decreases with increasing injection speed and increasing mold thickness. The combined data suggest that the majority of the orientation present comes from oriented crystal growth rather than residual chain orientation.

  17. Measurement of Melt Pressure Distribution on Injection Mold Cavity Surface

    NASA Astrophysics Data System (ADS)

    Murata, Yasuhiko; Nukariya, Akihiro; Matsui, Hiroshi; Yoshinaga, Kazuhiro; Yokoi, Hidetoshi

    In order to clarify undesirable molding phenomena in injection molding, it is important to measure melt pressure distribution on the injection mold cavity in detail. In a previous paper, we reported a new method for measuring melt pressure distribution on the injection mold cavity surface using a mold with a pressure transmission pin array and tactile sensor. In this study, we attempted to measure the variation of melt pressure distribution when the injection rate and the holding pressure are changed. The results indicate phenomenon in which pressure remains near the gate in the cavity until the instant the mold is opened. This phenomenon is considered to be due to the extreme increase in melt density from the filling process through the pressure holding process and cooling process, which causes the melt to cool and solidify before it can shrink adequately. Furthermore, it was also found that there exists a close relation between the thickness distribution, residual pressure distribution and birefringence pattern of molded products.

  18. Rapid control of mold temperature during injection molding process: Effect of packing pressure

    NASA Astrophysics Data System (ADS)

    Liparoti, Sara; Sorrentino, Andrea; Titomanlio, Giuseppe

    2015-12-01

    A thorough analysis of the effect of operative conditions of injection molding process on the morphology distribution inside the obtained molded is performed, with particular reference to semi- crystalline polymers. In particular, fully characterized injection molding tests are presented using an isotactic polypropylene, previously carefully characterized as far as most of properties of interest. The effects of mold temperature and packing conditions are analyzed. The mold temperature was controlled by a thin heating device, composed by polyimide as insulating layer and polyimide loaded carbon black as electrical conductive layer, that is able to increase temperature on mold surface in few seconds (70°C/s) by joule effect and cool down soon after. The shear layer thickness in the molded is reduced in the samples produced at high mold temperatures, that means high electrical power and long heating time, and this reduction is more significant at lower packing pressures, indeed, at 360bar as packing pressure and 20s as heating time the shear layer disappear. The resulting morphology was analyzed by optical microscope.

  19. Residual stresses in injection molded shape memory polymer parts

    NASA Astrophysics Data System (ADS)

    Katmer, Sukran; Esen, Huseyin; Karatas, Cetin

    2016-03-01

    Shape memory polymers (SMPs) are materials which have shape memory effect (SME). SME is a property which has the ability to change shape when induced by a stimulator such as temperature, moisture, pH, electric current, magnetic field, light, etc. A process, known as programming, is applied to SMP parts in order to alter them from their permanent shape to their temporary shape. In this study we investigated effects of injection molding and programming processes on residual stresses in molded thermoplastic polyurethane shape memory polymer, experimentally. The residual stresses were measured by layer removal method. The study shows that injection molding and programming process conditions have significantly influence on residual stresses in molded shape memory polyurethane parts.

  20. Autosterilization of biodegradable implants by injection molding process.

    PubMed

    König, C; Ruffieux, K; Wintermantel, E; Blaser, J

    1997-01-01

    Sterilization of degradable implants by standard procedures may damage the parts due to the labile chemical nature of the polymers. This study examined whether the injection molding process used for the production of polymeric parts may itself sterilize the implant due to high temperature, pressure, and shear forces applied. Poly-D,L-lactic acid (PDLLA) and poly-L-lactic acid (PLLA) granules were contaminated with thermoresistant spores of Bacillus stearothermophilus (>10(5) spores/g). Sterile and contaminated granules of both polymers were injection molded and tested for sterility. All 27 samples produced with sterile PDLLA and processed at 120 degrees C and all 18 samples produced with sterile PLLA at 200 degrees C remained sterile after injection molding and handling. However, in five out of 28 PDLLA samples and in one out of 26 PLLA samples produced with contaminated material, spores had survived the process. In conclusion, the injection molding process could not reliably sterilize parts produced with polylactic acid granules that were heavily contaminated with thermoresistant organisms. However, the number of viable spores was significantly reduced by more than 99.99%. Thus, the injection molding process might allow the autosterilization of parts produced with raw material that is not heavily contaminated. PMID:9178738

  1. Injection molded polymer optics in the 21st Century

    NASA Astrophysics Data System (ADS)

    Beich, William S.

    2005-08-01

    Precision polymer optics, manufactured by injection molding techniques, has been a key enabling technology for several decades now. The technology, which can be thought of as a subset of the wider field of precision optics manufacturing, was pioneered in the United States by companies such as Eastman Kodak, US Precision Lens, and Polaroid. In addition to suppliers in the U.S. there are several companies worldwide that design and manufacture precision polymer optics, for example Philips High Tech Plastics in Europe and Fujinon in Japan. Designers who are considering using polymer optics need a fundamental understanding of exactly how the optics are created. This paper will survey the technology and processes that are employed in the successful implementation of a polymer optic solution from a manufacturer's perspective. Special emphasis will be paid to the unique relationship between the molds and the optics that they produce. We will discuss the key elements of production: molding resins, molds and molding equipment, and metrology. Finally we will offer a case study to illustrate just how the optics designer carries a design concept through to production. The underlying theme throughout the discussion of polymer optics is the need for the design team to work closely with an experienced polymer optics manufacturer with a solid track record of success in molded optics. As will be seen shortly, the complex interaction between thermoplastics, molds, and molding machines dictates the need for working closely with a supplier who has the critical knowledge needed to manage all aspects of the program.

  2. An investigation into the injection molding of PMR-15 polyimide

    NASA Technical Reports Server (NTRS)

    Colaluca, M. A.

    1984-01-01

    The chemorheological behavior of the PRM-15 molding compounds were characterized, the range of suitable processing parameters for injection molding in a reciprocating screw injection molding machine was determined, and the effects of the injection molding processing parameters on the mechanical properties of molded PMR-15 parts were studied. The apparatus and procedures for measuring viscosity and for determining the physical response of the material during heating are described. Results show that capillary rheometry can be effectively used with thermosets if the equipment is designed to overcome some of the inherent problems of these materials. A uniform temperature was provided in the barrel by using a circulating hot oil system. Standard capillary rheometry methods can provide the dependence of thermoset apparent viscosity on shear rate, temperature, and time. Process conditions resulting in complete imidization should be carefully defined. Specification of controlled oven temperature is inadequate and can result in incomplete imidization. For completely imidized PMR-15 heat at 15 C/min melt flow without gas evolution occurs in the temperature range of 325 C to 400 C.

  3. PHYSICAL PROPERTIES OF EXTRUDED AND INJECTION MOLDED CORN GLUTEN MEAL

    Technology Transfer Automated Retrieval System (TEKTRAN)

    This study was performed to investigate the compounding of corn gluten meal (CGM) and decanoic acid and to evaluate their mechanical properties. The mixture of CGM and 30% decanoic acid was compounded in a twin screw extruder, followed by injection molding. Scanning electron microscopy (SEM), tens...

  4. Injection molding of optics for high volume consumer products

    NASA Astrophysics Data System (ADS)

    de Schipper, Rien

    2012-03-01

    For high volume consumer products using optical technology, plastics injection molding is a very suitable technology. In optical component fabrication, astonishing results are be booked. However, to achieve success, excellent performance is needed in mastering different technologies such as polymer processing, evaporated coatings, tool making, ultra-precision turning of metals and optical metrology.

  5. FPGA-Based Multiprocessor System for Injection Molding Control

    PubMed Central

    Muñoz-Barron, Benigno; Morales-Velazquez, Luis; Romero-Troncoso, Rene J.; Rodriguez-Donate, Carlos; Trejo-Hernandez, Miguel; Benitez-Rangel, Juan P.; Osornio-Rios, Roque A.

    2012-01-01

    The plastic industry is a very important manufacturing sector and injection molding is a widely used forming method in that industry. The contribution of this work is the development of a strategy to retrofit control of an injection molding machine based on an embedded system microprocessors sensor network on a field programmable gate array (FPGA) device. Six types of embedded processors are included in the system: a smart-sensor processor, a micro fuzzy logic controller, a programmable logic controller, a system manager, an IO processor and a communication processor. Temperature, pressure and position are controlled by the proposed system and experimentation results show its feasibility and robustness. As validation of the present work, a particular sample was successfully injected. PMID:23202036

  6. FPGA-based multiprocessor system for injection molding control.

    PubMed

    Muñoz-Barron, Benigno; Morales-Velazquez, Luis; Romero-Troncoso, Rene J; Rodriguez-Donate, Carlos; Trejo-Hernandez, Miguel; Benitez-Rangel, Juan P; Osornio-Rios, Roque A

    2012-01-01

    The plastic industry is a very important manufacturing sector and injection molding is a widely used forming method in that industry. The contribution of this work is the development of a strategy to retrofit control of an injection molding machine based on an embedded system microprocessors sensor network on a field programmable gate array (FPGA) device. Six types of embedded processors are included in the system: a smart-sensor processor, a micro fuzzy logic controller, a programmable logic controller, a system manager, an IO processor and a communication processor. Temperature, pressure and position are controlled by the proposed system and experimentation results show its feasibility and robustness. As validation of the present work, a particular sample was successfully injected. PMID:23202036

  7. Microinjection molding of thermoplastic polymers: morphological comparison with conventional injection molding

    NASA Astrophysics Data System (ADS)

    Giboz, Julien; Copponnex, Thierry; Mélé, Patrice

    2009-02-01

    The skin-core crystalline morphology of injection-molded semi-crystalline polymers is well documented in the scientific literature. The thermomechanical environment provokes temperature and shear gradients throughout the entire thickness of the part during molding, thus influencing the polymer crystallization. Crystalline morphologies of a high-density polyethylene (HDPE) micromolded part (μpart) and a classical part (macropart) are compared with optical, thermal and x-ray diffraction analyses. Results show that the crystalline morphologies with regard to thickness vary between the two parts. While a 'skin-core' morphology is present for the macropart, the μpart exhibits a specific 'core-free' morphology, i.e. no spherulite is present at the center of the thickness. This result seems to be generated under the specific conditions used in microinjection molding that lead to the formation of smaller and more oriented crystalline entities.

  8. Injection molding of thermoplastic elastomers for microstructured substrates

    NASA Astrophysics Data System (ADS)

    Birkar, Smita

    Amorphous and semi-crystalline thermoplastic polymers have been widely investigated for injection molding of parts with microstructured surfaces. Microstructured surfaces injection molded from thermoplastic elastomers have emerging applications as superhydrobic surfaces and patterned adhesives, but there is a limited understanding of the factors affecting replication with these materials. This research was a continued investigation of block copolymer thermoplastic elastomers as well as the first in-depth examination of thermoplastic vulcanizates for injection molding microfeatures. The first focus of this research was the interactions between tooling aspect ratio and feature orientation (negative and positive tooling) and thermoplastic elastomer hard segment content on microfeature replication. Electroformed nickel tooling having positive and negative features with different geometries and aspect ratios of 0.02:1 to 2:1 were molded from three copolyester thermoplastic elastomers with similar chemistry and different hardness values. The tooling and part features were characterized for feature depth and height as well as feature definition using scanning electron microscopy and optical profilometry. Results were correlated with elastomer properties. In the second parts of this research, the effects of microfeature spacing on the replication of thermoplastic elastomer features was investigated using micropillars with two diameters (10 and 20 mum) and three spacing ratios (0.5:1, 1:1, and 2:1). The tooling and part features were characterized for feature depth and height as well as feature definition using scanning electron microscopy and optical profilometry. Feature spacing significantly affected the replication of micropillars using a thermoplastic elastomer. This replication was competition between cooling and pressurization of the melt. Wider spacing between smaller features allowed cooling in the tooling lands to dominate the feature filling. Higher pressures did

  9. Direct processing of continuous fibers onto injection molding machines

    NASA Astrophysics Data System (ADS)

    Truckenmueller, F. M.

    1993-06-01

    A new injection molding process 'DIF' (Direct Incorporation of Continuous Fibers) is proposed whereby roving strands are directly incorporated into the polymer melt by using a reciprocating-screw-plasticating unit. The DIF-technology offers the possibility to substitute the relatively expensive pultrusion process which is used to produce long fiber pellets. Furthermore it can be used as a fast and flexible R&D tool. In order to improve fiber dispersion with minimum fiber breakage a new mixing non-return-valve 'LFMR' (Long Fiber Mixing Ring) was developed based on the 'Twente Mixing Ring'; Its mixing capacity and influence on processing characteristics, fiber breakage and property profile of the injection molded parts is examined and compared to a general purpose non-return-valve of the ring type. The results of fundamental mechanical and physical property investigations are presented including dispersion of fiber clusters and bundles, fiber length distribution and fiber orientation.

  10. Injection molding of iPP samples in controlled conditions and resulting morphology

    NASA Astrophysics Data System (ADS)

    Sessa, Nino; De Santis, Felice; Pantani, Roberto

    2015-12-01

    Injection molded parts are driven down in size and weight especially for electronic applications. In this work, an investigation was carried out on the process of injection molding of thin iPP samples and on the morphology of these parts. Melt flow in the mold cavity was analyzed and described with a mathematical model. Influence of mold temperature and injection pressure was analyzed. Samples orientation was studied using optical microscopy.

  11. Injection molding of iPP samples in controlled conditions and resulting morphology

    SciTech Connect

    Sessa, Nino De Santis, Felice Pantani, Roberto

    2015-12-17

    Injection molded parts are driven down in size and weight especially for electronic applications. In this work, an investigation was carried out on the process of injection molding of thin iPP samples and on the morphology of these parts. Melt flow in the mold cavity was analyzed and described with a mathematical model. Influence of mold temperature and injection pressure was analyzed. Samples orientation was studied using optical microscopy.

  12. A Novel Method of Injection Molding Titanium Components

    SciTech Connect

    Nyberg, Eric A.; Simmons, Kevin L.; Weil, K. Scott

    2005-05-01

    We have developed a unique blend of powder injection molding feedstock materials in which only a small volume fraction of binder (< 8%) is required; the remainder of the mixture consists of the metal powder and a solid aromatic solvent. Because of the nature of the decomposition in the binder system and the relatively small amount used, the binder is eliminated almost completely from the pre-sintered component during the initial stage of a two-step heat treatment process.

  13. Applications of thin carbon coatings and films in injection molding

    NASA Astrophysics Data System (ADS)

    Cabrera, Eusebio Duarte

    In this research, the technical feasibility of two novel applications of thin carbon coatings is demonstrated. The first application consists of using thin carbon coatings on molds for molding ultra-thin plastic parts (<0.5 mm thickness) with lower pressures by promoting wall slip. The second application consists of a new approach to provide electromagnetic interference (EMI) shielding for plastic parts using in mold coated nanoparticle thin films or nanopapers to create a conductive top layer. During this research, the technical feasibility of a new approach was proven which provides injection molding of ultra-thin parts at lower pressures, without the need of fast heating/fast cooling or other expensive mold modification. An in-house developed procedure by other members of our group, was employed for coating the mold surface using chemical vapor deposition (CVD) resulting in a graphene coating with carbide bonding to the mold surface. The coating resulted in a significant decrease of surface friction and consequently easiness of flow when compared to their uncoated counterparts. Thermoplastic polymers and their composites are a very attractive alternative but are hindered by the non-conductive nature of polymers. There are two general approaches used to date to achieve EMI shielding for plastic products. One is to spray a conductive metal coating onto the plastic surface forming a layer that must maintain its shielding effectiveness (SE), and its adhesion to the plastic throughout the expected life of the product. However, metal coatings add undesirable weight and tend to corrode over time. Furthermore, scratching the coating may create shielding failure; therefore, a protective topcoat may be required. The other approach is to use polymer composites filled with conductive fillers such as carbon black (CB), carbon nanofiber (CNF), and carbon nanotube (CNT). While conductive fillers may increase the electrical conductivity of polymer composites, the loading of

  14. Integral optical system design of injection molded optics

    NASA Astrophysics Data System (ADS)

    Baumer, Stefan M.; Shulepova, Lena; Willemse, Jan; Renkema, Kor

    2003-11-01

    Injection molded optics are frequently applied in many high volume applications. Bar code scanners, CD / DVD systems, CMOS cameras are a few examples. In all of these applications cost effective and fast design cycles are essential. At Philips High Tech Plastics we developed a design system that touches on all different aspects of the system design. Starting with traditional lens design (sequential ray tracing) and tolernacing we transport the initial design into mechanical solid modeling. During mechanical modeling, tolerances, injection molding design rules and integration of mechanical features, reference marks, etc. are incorporated as well. Here the full advantage of injection molding can be utilized. After the opto - mechanical modeling the system is ported back to non - sequential ray tracing for ghost - and stray light analysis. Finally extended tolerancing is performed in order to come to a robust high volume product. If necessary all or several steps in this design process are repeated in order to arrive at the final design. As an additional requirement the metrology possibilities for the design are checked in at an early stage. This integral system approach to optical design, including optical modeling (sequential and non-sequential) combined with mechanical solid modeling is presented using some recent examples.

  15. Investigation of interfacial fracture behavior on injection molded parts

    NASA Astrophysics Data System (ADS)

    Fischer, Matthieu; Ausias, Gilles; Kuehnert, Ines

    2016-03-01

    In this study the interfacial morphology of different polymers joined by various assembly injection molding (AIM) technologies were discussed. Melt streams were injected successively using tools with core-back or rotation techniques. To compare bulk specimen strength and weld line strength, the fracture behavior of different specimen scales and thin sections were investigated. An in-situ SEM tensile test and a new thin section testing device which is used in polarized (transmitted) light microscopy were used to observe specimen failure. The effects of processing on spherulitic structures were linked to bonding strength and mechanical properties.

  16. Investigations on injection molded, glass-fiber reinforced polyamide 6 integral foams using breathing mold technology

    NASA Astrophysics Data System (ADS)

    Roch, A.; Kehret, L.; Huber, T.; Henning, F.; Elsner, P.

    2015-05-01

    Investigations on PA6-GF50 integral foams have been carried out using different material systems: longfiber- and shortfiber-reinforced PA6 as well as unreinforced PA6 as a reference material. Both chemical and physical blowing agents were applied. Breathing mold technology (decompression of the mold) was selected for the foaming process. The integral foam design, which can be conceived as a sandwich structure, helps to save material in the neutral axis area and maintains a distance between load-bearing, unfoamed skin layers. For all test series an initial mold gap of 2.5 mm was chosen and the same amount of material was injected. In order to realize different density reductions, the mold opening stroke was varied. The experiments showed that, at a constant mass per unit area, integral polyamide 6 foams have a significantly higher bending stiffness than compact components, due to their higher area moment of inertia after foaming. At a constant surface weight the bending stiffness in these experiments could be increased by up to 600 %. Both shortfiber- and longfiber-reinforced polyamide 6 showed an increase in energy absorption during foaming.

  17. Injection molded 1{endash}3 piezocomposite velocity sensors

    SciTech Connect

    Gentilman, R.L.; Bowen, L.J.; Fiore, D.F.; Pham, H.T.; Serwatka, W.J.

    1996-04-01

    A cost-effective technology has been developed for producing 1{endash}3 piezoelectric ceramic/polymer composites and transducers for underwater actuators, pressure sensors, and velocity sensors. Applications include active and passive sonar, underwater imaging, and active surface control. The key technology in the manufacturing process in the PZT ceramic injection molding process, in which an entire array of piezoelectric elements is molded to final net shape in one operation. Several designs of low-profile, area-averaging 1{endash}3 piezocomposite accelerometers have been fabricated. The initial breadboard accelerometers were made using a prepoled 50{times}50 mm injection molded 1{endash}3 PZT-5H preforms, containing 361 identical rods on a common baseplate. Additional mass was attached to the baseplate, which was metallized to serve as an electrode, and the free ends of the PZT rods were bonded to a fixed surface, which also functions as the other electrode. Subsequently, a manufacturing process was developed to create accelerometer {open_quote}{open_quote}islands{close_quote}{close_quote} within a 1{endash}3 piezocomposite transducer. The accelerometers can be made in arbitrary areas, shapes, and arrangements within the transducer panel, with the remaining area used either as a hydrophone or an actuator. This integral accelerometer technology is being optimized as part of an ARPA-funded active surface control program. This paper reviews the current state-of-the-art of injection molded piezocomposite transducers and describes some of the velocity sensor configurations made using this technology. {copyright} {ital 1996 American Institute of Physics.}

  18. Modeling injection molding of net-shape active ceramic components.

    SciTech Connect

    Baer, Tomas; Cote, Raymond O.; Grillet, Anne Mary; Yang, Pin; Hopkins, Matthew Morgan; Noble, David R.; Notz, Patrick K.; Rao, Rekha Ranjana; Halbleib, Laura L.; Castaneda, Jaime N.; Burns, George Robert; Mondy, Lisa Ann; Brooks, Carlton, F.

    2006-11-01

    To reduce costs and hazardous wastes associated with the production of lead-based active ceramic components, an injection molding process is being investigated to replace the current machining process. Here, lead zirconate titanate (PZT) ceramic particles are suspended in a thermoplastic resin and are injected into a mold and allowed to cool. The part is then bisque fired and sintered to complete the densification process. To help design this new process we use a finite element model to describe the injection molding of the ceramic paste. Flow solutions are obtained using a coupled, finite-element based, Newton-Raphson numerical method based on the GOMA/ARIA suite of Sandia flow solvers. The evolution of the free surface is solved with an advanced level set algorithm. This approach incorporates novel methods for representing surface tension and wetting forces that affect the evolution of the free surface. Thermal, rheological, and wetting properties of the PZT paste are measured for use as input to the model. The viscosity of the PZT is highly dependent both on temperature and shear rate. One challenge in modeling the injection process is coming up with appropriate constitutive equations that capture relevant phenomenology without being too computationally complex. For this reason we model the material as a Carreau fluid and a WLF temperature dependence. Two-dimensional (2D) modeling is performed to explore the effects of the shear in isothermal conditions. Results indicate that very low viscosity regions exist near walls and that these results look similar in terms of meniscus shape and fill times to a simple Newtonian constitutive equation at the shear-thinned viscosity for the paste. These results allow us to pick a representative viscosity to use in fully three-dimensional (3D) simulation, which because of numerical complexities are restricted to using a Newtonian constitutive equation. Further 2D modeling at nonisothermal conditions shows that the choice of

  19. Investigation of micro-injection molding based on longitudinal ultrasonic vibration core.

    PubMed

    Qiu, Zhongjun; Yang, Xue; Zheng, Hui; Gao, Shan; Fang, Fengzhou

    2015-10-01

    An ultrasound-assisted micro-injection molding method is proposed to improve the rheological behavior of the polymer melt radically, and a micro-injection molding system based on a longitudinal ultrasonic vibration core is developed and employed in the micro-injection molding process of Fresnel lenses. The verification experiments show that the filling mold area of the polymer melt is increased by 6.08% to 19.12%, and the symmetric deviation of the Fresnel lens is improved 15.62% on average. This method improved the filling performance and replication quality of the polymer melt in the injection molding process effectively. PMID:26479615

  20. Rapid and low-cost prototyping of medical devices using 3D printed molds for liquid injection molding.

    PubMed

    Chung, Philip; Heller, J Alex; Etemadi, Mozziyar; Ottoson, Paige E; Liu, Jonathan A; Rand, Larry; Roy, Shuvo

    2014-01-01

    Biologically inert elastomers such as silicone are favorable materials for medical device fabrication, but forming and curing these elastomers using traditional liquid injection molding processes can be an expensive process due to tooling and equipment costs. As a result, it has traditionally been impractical to use liquid injection molding for low-cost, rapid prototyping applications. We have devised a method for rapid and low-cost production of liquid elastomer injection molded devices that utilizes fused deposition modeling 3D printers for mold design and a modified desiccator as an injection system. Low costs and rapid turnaround time in this technique lower the barrier to iteratively designing and prototyping complex elastomer devices. Furthermore, CAD models developed in this process can be later adapted for metal mold tooling design, enabling an easy transition to a traditional injection molding process. We have used this technique to manufacture intravaginal probes involving complex geometries, as well as overmolding over metal parts, using tools commonly available within an academic research laboratory. However, this technique can be easily adapted to create liquid injection molded devices for many other applications. PMID:24998993

  1. Rapid and Low-cost Prototyping of Medical Devices Using 3D Printed Molds for Liquid Injection Molding

    PubMed Central

    Chung, Philip; Heller, J. Alex; Etemadi, Mozziyar; Ottoson, Paige E.; Liu, Jonathan A.; Rand, Larry; Roy, Shuvo

    2014-01-01

    Biologically inert elastomers such as silicone are favorable materials for medical device fabrication, but forming and curing these elastomers using traditional liquid injection molding processes can be an expensive process due to tooling and equipment costs. As a result, it has traditionally been impractical to use liquid injection molding for low-cost, rapid prototyping applications. We have devised a method for rapid and low-cost production of liquid elastomer injection molded devices that utilizes fused deposition modeling 3D printers for mold design and a modified desiccator as an injection system. Low costs and rapid turnaround time in this technique lower the barrier to iteratively designing and prototyping complex elastomer devices. Furthermore, CAD models developed in this process can be later adapted for metal mold tooling design, enabling an easy transition to a traditional injection molding process. We have used this technique to manufacture intravaginal probes involving complex geometries, as well as overmolding over metal parts, using tools commonly available within an academic research laboratory. However, this technique can be easily adapted to create liquid injection molded devices for many other applications. PMID:24998993

  2. Foam injection molding of elastomers with iron microparticles

    NASA Astrophysics Data System (ADS)

    Volpe, Valentina; D'Auria, Marco; Sorrentino, Luigi; Davino, Daniele; Pantani, Roberto

    2015-12-01

    In this work, a preliminary study of foam injection molding of a thermoplastic elastomer, Engage 8445, and its microcomposite loaded with iron particles was carried out, in order to evaluate the effect of the iron microparticles on the foaming process. In particular, reinforced samples have been prepared by using nanoparticles at 2% by volume. Nitrogen has been used as physical blowing agent. Foamed specimens consisting of neat and filled elastomer were characterized by density measurements and morphological analysis. While neat Engage has shown a well developed cellular morphology far from the injection point, the addition of iron microparticles considerably increased the homogeneity of the cellular morphology. Engage/iron foamed samples exhibited a reduction in density greater than 32%, with a good and homogeneous cellular morphology, both in the transition and in the core zones, starting from small distances from the injection point.

  3. Ion channel recordings on an injection-molded polymer chip.

    PubMed

    Tanzi, Simone; Matteucci, Marco; Christiansen, Thomas Lehrmann; Friis, Søren; Christensen, Mette Thylstrup; Garnaes, Joergen; Wilson, Sandra; Kutchinsky, Jonatan; Taboryski, Rafael

    2013-12-21

    In this paper, we demonstrate recordings of the ion channel activity across the cell membrane in a biological cell by employing the so-called patch clamping technique on an injection-molded polymer microfluidic device. The findings will allow direct recordings of ion channel activity to be made using the cheapest materials and production platform to date and with the potential for very high throughput. The employment of cornered apertures for cell capture allowed the fabrication of devices without through holes and via a scheme comprising master origination by dry etching in a silicon substrate, electroplating in nickel and injection molding of the final part. The most critical device parameters were identified as the length of the patching capillary and the very low surface roughness on the inside of the capillary. The cross-sectional shape of the orifice was found to be less critical, as both rectangular and semicircular profiles seemed to have almost the same ability to form tight seals with cells with negligible leak currents. The devices were functionally tested using human embryonic kidney cells expressing voltage-gated sodium channels (Nav1.7) and benchmarked against a commercial state-of-the-art system for automated ion channel recordings. These experiments considered current-voltage (IV) relationships for activation and inactivation of the Nav1.7 channels and their sensitivity to a local anesthetic, lidocaine. Both IVs and lidocaine dose-response curves obtained from the injection-molded polymer device were in good agreement with data obtained from the commercial system. PMID:24154831

  4. The technology and commercial status of powder-injection molding

    NASA Astrophysics Data System (ADS)

    Bose, Animesh

    1995-08-01

    The process of powder-injection molding (PIM) is a viable and competitive commercial technique that is being used to process complex-shaped parts of various materials in moderate to high volumes. The hey advantage of the process is its unique ability to combine materials selection flexibility with the complex shape-forming ability of plastics. Although the PIM process has been discussed in the open literature for more than quarter of a century, it has become a commercial reality only during the last decade or so. Currently, there is a tremendous interest in this unique technology throughout the world. As a result, the PIM industry is poised for significant growth.

  5. Atmosphere control during debinding of powder injection molded parts

    NASA Astrophysics Data System (ADS)

    Moore, J. A.; Jarding, B. P.; Lograsso, B. K.; Anderson, I. E.

    1995-06-01

    Atmosphere control during debinding of powder injection molded (PIM) parts is an important parameter to consider. Experimental results have shown that a stagnant atmosphere containing volatiles evolved during debinding can cause slumping of the green samples. Removal of volatiles from the sample zone aids debinding and can reduce cycle times and improve sample quality. Residual carbon and oxygen can be controlled during debinding by adjusting the atmosphere composition. This paper presents the results of PIM 70 vol% spherical copper powder and 30 vol% binder. Debinding atmospheres were altered to determine the effect of debinding on the green body and the sintered sample.

  6. Capabilities Of Micro Powder Injection Molding For Microparts Manufacturing

    NASA Astrophysics Data System (ADS)

    Kong, X.; Barriere, T.; Gelin, J. C.

    2011-01-01

    The Micro-PIM processing technology satisfies the increasing demand in terms of smaller parts and miniaturization. Research works in this area have been carried out at FEMTO-ST Institute by performing the injection molding with 316L stainless steel fine powders and polymer binders. Several formulations with different proportion of powders and binders as well various polymers have been tested, and then a well adapted one has been selected. The process to select the well adapted formulation and the rheological characteristics of the feedstock realized according with the selected formulation are also detailed. Several test specimens have been successfully manufactured.

  7. Molds

    MedlinePlus

    ... touching mold or mold spores may cause allergic reactions or asthma attacks in sensitive people. Molds can cause fungal infections. In addition, mold exposure may irritate your eyes, skin, nose, ...

  8. Fabrication of Composite Material Using Gettou Fiber by Injection Molding

    NASA Astrophysics Data System (ADS)

    Setsuda, Roy; Fukumoto, Isao; Kanda, Yasuyuki

    This study investigated the mechanical properties of composite using gettou (shell ginger) fiber as reinforcement fabricated from injection molding. Gettou fiber is a natural fiber made from gettou, a subtropical plant that is largely abundant in Okinawa, Japan. We used the stem part of gettou plant and made the gettou fiber by crushing the stem. The composite using gettou fiber contributed to low shrinkage ratio, high bending strength and high flexural modulus. The mechanical strength of composite using long gettou fiber showed higher value than composite using short gettou fiber. Next, because gettou is particularly known for its anti-mold characteristic, we investigated the characteristic in gettou plastic composite. The composite was tested against two molds: aspergillius niger and penicillium funiculosum. The 60% gettou fiber plastic composite was found to satisfy the JISZ2801 criterion. Finally, in order to predict the flexural modulus of composite using gettou fiber by Halpin-Tsai equation, the tensile elastic modulus of single gettou fiber was measured. The tendency of the experimental results of composite using gettou fiber was in good agreement with Halpin-Tsai equation.

  9. A micro powder injection molding apparatus for high aspect ratio metal micro-structure production

    NASA Astrophysics Data System (ADS)

    Fu, Gang; Tor, Shubeng; Loh, Ngiaphiang; Tay, Beeyen; Hardt, David E.

    2007-09-01

    A new variotherm molding apparatus is presented in this paper for the fabrication of high aspect ratio 316L stainless steel micro-structures using micro powder injection molding (μPIM) technology. The molding apparatus prototype includes an injection mold in which a silicon insert with an array of 24 × 24 (576) microcavities is mounted, a set of rapid tempering systems for the mold and a set of vacuum systems. The key advantage of this molding apparatus lies in the real-time monitoring and rapid adjustment of the mold cavity temperature during injection molding and part ejection, which makes molding and demolding of high aspect ratio green micro-structures possible. For example, incomplete filling occurs while injection molding micro-structures of 60 µm × height 191 µm with an aspect ratio of 3.2 using a conventional mold. In comparison, smaller micro-structures with higher aspect ratio are produced successfully in the case of the new molding apparatus, e.g. micro-structures of 40 µm × height 174 µm with an aspect ratio of 4.35 and 20 µm × height 160 µm with an aspect ratio of 8 were molded successfully.

  10. CREEP MODELING FOR INJECTION-MOLDED LONG-FIBER THERMOPLASTICS

    SciTech Connect

    Nguyen, Ba Nghiep; Kunc, Vlastimil; Bapanapalli, Satish K.

    2008-06-30

    This paper proposes a model to predict the creep response of injection-molded long-fiber thermoplastics (LFTs). The model accounts for elastic fibers embedded in a thermoplastic resin that exhibits the nonlinear viscoelastic behavior described by the Schapery’s model. It also accounts for fiber length and orientation distributions in the composite formed by the injection-molding process. Fiber length and orientation distributions were measured and used in the analysis that applies the Eshelby’s equivalent inclusion method, the Mori-Tanaka assumption (termed as the Eshelby-Mori-Tanaka approach) and the fiber orientation averaging technique to compute the overall strain increment resulting from an overall constant applied stress during a given time increment. The creep model for LFTs has been implemented in the ABAQUS finite element code via user-subroutines and has been validated against the experimental creep data obtained for long-glass-fiber/polypropylene specimens. The effects of fiber orientation and length distributions on the composite creep response are determined and discussed.

  11. Injection molded high precision freeform optics for high volume applications

    NASA Astrophysics Data System (ADS)

    Dick, Lars; Risse, Stefan; Tünnermann, Andreas

    2012-03-01

    Injection molding offers a cost-efficient method for manufacturing high precision plastic optics for high-volume applications. Optical surfaces such as flats, spheres and also aspheres are meanwhile state-of-the-art in the field of plastic optics. The demand for surfaces without symmetric properties, commonly referred to as freeform surfaces, continues to rise. Currently, new mathematical approaches are under consideration which allow for new complex optical designs. Such novel optical designs strongly encourage development of new manufacturing methods. Specifically, new surface descriptions without an axis of symmetry, new ultra precision machining methods and non-symmetrical shrinkage compensation strategies have to be developed to produce freeform optical surfaces with high precision for high-volume applications. This paper will illustrate a deterministic and efficient way for the manufacturing of ultra precision injection molding tool inserts with submicron precision and show the manufacturing of replicated freeform surfaces with micrometer range shape accuracy at diameters up to 40 mm with a surface roughness of approximately 2 nm.

  12. A Study on the Optimization for Metal Injection Molding Process

    NASA Astrophysics Data System (ADS)

    Jung, M. K.; Jang, K. C.; Lee, D. G.; Kim, M. H.

    2011-01-01

    The objective of this paper is study the optimization for metal injection molding process by using the design of experiments (DOE) and numerical analysis. In order to determine optimal process parameters, experiment and computerized analysis have been performed for various process conditions. Proper coded and uncoded regression equations and optimization for responses (flow front temperature, part weight, filling time, cycle time, and volumetric shrinkage) achieved from studying and verifying interrelation of the factors. About 70% of whole binder extracted within about 10 minutes and temperature of solvent is higher, the debinding rate is fast. 50° C was the most suitable condition for solvent extraction because of crack occurrence on green body at 55° C. It took about 14.5 hours to perform secondary thermal debinding, which was only about 35% of the entire time taken compared with single thermal debinding process, even if it considers solvent extraction time required. Therefore, the applied method greatly reduces the debinding time. The excellent process capability showed that the PPM total and Z.Bench were 9,946.8 and 2.33 showing good quality rate of around 99.01% and sigma level of 3.83. As a result, the process and optimization have been improved, and the proposed approach could be successfully reflected on the metal injection molding.

  13. Interrelationship between structure-property-processings in injection molded polymeric products

    SciTech Connect

    Kim, Hyun Seog; Lee, Jae Wook

    1996-12-31

    Injection molding process is one of the major polymer processings for the polymeric products. This process is extensively used in the net-shaped production of plastic parts due to its capability to meet requirements of stringent dimensional accuracy and short cycle time. Specially the injection molding process consists of large, fast deformation and phase changes, which has much of processing parameters. Therefore it is important to optimize the injection molding conditions from the point of view of both productivity and product quality. In this study, we have investigated in the injection molding process for polymeric systems focusing on the understanding of structure-property-processing interrelationship and its utilization in the processing.

  14. The use of variable speed drives to retrofit hydraulic injection molding machines

    SciTech Connect

    Ambs, L.; Frerker, M.M.

    1998-06-01

    Injection molding is a common method of plastic processing in which thermoplastic materials can be molded into arbitrary complex shapes. Most injection molding machines use complicated hydraulic systems to perform the necessary work of the process. Hydraulic system flow and pressure requirements vary throughout the cycle and in many cases, excess fluid that is not required by the process is throttled back to the reservoir, wasting motor energy and producing additional thermal load on the cooling system. Variable speed drives can be used to allow injection molding machine hydraulic systems to vary the amount of fluid being pumped and thus reduce the amount of fluid that is throttled reducing the amount of wasted energy. This article discusses injection molding machine processes and develops a protocol for assessing the efficacy of variable speed drive retrofits for hydraulic injection molding machines.

  15. Curing rate and flowing properties of silicone rubber at injection molding

    SciTech Connect

    Yoshino, M.; Nakamura, T. )

    1992-04-01

    Generally, silicone rubbers are mold-cured after mixing the rubber and peroxide curing agent with a two-roll mill or a kneader. Typically this is done at pressures of 5 MPa to 10 MPa and at temperatures between 120 to 200 C. Compression molding, transfer molding and injection molding are common molding ways for silicone rubbers. Recently, injection molding techniques are developing rapidly that have the advantages of molding automatically with high cycle mechanisms. To reduce the molding time and to make a precision part, both the flowing and curing properties of a particular rubber compound will be important. In this article, correlations between the curing and the flowing properties of silicone rubber are investigated by using the Rheovulkameter device.

  16. Investigation of the adhesion interface obtained through two-component injection molding

    NASA Astrophysics Data System (ADS)

    Fetecau, Catalin; Stan, Felicia; Dobrea, Daniel

    2011-01-01

    In this paper we study the interface strength obtained through two-component (2C) injection molding of LDPE-HDPE polymers. First, numerical simulation of the over-molding process is carried out using Moldflow technology. Second, butt-joint specimens were produced by over-molding under different process condition, and tested. Two injection sequences were considered, injection of LDPE on HDPE polymer, and HDLE on LDPE, respectively. To investigate the effects of the mold surface roughness on the polymers adhesion at interface, different inserts with different roughness are employed.

  17. Injection molded polymeric micropatterns for bone regeneration study.

    PubMed

    Zanchetta, Erika; Guidi, Enrica; Della Giustina, Gioia; Sorgato, Marco; Krampera, Mauro; Bassi, Giulio; Di Liddo, Rosa; Lucchetta, Giovanni; Conconi, Maria Teresa; Brusatin, Giovanna

    2015-04-01

    An industrially feasible process for the fast mass-production of molded polymeric micro-patterned substrates is here presented. Microstructured polystyrene (PS) surfaces were obtained through micro injection molding (μIM) technique on directly patterned stamps realized with a new zirconia-based hybrid spin-on system able to withstand 300 cycles at 90 °C. The use of directly patterned stamps entails a great advantage on the overall manufacturing process as it allows a fast, flexible, and simple one-step process with respect to the use of milling, laser machining, electroforming techniques, or conventional lithographic processes for stamp fabrication. Among the different obtainable geometries, we focused our attention on PS replicas reporting 2, 3, and 4 μm diameter pillars with 8, 9, 10 μm center-to-center distance, respectively. This enabled us to study the effect of the substrate topography on human mesenchymal stem cells behavior without any osteogenic growth factors. Our data show that microtopography affected cell behavior. In particular, calcium deposition and osteocalcin expression enhanced as diameter and interpillar distance size increases, and the 4-10 surface was the most effective to induce osteogenic differentiation. PMID:25756304

  18. 3D Fiber Orientation Simulation for Plastic Injection Molding

    NASA Astrophysics Data System (ADS)

    Lin, Baojiu; Jin, Xiaoshi; Zheng, Rong; Costa, Franco S.; Fan, Zhiliang

    2004-06-01

    Glass fiber reinforced polymer is widely used in the products made using injection molding processing. The distribution of fiber orientation inside plastic parts has direct effects on quality of molded parts. Using computer simulation to predict fiber orientation distribution is one of most efficient ways to assist engineers to do warpage analysis and to find a good design solution to produce high quality plastic parts. Fiber orientation simulation software based on 2-1/2D (midplane /Dual domain mesh) techniques has been used in industry for a decade. However, the 2-1/2D technique is based on the planar Hele-Shaw approximation and it is not suitable when the geometry has complex three-dimensional features which cannot be well approximated by 2D shells. Recently, a full 3D simulation software for fiber orientation has been developed and integrated into Moldflow Plastics Insight 3D simulation software. The theory for this new 3D fiber orientation calculation module is described in this paper. Several examples are also presented to show the benefit in using 3D fiber orientation simulation.

  19. Molds

    MedlinePlus

    Molds are fungi that can be found both outdoors and indoors. They grow best in warm, damp and humid conditions. If ... spots in your house, you will probably get mold. Molds can cause health problems. Inhaling or touching ...

  20. A wide variety of injection molding technologies is now applicable to small series and mass production

    SciTech Connect

    Bloß, P. E-mail: juettner@kuz-leipzig.de E-mail: loeser@kuz-leipzig.de E-mail: krajewsky@kuz-leipzig.de; Jüttner, G. E-mail: juettner@kuz-leipzig.de E-mail: loeser@kuz-leipzig.de E-mail: krajewsky@kuz-leipzig.de; Jacob, S. E-mail: juettner@kuz-leipzig.de E-mail: loeser@kuz-leipzig.de E-mail: krajewsky@kuz-leipzig.de; Löser, C. E-mail: juettner@kuz-leipzig.de E-mail: loeser@kuz-leipzig.de E-mail: krajewsky@kuz-leipzig.de; Michaelis, J. E-mail: juettner@kuz-leipzig.de E-mail: loeser@kuz-leipzig.de E-mail: krajewsky@kuz-leipzig.de; Krajewsky, P. E-mail: juettner@kuz-leipzig.de E-mail: loeser@kuz-leipzig.de E-mail: krajewsky@kuz-leipzig.de

    2014-05-15

    Micro plastic parts open new fields for application, e. g., to electronics, sensor technologies, optics, and medical engineering. Before micro parts can go to mass production, there is a strong need of having the possibility for testing different designs and materials including material combinations. Hence, flexible individual technical and technological solutions for processing are necessary. To manufacture high quality micro parts, a micro injection moulding machine named formicaPlast based on a two-step plunger injection technology was developed. Resulting from its design, the residence time and the accuracy problems for managing small shot volumes with reproducible high accuracy are uncompromisingly solved. Due to their simple geometry possessing smooth transitions and non adherent inner surfaces, the plunger units allow to process 'all' thermoplastics from polyolefines to high performance polymers, optical clear polymers, thermally sensitive bioresorbables, highly filled systems (the so-called powder injection molding PIM), and liquid silicon rubber (LSR, here with a special kit). The applied platform strategy in the 1K and 2K version allows integrating automation for assembling, handling and packaging. A perpendicular arrangement allows encapsulation of inserts, also partially, and integration of this machine into process chains. Considering a wide variety of different parts consisting of different materials, the high potential of the technology is demonstrated. Based on challenging industrial parts from electronic applications (2K micro MID and bump mat, where both are highly structured parts), the technological solutions are presented in more detail.

  1. A wide variety of injection molding technologies is now applicable to small series and mass production

    NASA Astrophysics Data System (ADS)

    Bloß, P.; Jüttner, G.; Jacob, S.; Löser, C.; Michaelis, J.; Krajewsky, P.

    2014-05-01

    Micro plastic parts open new fields for application, e. g., to electronics, sensor technologies, optics, and medical engineering. Before micro parts can go to mass production, there is a strong need of having the possibility for testing different designs and materials including material combinations. Hence, flexible individual technical and technological solutions for processing are necessary. To manufacture high quality micro parts, a micro injection moulding machine named formicaPlast based on a two-step plunger injection technology was developed. Resulting from its design, the residence time and the accuracy problems for managing small shot volumes with reproducible high accuracy are uncompromisingly solved. Due to their simple geometry possessing smooth transitions and non adherent inner surfaces, the plunger units allow to process "all" thermoplastics from polyolefines to high performance polymers, optical clear polymers, thermally sensitive bioresorbables, highly filled systems (the so-called powder injection molding PIM), and liquid silicon rubber (LSR, here with a special kit). The applied platform strategy in the 1K and 2K version allows integrating automation for assembling, handling and packaging. A perpendicular arrangement allows encapsulation of inserts, also partially, and integration of this machine into process chains. Considering a wide variety of different parts consisting of different materials, the high potential of the technology is demonstrated. Based on challenging industrial parts from electronic applications (2K micro MID and bump mat, where both are highly structured parts), the technological solutions are presented in more detail.

  2. Fabrication of injection molded sintered alpha SiC turbine components

    NASA Technical Reports Server (NTRS)

    Storm, R. S.; Ohnsorg, R. W.; Frechette, F. J.

    1981-01-01

    Fabrication of a sintered alpha silicon carbide turbine blade by injection molding is described. An extensive process variation matrix was carried out to define the optimum fabrication conditions. Variation of molding parameters had a significant impact on yield. Turbine blades were produced in a reasonable yield which met a rigid quality and dimensional specification. Application of injection molding technology to more complex components such as integral rotors is also described.

  3. A senior manufacturing laboratory for determining injection molding process capability

    NASA Technical Reports Server (NTRS)

    Wickman, Jerry L.; Plocinski, David

    1992-01-01

    The following is a laboratory experiment designed to further understanding of materials science. This subject material is directed at an upper level undergraduate/graduate student in an Engineering or Engineering Technology program. It is assumed that the student has a thorough understanding of the process and quality control. The format of this laboratory does not follow that which is normally recommended because of the nature of process capability and that of the injection molding equipment and tooling. This laboratory is instead developed to be used as a point of departure for determining process capability for any process in either a quality control laboratory or a manufacturing environment where control charts, process capability, and experimental or product design are considered important topics.

  4. Microcellular foam injection molding with cellulose nanofibers (CNFs)

    NASA Astrophysics Data System (ADS)

    Ohshima, Masahiro; Kubota, Masaya; Ishihara, Shota; Hikima, Yuta; Sato, Akihiro; Sekiguchi, Takafumi

    2016-03-01

    Cellulose nanofibers (CNFs) nanocomposites polypropylene foams are prepared by microcellular foam injection molding with core-back operation. The modified CNFs were blended with isotactic-polypropylene (i-PP) at different CNFs weight percentages and foamed to investigate the effect of CNFs on cell morphology. CNFs in i-PP increased the elastic modulus and induced a strain hardening behavior. CNFs also shifted the crystallization temperature of i-PP to higher temperature and enhanced crystallization. With these changes in rheological and thermal properties, CNFs could reduce the cell size and increase the cell density of the foams. By adjusting the core-back timing i.e., foaming temperature, the closed cell and the nano-fibrillated open cellular structure could be produced. The flexural modulus and bending strength of foams were measured by three point flexural tester. The flexural modulus and bending strength were increased as the CNFs content in i-PP was increased at any foam expansion ratio.

  5. Imprinted and injection-molded nano-structured optical surfaces

    NASA Astrophysics Data System (ADS)

    Christiansen, Alexander B.; Højlund-Nielsen, Emil; Clausen, Jeppe; Caringal, Gideon P.; Mortensen, N. Asger; Kristensen, Anders

    2013-09-01

    Inspired by nature, nano-textured surfaces have attracted much attention as a method to realize optical surface functionality. The moth-eye antireflective structure and the structural colors of Morpho butterflies are well- known examples used for inspiration for such biomimetic research. In this paper, nanostructured polymer surfaces suitable for up-scalable polymer replication methods, such as imprinting/embossing and injection-molding, are discussed. The limiting case of injection-moulding compatible designs is investigated. Anti-reflective polymer surfaces are realized by replication of Black Silicon (BSi) random nanostructure surfaces. The optical transmission at normal incidence is measured for wavelengths from 400 nm to 900 nm. For samples with optimized nanostructures, the reflectance is reduced by 50 % compared to samples with planar surfaces. The specular and diffusive reflection of light from polymer surfaces and their implication for creating structural colors is discussed. In the case of injection-moulding compatible designs, the maximum reflection of nano-scale textured surfaces cannot exceed the Fresnel reflection of a corresponding flat polymer surface, which is approx. 4 % for normal incidence. Diffraction gratings provide strong color reflection defined by the diffraction orders. However, the apperance varies strongly with viewing angles. Three different methods to address the strong angular-dependence of diffraction grating based structural color are discussed.

  6. Effect of cross sectional geometry on PDMS micro peristaltic pump performance: comparison of SU-8 replica molding vs. micro injection molding.

    PubMed

    Graf, Neil J; Bowser, Michael T

    2013-10-01

    Two different fabrication methods were employed to fabricate micropumps with different cross-sectional channel geometries. The first was to fabricate rectangular cross-sectional microchannel geometries using the well known fabrication method of replica molding (REM). The second, and far less utilized fabrication technique, was to create microchannel molds using an in-house fabricated handheld micro injection molding apparatus. The injection mold apparatus was designed for use with elastomeric room temperature vulcanization (RTV) polymers, as opposed to most other injection molding machines, which are designed for use with thermoplastic polymers. The injection mold's bottom plate was used as a microchannel molding template. The molding template was created by threading a small-diameter wire (150 μm or less) through the injection mold's bottom plate, with subsequent adhesion and smoothing of a thin piece of aluminum foil over the wire-raised injection mold template. When molded against, the template produced a rounded/Gaussian-shaped PDMS microchannel. The design of the injection mold will be presented, along with a direct comparison for micropump performance metrics such as flow rate, valving characteristics, and maximum backpressures attainable for each of the respective micropump channel geometries. PMID:23917263

  7. Modeling and flow analysis of pure nylon polymer for injection molding process

    NASA Astrophysics Data System (ADS)

    Nuruzzaman, D. M.; Kusaseh, N.; Basri, S.; Oumer, A. N.; Hamedon, Z.

    2016-02-01

    In the production of complex plastic parts, injection molding is one of the most popular industrial processes. This paper addresses the modeling and analysis of the flow process of the nylon (polyamide) polymer for injection molding process. To determine the best molding conditions, a series of simulations are carried out using Autodesk Moldflow Insight software and the processing parameters are adjusted. This mold filling commercial software simulates the cavity filling pattern along with temperature and pressure distributions in the mold cavity. In the modeling, during the plastics flow inside the mold cavity, different flow parameters such as fill time, pressure, temperature, shear rate and warp at different locations in the cavity are analyzed. Overall, this Moldflow is able to perform a relatively sophisticated analysis of the flow process of pure nylon. Thus the prediction of the filling of a mold cavity is very important and it becomes useful before a nylon plastic part to be manufactured.

  8. Injection molding as a one-step process for the direct production of pharmaceutical dosage forms from primary powders.

    PubMed

    Eggenreich, K; Windhab, S; Schrank, S; Treffer, D; Juster, H; Steinbichler, G; Laske, S; Koscher, G; Roblegg, E; Khinast, J G

    2016-05-30

    The objective of the present study was to develop a one-step process for the production of tablets directly from primary powder by means of injection molding (IM), to create solid-dispersion based tablets. Fenofibrate was used as the model API, a polyvinyl caprolactame-polyvinyl acetate-polyethylene glycol graft co-polymer served as a matrix system. Formulations were injection-molded into tablets using state-of-the-art IM equipment. The resulting tablets were physico-chemically characterized and the drug release kinetics and mechanism were determined. Comparison tablets were produced, either directly from powder or from pre-processed pellets prepared via hot melt extrusion (HME). The content of the model drug in the formulations was 10% (w/w), 20% (w/w) and 30% (w/w), respectively. After 120min, both powder-based and pellet-based injection-molded tablets exhibited a drug release of 60% independent of the processing route. Content uniformity analysis demonstrated that the model drug was homogeneously distributed. Moreover, analysis of single dose uniformity also revealed geometric drug homogeneity between tablets of one shot. PMID:27012981

  9. Effects of process parameters in plastic, metal, and ceramic injection molding processes

    NASA Astrophysics Data System (ADS)

    Lee, Shi W.; Ahn, Seokyoung; Whang, Chul Jin; Park, Seong Jin; Atre, Sundar V.; Kim, Jookwon; German, Randall M.

    2011-09-01

    Plastic injection molding has been widely used in the past and is a dominant forming approach today. As the customer demands require materials with better engineering properties that were not feasible with polymers, powder injection molding with metal and ceramic powders has received considerable attention in recent decades. To better understand the differences in the plastic injection molding, metal injection molding, and ceramic injection molding, the effects of the core process parameters on the process performances has been studied using the state-of-the-art computer-aided engineering (CAE) design tool, PIMSolver® The design of experiments has been conducted using the Taguchi method to obtain the relative contributions of various process parameters onto the successful operations.

  10. Low Cost Injection Mold Creation via Hybrid Additive and Conventional Manufacturing

    SciTech Connect

    Dehoff, Ryan R.; Watkins, Thomas R.; List, III, Frederick Alyious; Carver, Keith; England, Roger

    2015-12-01

    The purpose of the proposed project between Cummins and ORNL is to significantly reduce the cost of the tooling (machining and materials) required to create injection molds to make plastic components. Presently, the high cost of this tooling forces the design decision to make cast aluminum parts because Cummins typical production volumes are too low to allow injection molded plastic parts to be cost effective with the amortized cost of the injection molding tooling. In addition to reducing the weight of components, polymer injection molding allows the opportunity for the alternative cooling methods, via nitrogen gas. Nitrogen gas cooling offers an environmentally and economically attractive cooling option, if the mold can be manufactured economically. In this project, a current injection molding design was optimized for cooling using nitrogen gas. The various components of the injection mold tooling were fabricated using the Renishaw powder bed laser additive manufacturing technology. Subsequent machining was performed on the as deposited components to form a working assembly. The injection mold is scheduled to be tested in a projection setting at a commercial vendor selected by Cummins.

  11. Flexural Properties of Injection-Molded Bamboo/pbs Composites

    NASA Astrophysics Data System (ADS)

    Ohkita, Kazuya; Takagi, Hitoshi

    In recent years, from an environmental perspective, there has been increasing interest in the change to a sustainable society. The use of natural-fiber-reinforced biodegradable composites has been proposed as one solution. Bamboo is an often used renewable bio-resource; it has an inherent advantage of rapid growth. Polybutylene succinate (PBS), used as matrix resin, has biodegradable characteristics. This paper describes flexural properties of bamboo/PBS composites prepared by injection molding. The following results were obtained. The flexural modulus was improved with increasing bamboo powder contents when the cylinder temperature of the injection molder was 140°C. However, the flexural strength showed the opposite tendency to be decreased with increasing bamboo powder contents. An SEM photomicrograph of the fracture surface for bamboo/PBS composites showed typical fracture behavior of pull-out fibers without fiber fracture. Furthermore, there was no adhesion of PBS resin on the bamboo fiber surface. Processing conditions affected mechanical properties of bamboo/PBS composites, imparting higher flexural strength and flexural modulus at high cylinder temperatures such as 180°C and 200°C.

  12. Process and mold for molding foamed plastic articles

    SciTech Connect

    Baumrucker, E.J.

    1984-10-30

    A method for forming foamed plastic articles which includes the steps of closing a mold; prepressurizing the mold cavity with gas to prevent premature diffusion of blowing gas from the material injected into the cavity; injecting a short shot of molten synthetic resin material containing a blowing agent into the cavity; venting a portion of the prepressurization gas during the injection step; and venting the remaining prepressurization gas from the mold cavity to a vacuum chamber means to allow expansion of the injected foamable resin material within the mold cavity, the vacuum drawing the resin material throughout the mold cavity. In addition, the vacuum chamber is coupled to the mold cavity through plural spaced passageways so that the vacuum is drawn at various locations throughout the cavity to thereby enhance the complete filling of the cavity with the injected material as it expands. The mold is vented following the injection step automatically at the expiration of a predetermined time following the closing of a nozzle of the injection apparatus. A mold for carrying out the process includes improved gas flow means for delivering gas to and venting gas from the mold cavity. The mold also includes improved sealing means for sealing the mold to maintain it in a pressurized state as desired.

  13. Analyzing melt homogeneity in a single screw plasticizing unit of an injection molding machine

    NASA Astrophysics Data System (ADS)

    Straka, K.; Praher, B.; Steinbichler, G.

    2013-10-01

    In injection molding investigations on mixing efficiency and thermal homogeneity of the melt in the screw chamber are of great interest as the directly effect the quality of the molded parts. For most injection molding applications mixing is performed in the single screw plasticizing unit of the injection molding machine. In this work, a CFD approach with two coupled fluid domains is used in order to describe the plasticizing process in an injection molding machine. One domain rotates and translates in axial direction (screw), the other one increases its length (chamber). On basis of the calculated pressure, velocity and temperature field of the polymer melt the thermal melt homogeneity is investigated. To analyze the optical-mechanical homogeneity of the melt a Euler-Lagrangian method is used to calculate the distribution of tracer particles within the screw chamber.

  14. FIBER LENGTH DISTRIBUTION MEASUREMENT FOR LONG GLASS AND CARBON FIBER REINFORCED INJECTION MOLDED THERMOPLASTICS

    SciTech Connect

    Kunc, Vlastimil; Frame, Barbara J; Nguyen, Ba N.; TuckerIII, Charles L.; Velez-Garcia, Gregorio

    2007-01-01

    Procedures for fiber length distribution (FLD) measurement of long fiber reinforced injection molded thermoplastics were refined for glass and carbon fibers. Techniques for sample selection, fiber separation, digitization and length measurement for both fiber types are described in detail. Quantitative FLD results are provided for glass and carbon reinforced polypropylene samples molded with a nominal original fiber length of 12.7 mm (1/2 in.) using equipment optimized for molding short fiber reinforced thermoplastics.

  15. Effect of Cross Sectional Geometry on PDMS Micro Peristaltic Pump Performance: Comparison of SU-8 Replica Molding vs. Micro Injection Molding

    PubMed Central

    Graf, Neil J.

    2013-01-01

    Two different fabrication methods were employed to fabricate micropumps with different cross-sectional channel geometries. The first was to fabricate rectangular cross-sectional microchannel geometries using the well known fabrication method of replica molding (REM).1 The second, and far less utilized fabrication technique, was to create microchannel molds using an in-house fabricated handheld micro injection molding apparatus. The injection mold apparatus was designed for use with elastomeric room temperature vulcanization (RTV) polymers, as opposed to most other injection molding machines, which are designed for use with thermoplastic polymers. The injection mold’s bottom plate was used as a microchannel molding template. The molding template was created by threading a small-diameter wire (150 μm or less) through the injection mold’s bottom plate, with subsequent adhesion and smoothing of a thin piece of aluminum foil over the wire-raised injection mold template. When molded against, the template produced a rounded/Gaussian-shaped PDMS microchannel. The design of the injection mold will be presented, along with a direct comparison for micropump performance metrics such as flow rate, valving characteristics, and maximum backpressures attainable for each of the respective micropump channel geometries. PMID:23917263

  16. Processing study of injection molding of silicon nitride for engine applications

    NASA Technical Reports Server (NTRS)

    Rorabaugh, M. E.; Yeh, H. C.

    1985-01-01

    The high hardness of silicon nitride, which is currently under consideration as a structural material for such hot engine components as turbine blades, renders machining of the material prohibitively costly; the near net shape forming technique of injection molding is accordingly favored as a means for component fabrication. Attention is presently given to the relationships between injection molding processing parameters and the resulting microstructural and mechanical properties of the resulting engine parts. An experimental program has been conducted under NASA sponsorship which tests the quality of injection molded bars of silicon nitride at various stages of processing.

  17. Improved silicon carbide for advanced heat engines. I - Process development for injection molding

    NASA Technical Reports Server (NTRS)

    Whalen, Thomas J.; Trela, Walter

    1989-01-01

    Alternate processing methods have been investigated as a means of improving the mechanical properties of injection-molded SiC. Various mixing processes (dry, high-sheer, and fluid) were evaluated along with the morphology and particle size of the starting beta-SiC powder. Statistically-designed experiments were used to determine significant effects and interactions of variables in the mixing, injection molding, and binder removal process steps. Improvements in mechanical strength can be correlated with the reduction in flaw size observed in the injection molded green bodies obtained with improved processing methods.

  18. Properties of high density polyethylene – Paulownia wood flour composites via injection molding

    Technology Transfer Automated Retrieval System (TEKTRAN)

    Paulownia wood (PW) flour is evaluated as a bio-based fiber reinforcement. Composites of high density polyethylene (HDPE), 25% by weight of PW, and either 0% or 5% by weight of maleated polyethylene (MAPE) were produced by twin screw compounding followed by injection molding. Molded test composite...

  19. Optimization of injection molding parameters for poly(styrene-isobutylene-styrene) block copolymer

    NASA Astrophysics Data System (ADS)

    Fittipaldi, Mauro; Garcia, Carla; Rodriguez, Luis A.; Grace, Landon R.

    2016-03-01

    Poly(styrene-isobutylene-styrene) (SIBS) is a widely used thermoplastic elastomer in bioimplantable devices due to its inherent stability in vivo. However, the properties of the material are highly dependent on the fabrication conditions, molecular weight, and styrene content. An optimization method for injection molding is herein proposed which can be applied to varying SIBS formulations in order to maximize ultimate tensile strength, which is critical to certain load-bearing implantable applications. The number of injection molded samples required to ascertain the optimum conditions for maximum ultimate tensile strength is limited in order to minimize experimental time and effort. Injection molding parameters including nozzle temperature (three levels: 218, 246, and 274 °C), mold temperature (three levels: 50, 85, and 120 °C), injection speed (three levels: slow, medium and fast) and holding pressure time (three levels: 2, 6, and 10 seconds) were varied to fabricate dumbbell specimens for tensile testing. A three-level L9 Taguchi method utilizing orthogonal arrays was used in order to rank the importance of the different injection molding parameters and to find an optimal parameter setting to maximize the ultimate tensile strength of the thermoplastic elastomer. Based on the Taguchi design results, a Response Surface Methodology (RSM) was applied in order to build a model to predict the tensile strength of the material at different injection parameters. Finally, the model was optimized to find the injection molding parameters providing maximum ultimate tensile strength. Subsequently, the theoretically-optimum injection molding parameters were used to fabricate additional dumbbell specimens. The experimentally-determined ultimate tensile strength of these samples was found to be in close agreement (1.2%) with the theoretical results, successfully demonstrating the suitability of the Taguchi Method and RSM for optimizing injection molding parameters of SIBS.

  20. Numerical prediction of flow induced fibers orientation in injection molded polymer composites

    NASA Astrophysics Data System (ADS)

    Oumer, A. N.; Hamidi, N. M.; Mat Sahat, I.

    2015-12-01

    Since the filling stage of injection molding process has important effect on the determination of the orientation state of the fibers, accurate analysis of the flow field for the mold filling stage becomes a necessity. The aim of the paper is to characterize the flow induced orientation state of short fibers in injection molding cavities. A dog-bone shaped model is considered for the simulation and experiment. The numerical model for determination of the fibers orientation during mold-filling stage of injection molding process was solved using Computational Fluid Dynamics (CFD) software called MoldFlow. Both the simulation and experimental results showed that two different regions (or three layers of orientation structures) across the thickness of the specimen could be found: a shell region which is near to the mold cavity wall, and a core region at the middle of the cross section. The simulation results support the experimental observations that for thin plates the probability of fiber alignment to the flow direction near the mold cavity walls is high but low at the core region. It is apparent that the results of this study could assist in decisions regarding short fiber reinforced polymer composites.

  1. Injection-Molded Soft Magnets Prepared from Fe-Based Metallic Glass: Mechanical and Magnetic Properties

    NASA Astrophysics Data System (ADS)

    Zhong, Tian; Huang, Ran; Huang, Jia; Ouyang, Wei

    2015-10-01

    The injection-molded metallic glass soft magnet is prepared from the powder of melt-spun ribbon of Fe36Co36B20Si4Nb4 glassy alloy and Nylon 6,6 of wt.% from 5 to 20 via the polymer injection molding technology. The product is characterized by the SEM, mechanical, and magnetic test. The results indicate that this type of materials has comparable mechanical properties and morphological feature with the conventional injection-molded NdFeB magnet and exhibits excellent soft magnetic behaviors. The magnetic properties of the injected magnets are compared with the raw metallic glass, solvent-casted resin bonding magnets, and thermal-treated magnets to confirm that the processing temperature of Nylon injection does not affect the magnetism. The injection technology is a practical processing method to be applied on the metallic glass for potential usage.

  2. Influence of the polypropylene structure on the replication of nanostructures by injection molding

    NASA Astrophysics Data System (ADS)

    Vera, Julie; Brulez, Anne-Catherine; Contraires, Elise; Larochette, Mathieu; Valette, Stéphane; Benayoun, Stéphane

    2015-11-01

    In this paper, an experimental study of replication by injection molding of sub-micrometer features is presented. Two polypropylenes with different melt flow rates (MFR) were used throughout this study. The used removable mold insert was textured with a femtosecond laser. Replication of these periodic structures, called ripples, is thus investigated. Despite different MFR, we show that the viscosities of the two polymers at the investigated temperatures and injection shear rates are similar. The reproducibility of the injected molded samples and the texture of the mold were analyzed. We propose a specific methodology to quantify the reproducibility quality replicas. The latter introduces morphological parameters such as anisotropy rate, power density, etc. A difference between the two replicas was noticeable. Based on rheological analysis, the viscosity was ruled out as the origin of this difference. Other properties were identified as the source such as the chain length and the stress relaxation time. Their impact on the replication quality was investigated and found interesting.

  3. Design and fabrication of optical homogenizer with micro structure by injection molding process

    NASA Astrophysics Data System (ADS)

    Chen, C.-C. A.; Chang, S.-W.; Weng, C.-J.

    2008-08-01

    This paper is to design and fabricate an optical homogenizer with hybrid design of collimator, toroidal lens array, and projection lens for beam shaping of Gaussian beam into uniform cylindrical beam. TracePro software was used to design the geometry of homogenizer and simulation of injection molding was preceded by Moldflow MPI to evaluate the mold design for injection molding process. The optical homogenizer is a cylindrical part with thickness 8.03 mm and diameter 5 mm. The micro structure of toroidal array has groove height designed from 12 μm to 99 μm. An electrical injection molding machine and PMMA (n= 1.4747) were selected to perform the experiment. Experimental results show that the optics homogenizer has achieved the transfer ratio of grooves (TRG) as 88.98% and also the optical uniformity as 68% with optical efficiency as 91.88%. Future study focuses on development of an optical homogenizer for LED light source.

  4. Mechanical and Electrical Properties of Vapor Grown Carbon Fiber/Polypropylene Composites Made by Injection Molding

    NASA Astrophysics Data System (ADS)

    Takahashi, Yoshihiko; Yamagiwa, Yoshitoshi; Kiyono, Ryoutaro; Fujii, Tsuneo

    We made pellets by adding 0-20 wt% vapor grown carbon fiber (VGCF) to polypropylene and made an injection molding test piece with the pellets so as to test the rheological, as well as the mechanical, electrical, and injection molding properties. In the test piece made by injection molding, the quantity of VGCF in the surface layer is extremely small as compared to the quantity of addition. The value of resistance at the end of flow of the injection-molded product is smaller than that measured at other locations, which is considered to be the influence of the fountain flow at the end of flow. In addition, it is known that the above phenomenon is attributable to the fact that the orientation is in the direction of thickness in the same way as the orientation of glass fiber and carbon fiber. Even if the additive rate of VGCF is the same, the value of resistance changes substantially depending on the thickness of injection-molded products. One of the causes is considered to be the orientation of VGCF, and the orientation of VGCF in the test piece is considered to be strong in the direction of flow. There exists a proportionality relation between the shear rate and the value of resistance calculated on the basis of the rate of flow, which is one of the molding conditions.

  5. Experimental and numerical analysis of the temperature distribution of injection molded products using protruding microprobes

    NASA Astrophysics Data System (ADS)

    Liu, Shih-Jung; Ho, Chia-Wei

    2011-05-01

    Injection molding has been one of the most important polymer processing methods for manufacturing plastic parts. In the process, the temperature is an important parameter that influences process features such as cycle times, crystallization rates, degree of crystallinity, melt flow properties, and molded product qualities. This study aims to, experimentally and numerically, examine the three-dimensional temperature distribution along the melt flow path of injection molded parts. A special experimental set-up, which includes an injection mold equipped with protruding microprobes for guiding embedded thermocouples, was designed and built to measure the temperature field along the flow path, i.e., inside the runner and the cavity, of injection molded products. The experimental results suggested that the disturbance induced by the probes remained negligible and precise temperature profiles could be measured at various positions inside the cavity. A significant increase of melt temperature was found to result from the viscous dissipation of the polymeric materials in the runner. Additionally, a commercially available code was employed to simulate and predict the temperature variation in injection molded parts. It was shown that the numerical simulation predicted better the temperature distributions inside the cavity than those along the runner.

  6. Reduction of birefringence in a skin-layer of injection molded polymer strips using CO{sub 2} laser irradiation

    SciTech Connect

    Kurosaki, Yasuo; Satoh, Isao; Saito, Takushi

    1995-12-31

    Injection molding of polymers is currently utilized for numerous industrial applications. Because of high productivity and stable quality of molded products, the injection-molding process makes the production costs lower, and therefore, is expected to spread more widely in the future. This paper deals with a technique for improving the optical quality of injection molded polymer products using radiative heating. The birefringence frozen in a skin-layer of the molded part was reduced by CO{sub 2} laser heating, and the efficiency of this technique was investigated experimentally. Namely, a simple numerical calculation was performed to estimate the heating efficiency of CO{sub 2} laser in the polymer, effects of radiation heating on the skin-layer of the molded polymer were observed by using a mold with transparent windows, and the residual birefringence frozen in the final molded specimen was measured. The results clearly showed that the birefringence in the skin-layer of injection molded polymer strips was reduced with CO{sub 2} laser heating. The authors believe that the proposed method for reducing the birefringence frozen in injection-molded polymer products is suitable for practical molding, because process time required for the injection-molding is only slightly increased with this method.

  7. Microcellular injection molding and particulate leaching of thermoplastic polyurethane (TPU) scaffolds

    NASA Astrophysics Data System (ADS)

    Mi, Hao-Yang; Jing, Xin; Turng, Lih-Sheng; Peng, Xiang-Fang

    2014-05-01

    Microcellular injection moldingand particulate leaching methods were combined to fabricate porousand interconnectedthermoplastic polyurethane (TPU) tissue engineering scaffolds. Water soluble polyvinyl alcohol (PVOH) and sodium chloride (NaCl) were used as porogens to improve the porosity and interconnectivity, as well as the hydrophilicity, of the scaffolds. The effect of each factor-namely, PVOH, NaCl, and microcellular injection molding-on scaffold morphology was investigated. It was found that the microcellular injection molding processwas effectiveatproducing high pore density and porosity. The addition of PVOH decreasedthe pore diameter and increasedthe pore density. Furthermore, scaffolds with NaCl and PVOH porogens hadbetter interconnectivity. The residual PVOH improved the hydrophilicity of the scaffold.

  8. Study of process parameters on optical qualities for injection-molded plastic lenses.

    PubMed

    Lai, Huai En; Wang, Pei Jen

    2008-04-20

    Numerical simulations for mold-flow analysis and experimental measurements of injection-molded plastic lenses have been conducted for investigation of optical qualities, residual birefringence, and form accuracy resulting from various pertinent process conditions. First, residual birefringence distributions on the lens have been predicted and verified experimentally. Furthermore, full-scale factorial design of experiments was conducted to comprehend the influences of qualities, such as shear stresses, form accuracy, and volumetric deviation, on the measured primary or Seidel aberrations. In conclusion, residual birefringence induced by stresses represented by photoelasticity measurements agrees well with the numerical predictions and the experimental results indicate that the residual birefringence is mainly generated during the mold-filling stage. In addition, spherical aberration of the injection-molded plastic lenses is more sensitive to the pertinent qualities as compared to coma and astigmatism. PMID:18425174

  9. A Model for Fiber Length Attrition in Injection-Molded Long-Fiber Composites

    SciTech Connect

    TuckerIII, Charles L.; Phelps, Jay H; El-Rahman, Ahmed Abd; Kunc, Vlastimil

    2013-01-01

    Long-fiber thermoplastic (LFT) composites consist of an engineering thermoplastic matrix with glass or carbon reinforcing fibers that are initially 10 to 13 mm long. When an LFT is injection molded, flow during mold filling orients the fibers and degrades the fiber length. Fiber orientation models for injection molding are well developed, and special orientation models for LFTs have been developed. Here we present a detailed quantitative model for fiber length attrition in a flowing fiber suspension. The model tracks a discrete fiber length distribution (FLD) at each spatial node. Key equations are a conservation equation for total fiber length, and a breakage rate equation. The breakage rate is based on buckling of fibers due to hydrodynamic forces, when the fibers are in unfavorable orientations. The FLD model is combined with a mold filling simulation to predict spatial and temporal variations in fiber length distribution in a mold cavity during filling. The predictions compare well to experiments on a glassfiber/ PP LFT molding. Fiber length distributions predicted by the model are easily incorporated into micromechanics models to predict the stress-strain behavior of molded LFT materials. Author to whom correspondence should be addressed; electronic mail: ctucker@illinois.edu 1

  10. Electrical and dielectric properties of foam injection-molded polypropylene/multiwalled carbon nanotube composites

    SciTech Connect

    Ameli, A.; Nofar, M.; Saniei, M.; Hossieny, N.; Park, C. B.; Pötschke, P.

    2015-05-22

    A combination of high dielectric permittivity (ε′) and low dielectric loss (tan δ) is required for charge storage applications. In percolative systems such as conductive polymer composites, however, obtaining high ε′ and low tan δ is very challenging due to the sharp insulation-conduction transition near the threshold region. Due to the particular arrangement of conductive fillers induced by both foaming and injection molding processes, they may address this issue. Therefore, this work evaluates the application of foam injection molding process in fabricating polymer nanocomposites for energy storage. Polypropylene-multiwalled carbon nanotubes (PP-MWCNT) composites were prepared by melt mixing and foamed in an injection molding process. Electrical conductivity (σ), ε′ and tan δ were then characterized. Also, scanning and transmission electron microscopy (SEM and TEM) was used to investigate the carbon nanotube’s arrangement as well as cellular morphology. The results showed that foam injection-molded composites exhibited highly superior dielectric properties to those of solid counterparts. For instance, foamed samples had ε′=68.3 and tan δ =0.05 (at 1.25 vol.% MWCNT), as opposed to ε′=17.8 and tan δ=0.04 in solid samples (at 2.56 vol.% MWCNT). The results of this work reveal that high performance dielectric nanocomposites can be developed using foam injection molding technologies for charge storage applications.

  11. Electrical and dielectric properties of foam injection-molded polypropylene/multiwalled carbon nanotube composites

    NASA Astrophysics Data System (ADS)

    Ameli, A.; Nofar, M.; Saniei, M.; Hossieny, N.; Park, C. B.; Pötschke, P.

    2015-05-01

    A combination of high dielectric permittivity (ɛ') and low dielectric loss (tan δ) is required for charge storage applications. In percolative systems such as conductive polymer composites, however, obtaining high ɛ' and low tan δ is very challenging due to the sharp insulation-conduction transition near the threshold region. Due to the particular arrangement of conductive fillers induced by both foaming and injection molding processes, they may address this issue. Therefore, this work evaluates the application of foam injection molding process in fabricating polymer nanocomposites for energy storage. Polypropylene-multiwalled carbon nanotubes (PP-MWCNT) composites were prepared by melt mixing and foamed in an injection molding process. Electrical conductivity (σ), ɛ' and tan δ were then characterized. Also, scanning and transmission electron microscopy (SEM and TEM) was used to investigate the carbon nanotube's arrangement as well as cellular morphology. The results showed that foam injection-molded composites exhibited highly superior dielectric properties to those of solid counterparts. For instance, foamed samples had ɛ'=68.3 and tan δ =0.05 (at 1.25 vol.% MWCNT), as opposed to ɛ'=17.8 and tan δ=0.04 in solid samples (at 2.56 vol.% MWCNT). The results of this work reveal that high performance dielectric nanocomposites can be developed using foam injection molding technologies for charge storage applications.

  12. Dimensional Changes of Acrylic Resin Denture Bases: Conventional Versus Injection-Molding Technique

    PubMed Central

    Gharechahi, Jafar; Asadzadeh, Nafiseh; Shahabian, Foad; Gharechahi, Maryam

    2014-01-01

    Objective: Acrylic resin denture bases undergo dimensional changes during polymerization. Injection molding techniques are reported to reduce these changes and thereby improve physical properties of denture bases. The aim of this study was to compare dimensional changes of specimens processed by conventional and injection-molding techniques. Materials and Methods: SR-Ivocap Triplex Hot resin was used for conventional pressure-packed and SR-Ivocap High Impact was used for injection-molding techniques. After processing, all the specimens were stored in distilled water at room temperature until measured. For dimensional accuracy evaluation, measurements were recorded at 24-hour, 48-hour and 12-day intervals using a digital caliper with an accuracy of 0.01 mm. Statistical analysis was carried out by SPSS (SPSS Inc., Chicago, IL, USA) using t-test and repeated-measures ANOVA. Statistical significance was defined at P<0.05. Results: After each water storage period, the acrylic specimens produced by injection exhibited less dimensional changes compared to those produced by the conventional technique. Curing shrinkage was compensated by water sorption with an increase in water storage time decreasing dimensional changes. Conclusion: Within the limitations of this study, dimensional changes of acrylic resin specimens were influenced by the molding technique used and SR-Ivocap injection procedure exhibited higher dimensional accuracy compared to conventional molding. PMID:25584050

  13. The reflectivity, wettability and scratch durability of microsurface features molded in the injection molding process using a dynamic tool tempering system

    NASA Astrophysics Data System (ADS)

    Kuhn, Sascha; Burr, August; Kübler, Michael; Deckert, Matthias; Bleesen, Christoph

    2011-02-01

    In this paper the replication qualities of periodically and randomly arranged micro-features molded in the injection molding process and their effects on surface properties are studied. The features are molded in PC, PMMA and PP at different mold wall temperatures in order to point out the necessity and profitability of a variotherm mold wall temperature control system. A one-dimensional heat conduction model is proposed to predict the cycle times of the variotherm injection molding processes. With regard to these processes, the molding results are compared to the molded surface feature heights using an atomic force microscope. In addition, the effects of the molded surface features on macroscopic surfaces are characterized in terms of light reflection using a spectrometer and in terms of water wettability by measuring the static contact angle. Furthermore, due to the sensitivity of the surface features on the molded parts, their durability is compared in a scratch test with a diamond tip. This leads to successful implementation in applications in which the optical appearance, in terms of gloss and reflection, and the water repellence, in terms of drag flow and adhesion, are of importance.

  14. Bio-inspired piezoelectric artificial hair cell sensor fabricated by powder injection molding

    NASA Astrophysics Data System (ADS)

    Han, Jun Sae; Oh, Keun Ha; Moon, Won Kyu; Kim, Kyungseop; Joh, Cheeyoung; Seo, Hee Seon; Bollina, Ravi; Park, Seong Jin

    2015-12-01

    A piezoelectric artificial hair cell sensor was fabricated by the powder injection molding process in order to make an acoustic vector hydrophone. The entire process of powder injection molding was developed and optimized for PMN-PZT ceramic powder. The artificial hair cell sensor, which consists of high aspect ratio hair cell and three rectangular mechanoreceptors, was precisely fabricated through the developed powder injection molding process. The density and the dielectric property of the fabricated sensor shows 98% of the theoretical density and 85% of reference dielectric property of PMN-PZT ceramic powder. With regard to homogeneity, three rectangular mechanoreceptors have the same dimensions, with 3 μm of tolerance with 8% of deviation of dielectric property. Packaged vector hydrophones measure the underwater acoustic signals from 500 to 800 Hz with -212 dB of sensitivity. Directivity of vector hydrophone was acquired at 600 Hz as analyzing phase differences of electric signals.

  15. Cooling effects study by considering a turbulence model in injection molding

    NASA Astrophysics Data System (ADS)

    Hsu, Fu-Hung; Wu, Bo-Han; Huang, Chao-Tsai; Chang, Rong-Yeu

    2014-05-01

    Cooling stage is critical in injection molding process. A well designed cooling system can effectively shorten cycle time and improve product quality. Three-dimensional cooling analysis has been embedded in injection molding simulation which provides a useful tool for cooling system design validation. However, the current simulation tool is not perfect yet since it does not consider turbulent flow and pipe surface roughness effect. In the current study, a latest simulation tool was applied which can predict the turbulent flow effect on cooling. Two cooling systems (conventional and conformal) were simulated and compared to each other. Turbulence model and surface roughness effects were also studied. The simulation results show a good agreement with experimental data which is helpful at the design stage of an injection molding cooling system.

  16. Influence of Mold Surface Treatments on Flow of Polymer in Injection Moulding. Application to Weldlines

    NASA Astrophysics Data System (ADS)

    Chailly, M.; Charmeau, J.-Y.; Bereaux, Y.; Monasse, B.

    2007-04-01

    Due to increasing expectations from the market, the aspect of molded parts has to be improved constantly. Some of the defects observed on these parts such as weldlines are related to the filling stage. To limit this, we investigated the influence on weldlines using various surface deposits on the mold surface, mainly PVD and PACVD deposits : Chromium nitride (CrN), Titanium nitride (TiN), Diamond like Carbon (DLC), Chromium and polished steel (PG) on an instrumented plate mold. Injection campaign was led on three polymers which differ in terms of nature (amorphous, semi-crystalline, copolymers). We studied the evolution of the dimensions of weldlines appearing on the plate using the same injection parameters for a given polymer, but with various deposits and thicknesses. Another aspect that had been investigated is the morphology of the weldline through the thickness of the part, depending on polymer nature. Adhesion of polymer at the flow front with the mold surface proved to change. The modification of the initial contact in the filling stage and thus the thermal resistance at the mold implied a change in the process, increasing or reducing the pressure loss in the flow and differential shrinkage in the final part. The induced impact on dimensions of the weldlines allowed to distinguish which surface treatments were able to reduce the defect. A complementary study was led on both polymers in molten state and deposits in terms of wetting using a sessile drop method to confirm the adhesion at the polymer/mold interface. This study proved the influence of the use of surface treatments has clearly an impact on the filling stage of the injection molding process, and it is necessary to get a better knowledge of the interactions between physical adhesion, tribology of polymer/mold contact, and thermal properties of the coatings and their impact on solidification of the polymer.

  17. The shrinkage behavior and surface topographical investigation for micro metal injection molding

    NASA Astrophysics Data System (ADS)

    Islam, A.; Giannekas, N.; Marhöfer, D. M.; Tosello, G.; Hansen, H. N.

    2015-05-01

    Metal injection molding (MIM) is a near net shape manufacturing technology that can produce highly complex and dimensionally stable parts for high end engineering applications. Despite the recent growth and industrial interest, micro metal molding is yet to be the field of extensive research especially when it is compared with micro molding of thermoplastics. The current paper presents a thorough investigation on the process of metal injection molding where it systematically characterizes the effects of important process conditions on the shrinkage and surface quality of molded parts with micro features. Effects of geometrical factors like feature dimensions and distance from the gate on the replication quality are studied. The influence of process conditions on the achievable roughness for the final metal parts is discussed based on the experimental findings. The test geometry is characterized by 2½D surface structures containing thin ribs of different aspect ratios and thicknesses in the sub-mm dimensional range. The test parts were molded from Catamold 316L with a conventional injection molding machine. Afterwards, the parts were de-binded and sintered to produce the final test samples. Among the different process parameters studied, the melt temperature was the most influential parameters for better replication and dimensional stability of the final part. The results presented in the paper clearly show that the shrinkage in metal part is not uniform in the micro scale. It depends on the feature dimensions and also on the process conditions. A thin section of the part exhibits higher relative shrinkage compared with a thicker section. Based on these findings, it can be concluded that a micro part molded by MIM process will have higher relative shrinkage compared to a macro part made with the same process.

  18. Long-Fiber Thermoplastic Injection Molded Composites: from Process Modeling to Property Prediction

    SciTech Connect

    Nguyen, Ba Nghiep; Holbery, Jim D.; Johnson, Kenneth I.; Smith, Mark T.

    2005-09-01

    Recently, long-fiber filled thermoplastics have become a great interest to the automotive industry since these materials offer much better property performance (e.g. elastic moduli, strength, durability…) than their short-fiber analogues, and they can be processed through injection molding with some specific tool design. However, in order that long-fiber thermoplastic injection molded composites can be used efficiently for automotive applications, there is a tremendous need to develop process and constitutive models as well as computational tools to predict the microstructure of the as-formed composite, and its resulting properties and macroscopic responses from processing to the final product. The microstructure and properties of such a composite are governed by i) flow-induced fiber orientation, ii) fiber breakage during injection molding, and iii) processing conditions (e,g. pressure, mold and melt temperatures, mold geometries, injection speed, etc.). This paper highlights our efforts to address these challenging issues. The work is an integrated part of a research program supported by the US Department of Energy, which includes • The development of process models for long-fiber filled thermoplastics, • The construction of an interface between process modeling and property prediction as well as the development of new constitutive models to perform linear and nonlinear structural analyses, • Experimental characterization of model parameters and verification of the model predictions.

  19. An apparatus for in situ x-ray scattering measurements during polymer injection molding

    NASA Astrophysics Data System (ADS)

    Rendon, Stanley; Fang, Jun; Burghardt, Wesley R.; Bubeck, Robert A.

    2009-04-01

    We report a novel instrument for synchrotron-based in situ x-ray scattering measurements during injection molding processing. It allows direct, real-time monitoring of molecular-scale structural evolution in polymer materials undergoing a complex processing operation. The instrument is based on a laboratory-scale injection molding machine, and employs customized mold tools designed to allow x-ray access during mold filling and subsequent solidification, while providing sufficient robustness to withstand high injection pressures. The use of high energy, high flux synchrotron radiation, and a fast detector allows sufficiently rapid data acquisition to resolve time-dependent orientation dynamics in this transient process. Simultaneous monitoring of temperature and pressure signals allows transient scattering data to be referenced to various stages of the injection molding cycle. Representative data on a commercial liquid crystalline polymer, Vectra® B950, are presented to demonstrate the features of this apparatus; however, it may find application in a wide range of polymeric materials such as nanocomposites, semicrystalline polymers and fiber-reinforced thermoplastics.

  20. Flow-induced birefringence: the hidden PSF killer in high performance injection-molded plastic optics

    NASA Astrophysics Data System (ADS)

    Chidley, Matthew D.; Tkaczyk, Tomasz; Kester, Robert; Descour, Michael R.

    2006-02-01

    A 7-mm OD, NA = 1 water immersion injection-molded plastic endoscope objective has been fabricated for a laser scanning fiber confocal reflectance microscope (FCRM) system specifically designed for in vivo detection of cervical and oral pre-cancers. Injection-molded optics was selected for the ability to incorporate aspheric surfaces into the optical design and its high volume capabilities. Our goal is high performance disposable endoscope probes. This objective has been built and tested as a stand-alone optical system, a Strehl ratio greater than 0.6 has been obtained. One of the limiting factors of optical performance is believed to be flow-induced birefringence. We have investigated different configurations for birefringence visualization and believe the circular polariscope is most useful for inspection of injection-molded plastic optics. In an effort to decrease birefringence effects, two experiments were conducted. They included: (1) annealing of the optics after fabrication and (2) modifying the injection molding prameters (packing pressures, injection rates, and hold time). While the second technique showed improvement, the annealing process could not improve quality without physically warping the lenses. Therefore, to effectively reduce flow-induced birefringence, molding conditions have to be carefully selected. These parameters are strongly connected to the physical part geometry. Both optical design and fabrication technology have to be considered together to deliver low birefringence while maintaining the required manufacturing tolerances. In this paper we present some of our current results that illustrate how flow-induced birefringence can degrade high performance injection-molded plastic optical systems.

  1. An easy-to-decompose binder for Ti metal injection molding: Preparation and characterization of feedstock

    NASA Astrophysics Data System (ADS)

    Hayat, Muhammad Dilawer; Wen, Guian; Cao, Peng

    2015-03-01

    Impurity control is crucial to Ti metal powder injection molding (Ti-MIM) since titanium is a universal solvent to interstitial elements such as oxygen, carbon and nitrogen. In this study, a low decomposition temperature binder system was developed; the rheological and solvent debinding assessments of the feedstock formulated from this binder were performed. Solvent mixing was employed to prepare homogeneous feedstocks. Effects of powder shape and solid loading on rheological properties were evaluated. After injection molding, a debinding profile was constructed. The debound parts were then characterized by microstructural observation.

  2. A new binder for powder injection molding titanium and other reactive metals

    SciTech Connect

    Weil, K. Scott; Nyberg, Eric A.; Simmons, Kevin L.

    2006-06-26

    We have developed a new aromatic-based binder for powder injection molding (PIM) reactive metals, such as titanium, zirconium, niobium, tungsten, and molybdenum. Because of careful selection of the binder constituents, thermal removal is readily accomplished at low temperatures and short-times via vacuum sublimation. In this way the binder can be cleanly extracted from the green part prior to sintering to minimize the amount of residual carbon left in the final component. Rheological measurements indicate that powder loadings in the PIM feedstock as high as 67 vol% could be achieved using the new binder system, while still maintaining low mixing torques and injection molding pressures.

  3. Surface topographic characterization for polyamide composite injection molds made of aluminum and copper alloys.

    PubMed

    Pereira, A; Hernández, P; Martinez, J; Pérez, J A; Mathia, T G

    2014-01-01

    In order to ensure flexibility and rapid new product development, the mold industry made use of soft materials for cavity inserts in injection molds. However, materials of this kind are prone to wear. This article analyzes the topographic characterization of the surface and wear processes in injection molds cavities. Two materials have been used to produce the cavities: aluminum alloy EN AW‐6082 T4 and copper alloy Cu Zn39 Pb3. The surface topography was measured with the use of optical interferometry profiling technology; roughness and surface parameters were determined according to ISO 4287, ISO 25178, and EUR 15178N. In order to complete this research, an experimental part with different thicknesses and shapes was designed, and cavity inserts of aluminum and copper were made. Polyamide PA6, with 30% fiberglass reinforcement, was employed in the experimental procedure. Measurements of cavity mold surfaces were performed after 9,200 cycles on each mold and at different locations on the mold. The surface measurement was made with a white light vertical scanning interferometry, also known as coherence scanning interferometry (ISO DIS 25178‐604). The results are analyzed and differences between the two types of cavity inserts materials are discussed. PMID:23447356

  4. Three-Dimensional Simulation And Design Sensitivity Analysis Of The Injection Molding Process

    NASA Astrophysics Data System (ADS)

    Ilinca, Florin; Hétu, Jean-François

    2004-06-01

    Getting the proper combination of different process parameters such as injection speed, melt temperature and mold temperature is important in getting a part that minimizes warpage and has the desired mechanical properties. Very often a successful design in injection molding comes at the end of a long trial and error process. Design Sensitivity Analysis (DSA) can help molders improve the design and can produce substantial investment savings in both time and money. This paper investigates the ability of the sensitivity analysis to drive an optimization tool in order to improve the quality of the injected part. The paper presents the solution of the filling stage of the injection molding process by a 3D finite element solution algorithm. The sensitivity of the solution with respect to different process parameters is computed using the continuous sensitivity equation method. Solutions are shown for the non-isothermal filling of a rectangular plate with a polymer melt behaving as a non-Newtonian fluid. The paper presents the equations for the sensitivity of the velocity, pressure and temperature and their solution by finite elements. Sensitivities of the solution with respect to the injection speed, the melt and mold temperatures are shown.

  5. Foam injection molding of poly(lactic acid) with physical blowing agents

    NASA Astrophysics Data System (ADS)

    Pantani, R.; Sorrentino, A.; Volpe, V.; Titomanlio, G.

    2014-05-01

    Foam injection molding uses environmental friendly blowing agents under high pressure and temperature to produce parts having a cellular core and a compact solid skin (the so-called "structural foam"). The addition of a supercritical gas reduces the part weight and at the same time improves some physical properties of the material through the promotion of a faster crystallization; it also leads to the reduction of both the viscosity and the glass transition temperature of the polymer melt, which therefore can be injection molded adopting lower temperatures and pressures. These aspects are of extreme interest for biodegradable polymers, which often present a very narrow processing window, with the suitable processing temperatures close to the degradation conditions. In this work, foam injection molding was carried out by an instrumented molding machine, able to measure the pressure evolution in different positions along the flow-path. The material adopted was a biodegradable polymer, namely the Poly(lactic acid), PLA. The effect of a physical blowing agent (PBA) on the viscosity was measured. The density reduction and the morphology of parts obtained by different molding conditions was assessed.

  6. Measurement and computation of thermal stresses in injection molding of amorphous and crystalline polymers

    NASA Astrophysics Data System (ADS)

    Farhoudi, Yalda

    1998-12-01

    An integrated experimental and theoretical study of the residual thermal stresses has been carried out. The final stress profiles along the thickness were measured in an amorphous and a semi-crystalline injection molded polymer using the layer removal technique. The two materials exhibited drastically distinct residual profiles. Furthermore, processing parameters such as melt and coolant temperatures, pressure history, and mold thickness were found to modify the profiles. In order to elucidate the findings, two models were derived. The two-dimensional free mold shrinkage model was developed to provide a rapid estimation of thermal stresses and the main features of their profile. A more complex model was developed by integrating the stress analysis with the simulation of the complete injection molding cycle by McKam. This model accounts for the fountain flow effect, the crystallization, and the PVT behavior of the material. With the help of the model predictions, explanations were provided for the occurrence of various regions in the residual stress profiles. Transitions or reversal of the regions under variable conditions or material properties were observed to be mainly determined by the ratio of the thermal to the pressure effects. Using these concepts, practical conclusions were drawn for controlling the residual stresses. As an alternative for optimization of injection molding with respect to residual stresses, inverse methods were developed to calculate the pressure history or the initial temperature distribution required to produce a prescribed residual stress distribution. These methods were tested using direct solutions with added errors and experimental stress data.

  7. Adhesion strength between thermoplastics and its polyurethane coating made by using the technology combination of injection molding and reaction injection molding

    NASA Astrophysics Data System (ADS)

    Bloß, P.; Böhme, A.; Müller, J.; Krajewsky, P.; Michaelis, J.

    2014-05-01

    A complete equipment for injection molding (IM) of a thermoplastic (TP) carrier and reaction injection molding (RIM) of polyurethane (PUR) coatings including IM and RIM machines, a color module for PUR, and a robot was built up. A modularly composed sliding split mold was constructed and manufactured allowing different parts including thicker (2 mm thickness) soft touch and thin (0.4 mm) lacquer PUR coatings. As TP PC/ABS and PA6 GF15 compounds were used, and aromatic and aliphatic PUR systems as well. From the parts made by IM+RIM, test specimens for peel force measurements were cut. These investigations were performed prior and after ageing under climatic conditions @ 50 % RH and temperature changes between -30 °C and 90 °C. By varying IM processing parameters, we have found that mold and TP temperatures are particularly important for the adhesion strength between TP and PUR. The waiting time between the end of TP cooling and PUR injection has a minor influence on its mean value. However, to short waiting times may result in inhomogeneous adhesion. It was surprising that surface defects of the TP carrier leads also to inhomogeneous adhesion. We have observed that ageing may cause an increase and decrease of adhesions strength depending on the TP+PUR system used. We have found that the results are valid only for the actual TP and PUR combination. A generalization seems to be inappropriate, hence, the actual combination should be investigated to prevent unwanted surprises when the coated TP part is in its application.

  8. Powder Injection Molding of Ceria-Stabilized, Zirconia-Toughened Mullite Parts for UAV Engine Components

    NASA Astrophysics Data System (ADS)

    Martin, Renee; Vick, Michael; Enneti, Ravi K.; Atre, Sundar V.

    2013-11-01

    Powder injection molding (PIM) of ceria-stabilized, zirconia-toughened mullite composites were investigated in the present article with the goal of obtaining performance enhancement in complex geometries for energy and transportation applications. A powder-polymer mixture (feedstock) was developed and characterized to determine its suitability for fabricating complex components using the PIM process. Test specimens were injection molded and subsequently debound and sintered. The sintered properties indicated suitable properties for engine component applications used in unmanned aerial vehicles (UAVs). The measured feedstock properties were used in computer simulations to assess the mold-filling behavior for a miniature turbine stator. The results from the measurements of rheological and thermal properties of the feedstock combined with the sintered properties of the ceria-stabilized, zirconia-toughened mullite strongly indicate the potential for enhancing the performance of complex geometries used in demanding operating conditions in UAV engines.

  9. Validation of New Process Models for Large Injection-Molded Long-Fiber Thermoplastic Composite Structures

    SciTech Connect

    Nguyen, Ba Nghiep; Jin, Xiaoshi; Wang, Jin; Kunc, Vlastimil; Tucker III, Charles L.

    2012-02-23

    This report describes the work conducted under the CRADA Nr. PNNL/304 between Battelle PNNL and Autodesk whose objective is to validate the new process models developed under the previous CRADA for large injection-molded LFT composite structures. To this end, the ARD-RSC and fiber length attrition models implemented in the 2013 research version of Moldflow was used to simulate the injection molding of 600-mm x 600-mm x 3-mm plaques from 40% glass/polypropylene (Dow Chemical DLGF9411.00) and 40% glass/polyamide 6,6 (DuPont Zytel 75LG40HSL BK031) materials. The injection molding was performed by Injection Technologies, Inc. at Windsor, Ontario (under a subcontract by Oak Ridge National Laboratory, ORNL) using the mold offered by the Automotive Composite Consortium (ACC). Two fill speeds under the same back pressure were used to produce plaques under slow-fill and fast-fill conditions. Also, two gating options were used to achieve the following desired flow patterns: flows in edge-gated plaques and in center-gated plaques. After molding, ORNL performed measurements of fiber orientation and length distributions for process model validations. The structure of this report is as follows. After the Introduction (Section 1), Section 2 provides a summary of the ARD-RSC and fiber length attrition models. A summary of model implementations in the latest research version of Moldflow is given in Section 3. Section 4 provides the key processing conditions and parameters for molding of the ACC plaques. The validations of the ARD-RSC and fiber length attrition models are presented and discussed in Section 5. The conclusions will be drawn in Section 6.

  10. Thermal properties of extruded/injection-molded poly(lactic acid) and biobased composites

    Technology Transfer Automated Retrieval System (TEKTRAN)

    In order to determine the degree of compatibility between PLA and different biomaterials (fibers), PLA was compounded with sugar beet pulp and apple fibers. Fibers were added at 85:15 and 70:30 PLA:Fiber. The composites were blended by extrusion followed by injection molding. Differential Scannin...

  11. DAMAGE MODELING OF INJECTION-MOLDED SHORT- AND LONG-FIBER THERMOPLASTICS

    SciTech Connect

    Nguyen, Ba Nghiep; Kunc, Vlastimil; Bapanapalli, Satish K.; Phelps, Jay; Tucker III, Charles L.

    2009-10-30

    This article applies the recent anisotropic rotary diffusion – reduced strain closure (ARD-RSC) model for predicting fiber orientation and a new damage model for injection-molded long-fiber thermoplastics (LFTs) to analyze progressive damage leading to total failure of injection-molded long-glass-fiber/polypropylene (PP) specimens. The ARD-RSC model was implemented in a research version of the Autodesk Moldflow Plastics Insight (MPI) processing code, and it has been used to simulate injection-molding of a long-glass-fiber/PP plaque. The damage model combines micromechanical modeling with a continuum damage mechanics description to predict the nonlinear behavior due to plasticity coupled with damage in LFTs. This model has been implemented in the ABAQUS finite element code via user-subroutines and has been used in the damage analyses of tensile specimens removed from the injection-molded long-glass-fiber/PP plaques. Experimental characterization and mechanical testing were performed to provide input data to support and validate both process modeling and damage analyses. The predictions are in agreement with the experimental results.

  12. CO-INJECTION RESIN TRANSFER MOLDING FOR OPTIMIZATION OF INTEGRAL ARMOR

    EPA Science Inventory

    To address the cost and performance barriers which hinder the introduction of composite materials for combat ground vehicle applications, Co-Injection Resin Transfer Molding (CIRTM) and Diffusion Enhanced Adhesion (DEA) have been recently invented and developed at the Army Resear...

  13. Predictive engineering tools for injection-molded long-carbon-fiber thermoplastic composites - FY 2015 third quarterly report

    SciTech Connect

    Nguyen, Ba Nghiep; Fifield, Leonard S.; Mori, Steven; Gandhi, Umesh N.; Wang, Jin; Costa, Franco; Wollan, Eric J.; Tucker, III, Charles L.

    2015-07-01

    During the third quarter of FY 2015, the following technical progress has been made toward project milestones: 1) Magna oversaw the tool build and prepared the molding plan for the complex part of Phase II. 2) PlastiComp hosted a visit by Magna and Toyota on April 23rd to finalize the molding scope and schedule. The plan for molding trials including selection of molding parameters for both LFT and D-LFT for the U-shape complex part was established. 3) Toyota shipped the U-shape complex part tool to Magna on May 28th, 2015. 4) Plasticomp provided 30wt% LCF/PP and 30wt% LCF/PA66 compounded pellets to Magna for molding the complex part. 5) Magna performed preliminary molding trials on June 2nd, 2015 to validate wall thickness, fill profile, tool temperature and shot size requirements for the complex part. 6) Magna performed the first complex part run on June 16th and 17th, 2015 at Magna’s Composite Centre of Excellence in Concord, ON, Canada. Dale Roland of Plasticomp, and Umesh Gandhi of Toyota also attended the molding. 7) Magna discussed and finalized the plan with PNNL and the team for cutting samples from molded parts at selected locations for fiber orientation and length measurements. 8) Magna provided the computer-aided design (CAD) files of the complex parts with and without ribs to PNNL and Autodesk to build the corresponding ASMI models for injection molding simulations. Magna also provided the actual parameters used. 9) Plasticomp’s provided knowledge and experience of molding LCF materials essential to the successful molding of the parts including optimization of fill speed, tool temperatures, and plasticizing conditions for the 30wt% LCF/PP and 30wt% LCF/PA66 materials in both rib and non-rib versions. 10) Magna molded additional parts for evaluation of mechanical property testing including torsional stiffness on June 29th and 30th, 2015 at Magna’s Composite Center of Excellence. 11) Toyota began preparation for the torsion test of the specimens

  14. A Study of Micro Injection Molding for High-Aspect-Ratio Optical Fiber Ferrules

    NASA Astrophysics Data System (ADS)

    Lin, Zheng-Guan.; Tseng, Shi-Chang; Wang, James; Su, Yi-Chung

    2004-06-01

    This study focused on manufacture of high-aspect-ratio optical fiber ferrules by micro thermoplastic injection molding technique. In the past, the optical fiber connectors were produced by ceramic powder injection molding and subsequent precision grinding process. In this work, plastic micro injection molding technique was attempted to manufacture net-shaped products at once. Each ferrule has a micro through hole in the center. The hole's diameter is 125±1μm, and its length is 9mm. During micro molding, how to keep the micro core pin at the center becomes a critical issue. In this work, a guiding slide system is introduced to hold the micro pin continuously. And the slide movement was controlled by a spring behind it. Such a guiding system can help reduce mis-alignment of the micro core pin and increase its life time. Taguchi's design of experiment was used to evaluate the effects of processing parameters on final properties. Experimental results reveal that the higher the spring force, the larger the product weight and the lower the shrinkage. In order to obtain better uniformity of diameters at different locations, diameters at three locations were measured. Measured data showed the shrinkage of diameter in the middle is greater than those at two ends. It is because the two ends cooled faster than the center region. This can be improved by applying higher mold temperature or appropriate holding pressure or holding time. The new design concept can be applied in molding micro tubes, especially for the high aspect ratio cases.

  15. In-situ Formation of Ti Alloys via Powder Injection Molding

    SciTech Connect

    Simmons, Kevin L.; Nyberg, Eric A.; Weil, K. Scott; Miller, Megan R.

    2005-01-01

    We have developed a unique blend of powder injection molding (PIM) feedstock materials in which only a small volume fraction of binder (< 8%) is required; the remainder of the mixture consists of the metal powder and a solid aromatic solvent. Because of the nature of the decomposition in the binder system and the relatively small amount used, the binder can be completely removed from the molded component during heat treatment. Here, we present results from an initial study on in-situ titanium alloy formation in near-net shape components manufactured by this novel PIM technique.

  16. Determination of injection molding process windows for optical lenses using response surface methodology.

    PubMed

    Tsai, Kuo-Ming; Wang, He-Yi

    2014-08-20

    This study focuses on injection molding process window determination for obtaining optimal imaging optical properties, astigmatism, coma, and spherical aberration using plastic lenses. The Taguchi experimental method was first used to identify the optimized combination of parameters and significant factors affecting the imaging optical properties of the lens. Full factorial experiments were then implemented based on the significant factors to build the response surface models. The injection molding process windows for lenses with optimized optical properties were determined based on the surface models, and confirmation experiments were performed to verify their validity. The results indicated that the significant factors affecting the optical properties of lenses are mold temperature, melt temperature, and cooling time. According to experimental data for the significant factors, the oblique ovals for different optical properties on the injection molding process windows based on melt temperature and cooling time can be obtained using the curve fitting approach. The confirmation experiments revealed that the average errors for astigmatism, coma, and spherical aberration are 3.44%, 5.62%, and 5.69%, respectively. The results indicated that the process windows proposed are highly reliable. PMID:25321095

  17. Surface Orientation in Injection-Molded Thermotropic Liquid Crystalline Copolyester (TLCP) Plaques

    NASA Astrophysics Data System (ADS)

    Bubeck, Robert; Fang, Jun; Burghardt, Wesley; Burgard, Susan; Robertson, Katherine; Fischer, Daniel

    2008-03-01

    Attenuated total reflection Fourier transform infra-red (ATR-FTIR), C K edge near edge X-ray adsorption fine structure (NEXAFS) spectroscopies, and 2-D WAXS in transmission were used to characterize surface orientation in thermotropic liquid crystalline copolyester (TLCP) injection-molded plaques to varying depths into the samples. Injection-molded TLCPs have bimodal orientation states due to contributions from ``skin'' and ``core'' regions resulting from extensional and shear flow, respectively, in the mold. The NEXAFS is sensitive to the orientation of the molecular pi orbital of backbone phenyl groups of the top 2 nm of a surface. ATR-FTIR obtained using a Herrick Seagull variable angle reflectance accessory is sensitive for dichroic ratios to a depth of 5 microns. Orientation parameters derived from the 1502/cm absorption band for equivalent positions are often typically about 5 to 10 percent less by ATR-FTIR than by NEXAFS. The orientational states are being correlated with physical properties of injection-molded TLCP samples.

  18. Evaluation of Mechanical Properties of Injection Molding Composites Reinforced by Bagasse Fiber

    NASA Astrophysics Data System (ADS)

    Cao, Yong; Fukumoto, Isao

    BMC (Bulk Molding Compound) is composed of UP (Unsaturated Polyester) resin, glass fibers, and bagasse fibers which have been obtained after squeezing sugar cane. Our purpose is to use the bagasse fibers as reinforcement and filler in BMC to fabricate composites by injection molding and injection compression molding. The mechanical properties of injection molding composites were improved after adding the bagasse fibers. Observing the fracture surface of the tensile test specimen through SEM, we could notice the glass fibers were penetrated into the bagasse fibers longitudinally. Along with UP resin solidifying, the glass fibers were firmly fixed in the bagasse fibers and finally united with them. This phenomenon could bring on the same effect as the glass fibers length was prolonged, so that the adhesion interface between fiber and matrix resin became larger, which leads to the increase in the mechanical properties. Otherwise, it was observed that UP resin sufficiently permeated the bagasse fibers and solidified. This also contributes to enhancing the mechanical properties drastically.

  19. A review of contamination related hydraulic pump problems in Japanese injection molding, extrusion and rubber molding industries

    SciTech Connect

    Sasaki, Akira

    1997-12-31

    It is known that contamination of hydraulic oil is one of the major factors causing hydraulic pump problems. Many test reports on contaminant sensibility of hydraulic pumps have been published with new oil and standard dusts but the results of these tests could not guarantee to predict in-service performance. This report describes three cases investigated. The first investigation was done on hydraulic pumps used for injection molding machines application. The causes of pump problems were examined by analysis of maintenance records. The second investigation was performed to determine overhaul frequency of hydraulic pumps used for aluminum extruders. By introducing a new method of hydraulic oil management which reduces oil oxidation products, pump life was extended from 3,000 to 15,000 hours. The third investigation was done to determine the relationship between pump problems and contamination levels of hydraulic oils of 411 rubber molding machines for 20 months. The results showed that pump problems appeared at half the recommended oil lifetimes for these fluids. These studies showed that the cause of pump problems was clogging of suction strainers leading to pump cavitation. The clogged strainers were washed with several different solvents to identify the causes of suction strainer clogging. Clogging of suction strainers was attributable to sticky oxidation products of hydraulic oils. Electrostatic oil cleaners removed not only micron range solid particles bu also submicron size particles. Hydraulic pump problems have been substantially reduced by introducing this new method of contamination control.

  20. Dynamic penetration behavior of core-material in multi-cavity co-injection molding

    NASA Astrophysics Data System (ADS)

    Huang, Chao-Tsai CT; Yang, Jackie; Chang, Rong-Yeu

    2015-12-01

    Co-Injection Molding and multi-cavity molding are very common processes for plastic manufacturing. These two systems are sometimes combined and applied to some structure products. The core penetration and flow balance control problems are very difficult to manage. The inside mechanism of co-injection multi-cavity system is not fully figured out yet. In this study, we have focused on the penetration phenomena of core-material in a co-injection multi-cavity molding. The dynamic penetration behavior of core is very sensitive to injection flow rate and skin/core ratio. The longest core penetration has been shown to change dramatically from one runner to the other. In addition, the core penetration behavior will display imbalance at the end of filling. The more core ratio it is, the longer core penetration flows through runner to cavity. However, due to the multi-cavity geometrical structure, the balance of the core penetration for multi-cavity is still challenging. Finally, the simulation is validated with some literature. The results showed that both simulation and experiment are in a good agreement in trend

  1. Foam injection molding of thermoplastic elastomers: Blowing agents, foaming process and characterization of structural foams

    NASA Astrophysics Data System (ADS)

    Ries, S.; Spoerrer, A.; Altstaedt, V.

    2014-05-01

    Polymer foams play an important role caused by the steadily increasing demand to light weight design. In case of soft polymers, like thermoplastic elastomers (TPE), the haptic feeling of the surface is affected by the inner foam structure. Foam injection molding of TPEs leads to so called structural foam, consisting of two compact skin layers and a cellular core. The properties of soft structural foams like soft-touch, elastic and plastic behavior are affected by the resulting foam structure, e.g. thickness of the compact skins and the foam core or density. This inner structure can considerably be influenced by different processing parameters and the chosen blowing agent. This paper is focused on the selection and characterization of suitable blowing agents for foam injection molding of a TPE-blend. The aim was a high density reduction and a decent inner structure. Therefore DSC and TGA measurements were performed on different blowing agents to find out which one is appropriate for the used TPE. Moreover a new analyzing method for the description of processing characteristics by temperature dependent expansion measurements was developed. After choosing suitable blowing agents structural foams were molded with different types of blowing agents and combinations and with the breathing mold technology in order to get lower densities. The foam structure was analyzed to show the influence of the different blowing agents and combinations. Finally compression tests were performed to estimate the influence of the used blowing agent and the density reduction on the compression modulus.

  2. From Process Modeling to Elastic Property Prediction for Long-Fiber Injection-Molded Thermoplastics

    SciTech Connect

    Nguyen, Ba Nghiep; Kunc, Vlastimil; Frame, Barbara J.; Phelps, Jay; Tucker III, Charles L.; Bapanapalli, Satish K.; Holbery, James D.; Smith, Mark T.

    2007-09-13

    This paper presents an experimental-modeling approach to predict the elastic properties of long-fiber injection-molded thermoplastics (LFTs). The approach accounts for fiber length and orientation distributions in LFTs. LFT samples were injection-molded for the study, and fiber length and orientation distributions were measured at different locations for use in the computation of the composite properties. The current fiber orientation model was assessed to determine its capability to predict fiber orientation in LFTs. Predicted fiber orientations for the studied LFT samples were also used in the calculation of the elastic properties of these samples, and the predicted overall moduli were then compared with the experimental results. The elastic property prediction was based on the Eshelby-Mori-Tanaka method combined with the orientation averaging technique. The predictions reasonably agree with the experimental LFT data

  3. Simulation-based process windows simultaneously considering two and three conflicting criteria in injection molding

    PubMed Central

    Rodríguez-Yáñez, Alicia Berenice; Méndez-Vázquez, Yaileen

    2014-01-01

    Process windows in injection molding are habitually built with only one performance measure in mind. In reality, a more realistic picture can be obtained when considering multiple performance measures at a time, especially in the presence of conflict. In this work, the construction of process windows for injection molding (IM) is undertaken considering two and three performance measures in conflict simultaneously. The best compromises between the criteria involved are identified through the direct application of the concept of Pareto-dominance in multiple criteria optimization. The aim is to provide a formal and realistic strategy to set processing conditions in IM operations. The resulting optimization approach is easily implementable in MS Excel. The solutions are presented graphically to facilitate their use in manufacturing plants. PMID:25530927

  4. Monitoring of binder removal from injection molded ceramics using air-coupled ultrasound at high temperature.

    PubMed

    Wright, W D; Hutchins, D A

    1999-01-01

    A pair of capacitance-type air-coupled ultrasonic transducers have been constructed that were capable of operating in air at temperatures of 500 to 600 degrees C. These devices were then used to monitor the pyrolytic removal of organic binder from injection molded silicon nitride ceramic components using air-coupled ultrasound inside a furnace at elevated temperatures. Through-thickness waveforms were obtained in the ceramic and compared with simultaneous measurements of the mass of the sample. Both the ultrasonic velocity and signal amplitudes could be used to monitor the change in mass of the injection molded ceramic, and other phenomena (such as softening and redistribution of the binder) were observed. PMID:18238465

  5. Anisotropic injection molding of strontium ferrite powder using a PP/PEG binder system

    NASA Astrophysics Data System (ADS)

    Lee, S. H.; Jeung, W. Y.

    2001-05-01

    In this study, new binder system for anisotropic injection molding of Sr-ferrite was developed and a process for injection molding of Sr-ferrite was optimized. The developed binder system is composed of 30 vol% PP, 60 vol% PEG-20 000 and 10 vol% PEG-4000. The extraction by water was applied to remove the major binder components PEGs and the minor binder component, PP, was subsequently burned out in air. Behaviors of extraction and thermal debinding with time and debinding atmosphere and variations of the magnetic properties with sintering temperature were studied. The sintered magnets made by PIM process showed residual carbon content of 230 ppm and a maximum energy product of 4.2 MGOe.

  6. Two component tungsten powder injection molding - An effective mass production process

    NASA Astrophysics Data System (ADS)

    Antusch, Steffen; Commin, Lorelei; Mueller, Marcus; Piotter, Volker; Weingaertner, Tobias

    2014-04-01

    Tungsten and tungsten-alloys are presently considered to be the most promising materials for plasma facing components for future fusion power plants. The Karlsruhe Institute of Technology (KIT) divertor design concept for the future DEMO power plant is based on modular He-cooled finger units and the development of suitable mass production methods for such parts was needed. A time and cost effective near-net-shape forming process with the advantage of shape complexity, material utilization and high final density is Powder Injection Molding (PIM). This process allows also the joining of two different materials e.g. tungsten with a doped tungsten alloy, without brazing. The complete technological process of 2-Component powder injection molding for tungsten materials and its application on producing real DEMO divertor parts, characterization results of the finished parts e.g. microstructure, hardness, density and joining zone quality are discussed in this contribution.

  7. Optimization and evaluation of metal injection molding by using X-ray tomography

    SciTech Connect

    Yang, Shidi; Zhang, Ruijie; Qu, Xuanhui

    2015-06-15

    6061 aluminum alloy and 316L stainless steel green bodies were obtained by using different injection parameters (injection pressure, speed and temperature). After injection process, the green bodies were scanned by X-ray tomography. The projection and reconstruction images show the different kinds of defects obtained by the improper injection parameters. Then, 3D rendering of the Al alloy green bodies was used to demonstrate the spatial morphology characteristics of the serious defects. Based on the scanned and calculated results, it is convenient to obtain the proper injection parameters for the Al alloy. Then, reasons of the defect formation were discussed. During mold filling, the serious defects mainly formed in the case of low injection temperature and high injection speed. According to the gray value distribution of projection image, a threshold gray value was obtained to evaluate whether the quality of green body can meet the desired standard. The proper injection parameters of 316L stainless steel can be obtained efficiently by using the method of analyzing the Al alloy injection. - Highlights: • Different types of defects in green bodies were scanned by using X-ray tomography. • Reasons of the defect formation were discussed. • Optimization of the injection parameters can be simplified greatly by the way of X-ray tomography. • Evaluation standard of the injection process can be obtained by using the gray value distribution of projection image.

  8. Correlation between Rheotens measurements and reinforcement of polymer nanocomposites in the injection molding compounder

    NASA Astrophysics Data System (ADS)

    Battisti, Markus G.; Friesenbichler, Walter; Duretek, Ivica; Guttmann, Peter

    2015-04-01

    The evaluation of the effectiveness of reinforcement of polymers and polymer nanocomposites(PNCs), in particular the improvement of Young's modulus, is made by performing standardized tensile tests. Structural and morphological characterizations typically are investigated using expensive techniques like transmission electron microscopy (TEM), X- ray scattering and sometimes also rheological analyses (rotational rheometry). The objective of this study is to generate faster and economically advantageous data to verify the quality of the produced PNC-compound in an on-line measurement system. Subsequently injection molded parts are processed by using the Injection Molding Compounder (PNC-IMC) “by only one plasticizing process”. In comparison to the conventional compounding process, where the compound has to be pelletized and fed into the injection molding machine for the second plasticizing process, injection molding compounding combines these two processing steps. This paper shows first results and problems with the implementation of the Rheotens equipment into the concept of the IMC. Different processing techniques and various processing conditions were compared and the occurring effects were detected both with tensile testing and extensional melt rheology. Both, the increase of the Young's modulus by using layered silicates as nanofillersis compared to the virgin polypropylene and the correlation of the level of melt strength with Rheotens measurements is shown. These results give a good overview on both the possibilities and the limitations of the material pre-tests by the use of extensional rheology in the concept of the IMC for producing PNCs. Further studies to enable a fast and efficient way of estimating the level of reinforcement in PNCs by means of Rheotens measurements will be carried out towards industrial usability. Furthermore the verification of exfoliation and intercalation of the layered silicates in the polymer matrix using small angle X- ray

  9. Particle morphology influence on mechanical and biocompatibility properties of injection molded Ti alloy powder.

    PubMed

    Gülsoy, H Özkan; Gülsoy, Nagihan; Calışıcı, Rahmi

    2014-01-01

    Titanium and Titanium alloys exhibits properties that are excellent for various bio-applications. Metal injection molding is a processing route that offers reduction in costs, with the added advantage of near net-shape components. Different physical properties of Titanium alloy powders, shaped and processed via injection molding can achieve high complexity of part geometry with mechanical and bioactivity properties, similar or superior to wrought material. This study describes that the effect of particle morphology on the microstructural, mechanical and biocompatibility properties of injection molded Ti-6Al-4V (Ti64) alloy powder for biomaterials applications. Ti64 powders irregular and spherical in shape were injection molded with wax based binder. Binder debinding was performed in solvent and thermal method. After debinding the samples were sintered under high vacuum. Metallographic studies were determined to densification and the corresponding microstructural changes. Sintered samples were immersed in a simulated body fluid (SBF) with elemental concentrations that were comparable to those of human blood plasma for a total period of 15 days. Both materials were implanted in fibroblast culture for biocompatibility evaluations were carried out. The results show that spherical and irregular powder could be sintered to a maximum theoretical density. Maximum tensile strength was obtained for spherical shape powder sintered. The tensile strength of the irregular shape powder sintered at the same temperature was lower due to higher porosity. Finally, mechanical tests show that the irregular shape powder has lower mechanical properties than spherical shape powder. The sintered irregular Ti64 powder exhibited better biocompatibility than sintered spherical Ti64 powder. Results of study showed that sintered spherical and irregular Ti64 powders exhibited high mechanical properties and good biocompatibility properties. PMID:25201399

  10. Injection molding of silicon carbide capable of being sintered without pressure

    NASA Technical Reports Server (NTRS)

    Muller-Zell, A.; Schwarzmeier, R.

    1984-01-01

    The most suitable SiC mass for injection molding of SiC articles (for subsequent pressureless sintering) consisted of beta SiC 84, a wax mixture 8, and polyethylene or polystyrene 8 parts. The most effective method for adding the binders was by dissolving them in a solvent and subsequent evaporation. The sequence of component addition was significant, and all parameters were optimized together rather than individually.

  11. Study of tile/fiber systems manufactured from Kharkov injection molded and Kuraray SCSN-81 scintillators

    NASA Astrophysics Data System (ADS)

    Nemashkalo, A.; Popov, V.; Rubashkin, A.; Sorokin, P.; Zatserklianiy, A.; Borisenko, A.; Senchishin, V.; Skrebtsov, O.; Bolotov, V.

    1998-12-01

    We present the measurements of light output, light yield uniformity, and recovery after radiation damage of the tile/fiber systems made from the Kharkov injection molded and Kuraray SCSN-81 scintillators. The tiles were trapezoidal in shape, 131×90×122 mm3, with a Kuraray Y11 multiclad WLS read-out. The results are compared with those obtained using the tile/fiber systems manufactured from the Kuraray SCSN-81 scintillator and tested under the same conditions.

  12. Sub-Poissonian shot noise of a high internal gain injection photon detector.

    PubMed

    Memis, Omer Gokalp; Katsnelson, Alex; Kong, Soon-Cheol; Mohseni, Hooman; Yan, Minjun; Zhang, Shuang; Hossain, Tim; Jin, Niu; Adesida, Ilesanmi

    2008-08-18

    The noise performance of an infrared injection photon detector with very high internal gain was investigated at a wavelength of 1.55 mum. The devices showed sub-Poissonian shot noise with Fano factors around 0.55 at 0.7 V at room temperature. Optical to electrical conversion factors of 3000 electrons per absorbed photon were recorded at 0.7 V. The change in noise-equivalent power with respect to bias voltage was evaluated. The optical to electrical conversion factor and Fano factor were measured under increasing illumination and compared to theoretical expectations. PMID:18711508

  13. Prediction of fiber orientation in injection-molded parts using three-dimensional simulations

    NASA Astrophysics Data System (ADS)

    Wang, Jin; Cook, Peter; Bakharev, Alex; Costa, Franco; Astbury, David

    2016-03-01

    The Folgar-Tucker (F-T) model is widely used in most commercial software packages and research programs to predict the fiber orientation distribution in injection-molded fiber-reinforced composites. However, experimental measurements reveal that the F-T model normally results in much higher fiber alignment than observed because it tends to over-predict the orientation kinetics. The Reduced Strain Closure (RSC) model was developed, based on the F-T model, to capture the slow orientation kinetics in an objective fashion. Previous studies demonstrate that t he RSC model yields good agreement of fiber orientation with experimental measurements in shell element simulations using the Hele-Shaw flow approximation. This paper focuses on the RSC model in three-dimensional finite element simulations. The fiber orientation predictions were compared to the orientation measurements in a number of injection-molded parts of various shapes and dimensions and molded with various injection speeds. The RSC model is able to capture the orientation distribution through the part thickness and the average orientation trends along the flow length without the need to tailor the inlet orientation condition to pre-existing data.

  14. An Elastic-Plastic and Strength Prediction Model for Injection-Molded Long-Fiber Thermoplastics

    SciTech Connect

    Nguyen, Ba Nghiep; Kunc, Vlastimil; Phelps, Jay; Tucker III, Charles L.; Bapanapalli, Satish K.

    2008-09-01

    This paper applies a recently developed model to predict the elastic-plastic stress/strain response and strength of injection-molded long-fiber thermoplastics (LFTs). The model combines a micro-macro constitutive modeling approach with experimental characterization and modeling of the composite microstructure to determine the composite stress/strain response and strength. Specifically, it accounts for elastic fibers embedded in a thermoplastic resin that exhibits the elastic-plastic behavior obeying the Ramberg-Osgood relation and J-2 deformation theory of plasticity. It also accounts for fiber length, orientation and volume fraction distributions in the composite formed by the injection-molding process. Injection-molded-long-glass-fiber/polypropylene (PP) specimens were prepared for mechanical characterization and testing. Fiber length, orientation, and volume fraction distributions were then measured at some selected locations for use in the computation. Fiber orientations in these specimens were also predicted using an anisotropic rotary diffusion model developed for LFTs. The stress-strain response of the as-formed composite was computed by an incremental procedure that uses the Eshelby’s equivalent inclusion method, the Mori-Tanaka assumption and a fiber orientation averaging technique. The model has been validated against the experimental stress-strain results obtained for these long-glass-fiber/PP specimens.

  15. Color measurement of plastics - From compounding via pelletizing, up to injection molding and extrusion

    NASA Astrophysics Data System (ADS)

    Botos, J.; Murail, N.; Heidemeyer, P.; Kretschmer, K.; Ulmer, B.; Zentgraf, T.; Bastian, M.; Hochrein, T.

    2014-05-01

    The typical offline color measurement on injection molded or pressed specimens is a very expensive and time-consuming process. In order to optimize the productivity and quality, it is desirable to measure the color already during the production. Therefore several systems have been developed to monitor the color e.g. on melts, strands, pellets, the extrudate or injection molded part already during the process. Different kinds of inline, online and atline methods with their respective advantages and disadvantages will be compared. The criteria are e.g. the testing time, which ranges from real-time to some minutes, the required calibration procedure, the spectral resolution and the final measuring precision. The latter ranges between 0.05 to 0.5 in the CIE L*a*b* system depending on the particular measurement system. Due to the high temperatures in typical plastics processes thermochromism of polymers and dyes has to be taken into account. This effect can influence the color value in the magnitude of some 10% and is barely understood so far. Different suitable methods to compensate thermochromic effects during compounding or injection molding by using calibration curves or artificial neural networks are presented. Furthermore it is even possible to control the color during extrusion and compounding almost in real-time. The goal is a specific developed software for adjusting the color recipe automatically with the final objective of a closed-loop control.

  16. Quality Control of Injection Molded Eyewear by Non-Contact Deflectometry

    NASA Astrophysics Data System (ADS)

    Speck, A.; Zelzer, B.; Langenbucher, A.; Eppig, T.

    2014-07-01

    Occupational eye wear such as safety spectacles are manufactured by injection molding techniques. Testing of the assembled safety spectacle lenses in transmission is state of the art, but there is a lack of surface measurement systems for occupational safety lenses. The purpose of this work was to validate a deflectometric setup for topography measurement, detection of defects and visualization of the polishing quality, e.g. casting indentations or impressions, for the production process of safety spectacles. The setup is based on a customized stereo phase measuring deflectometer (PMD), equipped with 3 cameras with f'1,2 = 16 mm and f'3 = 8.5 mm and a specified measurement uncertainty of ± 3 μm. Sixteen plastic lenses and 8 corresponding injection molds from 4 parallel cavities were used for validation of the deflectometer. For comparison an interferometric method and a reference standard (< λ/10 super polished) was used. The accuracy and bias with a spherical safety spectacle sample was below 1 μm, according to DIN ISO 5725-2.2002-12. The repeatability was 2.1 μm and 35.7 μm for a blind radius fit. In conclusion, the PMD technique is an appropriate tool for characterizing occupational safety spectacle and injections mold surfaces. With the presented setup we were able to quantify the surface quality. This can be useful and may optimize the quality of the end product, in addition to standardized measuring systems in transmission.

  17. Recycling plastic scrap: Injection molding. (Latest citations from the Rubber and Plastics Research Association database). Published Search

    SciTech Connect

    1995-01-01

    The bibliography contains citations concerning the recycling of scrap plastic produced in the injection molding process. Plastic pellets made from scrap, that are used in the injection molding process, are also discussed. Recycling equipment and automated recycling systems are described. The reuse of plastic scrap culled from junk automobiles and packaging materials is discussed, and waste byproducts from polyurethane production are described. (Contains a minimum of 88 citations and includes a subject term index and title list.)

  18. Recycling plastic scrap: Injection molding. (Latest citations from the Rubber and Plastics Research Association database). Published Search

    SciTech Connect

    1996-04-01

    The bibliography contains citations concerning the recycling of scrap plastic produced in the injection molding process. Plastic pellets made from scrap, that are used in the injection molding process, are also discussed. Recycling equipment and automated recycling systems are described. The reuse of plastic scrap culled from junk automobiles and packaging materials is discussed, and waste byproducts from polyurethane production are described. (Contains 50-250 citations and includes a subject term index and title list.) (Copyright NERAC, Inc. 1995)

  19. Wall-slip of highly filled powder injection molding compounds: Effect of flow channel geometry and roughness

    SciTech Connect

    Hausnerova, Berenika; Sanetrnik, Daniel; Paravanova, Gordana

    2014-05-15

    The paper deals with the rheological behavior of highly filled compounds proceeded via powder injection molding (PIM) and applied in many sectors of industry (automotive, medicine, electronic or military). Online rheometer equipped with slit dies varying in surface roughness and dimensions was applied to investigate the wall-slip as a rheological phenomenon, which can be considered as a parameter indicating the separation of compound components (polymer binder and metallic powder) during high shear rates when injection molded.

  20. Recycling plastic scrap: Injection molding. (Latest citations from the Rubber and Plastics Research Association database). Published Search

    SciTech Connect

    Not Available

    1994-05-01

    The bibliography contains citations concerning the recycling of scrap plastic produced in the injection molding process. Plastic pellets made from scrap, that are used in the injection molding process, are also discussed. Recycling equipment and automated recycling systems are described. The reuse of plastic scrap culled from junk automobiles and packaging materials is discussed, and waste byproducts from polyurethane production are described. (Contains a minimum of 80 citations and includes a subject term index and title list.)

  1. Recycling plastic scrap: Injection molding. (Latest citations from the Rubber and Plastics Research Association database). Published Search

    SciTech Connect

    1997-02-01

    The bibliography contains citations concerning the recycling of scrap plastic produced in the injection molding process. Plastic pellets made from scrap, that are used in the injection molding process, are also discussed. Recycling equipment and automated recycling systems are described. The reuse of plastic scrap culled from junk automobiles and packaging materials is discussed, and waste byproducts from polyurethane production are described. (Contains 50-250 citations and includes a subject term index and title list.) (Copyright NERAC, Inc. 1995)

  2. Wall-slip of highly filled powder injection molding compounds: Effect of flow channel geometry and roughness

    NASA Astrophysics Data System (ADS)

    Hausnerova, Berenika; Sanetrnik, Daniel; Paravanova, Gordana

    2014-05-01

    The paper deals with the rheological behavior of highly filled compounds proceeded via powder injection molding (PIM) and applied in many sectors of industry (automotive, medicine, electronic or military). Online rheometer equipped with slit dies varying in surface roughness and dimensions was applied to investigate the wall-slip as a rheological phenomenon, which can be considered as a parameter indicating the separation of compound components (polymer binder and metallic powder) during high shear rates when injection molded.

  3. Structural scheme optimization design for the stationary platen of a precision plastic injection molding machine

    NASA Astrophysics Data System (ADS)

    Ren, Bin; Zhang, Shuyou; Tan, Jianrong

    2014-07-01

    The current development of precision plastic injection molding machines mainly focuses on how to save material and improve precision, but the two aims contradict each other. For a clamp unit, clamping precision improving depends on the design quality of the stationary platen. Compared with the parametric design of stationary platen, structural scheme design could obtain the optimization model with double objectives and multi-constraints. In this paper, a SE-160 precision plastic injection molding machine with 1600 kN clamping force is selected as the subject in the case study. During the motion of mold closing and opening, the stationary platen of SE-160 is subjected to a cyclic loading, which would cause the fatigue rupture of the tie bars in periodically long term operations. In order to reduce the deflection of the stationary platen, the FEA method is introduced to optimize the structure of the stationary platen. Firstly, an optimal topology model is established by variable density method. Then, structural topology optimizations of the stationary platen are done with the removable material from 50%, 60% to 70%. Secondly, the other two recommended optimization schemes are given and compared with the original structure. The result of performances comparison shows that the scheme II of the platen is the best one. By choosing the best alternative, the volume and the local maximal stress of the platen could be decreased, corresponding to cost-saving material and better mechanical properties. This paper proposes a structural optimization design scheme, which can save the material as well as improve the clamping precision of the precision plastic injection molding machine.

  4. An application of CO{sub 2} laser interference heating for polymer injection molding process

    SciTech Connect

    Saito, Takushi; Satoh, Isao; Kurosaki, Yasuo

    1999-07-01

    In this paper, the authors studied the small scale (less than 1 mm) local heat transfer control of injection molded polymer products by using CO{sub 2} laser interferometry. This technique could provide precise local temperature control of the product surface during the process. Residual birefringence of the irradiated surface was successfully distributed according to the interference pattern. This scale of heat transfer control has not been realized through common conductive heat transfer methods. To establish the laser interference heating, a CO{sub 2} laser, a set of optical equipment, and a transparent window of Zinc-selenide were used. To control the heat transfer on the molded polymer surface, the interfered laser beam was introduced through the window. Polystyrene resin was used to investigate the feasibility of this method. In the experiment, the control ability of the property distribution on a molded polymer surface was studied under various conditions. To confirm the viability of this technique, optical strain frozen in the molded polymer surface was measured with a polarizing microscope as birefringence. As the result, it was clearly shown that the residual birefringence had an equal spaced distribution. Also, the contrast between the irradiated and un-irradiated portions was obvious regardless of the polymer melt velocity and radiation intensity. This method may be applied to the production of diffraction gratings which have geometrically smooth surfaces.

  5. Numerical approach of the injection molding process of fiber-reinforced composite with considering fiber orientation

    SciTech Connect

    Nguyen Thi, T. B. E-mail: yokoyama@kit.ac.jp; Yokoyama, A. E-mail: yokoyama@kit.ac.jp; Ota, K. E-mail: katsuhiro-kodama@toyobo.jp E-mail: yumiko-isogai@toyobo.jp E-mail: chisato-nonomura@toyobo.jp; Kodama, K. E-mail: katsuhiro-kodama@toyobo.jp E-mail: yumiko-isogai@toyobo.jp E-mail: chisato-nonomura@toyobo.jp; Yamashita, K. E-mail: katsuhiro-kodama@toyobo.jp E-mail: yumiko-isogai@toyobo.jp E-mail: chisato-nonomura@toyobo.jp; Isogai, Y. E-mail: katsuhiro-kodama@toyobo.jp E-mail: yumiko-isogai@toyobo.jp E-mail: chisato-nonomura@toyobo.jp; Furuichi, K. E-mail: katsuhiro-kodama@toyobo.jp E-mail: yumiko-isogai@toyobo.jp E-mail: chisato-nonomura@toyobo.jp; Nonomura, C. E-mail: katsuhiro-kodama@toyobo.jp E-mail: yumiko-isogai@toyobo.jp E-mail: chisato-nonomura@toyobo.jp

    2014-05-15

    One of the most important challenges in the injection molding process of the short-glass fiber/thermoplastic composite parts is being able to predict the fiber orientation, since it controls the mechanical and the physical properties of the final parts. Folgar and Tucker included into the Jeffery equation a diffusive type of term, which introduces a phenomenological coefficient for modeling the randomizing effect of the mechanical interactions between the fibers, to predict the fiber orientation in concentrated suspensions. Their experiments indicated that this coefficient depends on the fiber volume fraction and aspect ratio. However, a definition of the fiber interaction coefficient, which is very necessary in the fiber orientation simulations, hasn't still been proven yet. Consequently, this study proposed a developed fiber interaction model that has been introduced a fiber dynamics simulation in order to obtain a global fiber interaction coefficient. This supposed that the coefficient is a sum function of the fiber concentration, aspect ratio, and angular velocity. The proposed model was incorporated into a computer aided engineering simulation package C-Mold. Short-glass fiber/polyamide-6 composites were produced in the injection molding with the fiber weight concentration of 30 wt.%, 50 wt.%, and 70 wt.%. The physical properties of these composites were examined, and their fiber orientation distributions were measured by micro-computed-tomography equipment μ-CT. The simulation results showed a good agreement with experiment results.

  6. Numerical approach of the injection molding process of fiber-reinforced composite with considering fiber orientation

    NASA Astrophysics Data System (ADS)

    Nguyen Thi, T. B.; Yokoyama, A.; Ota, K.; Kodama, K.; Yamashita, K.; Isogai, Y.; Furuichi, K.; Nonomura, C.

    2014-05-01

    One of the most important challenges in the injection molding process of the short-glass fiber/thermoplastic composite parts is being able to predict the fiber orientation, since it controls the mechanical and the physical properties of the final parts. Folgar and Tucker included into the Jeffery equation a diffusive type of term, which introduces a phenomenological coefficient for modeling the randomizing effect of the mechanical interactions between the fibers, to predict the fiber orientation in concentrated suspensions. Their experiments indicated that this coefficient depends on the fiber volume fraction and aspect ratio. However, a definition of the fiber interaction coefficient, which is very necessary in the fiber orientation simulations, hasn't still been proven yet. Consequently, this study proposed a developed fiber interaction model that has been introduced a fiber dynamics simulation in order to obtain a global fiber interaction coefficient. This supposed that the coefficient is a sum function of the fiber concentration, aspect ratio, and angular velocity. The proposed model was incorporated into a computer aided engineering simulation package C-Mold. Short-glass fiber/polyamide-6 composites were produced in the injection molding with the fiber weight concentration of 30 wt.%, 50 wt.%, and 70 wt.%. The physical properties of these composites were examined, and their fiber orientation distributions were measured by micro-computed-tomography equipment μ-CT. The simulation results showed a good agreement with experiment results.

  7. Optimization of Micro Metal Injection Molding By Using Grey Relational Grade

    SciTech Connect

    Ibrahim, M. H. I.; Muhamad, N.; Sulong, A. B.; Nor, N. H. M.; Harun, M. R.; Murtadhahadi; Jamaludin, K. R.

    2011-01-17

    Micro metal injection molding ({mu}MIM) which is a variant of MIM process is a promising method towards near net-shape of metallic micro components of complex geometry. In this paper, {mu}MIM is applied to produce 316L stainless steel micro components. Due to highly stringent characteristic of {mu}MIM properties, the study has been emphasized on optimization of process parameter where Taguchi method associated with Grey Relational Analysis (GRA) will be implemented as it represents novel approach towards investigation of multiple performance characteristics. Basic idea of GRA is to find a grey relational grade (GRG) which can be used for the optimization conversion from multi objectives case which are density and strength to a single objective case. After considering the form 'the larger the better', results show that the injection time(D) is the most significant followed by injection pressure(A), holding time(E), mold temperature(C) and injection temperature(B). Analysis of variance (ANOVA) is also employed to strengthen the significant of each parameter involved in this study.

  8. Injection-Molded Long-Fiber Thermoplastic Composites: From Process Modeling to Prediction of Mechanical Properties

    SciTech Connect

    Nguyen, Ba Nghiep; Kunc, Vlastimil; Jin, Xiaoshi; Tucker III, Charles L.; Costa, Franco

    2013-12-18

    This article illustrates the predictive capabilities for long-fiber thermoplastic (LFT) composites that first simulate the injection molding of LFT structures by Autodesk® Simulation Moldflow® Insight (ASMI) to accurately predict fiber orientation and length distributions in these structures. After validating fiber orientation and length predictions against the experimental data, the predicted results are used by ASMI to compute distributions of elastic properties in the molded structures. In addition, local stress-strain responses and damage accumulation under tensile loading are predicted by an elastic-plastic damage model of EMTA-NLA, a nonlinear analysis tool implemented in ABAQUS® via user-subroutines using an incremental Eshelby-Mori-Tanaka approach. Predicted stress-strain responses up to failure and damage accumulations are compared to the experimental results to validate the model.

  9. Determination of physical properties in injection molded composites using the design of experiments method

    SciTech Connect

    Hawks, V.; Saunders, D.; Strong, A.B.; Cole, D. )

    1992-07-01

    The benefits of using Design of Experiments (DOE) for determining effects of critical factors are significantly greater than using one-at-a-time experimental techniques. The volume and validity of the information gained from DOE, especially for manufacturing processes, is very high due to the strong statistical basis of the method and highly organized nature of the results. The use of DOE is described in the case of injection molding of composites to improve and better understand the effects of critical factors on the physical properties of the finished parts. The factors, fiber length, fiber concentration, part temperature, and mold thickness, were tested using a full factorial experiment. The results demonstrated the significance of the factors and their interactions on tensile strength, modulus of elasticity, and elongation.

  10. The demolding of powder injection molded micro-structures: analysis, simulation and experiment

    NASA Astrophysics Data System (ADS)

    Fu, G.; Tor, S. B.; Loh, N. H.; Tay, B. Y.; Hardt, D. E.

    2008-07-01

    This paper studies the demolding of an array of powder injection molded micro-structures based on a variotherm mold. The demolding of the micro-structures array was analyzed both theoretically and experimentally. Finite element method (FEM) software ABAQUS was used to analyze and simulate the demolding of an array of 24 × 24 (total of 576) micro-structures. It was found that there exists a 'critical temperature' at which the demolding force for the micro-structures array is a minimum. The stress distribution of the micro-structures and demolding force for the micro-structures during the course of demolding were analyzed for both demolding temperatures higher and lower than the critical temperature. Packing pressure and demolding temperature have an apparent impact on the demolding force. A series of demolding force measuring experiments at different packing pressures and demolding temperatures were conducted to verify the theoretical results.

  11. Simulation and experiment research on the proportional pressure control of water-assisted injection molding

    NASA Astrophysics Data System (ADS)

    Zhou, Hua; Chen, Yinglong; Zhang, Zengmeng; Yang, Huayong

    2012-05-01

    Water-assisted injection molding (WAIM), a newly developed fluid-assisted injection molding technology has drawn more and more attentions for the energy saving, short cooling circle time and high quality of products. Existing research for the process of WAIM has shown that the pressure control of the injecting water is mostly important for the WAIM. However, the proportional pressure control for the WAIM system is quite complex due to the existence of nonlinearities in the water hydraulic system. In order to achieve better pressure control performance of the injecting water to meet the requirements of the WAIM, the proportional pressure control of the WAIM system is investigated both numerically and experimentally. A newly designed water hydraulic system for WAIM is first modeled in AMEsim environment, the load characteristics and the nonlinearities of water hydraulic system are both considered, then the main factors affecting the injecting pressure and load flow rate are extensively studied. Meanwhile, an open-loop model-based compensation control strategy is employed to regulate the water injection pressure and a feedback proportional integrator controller is further adopted to achieve better control performance. In order to verify the AMEsim simulation results WAIM experiment for particular Acrylonitrile Butadiene Styrene (ABS) parts is implemented and the measured experimental data including injecting pressure and flow rate results are compared with the simulation. The good coincidence between experiment and simulation shows that the AMEsim model is accurate, and the tracking performance of the load pressure indicates that the proposed control strategy is effective for the proportional pressure control of the nonlinear WAIM system. The proposed proportional pressure control strategy and the conclusions drawn from simulation and experiment contribute to the application of water hydraulic proportional control and WAIM technology.

  12. Results on powder injection molding of Ni{sub 3}Al and application to other intermetallic compositions

    SciTech Connect

    Cooper, R.M.

    1992-12-31

    Net forming processes are under development to allow affordable production of intermetallic components. Powder injection molding (PIM) mav be employed for the production of complex-shaped intermetallic geometries. Proper choice of powder parameters and processing conditions can lead to the formation of fullv dense structures through pressure-less sintering. In this study, Ni{sub 3}Al with 0.04 wt.-% boron has been successfully injection molded and sintered to full density. A yield strength of 340 MPa, ultimate tensile strength (UTS) of 591 MPa, and 8% elongation were attained for injection molded and sintered tensile bars. Powder characteristics and sintering behavior are given for the nickel aluminide employed in this study to highlight the powder attributes needed for injection molding. Molding parameters, debinding and sintering schedules, along, with mechanical properties are presented to indicate the viability of PIM for intermetallics. This approach based on the understanding of key powder characteristics and use of the reactive synthesis powder process mav be extended to the successful injection molding of other intermetallic systems.

  13. Results on powder injection molding of Ni[sub 3]Al and application to other intermetallic compositions

    SciTech Connect

    Cooper, R.M.

    1992-01-01

    Net forming processes are under development to allow affordable production of intermetallic components. Powder injection molding (PIM) mav be employed for the production of complex-shaped intermetallic geometries. Proper choice of powder parameters and processing conditions can lead to the formation of fullv dense structures through pressure-less sintering. In this study, Ni[sub 3]Al with 0.04 wt.-% boron has been successfully injection molded and sintered to full density. A yield strength of 340 MPa, ultimate tensile strength (UTS) of 591 MPa, and 8% elongation were attained for injection molded and sintered tensile bars. Powder characteristics and sintering behavior are given for the nickel aluminide employed in this study to highlight the powder attributes needed for injection molding. Molding parameters, debinding and sintering schedules, along, with mechanical properties are presented to indicate the viability of PIM for intermetallics. This approach based on the understanding of key powder characteristics and use of the reactive synthesis powder process mav be extended to the successful injection molding of other intermetallic systems.

  14. Using Direct Metal Deposition to Fabricate Mold Plates for an Injection Mold Machine Allowing for the Evaluation of Cost Effective Near-Sourcing Opportunities in Larger, High Volume Consumer Products

    SciTech Connect

    Duty, Chad E; Groh, Bill

    2014-10-31

    ORNL collaborated with Radio Systems Corporation to investigate additive manufacturing (AM) of mold plates for plastic injection molding by direct metal deposition. The team s modelling effort identified a 100% improvement in heat transfer through use of conformal cooling lines that could be built into the mold using a revolutionary design enabled by additive manufacturing. Using the newly installed laser deposition system at the ORNL Manufacturing Demonstration Facility (MDF) a stainless steel mold core was printed.

  15. Effect of pressure on viscosity at high shear rates by using an injection molding machine

    NASA Astrophysics Data System (ADS)

    Volpe, Valentina; Pantani, Roberto

    2015-12-01

    The difficulties in performing accurate measurements of the effect of pressure on the viscosity of the polymeric materials results in a shortage of relevant experimental data in the literature. In this work, an atactic polystyrene has been characterized to determine the effect of pressure on viscosity during the injection molding process. In particular, the nozzle of the injection molding machine has been modified to host a slit rheometer that allows obtaining in-line rheological measurements by means of two pressure transducers. Slits with two different geometries have been adopted, in order to obtain a wide range of shear rates (102-105 s-1). Experiments have been conducted at increasing injection flow rates, corresponding to different shear rates. By analyzing the measured pressures it has been possible to determine the coefficient β, which describes the effect of pressure on viscosity. Results show that the effect of pressure on viscosity decreases on increasing the shear rate until a plateau is reached at very high shear rates.

  16. Numerical Simulation of the Flow Behavior and Breakthrough Phenomenon in Co-Injection Molding

    NASA Astrophysics Data System (ADS)

    Ilinca, Florin; Hétu, Jean-François

    2007-05-01

    A study of the flow behavior during sequential co-injection molding is shown using a three-dimensional finite element flow analysis code. Solutions of the non-Newtonian, non-isothermal melt flow are obtained by solving the momentum, continuity and energy equations. Two additional transport equations are solved for tracking polymer/air and skin/core polymers interfaces. The co-injection model is integrated into the NRC's 3D injection molding software. Solutions are shown for the filling of a spiral-flow mould for which experimental measurements are available. The numerical approach predicts the core advance stage during which the core flow front catches up on the skin flow front and the core expansion phase when the flow fronts of core and skin materials advance together without breakthrough. The breakthrough phenomenon is also predicted. The predicted flow front behavior is compared to the experimental observations for various skin/core melt temperature and skin/core viscosity ratio. Simulation results are in good agreement with experimental data and indicate correctly the trends in solution change when processing parameters are changing.

  17. CE chips fabricated by injection molding and polyethylene/thermoplastic elastomer film packaging methods.

    PubMed

    Huang, Fu-Chun; Chen, Yih-Far; Lee, Gwo-Bin

    2007-04-01

    This study presents a new packaging method using a polyethylene/thermoplastic elastomer (PE/TPE) film to seal an injection-molded CE chip made of either poly(methyl methacrylate) (PMMA) or polycarbonate (PC) materials. The packaging is performed at atmospheric pressure and at room temperature, which is a fast, easy, and reliable bonding method to form a sealed CE chip for chemical analysis and biomedical applications. The fabrication of PMMA and PC microfluidic channels is accomplished by using an injection-molding process, which could be mass-produced for commercial applications. In addition to microfluidic CE channels, 3-D reservoirs for storing biosamples, and CE buffers are also formed during this injection-molding process. With this approach, a commercial CE chip can be of low cost and disposable. Finally, the functionality of the mass-produced CE chip is demonstrated through its successful separation of phiX174 DNA/HaeIII markers. Experimental data show that the S/N for the CE chips using the PE/TPE film has a value of 5.34, when utilizing DNA markers with a concentration of 2 ng/microL and a CE buffer of 2% hydroxypropyl-methylcellulose (HPMC) in Tris-borate-EDTA (TBE) with 1% YO-PRO-1 fluorescent dye. Thus, the detection limit of the developed chips is improved. Lastly, the developed CE chips are used for the separation and detection of PCR products. A mixture of an amplified antibiotic gene for Streptococcus pneumoniae and phiX174 DNA/HaeIII markers was successfully separated and detected by using the proposed CE chips. Experimental data show that these DNA samples were separated within 2 min. The study proposed a promising method for the development of mass-produced CE chips. PMID:17311242

  18. Compact surface plasmon resonance biosensor utilizing an injection-molded prism

    NASA Astrophysics Data System (ADS)

    Chen, How-Foo; Chen, Chih-Han; Chang, Yun-Hsiang; Chuang, Hsin-Yuan

    2016-05-01

    Targeting at a low cost and accessible diagnostic device in clinical practice, a compact surface plasmon resonance (SPR) biosensor with a large dynamic range in high sensitivity is designed to satisfy commercial needs in food safety, environmental bio-pollution monitoring, and fast clinical diagnosis. The core component integrates an optical coupler, a sample-loading plate, and angle-tuning reflectors is injection-molded as a free-from prism made of plastic optics. This design makes a matching-oil-free operation during operation. The disposability of this low-cost component ensures testing or diagnosis without cross contamination in bio-samples.

  19. Microstructure and Mechanical Properties of Titanium Components Fabricated by a New Powder Injection Molding Technique

    SciTech Connect

    Nyberg, Eric A.; Miller, Megan R.; Simmons, Kevin L.; Weil, K. Scott

    2005-05-01

    We have developed a powder injection molding (PIM) binder system for titanium that employs naphthalene as the primary constituent to facilitate easy binder removal and mitigate problems with carbon contamination. In the study presented here, we examined densification behavior, microstructure, and mechanical properties in specimens formed by this process. In general, we found that we could achieve tensile strengths comparable to wrought titanium in the PIM-formed specimens, but that maximum elongation was less than expected. Chemical and microstructural analyses suggest that use of higher purity powder and further process optimization will lead to significant improvements in ductility.

  20. Mechanical Properties of Injection Molded B 4C-C Ceramics

    NASA Astrophysics Data System (ADS)

    Schwetz, Karl A.; Sigl, Lorenz S.; Pfau, Lothar

    1997-10-01

    Various mechanical properties of carbon-doped boron carbide ceramics, prepared by the fabrication route, injection molding/pressureless sintering/post-hot isostatic pressing (HIP) were investigated as a function of the sintering temperature and the carbon additive level used. An optimum combination of mechanical properties (flexural stregth, fracture toughness, Young's modulus, Knoop's hardness) is thus obtained with 100% dense and very fine grained materials (mean grain size 1-4 μm) which were sintered at temperatures from 2150 to 2175°C and post-HIPed at 2050°/200 MPa Ar, having an approximate final composition of 96 B4C-4C (wt%).

  1. Effect of rheological parameters on curing rate during NBR injection molding

    NASA Astrophysics Data System (ADS)

    Kyas, Kamil; Stanek, Michal; Manas, David; Skrobak, Adam

    2013-04-01

    In this work, non-isothermal injection molding process for NBR rubber mixture considering Isayev-Deng curing kinetic model, generalized Newtonian model with Carreau-WLF viscosity was modeled by using finite element method in order to understand the effect of volume flow rate, index of non-Newtonian behavior and relaxation time on the temperature profile and curing rate. It was found that for specific geometry and processing conditions, increase in relaxation time or in the index of non-Newtonian behavior increases the curing rate due to viscous dissipation taking place at the flow domain walls.

  2. Fabrication of Micro Gears by Micro-Powder Injection-Compression Molding

    NASA Astrophysics Data System (ADS)

    Jang, Jin Man; Lee, Wonsik; Son, Seong-Ho; Ko, Se-Hyun; Kim, Il-Ho

    Micro-spur gears were fabricated by powder injection-compression molding and micro-two-step gears were produced through stacking and sintering of the green parts. Shrinkage of micro-gears by sintering was larger in teeth and with increase of compression pressure, shrinkage was decreased due to increase of density in green parts. Surface roughness of sintered body was reduced to a few hundreds of nanometers by ultrasonic micro-polishing. The joining of green bodies by stacking and sintering was achieved using the pressurized sintering and insert of feedstock powders between both green bodies.

  3. Reaction injection molding and direct covalent bonding of OSTE+ polymer microfluidic devices

    NASA Astrophysics Data System (ADS)

    Sandström, N.; Shafagh, R. Z.; Vastesson, A.; Carlborg, C. F.; van der Wijngaart, W.; Haraldsson, T.

    2015-07-01

    In this article, we present OSTE+RIM, a novel reaction injection molding (RIM) process that combines the merits of off-stoichiometric thiol-ene epoxy (OSTE+) thermosetting polymers with the fabrication of high quality microstructured parts. The process relies on the dual polymerization reactions of OSTE+ polymers, where the first curing step is used in OSTE+RIM for molding intermediately polymerized parts with well-defined shapes and reactive surface chemistries. In the facile back-end processing, the replicated parts are directly and covalently bonded and become fully polymerized using the second curing step, generating complete microfluidic devices. To achieve unprecedented rapid processing, high replication fidelity and low residual stress, OSTE+RIM uniquely incorporates temperature stabilization and shrinkage compensation of the OSTE+ polymerization during molding. Two different OSTE+ formulations were characterized and used for the OSTE+RIM fabrication of optically transparent, warp-free and natively hydrophilic microscopy glass slide format microfluidic demonstrator devices, featuring a storage modulus of 2.3 GPa and tolerating pressures of at least 4 bars.

  4. Visualization analysis of injection molding phenomena in hot-runner system

    NASA Astrophysics Data System (ADS)

    Yokoi, Hidetoshi; Kanetoh, Yoshinori; Takamatsu, Ryohei; Endo, Takumi; Chang, Hao; Chayamichi, Toru

    2016-03-01

    Various unsolved defects are known to occur in hot-runner molds, such as stagnation of resins in the manifold channel, asymmetrical cavity filling behavior, flow marks, gate marks, etc. We have been clarifying the causes of various molding defects specifically using visualization technologies inside mold cavity and manifold. This report introduces and discusses the following topics, particularly focusing on clarifying the behavior of resins; (1) Comparison of the imbalanced cavity filling phenomena in between side-fed and center-fed types of valve-gate hot-runner systems, (2) Visualization analysis of the melt flow behaviors and stagnation phenomena inside hot-runner manifolds, (3) Behavior of each stagnant melt around the valve-pin and inner hot-nozzle surfaces, (4) Void generation phenomena remaining on the surface of the valve-pin tip, (5) Melt temperature distribution on the cavity surface during the filling process, (6) Melt temperature profile inside the flowing melt injected from the valve gate, etc.

  5. Enteric-coating of pulsatile-release HPC capsules prepared by injection molding.

    PubMed

    Macchi, E; Zema, L; Maroni, A; Gazzaniga, A; Felton, L A

    2015-04-01

    Capsular devices based on hydroxypropyl cellulose (Klucel® LF) intended for pulsatile release were prepared by injection molding (IM). In the present work, the possibility of exploiting such capsules for the development of colonic delivery systems based on a time-dependent approach was evaluated. For this purpose, it was necessary to demonstrate the ability of molded cores to undergo a coating process and that coated systems yield the desired performance (gastric resistance). Although no information was available on the coating of IM substrates, some issues relevant to that of commercially-available capsules are known. Thus, preliminary studies were conducted on molded disks for screening purposes prior to the spray-coating of HPC capsular cores with Eudragit® L 30 D 55. The ability of the polymeric suspension to wet the substrate, spread, start penetrating and initiate hydration/swelling, as well as to provide a gastroresistant barrier was demonstrated. The coating of prototype HPC capsules was carried out successfully, leading to coated systems with good technological properties and able to withstand the acidic medium with no need for sealing at the cap/body joint. Such systems maintained the original pulsatile release performance after dissolution of the enteric film in pH 6.8 fluid. Therefore, they appeared potentially suitable for the development of a colon delivery platform based on a time-dependent approach. PMID:25585355

  6. Development of a statistically proven injection molding method for reaction bonded silicon nitride, sintering reaction bonded silicon nitride, and sintered silicon nitride

    NASA Astrophysics Data System (ADS)

    Steiner, Matthias

    A statistically proven, series injection molding technique for ceramic components was developed for the construction of engines and gas turbines. The flow behavior of silicon injection-molding materials was characterized and improved. Hot-isostatic-pressing reaction bonded silicon nitride (HIPRBSN) was developed. A nondestructive component evaluation method was developed. An injection molding line for HIPRBSN engine components precombustion chamber, flame spreader, and valve guide was developed. This line allows the production of small series for engine tests.

  7. Rheological and thermal performance of newly developed binder systems for ceramic injection molding

    NASA Astrophysics Data System (ADS)

    Hausnerova, Berenika; Kasparkova, Vera; Hnatkova, Eva

    2016-05-01

    In a novel binder system, carnauba wax was considered to replace the synthetic backbone polymers (polyolefins) enhancing the environmental sustainability of Ceramic Injection Molding (CIM) technology. The paper presents comparison of the rheological performance and thermal behavior of the aluminum oxide CIM feedstocks based on a binder containing carnauba wax with those consisting of a commercial binder. Further, acrawax (N, N'-Ethylene Bis-stearamide) has been considered as another possible substitute of polyolefins. For both proposed substitutes there is a significant reduction in viscosity, and in case of carnauba wax based feedstock also in processing temperature, which is essential for injection molding of reactive powders. Thermal characterization comprised analyses of single neat binders, their mixtures and mixtures with aluminum oxide. The presence of powder lowered melting temperatures of all tested binders except of polyolefin. Further depression in melting point of poly(ethylene glycol) is observed in combination with polyolefin in the presence of powder, and it is related to changes in size of the crystalline domains.

  8. Effect of Fe3P addition on magnetic properties and microstructure of injection molded iron

    NASA Astrophysics Data System (ADS)

    Ma, Jidong; Qin, Mingli; Tian, Lusha; Zhang, Lin; Khan, Dil Faraz; Ding, Xiangying; Qu, Xuanhui; Zhang, Houan

    2016-01-01

    Phosphorus powder was used to improve the performance of iron based alloy products fabricated by metal injection molding. Seven kinds of Fe-xP soft magnetic alloys were formed using carbonyl iron powder and Phosphorus powder as raw materials where x=0-1.2 wt% with 0.2 wt% increment. Samples were sintered in hydrogen atmosphere at the temperature range of 1100-1450 °C for varied times. The effects of sintering temperature and time on the density, microstructure and magnetic properties like magnetic induction, maximum permeability and coercive force of the alloys were examined. The results demonstrated that better magnetic performances of the injection molded Fe-xP alloy is due to increased density of the sintered compacts because of formation of liquid phase at low temperature. For Fe-0.8%P alloy, optimum density 7.84 g/cm3 (relative density 99%) and magnetic induction (B6000) 1.77 T, maximum permeability 17,100 were obtained at sintering temperature 1420 °C while the coercive force was 21 A/m respectively.

  9. Magnesium Powder Injection Molding (MIM) of Orthopedic Implants for Biomedical Applications

    NASA Astrophysics Data System (ADS)

    Wolff, M.; Schaper, J. G.; Suckert, M. R.; Dahms, M.; Ebel, T.; Willumeit-Römer, R.; Klassen, T.

    2016-04-01

    Metal injection molding (MIM) has a high potential for the economic near-net-shape mass production of small-sized and complex-shaped parts. The motivation for launching Mg into the MIM processing chain for manufacturing biodegradable medical implants is related to its compatibility with human bone and its degradation in a non-toxic matter. It has been recognized that the load-bearing capacity of MIM Mg parts is superior to that of biodegradable polymeric components. However, the choice of appropriate polymeric binder components and alloying elements enabling defect-free injection molding and sintering is a major challenge for the use of MIM Mg parts. This study considered the full processing chain for MIM of Mg-Ca alloys to achieve ultimate tensile strength of up to 141 MPa with tensile yield strength of 73 MPa, elongation at fracture Af of 7% and a Young's modulus of 38 GPa. To achieve these mechanical properties, a thermal debinding study was performed to determine optimal furnace and atmosphere conditions, sintering temperature, heating rates, sintering time and pressure.

  10. The effects of process parameters on injection-molded PZT ceramics part fabrication- compounding process rheology.

    SciTech Connect

    Halbleib, Laura L.; Yang, Pin; Mondy, Lisa Ann; Burns, George Robert

    2005-05-01

    Solid solutions of lead-based perovskites are the backbone materials of the piezoelectric components for transducer, actuator, and resonator applications. These components, typically small in size, are fabricated from large sintered ceramic slugs using grinding and lapping processes. These operations increase manufacturing costs and produce a large hazardous waste stream, especially when component size decreases. To reduce costs and hazardous wastes associated with the production of these components, an injection molding technique is being investigated to replace the machining processes. The first step in the new technique is to compound an organic carrier with a ceramic powder. The organic carrier is a thermoplastic based system composed of a main carrier, a binder, and a surfactant. Understanding the rheology of the compounded material is necessary to minimize the creation of defects such as voids or cavities during the injection-molding process. An experiment was performed to model the effects of changes in the composition and processing of the material on the rheological behavior. Factors studied included: the surfactant of the organic carrier system, the solid loading of the compounded material, and compounding time. The effects of these factors on the viscosity of the material were investigated.

  11. Bulk and Surface Molecular Orientation Distribution in Injection-molded Liquid Crystalline Polymers: Experiment and Simulation

    SciTech Connect

    Fang, J.; Burghardt, W; Bubeck, R; Burgard, S; Fischer, D

    2010-01-01

    Bulk and surface distributions of molecular orientation in injection-molded plaques of thermotropic liquid crystalline polymers (TLCPs) have been studied using a combination of techniques, coordinated with process simulations using the Larson-Doi 'polydomain' model. Wide-angle X-ray scattering was used to map out the bulk orientation distribution. Fourier Transform Infrared Attenuated Total Reflectance (FTIR-ATR) and Near-Edge X-ray Absorption Fine Structure (NEXAFS) were utilized to probe the molecular orientation states to within about {approx}5 {micro}m and {approx}2 nm, respectively, of the sample surface. These noninvasive, surface-sensitive techniques yield reasonable self-consistency, providing complementary validation of the robustness of these methods. An analogy between Larson-Doi and fiber orientation models has allowed the first simulations of TLCP injection molding. The simulations capture many fine details in the bulk orientation distribution across the sample plaque. Direct simulation of surface orientation at the level probed by FTIR-ATR and NEXAFS was not possible due to the limited spatial resolution of the simulations. However, simulation results extracted from the shear-dominant skin region are found to provide a qualitatively accurate indicator of surface orientation. Finally, simulations capture the relation between bulk and surface orientation states across the different regions of the sample plaque.

  12. High numerical aperture injection-molded miniature objective for fiber-optic confocal reflectance microscopy

    NASA Astrophysics Data System (ADS)

    Chidley, Matthew Douglas

    This dissertation presents the design of a miniature injection-molded objective lens for a fiber-optic confocal reflectance microscope. This is part of an effort to demonstrate the ability to fabricate low cost, high performance biomedical optics for high resolution in vivo imaging. Disposable endoscopic microscope objectives could help in vivo confocal microscopy technology mature to enable large-scale clinical screening and detection of early cancers and pre-cancerous lesions. This five lens plastic objective has been tested as a stand-alone optical system and has been coupled to a confocal microscope for in vivo imaging of cells and tissue. Changing the spacing and rotation of the individual optical elements can compensate for fabrication inaccuracies and improve performance. An optical-bench testing system was constructed to allow interactive alignment during testing. The modulation transfer function (MTF) of the miniature objective lens is determined using the slanted-edge method. A custom MATLAB program, edgeMTF, was written to collect, analyze, and record test data. An estimated Strehl ratio of 0.64 and an MTF value of 0.70, at the fiber-optic bundle Nyquist frequency, have been obtained. The main performance limitations of the miniature objective are mechanical alignment and flow-induced birefringence. Annealing and experimental injection molding runs were conducted in effort to reduce birefringence.

  13. Modification of the logic and control system for the 80-ounce injection molding machine

    SciTech Connect

    Domer, G.A.

    1990-01-01

    The modification of the hydraulic logic and control system for the 80-ounce injection molding machine in the Molding and Machining, Plastics, department was required to allow production of near net size thick-walled parts and machining stock from high-shrinkage materials while retaining the original logic for standard product. The control system that was developed allows the new capability of open clamp injection. This capability will replace the present method of purchasing machining stock from an outside source. The control system was implemented with a Giddings Lewis Programmable Industrial Computer 409 (G L PiC 409). Hydraulic modifications included adding Vickers servo valves, an Inductosyn position transducer, and MOOG pressure transducers to perform force and position control. The control system provides two capabilities, NORMAL and SERVO. The NORMAL mode is defined as operating the machine according to original design specifications. The SERVO mode is defined as operating the machine according to a recipe in open loop position control then in closed loop force control. The G L PiC 409 controls the tasks of both modes. A selector switch determines the mode of operation (NORMAL or SERVO). The NORMAL mode uses the original hydraulic circuits, and the SERVO mode diverts fluid into the modified hydraulic circuits. 11 figs.

  14. Time-Dependent Properties of Multimodal Polyoxymethylene Based Binder for Powder Injection Molding

    NASA Astrophysics Data System (ADS)

    Gonzalez-Gutierrez, Joamin; Stringari, Gustavo Beulke; Zupancic, Barbara; Kubyshkina, Galina; Bernstorff, Bernd Von; Emri, Igor

    Powder injection molding (PIM) is one of the most versatile methods for the manufacturing of small complex shaped components from metal, ceramic or cemented carbide powders for the use in many applications. PIM consists of mixing the powder and a polymeric binder, injecting this mixture in a mold, debinding and then sintering. Catalytic debinding of polyoxymethylene (POM) is attractive since it shows high debinding rates and low risk of cracking. This work examines the possibility of using POM with bimodal molecular mass distribution as the main component of the binding agent by studying its time-dependent properties and comparing them to monomodal POM. Furthermore, possible optimization of the binder formulation was investigated by the addition of shorter polymeric chains (wax) to bimodal POM, as to create a multimodal material. It was observed that the magnitude of the complex viscosity for the commercial bimodal material was more than 2 times lower than for the chemically identical monomodal POM within the investigated frequency range and temperature. Viscosity values were observed to drop as the content of wax was increased, without compromising the binders mechanical properties in solid state. A new formulation of bimodal POM plus 8 wt.% of added wax provided the most appropriate results from investigated combinations. This work has shown how the addition of short polymeric chains in POM influences its time-dependent properties in solid and molten state, which can be an important tool for the optimization of binders designed to be used in PIM technology.

  15. (The control of microstructures during consolidation and injection molding of colloidal dispersions)

    SciTech Connect

    Not Available

    1991-01-01

    The existing three-year grant pertaining to The control of micro-structures during consolidation and injection molding of colloidal dispersions'' began July 1, 1988 as a continuation of a previous grant. The overall effort seeks to answer fundamental questions relevant to the colloidal processing of submicron particles leading to ceramic materials for strutural, electronic, or optical applications. At the outset two distinct projects were envisioned, an exploration of the ultrasonic enhancement of disorder-order transitions and a detailed study of injection molding of very dense dispersion, with each weighted toward experiments but with theoretical components. As the effort evolved the focus shifted in response to the interests of the students attracted to the project, the identification of interesting related problems through technical meetings, and different insights gained during participation in a DOE sponsored workshop. The scope that has emerged encompasses: completion of research begun during the first grant period on disorder-order transitions occurring during sedimentation, the consolidation of flocculated dispersions via filtration and the assembly of nanometer-sized particle into dense packings.

  16. Simulation of gas-assisted injection mold-cooling process using line source model approach for gas channel

    SciTech Connect

    Chang, Y.P.; Hu, S.Y.; Chen, S.C.

    1998-10-01

    Gas-assisted injection molding (GAIM) process, being an innovative injection molding process, can substantially reduce production expenses through reduction in material cost, reduction in clamp tonnage and reduction in cycle time. Whether it is feasible to perform an integrated simulation for process simulation based on a unified CAE model for gas-assisted injection molding (GAIM) is a great concern. In the present study, numerical algorithms based on the same CAE model used for process simulation regarding filling and packaging stages were developed to simulate the cooling phase of GAIM using a cycle-averaged three-dimensional modified boundary element technique similar to that used for conventional injection molding. However, to use the current CAE model for analysis, gas channel was modeled by two-node elements using line source approach. It was found that this new modeling not only affects the mold wall temperature calculation very slightly but also reduces the computer time by 95% as compared with a full gas channel modeling required a lot of triangular elements on gas channel surface. This investigation indicates that it is feasible to achieve an integrated process simulation for GAIM under one CAE model resulting in great computational efficiency for industrial application.

  17. Allergy Shots: Could They Help Your Allergies?

    MedlinePlus

    ... substance that you are allergic to (called the allergen). Common allergens include mold and pollen from grasses, ragweed and ... shot. Allergy shots help your body fight the allergen. When you get shots that contain the allergen, ...

  18. Numerical prediction of fiber orientation in injection-molded short-fiber/thermoplastic composite parts with experimental validation

    SciTech Connect

    Thi, Thanh Binh Nguyen; Morioka, Mizuki; Yokoyama, Atsushi; Hamanaka, Senji; Yamashita, Katsuhisa; Nonomura, Chisato

    2015-05-22

    Numerical prediction of the fiber orientation in the short-glass fiber (GF) reinforced polyamide 6 (PA6) composites with the fiber weight concentration of 30%, 50%, and 70% manufactured by the injection molding process is presented. And the fiber orientation was also directly observed and measured through X-ray computed tomography. During the injection molding process of the short-fiber/thermoplastic composite, the fiber orientation is produced by the flow states and the fiber-fiber interaction. Folgar and Tucker equation is the well known for modeling the fiber orientation in a concentrated suspension. They included into Jeffrey’s equation a diffusive type of term by introducing a phenomenological coefficient to account for the fiber-fiber interaction. Our developed model for the fiber-fiber interaction was proposed by modifying the rotary diffusion term of the Folgar-Tucker equation. This model was presented in a conference paper of the 29{sup th} International Conference of the Polymer Processing Society published by AIP conference proceeding. For modeling fiber interaction, the fiber dynamic simulation was introduced in order to obtain a global fiber interaction coefficient, which is sum function of the fiber concentration, aspect ratio, and angular velocity. The fiber orientation is predicted by using the proposed fiber interaction model incorporated into a computer aided engineering simulation package C-Mold. An experimental program has been carried out in which the fiber orientation distribution has been measured in 100 x 100 x 2 mm injection-molded plate and 100 x 80 x 2 mm injection-molded weld by analyzed with a high resolution 3D X-ray computed tomography system XVA-160α, and calculated by X-ray computed tomography imaging. The numerical prediction shows a good agreement with experimental validation. And the complex fiber orientation in the injection-molded weld was investigated.

  19. Numerical prediction of fiber orientation in injection-molded short-fiber/thermoplastic composite parts with experimental validation

    NASA Astrophysics Data System (ADS)

    Thi, Thanh Binh Nguyen; Morioka, Mizuki; Yokoyama, Atsushi; Hamanaka, Senji; Yamashita, Katsuhisa; Nonomura, Chisato

    2015-05-01

    Numerical prediction of the fiber orientation in the short-glass fiber (GF) reinforced polyamide 6 (PA6) composites with the fiber weight concentration of 30%, 50%, and 70% manufactured by the injection molding process is presented. And the fiber orientation was also directly observed and measured through X-ray computed tomography. During the injection molding process of the short-fiber/thermoplastic composite, the fiber orientation is produced by the flow states and the fiber-fiber interaction. Folgar and Tucker equation is the well known for modeling the fiber orientation in a concentrated suspension. They included into Jeffrey's equation a diffusive type of term by introducing a phenomenological coefficient to account for the fiber-fiber interaction. Our developed model for the fiber-fiber interaction was proposed by modifying the rotary diffusion term of the Folgar-Tucker equation. This model was presented in a conference paper of the 29th International Conference of the Polymer Processing Society published by AIP conference proceeding. For modeling fiber interaction, the fiber dynamic simulation was introduced in order to obtain a global fiber interaction coefficient, which is sum function of the fiber concentration, aspect ratio, and angular velocity. The fiber orientation is predicted by using the proposed fiber interaction model incorporated into a computer aided engineering simulation package C-Mold. An experimental program has been carried out in which the fiber orientation distribution has been measured in 100 x 100 x 2 mm injection-molded plate and 100 x 80 x 2 mm injection-molded weld by analyzed with a high resolution 3D X-ray computed tomography system XVA-160α, and calculated by X-ray computed tomography imaging. The numerical prediction shows a good agreement with experimental validation. And the complex fiber orientation in the injection-molded weld was investigated.

  20. Monitoring of residual stresses in injection-molded plastics with holographic interferometry

    NASA Astrophysics Data System (ADS)

    Sanchez, Lilia A.; Hornberger, Lee E.

    2002-01-01

    Residual stresses are often trapped in injection-molded plastic parts due to the rapid cooling of the material in this manufacturing process. These stresses are a common source of failure in plastic components in automobiles, appliances and computers and are difficult to measure with conventional residual-stress experimental methods. Real-time holographic interferometry appears to be a viable technique to identify and monitor these stresses in plastic parts. In this investigation, holographic interferometry was used to monitor the relaxation of residual stresses in the plastic-molded actuator arm of a computer hard drive. In the first phase of this study, the relaxation of these residual stresses as a function of temperature was observed. In the second phase, the time to completely relax the residual stresses in the plastic part at an elevated temperature, the annealing temperature, was determined. In the third phase of this investigation, the rate of relaxation of these residual stresses as a function of time at various operating temperatures, was studied. Based on the results of this study, holographic interferometry appears to be a powerful research tool in the study of residual stresses in plastic parts. It also has the potential to be a practical tool for the inspection of manufactured plastic parts for the presence of residual stress.

  1. Visualization analysis of tiger-striped flow mark generation phenomena in injection molding

    NASA Astrophysics Data System (ADS)

    Owada, Shigeru; Yokoi, Hidetoshi

    2016-03-01

    The generation mechanism of tiger-striped flow marks of polypropylene (PP)/rubber/talc blends in injection molding was investigated by dynamic visualization analysis in a glass-inserted mold. The analysis revealed that the behavior of the melt flow front correlates with the flow mark generation. The cloudy part in the tiger-striped flow marks corresponded to the low transcription rate area of the melt diverging near the cavity wall, while the glossy part corresponded to the high transcription rate area of the melt converging toward the cavity wall side. The melt temperature at the high transcription rate area was slightly lower than that at the low transcription rate area. These phenomena resulted due to the difference in the temperature of the melt front that was caused by the asymmetric fountain flow. These results suggest the followings; At the moment when the melt is broken near the one side of cavity wall due to piling the extensional strains up to a certain level, the melt spurts out near the broken side. It results in generating asymmetric fountain flow temporarily to relax the extensional front surface, which moves toward the opposite side to form the high transcription area.

  2. Biodegradability of injection molded bioplastic pots containing polylactic acid and poultry feather fiber.

    PubMed

    Ahn, H K; Huda, M S; Smith, M C; Mulbry, W; Schmidt, W F; Reeves, J B

    2011-04-01

    The biodegradability of three types of bioplastic pots was evaluated by measuring carbon dioxide produced from lab-scale compost reactors containing mixtures of pot fragments and compost inoculum held at 58 °C for 60 days. Biodegradability of pot type A (composed of 100% polylactic acid (PLA)) was very low (13 ± 3%) compared to literature values for other PLA materials. Near infrared spectroscopy (NIRS) results suggest that the PLA undergoes chemical structural changes during polymer extrusion and injection molding. These changes may be the basis of the low biodegradability value. Biodegradability of pot types B (containing 5% poultry feather, 80% PLA, 15% starch), and C (containing 50% poultry feather, 25% urea, 25% glycerol), were 53 ± 2% and 39 ± 3%, respectively. More than 85% of the total biodegradation of these bioplastics occurred within 38 days. NIRS results revealed that poultry feather was not degraded during composting. PMID:21320772

  3. Injection Molding of Polystyrene Matrix Composites Filled with Vapor Grown Carbon Fiber

    NASA Astrophysics Data System (ADS)

    Enomoto, Kazuki; Yasuhara, Toshiyuki; Ohtake, Naoto; Kato, Kazunori

    Vapor grown carbon fiber (VGCF) is a kind of carbon nanotube (CNT), which has outstanding properties such as high mechanical strength and high electrical conductivity. In this study, injection molding properties of polystyrene (PS) filled with VGCF and evaluation of mechanical and electrical properties are discussed in comparison with composites in which conventional carbon fillers were filled. As a result, volume resistivity of VGCF/PS composites dropped significantly between VGCF concentration of 3 and 4vol.%. Resistivity of the composites filled with VGCF was 1.2×102Ω·cm when VGCF concentration was 11.6vol.%. The resistivity was significantly lower than that of composites which were filled with conventional carbon fillers. The elastic modulus slightly increases with increasing VGCF concentration, whereas the tensile strength slightly decreases in the VGCF concentration in the range from 0 to 12vol.%.

  4. Research on properties of carbon black/polypropylene composites by dynamic injection molding

    NASA Astrophysics Data System (ADS)

    Wu, Ming-Chun; He, Guang-Jian; Huang, Zhao-Xia; Zhou, Li-Ying; He, He-Zhi

    2016-03-01

    Polymer composites filled with conductive carbon black (CB) are gaining popularity for electromagnetic shielding applications. Dynamic injection molding method was adopted to study the influences of vibration force field on electrical properties of polypropylene/CB composites. The results showed that the percolation phenomenon of conductivity of composites occurred at 15wt% and the calculated SE was positive correlated with the variation trend of conductivity. The calculated SE of composite was more than 30dB at a CB concentration of 30wt%, which could obtain good shielding effects. The result could offer optimum vibration parameters for producing electromagnetic shielding composites by respectively changing the amplitudes and frequencies of the vibration force field.

  5. End Uses Mechanical Properties Settled By The Modified Sintering Conditions Of The Metal Injection Molding Process

    SciTech Connect

    Marray, Tarek; Jaccquet, Philippe; Moinard-Checot, Delphine; Fabre, Agnes; Barrallier, Laurent

    2011-01-17

    Most common mechanical applications require parts with specific properties as hard faced features. It is well known that treating parts under suitable atmospheres may improve hardness and strength yield of steels. Heat treatment process and more particularly thermo-chemical diffusion processes (such as carburizing or its variation: carbonitriding) can be performed to reach the industrial hardness profile requirements. In this work, a low-alloyed steel feedstock based on water soluble binder system is submitted to the MIM process steps (including injection molding, debinding and sintering). As-sintered parts are then treated under a low pressure carbonitriding treatment. This contribution focuses on preliminary results such as microstructural analyses and mechanical properties which are established at each stage of the process to determine and monitor changes.

  6. Evaluation of the rigidity of dentures made of injection-molded materials.

    PubMed

    Wadachi, Juro; Sato, Masayuki; Igarashi, Yoshimasa

    2013-01-01

    Dentures made of 2 different types of injection-molded thermoplastic resins (polyamide resin and polyester resin) and a denture made of conventional heat-polymerized resin were used to create an experimental model of a mandibular molar region with a two-tooth gap. In the experimental model, a force of 100 N was applied onto the mesial fossa of the first molars of the dentures, and comparisons were performed by measuring the pressure applied under the denture base and the subsidence rate of the denture. The polyamide resin denture showed the highest subsidence, exerted the highest pressure on the underlying mucosa, and showed significant differences with the other types of dentures. The findings showed that polyamide resins have the lowest degree of elasticity, and that when resins with such low elasticities are used in the denture base, they should preferably be reinforced with metals. PMID:23719015

  7. Mechanical properties of injection molded B{sub 4}C-C ceramics

    SciTech Connect

    Schwetz, K.A.; Sigl, L.S.; Pfau, L.

    1997-10-01

    Various mechanical properties of carbon-doped boron carbide ceramics, prepared by the fabrication route, injection molding/pressureless sintering/post-hot isostatic pressing (HIP) were investigated as a function of the sintering temperature and the carbon additive level used. An optimum combination of mechanical properties (flexural strength, fracture toughness, Young`s modulus, Knoop`s hardness) is thus obtained with 100% dense and very fine grained materials (mean grain size 1-4 {mu}m) which were sintered at temperatures from 2150 to 2175{degrees}C and post HIPed at 2050{degrees}/200 MPa Ar, having an approximate final composition of 96 B{sub 4}C-4C (wt%).

  8. Microstructure and mechanical behavior of metal injection molded Ti-Nb binary alloys as biomedical material.

    PubMed

    Zhao, Dapeng; Chang, Keke; Ebel, Thomas; Qian, Ma; Willumeit, Regine; Yan, Ming; Pyczak, Florian

    2013-12-01

    The application of titanium (Ti) based biomedical materials which are widely used at present, such as commercially pure titanium (CP-Ti) and Ti-6Al-4V, are limited by the mismatch of Young's modulus between the implant and the bones, the high costs of products, and the difficulty of producing complex shapes of materials by conventional methods. Niobium (Nb) is a non-toxic element with strong β stabilizing effect in Ti alloys, which makes Ti-Nb based alloys attractive for implant application. Metal injection molding (MIM) is a cost-efficient near-net shape process. Thus, it attracts growing interest for the processing of Ti and Ti alloys as biomaterial. In this investigation, metal injection molding was applied to the fabrication of a series of Ti-Nb binary alloys with niobium content ranging from 10wt% to 22wt%, and CP-Ti for comparison. Specimens were characterized by melt extraction, optical microscopy, X-ray diffraction (XRD), scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), and transmission electron microscopy (TEM). Titanium carbide formation was observed in all the as-sintered Ti-Nb binary alloys but not in the as-sintered CP-Ti. Selected area electron diffraction (SAED) patterns revealed that the carbides are Ti2C. It was found that with increasing niobium content from 0% to 22%, the porosity increased from about 1.6% to 5.8%, and the carbide area fraction increased from 0% to about 1.8% in the as-sintered samples. The effects of niobium content, porosity and titanium carbides on mechanical properties have been discussed. The as-sintered Ti-Nb specimens exhibited an excellent combination of high tensile strength and low Young's modulus, but relatively low ductility. PMID:23994942

  9. Thermal Properties of Extruded Injection-Molded Polycaprolactone/Gluten Bioblends Characterized by TGA, DSC, SEM and Infrared Photoacoustic Spectroscopy

    Technology Transfer Automated Retrieval System (TEKTRAN)

    In order to determine the degree of compatibility between Polycaprolactone resin (PCL) and vital wheat gluten (VG), PCL was compounded with VG at 90:10, 80:20, 70:30, 60:40, 50:50, and 30:70. The composites were blended by extrusion followed by injection molding. Thermal, morphological, and struct...

  10. Study on the gas-liquid interface and polymer melt front in gas-assisted injection molding

    SciTech Connect

    Shen, Y.K.

    1997-03-01

    The algorithms are developed to predict the gas-liquid interface in gas-assisted injection molding. The simulation of two-dimensional, transient, non-isothermal and high viscous flow between two parallel plates with the generalized Newtonian fluid is presented in detail. The model takes into account the effects of the gas-liquid interface and polymer melt front.

  11. Development of an injection molded ethylene-vinyl acetate copolymer (EVA) intravaginal insert for the delivery of progesterone to cattle.

    PubMed

    Cappadoro, A J; Luna, J A

    2015-07-01

    The purpose of this study was to develop a new injection-molded intravaginal insert manufactured from ethylene-vinyl acetate containing progesterone for a 7-day insertion period in cattle. The manufacturing process resulted in a reduction in the residual drug compared to the silicone insert available while still maintaining biological performance. PMID:26022232

  12. CONVERSION OF WIND POWER TO HYDROGEN FUEL: DESIGN OF AN ALTERNATIVE ENERGY SYSTEM FOR AN INJECTION MOLDING FACILITY

    EPA Science Inventory

    Injection molding plants are large consumers of electricity. At its current level of operations, Harbec Plastics (Ontario, NY) uses about 2,000,000 kilowatt-hours of electricity per year. Based on the US average fuel mix, approximately 1.5 pounds of CO2

  13. The effects of boundary conditions on the dimensional changes and residual stresses in injection-molded parts

    SciTech Connect

    Bushko, W.C.; Stokes, V.K.

    1995-12-31

    The solidification of a molten layer of amorphous thermoplastic between cooled parallel plates is used to model the mechanics of part shrinkage and the buildup of residual stresses in the injection-molding process. Flow effects are neglected, and a thermorheologically simple thermoviscoelastic material model is assumed. The model allows material to be added to fill the space created by the pressure applied during solidification, so that this model can be used to assess packing-pressure effects in injection molding. The interactions between the mold surfaces and the solidifying material are accounted for by modeling different types of constraints through different model boundary conditions. For several different sets of boundary conditions, parametric results are presented on the effects of the packing pressure-the pressure applied during solidification to counteract the effects of volumetric shrinkage of the thermoplastic--on the in-plane and through-thickness shrinkages, and on residual stresses in plaque-like geometries. Plaques that can shrink in the in-plane direction while in the mold are shown to shrink more and to have higher residual stresses than plaques that are fully constrained while in the mold. Although the results are presented in terms of normalized variables based on the properties of bisphenol-A polycarbonate, they can be interpreted for other amorphous thermoplastics such as modified polyphenylene oxide, polyetherimide, and acrylonitrile-butadiene-styrene.

  14. Short-term and long-term behavior of PP-polymer nanocomposites produced by injection molding compounding

    NASA Astrophysics Data System (ADS)

    Battisti, M. G.; Guttmann, P.; Chitu, L.; Friesenbichler, W.

    2015-05-01

    There are only few investigations considering the impact of nanoscale fillers on the mechanical und thermo-mechanical properties of polymers. Particularly there is a lack of results regarding long term creep behavior of Polypropylene-based polymer nanocomposites (PNCs). Therefore, the objective of this study is to determine the influence of nanofiller content on the mechanical and thermo-mechanical behavior of Polypropylene-based PNCs. Processing of the test specimens was carried out using the Polymer NanoComposite Injection Molding Compounder (PNC-IMC). In comparison to the conventional compounding process, in which the compound must be pelletized and fed into the injection molding machine for the second plasticizing process, injection molding compounding combines these two processing steps. Material compounding and subsequent injection molding are done directly with only one plasticizing process, using a heated melt pipe and a melt accumulator for melt transfer from the compounder to the injection molding machine. The PNCs were produced in the 3-in-1 process at the PNC-IMC, where all components (polymer, compatibilizer, nanofiller) were added simultaneously into the compounder. Furthermore, the polymer melt was treated using elongational flow generating devices for better intercalation and exfoliation of the nanofillers. Tensile tests were made to characterize the short-term-mechanical properties. Tensile creep tests show the influence of nanofillers on the long-term-creep-performance and dynamic mechanical tests (DMA) were performed to investigate the thermo-mechanical behavior. Both, the improvements in the mechanical and thermo-mechanical properties in comparison to the pure polypropylene are shown and give an excellent overview of possibilities and limitations of the PNCs. Further research will focus on the detailed understanding of the different mechanisms of property improvement of layered silicates in polymer. By using small angle X-ray scattering

  15. Multiple-Step Injection Molding for Fibrin-Based Tissue-Engineered Heart Valves.

    PubMed

    Weber, Miriam; Gonzalez de Torre, Israel; Moreira, Ricardo; Frese, Julia; Oedekoven, Caroline; Alonso, Matilde; Rodriguez Cabello, Carlos J; Jockenhoevel, Stefan; Mela, Petra

    2015-08-01

    Heart valves are elaborate and highly heterogeneous structures of the circulatory system. Despite the well accepted relationship between the structural and mechanical anisotropy and the optimal function of the valves, most approaches to create tissue-engineered heart valves (TEHVs) do not try to mimic this complexity and rely on one homogenous combination of cells and materials for the whole construct. The aim of this study was to establish an easy and versatile method to introduce spatial diversity into a heart valve fibrin scaffold. We developed a multiple-step injection molding process that enables the fabrication of TEHVs with heterogeneous composition (cell/scaffold material) of wall and leaflets without the need of gluing or suturing components together, with the leaflets firmly connected to the wall. The integrity of the valves and their functionality was proved by either opening/closing cycles in a bioreactor (proof of principle without cells) or with continuous stimulation over 2 weeks. We demonstrated the potential of the method by the two-step molding of the wall and the leaflets containing different cell lines. Immunohistology after stimulation confirmed tissue formation and demonstrated the localization of the different cell types. Furthermore, we showed the proof of principle fabrication of valves using different materials for wall (fibrin) and leaflets (hybrid gel of fibrin/elastin-like recombinamer) and with layered leaflets. The method is easy to implement, does not require special facilities, and can be reproduced in any tissue-engineering lab. While it has been demonstrated here with fibrin, it can easily be extended to other hydrogels. PMID:25654448

  16. Multiple-Step Injection Molding for Fibrin-Based Tissue-Engineered Heart Valves

    PubMed Central

    Weber, Miriam; Gonzalez de Torre, Israel; Moreira, Ricardo; Frese, Julia; Oedekoven, Caroline; Alonso, Matilde; Rodriguez Cabello, Carlos J.

    2015-01-01

    Heart valves are elaborate and highly heterogeneous structures of the circulatory system. Despite the well accepted relationship between the structural and mechanical anisotropy and the optimal function of the valves, most approaches to create tissue-engineered heart valves (TEHVs) do not try to mimic this complexity and rely on one homogenous combination of cells and materials for the whole construct. The aim of this study was to establish an easy and versatile method to introduce spatial diversity into a heart valve fibrin scaffold. We developed a multiple-step injection molding process that enables the fabrication of TEHVs with heterogeneous composition (cell/scaffold material) of wall and leaflets without the need of gluing or suturing components together, with the leaflets firmly connected to the wall. The integrity of the valves and their functionality was proved by either opening/closing cycles in a bioreactor (proof of principle without cells) or with continuous stimulation over 2 weeks. We demonstrated the potential of the method by the two-step molding of the wall and the leaflets containing different cell lines. Immunohistology after stimulation confirmed tissue formation and demonstrated the localization of the different cell types. Furthermore, we showed the proof of principle fabrication of valves using different materials for wall (fibrin) and leaflets (hybrid gel of fibrin/elastin-like recombinamer) and with layered leaflets. The method is easy to implement, does not require special facilities, and can be reproduced in any tissue-engineering lab. While it has been demonstrated here with fibrin, it can easily be extended to other hydrogels. PMID:25654448

  17. The evaluation of vacuum venting and variotherm process for improving the replication by injection molding of high aspect ratio micro features for biomedical application

    NASA Astrophysics Data System (ADS)

    Sorgato, Marco; Lucchetta, Giovanni

    2015-05-01

    The aspect ratio achievable in replicating micro features is one of the most important process characteristics and it is a major manufacturing constraint in applying injection molding in a range of micro engineering applications. Vacuum venting has been reported to be an effective technique in replicating micro features by microinjection molding. High surface-to-volume ratio and reduced dimensions of micro parts promote the instantaneous drop of melt temperature and consequently lead to incomplete filling. This study aims to investigate the effects of variotherm process, cavity evacuation and their interaction on the production of a micro fluidic filter for biomedical applications. A low-viscosity polystyrene and a cyclic olefin copolymer were molded applying a combination of mold evacuation and a rapid mold temperature variation that keeps the cavity temperature above the glass transition temperature during the injection phase. The research revealed the importance of these molding technologies in enhancing part filling and the replication quality for high aspect ratio micro features.

  18. Modeling and Analysis of Process Parameters for Evaluating Shrinkage Problems During Plastic Injection Molding of a DVD-ROM Cover

    NASA Astrophysics Data System (ADS)

    Öktem, H.

    2012-01-01

    Plastic injection molding plays a key role in the production of high-quality plastic parts. Shrinkage is one of the most significant problems of a plastic part in terms of quality in the plastic injection molding. This article focuses on the study of the modeling and analysis of the effects of process parameters on the shrinkage by evaluating the quality of the plastic part of a DVD-ROM cover made with Acrylonitrile Butadiene Styrene (ABS) polymer material. An effective regression model was developed to determine the mathematical relationship between the process parameters (mold temperature, melt temperature, injection pressure, injection time, and cooling time) and the volumetric shrinkage by utilizing the analysis data. Finite element (FE) analyses designed by Taguchi (L27) orthogonal arrays were run in the Moldflow simulation program. Analysis of variance (ANOVA) was then performed to check the adequacy of the regression model and to determine the effect of the process parameters on the shrinkage. Experiments were conducted to control the accuracy of the regression model with the FE analyses obtained from Moldflow. The results show that the regression model agrees very well with the FE analyses and the experiments. From this, it can be concluded that this study succeeded in modeling the shrinkage problem in our application.

  19. Foam injection molding of polypropylene/stainless steel fiber composites for efficient EMI shielding

    NASA Astrophysics Data System (ADS)

    Ameli, A.; Nofar, M.; Saniei, M.; Wang, S.; Park, C. B.

    2016-03-01

    Lightweight polypropylene/stainless-steel fiber (PP-SSF) composites with 15-35% density reduction were fabricated using foam injection molding and supercritical carbon dioxide (CO2). The electrical percolation threshold, through-plane electrical conductivity, and electromagnetic interference (EMI) shielding effectiveness (SE) of the PP-SSF composite foams were characterized and compared against the solid samples. The effects of the plasticizing gas and the void fraction on fiber breakage and orientation were also investigated. Microstructure characterization showed that the presence of dissolved CO2 decreased fiber breakage by about 30%, and together with foaming action, contributed to less preferential orientation of fibers. Consequently, the percolation threshold decreased up to four folds from 0.85 to 0.21 vol.% as the void fraction increased from 0 to 35%. The specific EMI SE was also significantly enhanced. A maximum specific EMI SE of 75 dB.g-1cm3 was achieved in PP-1.1 vol.% SSF composite foams, which was highly superior to 38 dB.g-1cm3 of the solid PP-1.0 vol.% SSF composites. The results reveal that light and efficient products with a lower fiber content can be developed by foam for EMI shielding applications.

  20. Ceramic micro-injection molded nozzles for serial femtosecond crystallography sample delivery

    NASA Astrophysics Data System (ADS)

    Beyerlein, K. R.; Adriano, L.; Heymann, M.; Kirian, R.; Knoška, J.; Wilde, F.; Chapman, H. N.; Bajt, S.

    2015-12-01

    Serial femtosecond crystallography (SFX) using X-ray Free-Electron Lasers (XFELs) allows for room temperature protein structure determination without evidence of conventional radiation damage. In this method, a liquid suspension of protein microcrystals can be delivered to the X-ray beam in vacuum as a micro-jet, which replenishes the crystals at a rate that exceeds the current XFEL pulse repetition rate. Gas dynamic virtual nozzles produce the required micrometer-sized streams by the focusing action of a coaxial sheath gas and have been shown to be effective for SFX experiments. Here, we describe the design and characterization of such nozzles assembled from ceramic micro-injection molded outer gas-focusing capillaries. Trends of the emitted jet diameter and jet length as a function of supplied liquid and gas flow rates are measured by a fast imaging system. The observed trends are explained by derived relationships considering choked gas flow and liquid flow conservation. Finally, the performance of these nozzles in a SFX experiment is presented, including an analysis of the observed background.

  1. Influence of the power law index on the fiber breakage during injection molding by numerical simulations

    NASA Astrophysics Data System (ADS)

    Desplentere, Frederik; Six, Wim; Bonte, Hilde; Debrabandere, Eric

    2013-04-01

    In predictive engineering for polymer processes, the proper prediction of material microstructure from known processing conditions and constituent material properties is a critical step forward properly predicting bulk properties in the finished composite. Operating within the context of long-fiber thermoplastics (LFT, length > 15mm) this investigation concentrates on the influence of the power law index on the final fiber length distribution within the injection molded part. To realize this, the Autodesk Simulation Moldflow Insight Scandium 2013 software has been used. In this software, a fiber breakage algorithm is available from this release on. Using virtual material data with realistic viscosity levels allows to separate the influence of the power law index on the fiber breakage from the other material and process parameters. Applying standard settings for the fiber breakage parameters results in an obvious influence on the fiber length distribution through the thickness of the part and also as function of position in the part. Finally, the influence of the shear rate constant within the fiber breakage model has been investigated illustrating the possibility to fit the virtual fiber length distribution to the possible experimentally available data.

  2. Orientation distribution and process modeling of thermotropic liquid crystalline copolyester (TLCP) injection-moldings

    NASA Astrophysics Data System (ADS)

    Bubeck, Robert; Fang, Jun; Burghardt, Wesley; Burgard, Susan; Fischer, Daniel

    2009-03-01

    The influence of melt processing conditions upon mechanical properties and degrees of compound molecular orientation have been thoroughly studied for a series of well-defined injection molded samples fabricated from VECTRA (TM) A950 and 4,4'-dihydroxy-a-methylstilbene TLCPs. Fracture and tensile data were correlated with processing conditions, orientation, and molecular weight. Mechanical properties for both TLCPs were found to follow a ``universal'' Anisotropy Factor (AF) associated with the bimodal orientation states in the plaques determined from 2-D WAXS. Surface orientations were globally surveyed using Attenuated Total Reflectance -- Fourier Transform Infrared (ATR-FTIR) spectroscopy and C K edge Near-Edge X-ray Absorption Fine Structure (NEXAFS). The results derived from the two spectroscopy techniques confirmed each other well. These results along with those from 2-D WAXS in transmission were compared with the results of process modeling using a commercial program, MOLDFLOW(TM). The agreement between model predictions and the measured orientation states was gratifyingly good.

  3. Comparative study of pore structure evolution during solvent and thermal debinding of powder injection molded parts

    SciTech Connect

    Hwang, K.S.; Hsieh, Y.M.

    1996-02-01

    The solvent debinding process has been widely accepted in the powder injection molding (PIM) industry due to its short debinding cycle. In the current study, specimens were immersed in a heptane bath for different lengths of time, and the pore structure evolvement in the compact was analyzed. Mercury porosimetry analyses and scanning electron micrographs showed that the binder extraction started from the surface and progressed toward the center of the compacts. As the debinding continued, the pores grew and were widely distributed in size. This pore structure evolvement was different from that of straight thermal debinding in which the pore size distribution was quite narrow and the mean pore diameter shifted toward smaller sizes as debinding time increased. After the soluble binders were extracted, parts were subjected to a subsequent thermal debinding during which these pores served as conduits for decomposed gas to escape. Concurrently, the remaining binder became fluidlike and was redistributed within the compact due to capillarity. This pore structure, as observed from the mercury intrusion curves, showed a sharp increase in the pore volume at the 0.8-{micro}m size, followed by a series of fine pores, which is different from the pore structure of straight thermal debinding. The difference in the pore structure evolvement between solvent and thermal debinding and its effect on the debinding rate are discussed.

  4. Thermal shock behavior of tungsten based alloys manufactured via powder injection molding

    NASA Astrophysics Data System (ADS)

    Pintsuk, G.; Blagoeva, D.; Opschoor, J.

    2013-11-01

    The focus of this work is to address mechanical strength and recrystallization resistance through thermal shock investigation of newly developed fine grained tungsten base materials (i.e., pure tungsten and two doped tungsten-grades incorporating either 1 or 5 vol%Y2O3 produced via powder injection molding (PIM)). Therefore, repetitive ELM (edge localized mode)-like loads (n = 100) were applied by means of an electron beam at various temperatures between RT and 400 °C (673 K) with a pulse duration of 1 ms and an absorbed power density of up to 1.13 GW/m2. The microstructural properties, e.g. grain size, and Y2O3-particle distribution, were correlated with crack formation at a certain temperature, the crack propagation direction towards the bulk material and the amount of plastic deformation/surface roughening at higher temperatures. Thereby, it was shown that W-1 vol%Y2O3 outperformed all other investigated grades and reference materials from literature.

  5. Ceramic micro-injection molded nozzles for serial femtosecond crystallography sample delivery

    SciTech Connect

    Beyerlein, K. R.; Adriano, L.; Heymann, M.; Kirian, R.; Knoska, J.; Wilde, F.; Chapman, H. N.; Bajt, S.

    2015-12-08

    Serial femtosecond crystallography (SFX) using X-ray Free-Electron Lasers (XFELs) allows for room temperature protein structure determination without evidence of conventional radiation damage. In this method, a liquid suspension of protein microcrystals can be delivered to the X-ray beam in vacuum as a micro-jet, which replenishes the crystals at a rate that exceeds the current XFEL pulse repetition rate. Gas dynamic virtual nozzles produce the required micrometer-sized streams by the focusing action of a coaxial sheath gas and have been shown to be effective for SFX experiments. Here, we describe the design and characterization of such nozzles assembled from ceramic micro-injection molded outer gas-focusing capillaries. Trends of the emitted jet diameter and jet length as a function of supplied liquid and gas flow rates are measured by a fast imaging system. The observed trends are explained by derived relationships considering choked gas flow and liquidflow conservation. In conclusion, the performance of these nozzles in a SFX experiment is presented, including an analysis of the observed background.

  6. Comparative study of pore structure evolution during solvent and thermal debinding of powder injection molded parts

    NASA Astrophysics Data System (ADS)

    Hwang, K. S.; Hsieh, Y. M.

    1996-02-01

    The solvent debinding process has been widely accepted in the powder injection molding (PIM) industry due to its short debinding cycle. In the current study, specimens were immersed in a heptane bath for different lengths of time, and the pore structure evolvement in the compact was analyzed. Mercury porosimetry analyses and scanning electron micrographs showed that the binder extraction started from the surface and progressed toward the center of the compacts. As the debinding contin-ued, the pores grew and were widely distributed in size. This pore structure evolvement was different from that of straight thermal debinding in which the pore size distribution was quite narrow and the mean pore diameter shifted toward smaller sizes as debinding time increased. After the soluble binders were extracted, parts were subjected to a subsequent thermal debinding during which these pores served as conduits for decomposed gas to escape. Concurrently, the remaining binder became fluidlike and was redistributed within the compact due to capillarity. This pore structure, as observed from the mercury intrusion curves, showed a sharp increase in the pore volume at the 0.8-µm size, followed by a series of fine pores, which is different from the pore structure of straight thermal debinding. The difference in the pore structure evolvement between solvent and thermal debinding and its effect on the debinding rate are discussed.

  7. Simulation of polymer removal from a powder injection molding compact by thermal debinding

    NASA Astrophysics Data System (ADS)

    Lam, Y. C.; Yu, S. C. M.; Tam, K. C.; Shengjie, Ying

    2000-10-01

    Powder injection molding (PIM) is an important net-shape manufacturing process. Thermal debinding is a common methodology for the final removal of residual polymer from a PIM compact prior to sintering. This process is an intricate combination of evaporation, liquid and gas migration, pyrolysis of polymer, and heat transfer in porous media. A better understanding of thermal debinding could lead to optimization of the process to prevent the formation of defects. Simulation of the process based on an integrated mathematical model for mass and heat transfer in porous media is proposed. The mechanisms of mass transport, i.e., liquid flow, gas flow, vapor diffusion, and convection, as well as the phase transitions of polymer, and their interactions, are included in the model. The macroscopic partial differential equations are formulated by volume averaging of the microscopic conservation laws. The basic equations consist of mass conservation and energy conservation and are solved numerically. Polymer residue, pressure, and temperature distributions are predicted. The importance of the various mass transfer mechanisms is evaluated. The effects of key mass transfer parameters on thermal debinding are discussed. It is revealed from the results that the assumed binder front, which is supposed to recede into the powder compact as removal progresses, does not exist. The mass flux of polymer liquid is of the same order of the mass flux of polymer vapor in the gas phase, and the polymer vapor diffusion in the liquid phase is negligible.

  8. Debinding Process of Fe-6Ni-4Cu Compact Fabricated by Metal Injection Molding

    NASA Astrophysics Data System (ADS)

    Wang, Jenn-Shing; Lin, Shih-Pin; Hon, Min-Hsiung; Wang, Moo-Chin

    2000-02-01

    The debinding process in the case of metal injection molding for fabrication of the Fe-6Ni-4Cu compact and variables such as temperature and time has been studied. The debinding process of multiple organic binders in the Fe-6Ni-4Cu compact was investigated by thermal gravimetric analysis (TGA) weight loss and mercury porosimetry analysis. The weight loss of wax and SA dramatically increases from below 10 wt% to 76.0 wt% and 86.0 wt% after immersion in 35°C and 40°C n-hexane for 6 h, respectively. The interdiffusion coefficients of the binder and solvent are 9.763× 10-7 cm2/s and 1.295× 10-6 cm2/s, respectively. The temperature dependent interdiffusion coefficient for the Fe-6Ni-4Cu compact can be expressed as Dx=4.534× 10\\exp({-}5437.2/T). The distribution of pore size is about 0.1-1.9 μm for the Fe-6Ni-4Cu compact.

  9. Powder Injection Molding for mass production of He-cooled divertor parts

    NASA Astrophysics Data System (ADS)

    Antusch, S.; Norajitra, P.; Piotter, V.; Ritzhaupt-Kleissl, H.-J.

    2011-10-01

    A He-cooled divertor for future fusion power plants has been developed at KIT. Tungsten and tungsten alloys are presently considered the most promising materials for functional and structural divertor components. The advantages of tungsten materials lie, e.g. in the high melting point, and low activation, the disadvantages are high hardness and brittleness. The machinig of tungsten, e.g. milling, is very complex and cost-intensive. Powder Injection Molding (PIM) is a method for cost effective mass production of near-net-shape parts with high precision. The complete W-PIM process route is outlined and, results of product examination discussed. A binary tungsten powder feedstock with a grain size distribution in the range 0.7-1.7 μm FSSS, and a solid load of 50 vol.% was developed. After heat treatment, the successfully finished samples showed promising results, i.e. 97.6% theoretical density, a grain size of approximately 5 μm, and a hardness of 457 HV0.1.

  10. Ceramic micro-injection molded nozzles for serial femtosecond crystallography sample delivery

    SciTech Connect

    Beyerlein, K. R.; Heymann, M.; Kirian, R.; Adriano, L.; Bajt, S.; Knoška, J.; Wilde, F.; Chapman, H. N.

    2015-12-15

    Serial femtosecond crystallography (SFX) using X-ray Free-Electron Lasers (XFELs) allows for room temperature protein structure determination without evidence of conventional radiation damage. In this method, a liquid suspension of protein microcrystals can be delivered to the X-ray beam in vacuum as a micro-jet, which replenishes the crystals at a rate that exceeds the current XFEL pulse repetition rate. Gas dynamic virtual nozzles produce the required micrometer-sized streams by the focusing action of a coaxial sheath gas and have been shown to be effective for SFX experiments. Here, we describe the design and characterization of such nozzles assembled from ceramic micro-injection molded outer gas-focusing capillaries. Trends of the emitted jet diameter and jet length as a function of supplied liquid and gas flow rates are measured by a fast imaging system. The observed trends are explained by derived relationships considering choked gas flow and liquid flow conservation. Finally, the performance of these nozzles in a SFX experiment is presented, including an analysis of the observed background.

  11. Acoustic emission detection of macro-cracks on engraving tool steel inserts during the injection molding cycle using PZT sensors.

    PubMed

    Svečko, Rajko; Kusić, Dragan; Kek, Tomaž; Sarjaš, Andrej; Hančič, Aleš; Grum, Janez

    2013-01-01

    This paper presents an improved monitoring system for the failure detection of engraving tool steel inserts during the injection molding cycle. This system uses acoustic emission PZT sensors mounted through acoustic waveguides on the engraving insert. We were thus able to clearly distinguish the defect through measured AE signals. Two engraving tool steel inserts were tested during the production of standard test specimens, each under the same processing conditions. By closely comparing the captured AE signals on both engraving inserts during the filling and packing stages, we were able to detect the presence of macro-cracks on one engraving insert. Gabor wavelet analysis was used for closer examination of the captured AE signals' peak amplitudes during the filling and packing stages. The obtained results revealed that such a system could be used successfully as an improved tool for monitoring the integrity of an injection molding process. PMID:23673677

  12. Acoustic Emission Detection of Macro-Cracks on Engraving Tool Steel Inserts during the Injection Molding Cycle Using PZT Sensors

    PubMed Central

    Svečko, Rajko; Kusić, Dragan; Kek, Tomaž; Sarjaš, Andrej; Hančič, Aleš; Grum, Janez

    2013-01-01

    This paper presents an improved monitoring system for the failure detection of engraving tool steel inserts during the injection molding cycle. This system uses acoustic emission PZT sensors mounted through acoustic waveguides on the engraving insert. We were thus able to clearly distinguish the defect through measured AE signals. Two engraving tool steel inserts were tested during the production of standard test specimens, each under the same processing conditions. By closely comparing the captured AE signals on both engraving inserts during the filling and packing stages, we were able to detect the presence of macro-cracks on one engraving insert. Gabor wavelet analysis was used for closer examination of the captured AE signals' peak amplitudes during the filling and packing stages. The obtained results revealed that such a system could be used successfully as an improved tool for monitoring the integrity of an injection molding process. PMID:23673677

  13. PP-polymer nanocomposites with improved mechanical properties using elongational flow devices at the injection molding compounder

    NASA Astrophysics Data System (ADS)

    Battisti, M. G.; Friesenbichler, W.

    2014-05-01

    Numerous researches have been done in the field of improving PP by adding nanofillers. Consistently good scientific results and positive industrial feedback were reached; however, the industrial interest is still low due to the high technological and financial risks and too less benefit. Our experiments, using the worldwide unique Polymer NanoComposite Injection Molding Compounder (PNC-IMC) which combines the two processing steps of compounding and injection molding, showed an impressive increase of both mechanical and thermal properties, but more or less in the same range than in other publications. Thus we tried to improve the materials by using elongational flow generating devices for better intercalation and exfoliation of nanofillers in the polymer melt. This paper will give an overview on our first investigations, carried out on both a high pressure capillary rheometer (HPCR) and the injection molding machine (IMM) focusing on the mechanical properties. The PNCs were produced at the PNC-IMC with the 3in1 process. After the treatment in the HPCR the material was crushed, plates were prepared using a hydraulic vacuum press and tensile bars were milled, respectively tensile bars were produced with the IMM. The Young's modulus was successfully slightly improved. Thus future research will focus on both, the mechanism of improvement and the implementation of several of these devices into the PNC-IMC.

  14. Fabrication of Bonding-Type Hollow Microneedle Array by Injection Molding and Evaluation of its Puncture Characteristics

    NASA Astrophysics Data System (ADS)

    Ogai, Noriyuki; Sugimura, Ryo; Tamaru, Takuya; Takiguchi, Yoshihiro

    A microneedle array which consists from small needles compared to a conventional metal injection needle is expected as a low invasive transdermal medical treatment device, and many fabrication approach have been conducted. In this study, we fabricated plastic hollow microneedle array by a fabrication method based on the combination of injection molding, bonding and assembly techniques. To evaluate puncture characteristics of the fabricated needle, we measured a puncture force to silicone rubber by experimental equipment using loadcell and automatic stage. Furthermore, we propose and demonstrate a new method to measure actual punctured depth from punctured trace on the needle surface modified by O2 plasma treatment.

  15. One-Shot Percutaneous Ethanol Injection of Liver Tumors Under General Anesthesia: Preliminary Data on Efficacy and Complications

    SciTech Connect

    Giorgio, Antonio; Tarantino, Luciano; Francica, Giampiero; Mariniello, Nicola; Nuzzo, Antonio; Del Viscovo, Luca; Rotondo, Antonio

    1996-11-15

    Purpose: To verify the efficacy of ultrasound (US)-guided injection of large amounts of ethanol into large or multiple liver lesions, in a single session under general anesthesia (one-shot PEI) for percutaneous ablation of hepatic tumors. Methods: Twenty-nine patients (27 with 51 hepatocellular carcinoma (HCC) nodules on cirrhosis, diameter range 1.0<+>-<+>9.0 cm; two patients with a single metastasis from the gastroenteric tract, 5.0 and 9.0 cm, respectively, in diameter) were treated with one-shot PEI. Results: The total volume of alcohol delivered per patient ranged from 16 to 210 ml. Mean ethanol volume in all patients was 49 ml. Dynamic computed tomography (CT) examination showed complete necrosis in 41 of 50 lesions. Two patients died of hypovolemic shock due to massive upper gastrointestinal bleeding, 3 and 7 days, respectively, after the interventional procedure. All the remaining patients are alive (follow-up 5<+>-<+>14 months) except one who died of liver failure 5 months after. New HCC nodules occurred in six patients within 6 months and one intralesional relapse was recorded. Conclusion: In this preliminary experience, one-shot PEI is as effective in inducing liver tumor necrosis as traditional PEI; its advantages are shorter treatment time and the capability of treating larger and multiple liver lesions.

  16. In-line polariscopic checking of plastic molded-injected lenses: preliminary results

    NASA Astrophysics Data System (ADS)

    Arasa, J.; Mayershofer, D.; Romero, J.

    2015-05-01

    Plastic injection molded lenses have improved its performance and, nowadays, are as usual as glass lenses in image forming devices. However, the manufacturing process induces the surface generation and the material transformation in the same stage. Moreover, the process also includes an annealing stage to remove the internal stress with temperature cycles but only works up to a certain level and not beyond, leaving relevant traces for high values. During the manufacturing process of a plastic lens, a liquid-solid phase transformation occurs, and in this transition not all the volume of the lens achieves the same density. This change of density is translated into a local change of refractive index that can be expressed as a retardation phase plane using the Jones Matrix notation. The detection and measurement of the value of the retardation of the phase plane is thus the clue to manufacture good and controlled quality plastic lenses. We have tested an in-line polariscopic arrangement to obtain a 2D map of the tension distribution in the bulk of the lens. This test is performed in the first 30 seconds after the injection molding process for two main reasons: first the stress values are still high because the lenses do not have enough time to relax the internal tensions and obtain the final shape, and second, we can remove the wrong lenses in the first moments and introduce only the good lenses in the annealing stage. The proposed instrument is based in a transmission polariscopic arrangement. A collimated light beam is used to illuminate the sample, once the light crosses the sample, it is collected with an afocal system and the image is recorded in a CMOS sensor. Selecting an afocal system to capture the image is a useful decision because the lateral magnification can be maintained when small changes in the sample position are introduced. However the produced lenses can vary their focal lengths from on series to another. To avoid problems with the change of the

  17. Predictive Engineering Tools for Injection-molded Long-Carbon-Fiber Thermoplastic Composites - FY 2014 Third Quarterly Report

    SciTech Connect

    Nguyen, Ba Nghiep; Sanborn, Scott E.; Mathur, Raj N.; Sharma, Bhisham; Sangid, Michael D.; Wang, Jin; Jin, Xiaoshi; Costa, Franco; Gandhi, Umesh N.; Mori, Steven; Tucker III, Charles L.

    2014-08-15

    This report describes the technical progresses made during the third quarter of FY 2014: 1) Autodesk introduced the options for fiber inlet condition to the 3D solver. These options are already available in the mid-plane/dual domain solver. 2) Autodesk improved the accuracy of 3D fiber orientation calculation around the gate. 3) Autodesk received consultant services from Prof. C.L. Tucker at the University of Illinois on the implementation of the reduced order model for fiber length, and discussed with Prof. Tucker the methods to reduce memory usage. 4) PlastiComp delivered to PNNL center-gated and edge-fan-gated 20-wt% to 30-wt% LCF/PP and LCF/PA66 (7”x7”x1/8”) plaques molded by the in-line direct injection molding (D-LFT) process. 5) PlastiComp molded ASTM tensile, flexural and impact bars under the same D-LFT processing conditions used for plaques for Certification of Assessment and ascertaining the resultant mechanical properties. 6) Purdue developed a new polishing routine, utilizing the automated polishing machine, to reduce fiber damage during surface preparation. 7) Purdue used a marker-based watershed segmentation routine, in conjunction with a hysteresis thresholding technique, for fiber segmentation during fiber orientation measurement. 8) Purdue validated Purdue’s fiber orientation measurement method using the previous fiber orientation data obtained from the Leeds machine and manually measured data by the University of Illinois. 9) PNNL conducted ASMI mid-plane analyses for a 30wt% LCF/PP plaque and compared the predicted fiber orientations with the measured data provided by Purdue University at the selected locations on this plaque. 10) PNNL put together the DOE 2014 Annual Merit Review (AMR) presentation with the team and presented it at the AMR meetings on June 17, 2014. 11) PNNL built ASMI dual domain models for the Toyota complex part and commenced mold filling analyses of the complex part with different wall thicknesses in order to

  18. Reproducibility Study of NiTi Parts Made by Metal Injection Molding

    NASA Astrophysics Data System (ADS)

    Bram, M.; Bitzer, M.; Buchkremer, H. P.; Stöver, D.

    2012-12-01

    Powder metallurgy (P/M) is an attractive manufacturing process for net-shaped NiTi parts considering the limited machinability of NiTi alloys. Nevertheless, the industrial implementation of P/M processing for NiTi alloys is not trivial. To become competitive to manufacturing of NiTi alloys based on established ingot metallurgy, combination of fully pronounced shape memory behavior with sufficient mechanical properties is required. Successful use of P/M technology is strongly influenced by high affinity of NiTi alloys for uptake of oxygen and carbon, which leads to the formation of oxygen-containing Ti2Ni and TiC phases coupled with increase of Ni content in the matrix. In the case of Ni-rich NiTi alloys, this increase leads to a shift of phase transformation temperatures to lower values. Furthermore, precipitation of Ni4Ti3 during cooling from sintering temperature is difficult to avoid. Even if these precipitates might be used to decrease the Ni:Ti ratio of the matrix balancing oxygen and carbon uptake, significant loss of ductility arises, especially in the case of finely dispersed Ni4Ti3 precipitates. In the present work, each step of P/M manufacturing is discussed regarding its influence on the specific properties of NiTi alloys. The work is based on the application of prealloyed, gas atomized NiTi powders. Metal injection molding was used for net-shaped manufacturing of tensile samples, which enabled detailed study of sintering behavior combined with investigation of shape memory and mechanical properties depending on particle size, oxygen and carbon content as well as precipitation of Ni4Ti3 phase.

  19. Finger-powered microfluidic systems using multilayer soft lithography and injection molding processes.

    PubMed

    Iwai, Kosuke; Shih, Kuan Cheng; Lin, Xiao; Brubaker, Thomas A; Sochol, Ryan D; Lin, Liwei

    2014-10-01

    Point-of-care (POC) and disposable biomedical applications demand low-power microfluidic systems with pumping components that provide controlled pressure sources. Unfortunately, external pumps have hindered the implementation of such microfluidic systems due to limitations associated with portability and power requirements. Here, we propose and demonstrate a 'finger-powered' integrated pumping system as a modular element to provide pressure head for a variety of advanced microfluidic applications, including finger-powered on-chip microdroplet generation. By utilizing a human finger for the actuation force, electrical power sources that are typically needed to generate pressure head were obviated. Passive fluidic diodes were designed and implemented to enable distinct fluids from multiple inlet ports to be pumped using a single actuation source. Both multilayer soft lithography and injection molding processes were investigated for device fabrication and performance. Experimental results revealed that the pressure head generated from a human finger could be tuned based on the geometric characteristics of the pumping system, with a maximum observed pressure of 7.6 ± 0.1 kPa. In addition to the delivery of multiple, distinct fluids into microfluidic channels, we also employed the finger-powered pumping system to achieve the rapid formation of both water-in-oil droplets (106.9 ± 4.3 μm in diameter) and oil-in-water droplets (75.3 ± 12.6 μm in diameter) as well as the encapsulation of endothelial cells in droplets without using any external or electrical controllers. PMID:25102160

  20. Evaluation of Micro-drilling Technologies for Metal Injection Molded 420 Stainless Steel

    NASA Astrophysics Data System (ADS)

    Silverman, David Elion

    Metal injection molded (MIM) 420 stainless steel is a commonly used material for high-value products such as fuel injector nozzles. However, the trade-offs involved in using different micro-drilling processes on this material are not well-documented in literature. This thesis presents a micro-drilling study of MIM 420 stainless steel using four candidate processes, viz., micro-electrical discharge drilling (micro-EDD), ultrasonically-assisted micro-EDD, micro-mechanical drilling (micro-MD) and ultrasonically-assisted micro-MD. The micro-EDD results shows that the use of ultrasonic vibrations significantly improves the overall process time, spark erosion efficiency and material removal rate of the process. However, this improvement comes at the expense of increased tool wear and surface roughness, especially while machining under high discharge energy conditions. The micro-MD results show that the use of ultrasonic vibrations is beneficial in lowering the thrust force, drilling torque and tool-wear at chipload values greater than the minimum chip thickness of the material. However, the ultrasonic vibrations do not have a notable effect on the surface roughness or on the size of the exit burrs. The results obtained from this study have been used to develop a Likert-type comparison scale to enable application-specific selection of micro-drilling processes for MIM 420 stainless steel. Finally, the benefits of using the ultrasonically-assisted micro-EDD process seen during the laboratory tests at Rensselaer were observed to carry over to the production environment of our NYSERDA funded industrial sponsor.

  1. Tribological and mechanical performance evaluation of metal prosthesis components manufactured via metal injection molding.

    PubMed

    Melli, Virginia; Juszczyk, Mateusz; Sandrini, Enrico; Bolelli, Giovanni; Bonferroni, Benedetta; Lusvarghi, Luca; Cigada, Alberto; Manfredini, Tiziano; De Nardo, Luigi

    2015-01-01

    The increasing number of total joint replacements, in particular for the knee joint, has a growing impact on the healthcare system costs. New cost-saving manufacturing technologies are being explored nowadays. Metal injection molding (MIM) has already demonstrated its suitability for the production of CoCrMo alloy tibial trays, with a significant reduction in production costs, by holding both corrosion resistance and biocompatibility. In this work, mechanical and tribological properties were evaluated on tibial trays obtained via MIM and conventional investment casting. Surface hardness and wear properties were evaluated through Vickers hardness, scratch and pin on disk tests. The MIM and cast finished tibial trays were then subjected to a fatigue test campaign in order to obtain their fatigue load limit at 5 millions cycles following ISO 14879-1 directions. CoCrMo cast alloy exhibited 514 HV hardness compared to 335 HV of MIM alloy, furthermore it developed narrower scratches with a higher tendency towards microploughing than microcutting, in comparison to MIM CoCrMo. The observed fatigue limits were (1,766 ± 52) N for cast tibial trays and (1,625 ± 44) N for MIM ones. Fracture morphologies pointed out to a more brittle behavior of MIM microstructure. These aspects were attributed to the absence of a fine toughening and surface hardening carbide dispersion in MIM grains. Nevertheless, MIM tibial trays exhibited a fatigue limit far beyond the 900 N of maximum load prescribed by ISO and ASTM standards for the clinical application of these devices. PMID:25577214

  2. Miniature injection-molded optics for fiber-optic, in vivo confocal microscopy

    NASA Astrophysics Data System (ADS)

    Chidley, Matthew D.; Liang, Chen; Descour, Michael R.; Sung, Kung-Bin; Richards-Kortum, Rebecca R.; Gillenwater, Ann

    2002-12-01

    In collaboration with the Department of Biomedical Engineering at the University of Texas at Austin and the UT MD Anderson Cancer Center, a laser scanning fiber confocal reflectance microscope (FCRM) system has been designed and tested for in vivo detection of cervical and oral pre-cancers. This system along with specially developed diagnosis algorithms and techniques can achieve an unprecedented specificity and sensitivity for the diagnosis of pre-cancers in epithelial tissue. The FCRM imaging system consists of an NdYAG laser (1064 nm), scanning mirrors/optics, precision pinhole, detector, and an endoscopic probe (the objective). The objective is connected to the rest of the imaging system via a fiber bundle. The fiber bundle allows the rest of the system to be remotely positioned in a convenient location. Only the objective comes into contact with the patient. It is our intent that inexpensive mass-produced disposable endoscopic probes would be produced for large clinical trials. This paper touches on the general design process of developing a miniature, high numerical aperture, injection-molded (IM) objective. These IM optical designs are evaluated and modified based on manufacturing and application constraints. Based on these driving criteria, one specific optical design was chosen and a detailed tolerance analysis was conducted. The tolerance analysis was custom built to create a realistic statistical analysis for integrated IM lens elements that can be stacked one on top of another using micro-spheres resting in tiny circular grooves. These configurations allow each lens element to be rotated and possibly help compensate for predicted manufacturing errors. This research was supported by a grant from the National Institutes of Health (RO1 CA82880). Special thanks go to Applied Image Group/Optics for the numerous fabrication meetings concerning the miniature IM objective.

  3. Low Speed Technology for Small Turbine Development Reaction Injection Molded 7.5 Meter Wind Turbine Blade

    SciTech Connect

    David M. Wright; DOE Project Officer - Keith Bennett

    2007-07-31

    An optimized small turbine blade (7.5m radius) was designed and a partial section molded with the RIM (reaction-injection molded polymer) process for mass production. The intended market is for generic three-bladed wind turbines, 100 kilowatts or less, for grid-assist end users with rural and semi-rural sites, such as the farm/ranch market, having low to moderate IEC Class 3-4 wind regimes. This blade will have substantial performance improvements over, and be cheaper than, present-day 7.5m blades. This is made possible by the injection-molding process, which yields high repeatability, accurate geometry and weights, and low cost in production quantities. No wind turbine blade in the 7.5m or greater size has used this process. The blade design chosen uses a RIM skin bonded to a braided infused carbon fiber/epoxy spar. This approach is attractive to present users of wind turbine blades in the 5-10m sizes. These include rebladeing California wind farms, refurbishing used turbines for the Midwest farm market, and other manufacturers introducing new turbines in this size range.

  4. Comparison of peri-implant bone formation around injection-molded and machined surface zirconia implants in rabbit tibiae.

    PubMed

    Kim, Hong-Kyun; Woo, Kyung Mi; Shon, Won-Jun; Ahn, Jin-Soo; Cha, Seunghee; Park, Young-Seok

    2015-01-01

    The aim of this study was to compare osseointegration and surface characteristics of zirconia implants made by the powder injection molding (PIM) technique against those made by the conventional milling procedure in rabbit tibiae. Surface characteristics of 2 types of implants were evaluated. Sixteen rabbits received 2 types of external hex implants with similar geometry, either machined zirconia implants or PIM zirconia implants, in the tibiae. Removal torque tests and histomorphometric analyses were performed. The roughness of the PIM zirconia implants was higher than that of machined zirconia implants. The PIM zirconia implants exhibited significantly higher bone-implant contact and removal torque values than the machined zirconia implants (p<0.001). The osseointegration of the PIM zirconia implant is promising, and PIM, using the roughened mold etching technique, can produce substantially rougher surfaces on zirconia implants. PMID:26235717

  5. Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites - Fourth FY 2015 Quarterly Report

    SciTech Connect

    Nguyen, Ba Nghiep; Fifield, Leonard S.; Wollan, Eric J.; Roland, Dale; Gandhi, Umesh N.; Mori, Steven; Lambert, Gregory; Baird, Donald G.; Wang, Jin; Costa, Franco; Tucker III, Charles L.

    2015-11-13

    During the last quarter of FY 2015, the following technical progress has been made toward project milestones: 1) PlastiComp used the PlastiComp direct in-line (D-LFT) Pushtrusion system to injection mold 40 30wt% LCF/PP parts with ribs, 40 30wt% LCF/PP parts without ribs, 10 30wt% LCF/PA66 parts with ribs, and 35 30wt% LCF/PA66 parts without ribs. In addition, purge materials from the injection molding nozzle were obtained for fiber length analysis, and molding parameters were sent to PNNL for process modeling. 2) Magna cut samples at four selected locations (named A, B, C and D) from the non-ribbed Magna-molded parts based on a plan discussed with PNNL and the team and shipped these samples to Virginia Tech for fiber orientation and length measurements. 3) Virginia Tech started fiber orientation and length measurements for the samples taken from the complex parts using Virginia Tech’s established procedure. 4) PNNL and Autodesk built ASMI models for the complex parts with and without ribs, reviewed process datasheets and performed preliminary analyses of these complex parts using the actual molding parameters received from Magna and PlastiComp to compare predicted to experimental mold filling patterns. 5) Autodesk assisted PNNL in developing the workflow to use Moldflow fiber orientation and length results in ABAQUS® simulations. 6) Autodesk advised the team on the practicality and difficulty of material viscosity characterization from the D-LFT process. 7) PNNL developed a procedure to import fiber orientation and length results from a 3D ASMI analysis to a 3D ABAQUS® model for structural analyses of the complex part for later weight reduction study. 8) In discussion with PNNL and Magna, Toyota developed mechanical test setups and built fixtures for three-point bending and torsion tests of the complex parts. 9) Toyota built a finite element model for the complex parts subjected to torsion loading. 10) PNNL built the 3D ABAQUS® model of the complex ribbed

  6. A Fully Coupled Simulation and Optimization Scheme for the Design of 3D Powder Injection Molding Processes

    SciTech Connect

    Ayad, G.; Barriere, T.; Gelin, J. C.; Liu, B.

    2007-05-17

    The paper is concerned with optimization and parametric identification of Powder Injection Molding process that consists first in injection of powder mixture with polymer binder and then to the sintering of the resulting powders parts by solid state diffusion. In the first part, one describes an original methodology to optimize the injection stage based on the combination of Design Of Experiments and an adaptive Response Surface Modeling. Then the second part of the paper describes the identification strategy that one proposes for the sintering stage, using the identification of sintering parameters from dilatometer curves followed by the optimization of the sintering process. The proposed approaches are applied to the optimization for manufacturing of a ceramic femoral implant. One demonstrates that the proposed approach give satisfactory results.

  7. Single-Shot Epidural Injections in the Management of Radicular Pain

    PubMed Central

    Zarghooni, Kourosh; Rashidi, Ali; Siewe, Jan; Röllinghoff, Marc; Bredow, Jan; Eysel, Peer

    2015-01-01

    Epidural injections are commonly used in the treatment of chronic low back pain due to symptomatic lumbar spinal disorders. The aim of the present investigation was to study their therapeutic value for different age subgroups. A consecutive series of 356 patients were treated with at least one injection, and assessed before and after injection. Significant pain reduction was observed in all age groups following a series of injections with the greatest reduction after the first one. Especially in patients younger than 50 years, pain medication could be reduced substantially. Surgery was performed in 19.4% of patients (n=69) following a series of SSPDA injections. In the current study, interlaminar steroid injections for treatment of chronic low back and radicular pain caused sufficient improvement and significant reduction of medication especially in younger patients. PMID:26793292

  8. Spray-formed tooling for injection molding and die casting applications

    SciTech Connect

    K. M. McHugh; B. R. Wickham

    2000-06-26

    Rapid Solidification Process (RSP) Tooling{trademark} is a spray forming technology tailored for producing molds and dies. The approach combines rapid solidification processing and net-shape materials processing in a single step. The ability of the sprayed deposit to capture features of the tool pattern eliminates costly machining operations in conventional mold making and reduces turnaround time. Moreover, rapid solidification suppresses carbide precipitation and growth, allowing many ferritic tool steels to be artificially aged, an alternative to conventional heat treatment that offers unique benefits. Material properties and microstructure transformation during heat treatment of spray-formed H13 tool steel are described.

  9. Spray-formed Tooling for Injection Molding and Die Casting Applications

    SciTech Connect

    Mc Hugh, Kevin Matthew

    2000-06-01

    Rapid Solidification Process (RSP) ToolingTM is a spray forming technology tailored for producing molds and dies. The approach combines rapid solidification processing and net-shape materials processing in a single step. The ability of the sprayed deposit to capture features of the tool pattern eliminates costly machining operations in conventional mold making and reduces turnaround time. Moreover, rapid solidification suppresses carbide precipitation and growth, allowing many ferritic tool steels to be artificially aged, an alternative to conventional heat treatment that offers unique benefits. Material properties and microstructure transformation during heat treatment of spray-formed H13 tool steel are described.

  10. Application of Rapid Prototyping and Wire Arc Spray to the Fabrication of Injection Mold Tools (MSFC Center Director's Discretionary Fund)

    NASA Technical Reports Server (NTRS)

    Cooper, K. G.

    2000-01-01

    Rapid prototyping (RP) is a layer-by-layer-based additive manufacturing process for constructing three-dimensional representations of a computer design from a wax, plastic, or similar material. Wire arc spray (WAS) is a metal spray forming technique, which deposits thin layers of metal onto a substrate or pattern. Marshall Space Flight Center currently has both capabilities in-house, and this project proposed merging the two processes into an innovative manufacturing technique, in which intermediate injection molding tool halves were to be fabricated with RP and WAS metal forming.

  11. Improved silicon carbide for advanced heat engines. II - Pressureless sintering and mechanical properties of injection molded silicon carbide

    NASA Technical Reports Server (NTRS)

    Whalen, Thomas J.; Baer, J. R.

    1989-01-01

    The influence on density and strength of pressureless sintering in vacuum and argon environments has been evaluated with injection molded SiC materials. Main effects and two factor interactions of sintering (cycle variables temperature, time, heating rate, and atmosphere) were assessed. An improved understanding of the influence of the processing flaws and sintering conditions has been obtained. Strength and density have improved from a baseline level of 299 MPa (43.3 Ksi) and 94 pct of theoretical density to values greater than 483 MPa (70 Ksi) and 97 pct.

  12. Development of an injection molded poly(epsilon-caprolactone) intravaginal insert for the delivery of progesterone to cattle.

    PubMed

    Rathbone, Michael J; Bunt, Craig R; Ogle, Colin R; Burggraaf, Shane; Macmillan, Keith L; Pickering, Kim

    2002-12-13

    This paper reports experiments conducted to research, develop and clinically evaluate an injection molded intravaginal insert manufactured from the biodegradable polyester poly(epsilon-caprolactone). The study demonstrated that it is possible to engineer poly(epsilon-caprolactone) into a shape that is well retained, and can be used as a platform for the controlled delivery of progesterone via the vagina of cows. Field evaluation showed that the poly(epsilon-caprolactone) intravaginal inserts containing 10% (w/w) progesterone were at least as effective clinically as the commercially available CIDR intravaginal insert. PMID:12480312

  13. Portable CE system with contactless conductivity detection in an injection molded polymer chip for on-site food analysis

    NASA Astrophysics Data System (ADS)

    Becker, Holger; Mühlberger, Holger; Hoffmann, Werner; Clemens, Thomas; Klemm, Richard; Gärtner, Claudia

    2008-02-01

    We present a compact portable chip-based capillary electrophoresis system that employs capacitively coupled contactless conductivity detection (C 4D) operating at 4 MHz as an alternative detection method compared to the commonly used optical detection employing laser-induced fluorescence. The disposable chip for this system is fabricated out of PMMA using injection molding; the electrodes are screen-printed or thin-film electrodes. The system allows the measurement of small ions like Li, Na, K typically present in foodstuff like milk and mineral water as well as acids in wine.

  14. Evaluation of hot-melt extrusion and injection molding for continuous manufacturing of immediate-release tablets.

    PubMed

    Melocchi, Alice; Loreti, Giulia; Del Curto, Maria Dorly; Maroni, Alessandra; Gazzaniga, Andrea; Zema, Lucia

    2015-06-01

    The exploitation of hot-melt extrusion and injection molding for the manufacturing of immediate-release (IR) tablets was preliminarily investigated in view of their special suitability for continuous manufacturing, which represents a current goal of pharmaceutical production because of its possible advantages in terms of improved sustainability. Tablet-forming agents were initially screened based on processability by single-screw extruder and micromolding machine as well as disintegration/dissolution behavior of extruded/molded prototypes. Various polymers, such as low-viscosity hydroxypropylcellulose, polyvinyl alcohol, polyvinyl alcohol-polyethylene glycol graft copolymer, various sodium starch glycolate grades (e.g., Explotab(®) CLV) that could be processed with no need for technological aids, except for a plasticizer, were identified. Furthermore, the feasibility of both extruded and molded IR tablets from low-viscosity hydroxypropylcellulose or Explotab(®) CLV was assessed. Explotab(®) CLV, in particular, showed thermoplastic properties and a very good aptitude as a tablet-forming agent, starting from which disintegrating tablets were successfully obtained by either techniques. Prototypes containing a poorly soluble model drug (furosemide), based on both a simple formulation (Explotab(®) CLV and water/glycerol as plasticizers) and formulations including dissolution/disintegration adjuvants (soluble and effervescent excipients) were shown to fulfill the USP 37 dissolution requirements for furosemide tablets. PMID:25761921

  15. NON-POLLUTING COMPOSITES REPAIR AND REMANUFACTURING FOR MILITARY APPLICATIONS: CO-INJECTION RESIN TRANSFER MOLDING

    EPA Science Inventory

    Vacuum-assisted resin transfer molding (VARTM) processes have been proven to be cost-effective manufacturing techniques for large composite structures. However, their use has been limited to single resin systems. A large variety of composite structures requires multiple resins to...

  16. Fabrication of long-focal-length plano-convex microlens array by combining the micro-milling and injection molding processes.

    PubMed

    Chen, Lei; Kirchberg, Stefan; Jiang, Bing-Yan; Xie, Lei; Jia, Yun-Long; Sun, Lei-Lei

    2014-11-01

    A uniform plano-convex spherical microlens array with a long focal length was fabricated by combining the micromilling and injection molding processes in this work. This paper presents a quantitative study of the injection molding process parameters on the uniformity of the height of the microlenses. The variation of the injection process parameters, i.e., barrel temperature, mold temperature, injection speed, and packing pressure, was found to have a significant effect on the uniformity of the height of the microlenses, especially the barrel temperature. The filling-to-packing switchover point is also critical to the uniformity of the height of the microlenses. The optimal uniformity was achieved when the polymer melts completely filled the mold cavity, or even a little excessively filled the cavity, during the filling stage. In addition, due to the filling resistance, the practical filling-to-packing switchover point can vary with the change of the filling processing conditions and lead to a non-negligible effect on the uniformity of the height of the microlenses. Furthermore, the effect of injection speed on the uniformity of the height of the microlenses was analyzed in detail. The results indicated that the effect of injection speed on the uniformity of the height of the microlenses is mainly attributed to the two functions of injection speed: transferring the filling-to-packing switchover point and affecting the distribution of residual flow stress in the polymer melt. PMID:25402902

  17. Numerical simulation of fiber interaction in short-fiber injection-molded composite using different cavity geometries

    NASA Astrophysics Data System (ADS)

    Thi, Thanh Binh Nguyen; Yokoyama, Atsushi; Hamanaka, Senji; Yamashita, Katsuhisa; Nonomura, Chisato

    2016-03-01

    The theoretical fiber-interaction model for calculating the fiber orientation in the injection molded short fiber/thermoplastic composite parts was proposed. The proposed model included the fiber dynamics simulation in order to obtain an equation of the global interaction coefficient and accurate estimate of the fiber interacts at all orientation states. The steps to derive the equation for this coefficient in short fiber suspension as a function of the fiber aspect ratio, volume fraction and general shear rate are delineated. Simultaneously, the high-resolution 3D X-ray computed tomography system XVA-160α was used to observe fiber distribution of short-glass-fiber-reinforced polyamide specimens using different cavity geometries. The fiber orientation tensor components are then calculated. Experimental orientation measurements of short-glass-fiber-reinforced polyamide is used to check the ability of present theory for predicting orientation. The experiments and predictions show a quantitative agreement and confirm the basic understanding of fiber orientation in injection-molded composites.

  18. Prediction of the Elastic-Plastic Stress/Strain Response for Injection-Molded Long-Fiber Thermoplastics

    SciTech Connect

    Nguyen, Ba N.; Kunc, Vlastimil; Phelps, Jay H; TuckerIII, Charles L.; Bapanapalli, Satish K

    2009-01-01

    This paper proposes a model to predict the elastic-plastic response of injection-molded long-fiber thermoplastics (LFTs). The model accounts for elastic fibers embedded in a thermoplastic resin that exhibits the elastic-plastic behavior obeying the Ramberg-Osgood relation and J-2 deformation theory of plasticity. It also accounts for fiber length and orientation distributions in the composite formed by the injection-molding process. Fiber orientation was predicted using an anisotropic rotary diffusion model recently developed for LFTs. An incremental procedure using Eshelby's equivalent inclusion method and the Mori-Tanaka assumption is proposed to compute the overall stress increment resulting from an overall strain increment for an aligned-fiber composite that contains the same fiber volume fraction and length distribution as the actual composite. The incremental response of the latter is then obtained from the solution for the aligned-fiber composite by averaging over all fiber orientations. Failure during incremental loading is predicted using the Van Hattum-Bernado model. The model is validated against the experimental stress-strain results obtained for long-glass-fiber/polypropylene specimens.

  19. Fiber Length and Orientation in Long-Fiber Injection-Molded Thermoplastics. Part I: Modeling of Microstructure and Elastic Properties

    SciTech Connect

    Nguyen, Ba Nghiep; Bapanapalli, Satish K.; Holbery, James D.; Smith, Mark T.; Kunc, Vlastimil; Frame, Barbara J.; Phelps, Jay; Tucker III, Charles L.

    2008-05-01

    This paper investigates the effects of fiber length and orientation distributions on the elastic properties of long-fiber injection-molded thermoplastics (LFTs). The corrected experimental fiber length distribution and the predicted and experimental orientation distributions were used in modeling to compute the elastic properties of the composite. First, from the fiber length distribution (FLD) data in terms of number of fibers versus fiber length, the probability density functions were built and used in the computation. Also, it has been shown that the two-parameter Weibull’s distribution can be used to represent the actual FLD. Next, the Mori-Tanaka model that employs the Eshelby’s equivalent inclusion method was applied to calculate the stiffness matrix of the aligned fiber composite containing the established FLD. The stiffness of the actual as-formed composite was then determined from the stiffness of the computed aligned fiber composite that was averaged over all possible orientations using the orientation averaging method. The methodology to predict the elastic properties of LFTs was validated via experimental verification of the longitudinal and transverse moduli determined for long glass fiber injection-molded polypropylene specimens. Finally, a sensitivity analysis was conducted to determine the effect of a variation of FLD on the composite elastic properties.

  20. Prediction of the Elastic-Plastic Stress/Strain Response for Injection-Molded Long-Fiber Thermoplastics

    SciTech Connect

    Nguyen, Ba Nghiep; Bapanapalli, Satish K.; Kunc, Vlastimil; Phelps, Jay; Tucker III, Charles L.

    2009-01-26

    This paper proposes a model to predict the elastic-plastic response of injection-molded long-fiber thermoplastics (LFTs). The model accounts for elastic fibers embedded in a thermoplastic resin that exhibits the elastic-plastic behavior obeying the Ramberg-Osgood relation and J-2 deformation theory of plasticity. It also accounts for fiber length and orientation distributions in the composite formed by the injection-molding process. Fiber orientation was predicted using the anisotropic rotary diffusion model recently developed by Phelps and Tucker for LFTs. An incremental procedure using the Eshelby’s equivalent inclusion method and the Mori-Tanaka model is proposed to compute the overall stress increment resulting from an overall strain increment for an aligned fiber composite that contains the same fiber volume fraction and length distribution as the actual composite. The incremental response of the later is then obtained from the solution for the aligned fiber composite that is averaged over all possible fiber orientations using the orientation averaging method. Failure during incremental loading is predicted using the Van Hattum-Bernado model. The elastic-plastic and strength prediction model for LFTs was validated against the experimental stress-strain results obtained for long glass fiber/polypropylene specimens.

  1. Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites - FY 2014 Fourth Quarterly Report

    SciTech Connect

    Nguyen, Ba Nghiep; Fifield, Leonard S.; Mathur, Raj N.; Kijewski, Seth A.; Sangid, Michael D.; Wang, Jin; Jin, Xiaoshi; Costa, Franco; Gandhi, Umesh N.; Mori, Steven; Tucker, III, Charles L.

    2014-09-30

    extract machine purgings (purge materials) from Magna’s 200-Ton Injection Molding machine targeted to mold the complex part. 11) Toyota and Magna discussed with PNNL tool modification for molding the complex part.

  2. Suppressing the Skin-Core Structure of Injection-Molded Isotactic Polypropylene via Combination of an in situ Microfibrillar Network and an Interfacial Compatibilizer

    SciTech Connect

    X Yi; C Chen; G Zhong; L Xu; J Tang; X Ji; B Hsiao; Z Li

    2011-12-31

    Injection-molded semicrystalline polymer parts generally exhibited a so-called skin-core structure basically as a result of the large gradients of temperature, shear rate, stress, and pressure fields created by the boundary conditions of injection molding. Suppression of the skin-core structure is a long-term practical challenge. In the current work, the skin-core structure of the conventional injection-molded isotactic polypropylene (iPP) was largely relieved by the cooperative effects of an in situ microfibrillar network and interfacial compatibilizer. The in situ poly(ethylene terephthalate) microfibrils of 1-8 {micro}m in diameter and large aspect ratios of above 40 tended to entangle with each other to generate a microfibrillar network in the iPP melt. During injection molding, the iPP molecules experienced confined flow in the microchannels or pores formed by the microfibrillar network, which could redistribute and homogenize the flow field of polymer melt. Addition of the compatibilizer, glycidyl methacrylate-grafted iPP, restrained the molecular orientation but facilitated preservation of oriented molecules due to the chemical bonds at the interface between PET microfibrils and iPP. The cooperative effects of in situ microfibrillar network and interfacial compatibilizer led to almost the same molecular orientation across the whole thickness of the injection-molded parts. Additionally, the content of {beta} crystals in different layers of injection-molded iPP parts depended on the combined effects of the molecular orientation, the amount of oriented crystals, and the crystallization time between 105 and 140 C. The presence of the interfacial compatibilizer facilitated formation of the {beta} crystals because of preservation of the oriented molecules.

  3. Analysis of batch-related influences on injection molding processes viewed in the context of electro plating quality demands

    NASA Astrophysics Data System (ADS)

    Siepmann, Jens P.; Wortberg, Johannes; Heinzler, Felix A.

    2016-03-01

    The injection molding process is mandatorily influenced by the viscosity of the material. By varying the material batch the viscosity of the polymer changes. For the process and part quality the initial conditions of the material in addition to the processing parameters define the process and product quality. A high percentage of technical polymers processed in injection molding is refined in a follow-up production step, for example electro plating. Processing optimized for electro plating often requires avoiding high shear stresses by using low injection speed and pressure conditions. Therefore differences in the material charges' viscosity occur especially in the quality related low shear rate area. These differences and quality related influences can be investigated by high detail rheological analysis and process simulation based on adapted material describing models. Differences in viscosity between batches can be detected by measurements with high-pressure-capillary-rheometers or oscillatory rheometers for low shear rates. A combination of both measurement techniques is possible by the Cox-Merz-Relation. The detected differences in the rheological behavior of both charges are summarized in two material behavior describing model approaches and added to the simulation. In this paper the results of processing-simulations with standard filling parameters are presented with two ABS charges. Part quality defining quantities such as temperature, pressure and shear stress are investigated and the influence of charge variations is pointed out with respect to electro plating quality demands. Furthermore, the results of simulations with a new quality related process control are presented and compared to the standard processing.

  4. EXPERIMENTAL TARGET INJECTION AND TRACKING SYSTEM CONSTRUCTION AND SINGLE SHOT TESTING

    SciTech Connect

    PETZOLDT,R.W; ALEXANDER,N.B; DRAKE,T.J; GOODIN,D.T; JONESTRACK,K; VERMILLION,B.A

    2003-09-01

    Targets must be injected into an IFE power plant at a rate of approximately 5 to 10 Hz. Targets must be tracked very accurately to allow driver beams to be aligned with defined points on the targets with accuracy {+-} 150 {micro}m for indirect drive and {+-} 20 {micro}m for direct drive. An experimental target injection and tracking system has been constructed at General Atomics. The injector system will be used as a tool for testing the survivability of various target designs and provide feedback to the target designers. Helium gas propels the targets down an 8 m gun barrel up to 400 m/s. Direct-drive targets are protected in the barrel by sabots that are spring loaded to separate into two halves after acceleration. A sabot deflector directs the sabot halves away from the target injection path. Targets will be optically tracked with laser beams and line-scan cameras. Target position and arrival time will be predicted in real time based on early target position measurements. The system installation will be described. System testing to overcome excessive projectile wear and debris in the gun barrel is presented.

  5. Mold Allergy

    MedlinePlus

    ... navigation Home ▸ Conditions & Treatments ▸ Allergies ▸ Mold Allergy Share | Mold Allergy Overview Symptoms & Diagnosis Treatment & Management Mold Allergy Overview Molds are tiny fungi whose spores ...

  6. An injection molding process for manufacturing highly porous and interconnected biodegradable polymer matrices for use as tissue engineering scaffolds.

    PubMed

    Kramschuster, Adam; Turng, Lih-Sheng

    2010-02-01

    In this research, injection molding was combined with a novel material combination, supercritical fluid processing, and particulate leaching techniques to produce highly porous and interconnected structures that have the potential to act as scaffolds for tissue engineering applications. The foamed structures, molded with polylactide (PLA) and polyvinyl alcohol (PVOH) with salt as the particulate, were processed without the aid of organic solvents, which can be detrimental to tissue growth. The pore size in the scaffolds is controlled by salt particulates and interconnectivity is achieved by the co-continuous blending morphology of biodegradable PLA matrix with water-soluble PVOH. Carbon dioxide (CO(2)) at the supercritical state is used to serve as a plasticizer, thereby imparting moldability of blends even with an ultra high salt particulate content, and allows the use of low processing temperatures, which are desirable for temperature-sensitive biodegradable polymers. Interconnected pores of approximately 200 microm in diameter and porosities of approximately 75% are reported and discussed. PMID:19957359

  7. Use of a Naphthalene-Based Binder in Injection Molding Net-Shape Titanium Components of Controlled Porosity

    SciTech Connect

    Weil, K. Scott; Nyberg, Eric A.; Simmons, Kevin L.

    2005-07-01

    We have recently developed a naphthalene-based binder system for use in powder injection molding (PIM) of ceramic and metallic materials. The use of a binder that can be removed via sublimation offers several unique advantages relative to the typical thermoplastic and/or thermoset binders employed in PIM. One of these is that essentially no volume change takes place during debindering. This offers a relatively facile method of introducing porosity into a net-shape part of potentially complex geometry. In the study described in this paper, the effects of powder loading and subsequent isostatic compaction on the size and amount of porosity in the components produced by this technique were investigated. In general, it was found that the amount of porosity is inversely proportional to the initial concentration of metal powder in the PIM feedstock. Likewise, average pore size displays a similar relationship with powder loading.

  8. Effect of low doses beta irradiation on micromechanical properties of surface layer of injection molded polypropylene composite

    NASA Astrophysics Data System (ADS)

    Manas, David; Manas, Miroslav; Gajzlerova, Lenka; Ovsik, Martin; Kratky, Petr; Senkerik, Vojtěch; Skrobak, Adam; Danek, Michal; Manas, Martin

    2015-09-01

    The influence of beta radiation on the changes in the structure and selected properties (mechanical and thermal) was proved. Using low doses of beta radiation for 25% glass fiber filled polypropylene and its influence on the changes of micromechanical properties of surface layer has not been studied in detail so far. The specimens of 25% glass fiber filled PP were made by injection molding technology and irradiated by low doses of beta radiation (0, 15 and 33 kGy). The changes in the microstructure and micromechanical properties of surface layer were evaluated using FTIR, SEM, WAXS and instrumented microhardness test. The results of the measurements showed considerable increase in micromechanical properties (indentation hardness, indentation elastic modulus) when low doses of beta radiation are used.

  9. Producing Zirconium Diboride Components with Complex, Near-Net Shape Geometries by Aqueous Room-Temperature Injection Molding

    NASA Technical Reports Server (NTRS)

    Wiesner, Valerie L.; Youngblood, Jeffrey; Trice, Rodney

    2014-01-01

    Room-temperature injection molding is proposed as a novel, low-cost and more energy efficient manufacturing process capable of forming complex-shaped zirconium diboride (ZrB2) parts. This innovative processing method utilized aqueous suspensions with high powder loading and a minimal amount (5 vol.) of water-soluble polyvinylpyrrolidone (PVP), which was used as a viscosity modifier. Rheological characterization was performed to evaluate the room-temperature flow properties of ZrB2-PVP suspensions. ZrB2 specimens were fabricated with high green body strength and were machinable prior to binder removal despite their low polymer content. After binder burnout and pressureless sintering, the bulk density and microstructure of specimens were characterized using Archimedes technique and scanning electron microscopy. X-Ray Diffraction was used to determine the phase compositions present in sintered specimens. Ultimate strength of sintered specimens will be determined using ASTM C1323-10 compressive C-ring test.

  10. Solidification behavior of high-density polyethylene (HDPE) during injection molding: Correlation between crystallization kinetics and thermal gradient field

    NASA Astrophysics Data System (ADS)

    Yang, Bin; Deng, Yan-Li; Li, Gui-Jing; Miao, Ji-Bin; Xia, Ru; Qian, Jia-Sheng; Chen, Peng; Liu, Jing-Wang

    2015-07-01

    This work mainly investigated the effect of thermal field on the crystallization kinetics of high-density polyethylene (HDPE) during injection molding (IM) process. The thickness X = 0.4 was found to be a crucial location heavily influenced by thermal conduction. The temperature decay tended to be stable, with limited variation of the crystallization rate when X > 0.4. It was observed that the crystallization rate was in good proportion to the cooling rate (ϕ). Our experimental finding showed that the consequence of relative crystallinity (χ) was in agreement with that of the secondary temperature difference (STD). This study is practically significant to the further investigation on the relationship among “processing-structure-property” of polymeric materials.

  11. High-Temperature Oxidation Behavior of Two Nickel-Based Superalloys Produced by Metal Injection Molding for Aero Engine Applications

    NASA Astrophysics Data System (ADS)

    Albert, Benedikt; Völkl, Rainer; Glatzel, Uwe

    2014-09-01

    For different high-temperature applications like aero engines or turbochargers, metal injection molding (MIM) of superalloys is an interesting processing alternative. For operation at high temperatures, oxidation behavior of superalloys produced by MIM needs to match the standard of cast or forged material. The oxidation behavior of nickel-based superalloys Inconel 713 and MAR-M247 in the temperature interval from 1073 K to 1373 K (800 °C to 1100 °C) is investigated and compared to cast material. Weight gain is measured discontinuously at different oxidation temperatures and times. Analysis of oxidized samples is done via SEM and EDX-measurements. MIM samples exhibit homogeneous oxide layers with a thickness up to 4 µm. After processing by MIM, Inconel 713 exhibits lower weight gain and thinner oxide layers than MAR-M247.

  12. The Effect of Hydrolysis on the Mechanical Properties of Injection-Molded Poly(L-lactic acid)

    NASA Astrophysics Data System (ADS)

    Kobayashi, Satoshi; Todo, Mitsugu

    Injection molded bulk-shape Poly (L-lactide) (PLLA) specimens were hydrolyzed in the phosphate buffered solution and the mechanical properties were evaluated after the hydrolysis tests. In order to evaluated the effect of crystallinity on the hydrolysis, specimens were annealed with 70 and 130°C for 24h. Hydrolysis tests were conducted with soaking the specimens in the phosphate buffered solution (pH 7.4) in an incubator where temperature was kept as 37°C. Vickers hardness was not influenced by hydrolysis until 30 days. Tensile tests results, however, indicated the strength reduction with hydrolysis. From the appearance inspection, whitened regions were observed at the inner of the specimen. These results indicated the bulk erosion with accelerated inside erosion occurred.

  13. Biocompatibility of metal injection molded versus wrought ASTM F562 (MP35N) and ASTM F1537 (CCM) cobalt alloys.

    PubMed

    Chen, Hao; Sago, Alan; West, Shari; Farina, Jeff; Eckert, John; Broadley, Mark

    2011-01-01

    We present a comparative analysis between biocompatibility test results of wrought and Metal Injection Molded (MIM) ASTM F562-02 UNS R30035 (MP35N) and F1537 UNS R31538 (CCM) alloy samples that have undergone the same generic orthopedic implant's mechanical, chemical surface pre-treatment, and a designed pre-testing sample preparation method. Because the biocompatibility properties resulting from this new MIM cobalt alloy process are not well understood, we conducted tests to evaluate cytotoxicity (in vitro), hemolysis (in vitro), toxicity effects (in vivo), tissue irritation level (in vivo), and pyrogenicity count (in vitro) on such samples. We show that our developed MIM MP35N and CCM materials and treatment processes are biocompatible, and that both the MIM and wrought samples, although somewhat different in microstructure and surface, do not show significant differences in biocompatibility. PMID:21537059

  14. Hydrophilic thermoplastic polyurethanes for the manufacturing of highly dosed oral sustained release matrices via hot melt extrusion and injection molding.

    PubMed

    Verstraete, G; Van Renterghem, J; Van Bockstal, P J; Kasmi, S; De Geest, B G; De Beer, T; Remon, J P; Vervaet, C

    2016-06-15

    Hydrophilic aliphatic thermoplastic polyurethane (Tecophilic™ grades) matrices for high drug loaded oral sustained release dosage forms were formulated via hot melt extrusion/injection molding (HME/IM). Drugs with different aqueous solubility (diprophylline, theophylline and acetaminophen) were processed and their influence on the release kinetics was investigated. Moreover, the effect of Tecophilic™ grade, HME/IM process temperature, extrusion speed, drug load, injection pressure and post-injection pressure on in vitro release kinetics was evaluated for all model drugs. (1)H NMR spectroscopy indicated that all grades have different soft segment/hard segment ratios, allowing different water uptake capacities and thus different release kinetics. Processing temperature of the different Tecophilic™ grades was successfully predicted by using SEC and rheology. Tecophilic™ grades SP60D60, SP93A100 and TG2000 had a lower processing temperature than other grades and were further evaluated for the production of IM tablets. During HME/IM drug loads up to 70% (w/w) were achieved. In addition, Raman mapping and (M)DSC results confirmed the homogenous distribution of mainly crystalline API in all polymer matrices. Besides, hydrophilic TPU based formulations allowed complete and sustained release kinetics without using release modifiers. As release kinetics were mainly affected by drug load and the length of the PEO soft segment, this polymer platform offers a versatile formulation strategy to adjust the release rate of drugs with different aqueous solubility. PMID:27113866

  15. Innovative use of wood-plastic-composites (WPC) as a core material in the sandwich injection molding process

    NASA Astrophysics Data System (ADS)

    Moritzer, Elmar; Martin, Yannick

    2016-03-01

    The demand for materials based on renewable raw materials has risen steadily in recent years. With society's increasing interest for climate protection and sustainability, natural-based materials such as wood-plastic-composites (WPC) have gained market share thanks to their positive reputation. Due to advantages over unreinforced plastics such as cost reduction and weight savings it is possible to use WPC in a wide area of application. Additionally, an increase in mechanical properties such as rigidity and strength is achieved by the fibers compared to unreinforced polymers. The combination of plastic and wood combines the positive properties of both components in an innovative material. Despite the many positive properties of wood-plastic-composite, there are also negative characteristics that prevent the use of WPC in many product areas, such as automotive interiors. In particular, increased water intake, which may result in swelling of near-surface particles, increased odor emissions, poor surface textures and distortion of the components are unacceptable for many applications. The sandwich injection molding process can improve this situation by eliminating the negative properties of WPC by enclosing it with a pure polymer. In this case, a layered structure of skin and core material is produced, wherein the core component is completely enclosed by the skin component. The suitability of WPC as the core component in the sandwich injection molding has not yet been investigated. In this study the possibilities and limitations of the use of WPC are presented. The consideration of different fiber types, fiber contents, skin materials and its effect on the filling behavior are the focus of the presented analysis.

  16. Extruded/injection-molded composites containing unripe plantain flour, ethylene vinyl-alcohol and glycerol: Evaluation of color, mechanical property and biodegradability

    Technology Transfer Automated Retrieval System (TEKTRAN)

    Extruded/injection-molded composites were produced from plantain flour blended with ethylene vinyl-alcohol (EVA) and glycerol. Scanning electron microscopy showed composites had a smooth surface and excellent compatibility between plantain flour, EVA and glycerol. The impact of increased plantain fl...

  17. Visualization Analysis of Melt-Flow Behavior inside Sprue-Shaped Cavity in Ultra-High-Speed Injection Molding

    NASA Astrophysics Data System (ADS)

    Hasegawa, Shigeru; Yokoi, Hidetoshi

    In this study, the melt-flow behavior inside the sprue during the ultra-high-speed filling process of PP and GF-LCP was clarified using a modified glass-inserted mold. In particular, with the GF-LCP, melt-flow behavior within 3 ms was observed clearly and models of residual gas trapped in the resin were proposed in detail. The following results were obtained. 1) With the PP, the melt-flow behavior did not change at any injection rate in the range of 24.1 cm3/s to 804 cm3/s. 2) With the GF-LCP, jetting was generated at all injection rates and the jetted resin folded while filling by resin newly flowing in from the nozzle when the injection rate was less than 241 cm3/s. 3) When the injection rate was higher than 482 cm3/s with the GF-LCP, the jetted resin reached the sprue-end while maintaining a wave-form pattern and then filled back to the nozzle side while increasing the contact area with the cavity and glass surface from the sprue-end, without folding phenomenon. 4) At this time, V-notch shape resins were found to generate and disappear intermittently between the jetted resin and resin filling into its periphery. Based on these results, the mechanism of residual gas in the V-notch area trapping resins in was proposed in detail. 5) With the GF-LCP, resin pressure at the nozzle was reduced due to the jetting phenomenon, and temperature of the jetting resin gradually increased.

  18. The effect of injection molding conditions on the near-surface rubber morphology, surface chemistry, and adhesion performance of semi-crystalline and amorphous polymers

    NASA Astrophysics Data System (ADS)

    Weakley-Bollin, Shannon Christine

    This thesis investigated the effect of injection molding processing variables, resin formulation and mold material on the resulting morphology and properties of semi-crystalline and amorphous polymers in parts molded on large presses with fully developed flow. Five different polymer resins and two different coating types were investigated, and the near-surface morphology was found to be dependent on material formulation, processing parameters, and geometry. For painted TPO, changes in the near-surface rubber morphology and surface chemistry based on material and processing conditions had no significant effect on the adhesion performance. For metal plated ABS, the adhesion performance was found to be heavily dependent on the rubber surface morphology, which varied with material formulation and processing conditions. One of the most significant findings was that forged aluminum injection molding tooling had little effect on the surface morphology or adhesion performance of either polypropylene or the two TPO formulations examined, despite the five-fold increase in thermal conductivity over traditional tool steel. Surface chemistry, however, was found to be affected by cooling rate, depending on material formulation. A UV stabilizer additive was found concentrated at 2.5 atomic percent on the surface of the aluminum molded part, but not the steel molded part, demonstrating a possible opportunity for using additives and aluminum tooling to create "designer surfaces". Processing conditions were found to have a competing role in metal plated ABS, where conditions that lowered surface stress and improved adhesion by a factor of 15 also increased the amount of bulk molded-in stress by nearly 7%. Both factors were found to play an important role in adhesion performance due to the effect of surface stress on the quality of the resulting etch structure. The bulk stress must be minimized to due to the large mechanical and thermal mismatch between the polymer and metal layers

  19. Ceramic micro-injection molded nozzles for serial femtosecond crystallography sample delivery

    DOE PAGESBeta

    Beyerlein, K. R.; Adriano, L.; Heymann, M.; Kirian, R.; Knoska, J.; Wilde, F.; Chapman, H. N.; Bajt, S.

    2015-12-08

    Serial femtosecond crystallography (SFX) using X-ray Free-Electron Lasers (XFELs) allows for room temperature protein structure determination without evidence of conventional radiation damage. In this method, a liquid suspension of protein microcrystals can be delivered to the X-ray beam in vacuum as a micro-jet, which replenishes the crystals at a rate that exceeds the current XFEL pulse repetition rate. Gas dynamic virtual nozzles produce the required micrometer-sized streams by the focusing action of a coaxial sheath gas and have been shown to be effective for SFX experiments. Here, we describe the design and characterization of such nozzles assembled from ceramic micro-injectionmore » molded outer gas-focusing capillaries. Trends of the emitted jet diameter and jet length as a function of supplied liquid and gas flow rates are measured by a fast imaging system. The observed trends are explained by derived relationships considering choked gas flow and liquidflow conservation. In conclusion, the performance of these nozzles in a SFX experiment is presented, including an analysis of the observed background.« less

  20. Effect of Zr, Nb and Ti addition on injection molded 316L stainless steel for bio-applications: Mechanical, electrochemical and biocompatibility properties.

    PubMed

    Gulsoy, H Ozkan; Pazarlioglu, Serdar; Gulsoy, Nagihan; Gundede, Busra; Mutlu, Ozal

    2015-11-01

    The research investigated the effect of Zr, Nb and Ti additions on mechanical, electrochemical properties and biocompatibility of injection molded 316L stainless steel. Addition of elemental powder is promoted to get high performance of sintered 316L stainless steels. The amount of additive powder plays a role in determining the sintered microstructure and all properties. In this study, 316L stainless steel powders used with the elemental Zr, Nb and Ti powders. A feedstock containing 62.5 wt% powders loading was molded at different injection molded temperature. The binders were completely removed from molded components by solvent and thermal debinding at different temperatures. The debinded samples were sintered at 1350°C for 60 min. Mechanical, electrochemical property and biocompatibility of the sintered samples were performed mechanical, electrochemical, SBF immersion tests and cell culture experiments. Results of study showed that sintered 316L and 316L with additives samples exhibited high corrosion properties and biocompatibility in a physiological environment. PMID:26275484

  1. Thermoplastic polyurethanes for the manufacturing of highly dosed oral sustained release matrices via hot melt extrusion and injection molding.

    PubMed

    Claeys, Bart; Vervaeck, Anouk; Hillewaere, Xander K D; Possemiers, Sam; Hansen, Laurent; De Beer, Thomas; Remon, Jean Paul; Vervaet, Chris

    2015-02-01

    This study evaluated thermoplastic polyurethanes (TPUR) as matrix excipients for the production of oral solid dosage forms via hot melt extrusion (HME) in combination with injection molding (IM). We demonstrated that TPURs enable the production of solid dispersions - crystalline API in a crystalline carrier - at an extrusion temperature below the drug melting temperature (Tm) with a drug content up to 65% (wt.%). The release of metoprolol tartrate was controlled over 24h, whereas a complete release of diprophylline was only possible in combination with a drug release modifier: polyethylene glycol 4000 (PEG 4000) or Tween 80. No burst release nor a change in tablet size and geometry was detected for any of the formulations after dissolution testing. The total matrix porosity increased gradually upon drug release. Oral administration of TPUR did not affect the GI ecosystem (pH, bacterial count, short chain fatty acids), monitored via the Simulator of the Human Intestinal Microbial Ecosystem (SHIME). The high drug load (65 wt.%) in combination with (in vitro and in vivo) controlled release capacity of the formulations, is noteworthy in the field of formulations produced via HME/IM. PMID:25448075

  2. Mechanical and thermal properties of conventional and microcellular injection molded poly (lactic acid)/poly (ε-caprolactone) blends.

    PubMed

    Zhao, Haibin; Zhao, Guoqun

    2016-01-01

    In view of their complementary properties, blending polylactide (PLA) with poly (ε-caprolactone) (PCL) becomes a good choice to improve PLA's properties without compromising its biodegradability. A series of blends of biodegradable PLA and PCL with different mass fraction were prepared by melt mixing. Standard tensile bars were produced by both conventional and microcellular injection molding to study their mechanical and thermal properties. With the increase in PCL content, the blend showed decreased tensile strength and modulus; however, elongation was dramatically increased. With the addition of PCL, the failure mode changed from brittle fracture of the neat PLA to ductile fracture of the blend as demonstrated by tensile test. Various theoretical models based on dispersion and interface adhesion were used to predict the Young's modulus and the results shows the experimental data are consistent with the predictions of the foam model and Kerner-Uemura-Takayangi model. The thermal behavior of the blends was investigated by DSC and TGA. The melting temperature and the degree of crystallinity of PCL in the PLA/PCL did not significantly change with the PCL content increasing in the whole range of blends composition. PMID:26313249

  3. An Integrated Approach Linking Process to Structural Modeling With Microstructural Characterization for Injections-Molded Long-Fiber Thermoplastics

    SciTech Connect

    Nguyen, Ba Nghiep; Bapanapalli, Satish K.; Smith, Mark T.; Kunc, Vlastimil; Frame, Barbara; Norris, Robert E.; Phelps, Jay; Tucker III, Charles L.; Jin, Xiaoshi; Wang, Jin

    2008-09-01

    The objective of our work is to enable the optimum design of lightweight automotive structural components using injection-molded long fiber thermoplastics (LFTs). To this end, an integrated approach that links process modeling to structural analysis with experimental microstructural characterization and validation is developed. First, process models for LFTs are developed and implemented into processing codes (e.g. ORIENT, Moldflow) to predict the microstructure of the as-formed composite (i.e. fiber length and orientation distributions). In parallel, characterization and testing methods are developed to obtain necessary microstructural data to validate process modeling predictions. Second, the predicted LFT composite microstructure is imported into a structural finite element analysis by ABAQUS to determine the response of the as-formed composite to given boundary conditions. At this stage, constitutive models accounting for the composite microstructure are developed to predict various types of behaviors (i.e. thermoelastic, viscoelastic, elastic-plastic, damage, fatigue, and impact) of LFTs. Experimental methods are also developed to determine material parameters and to validate constitutive models. Such a process-linked-structural modeling approach allows an LFT composite structure to be designed with confidence through numerical simulations. Some recent results of our collaborative research will be illustrated to show the usefulness and applications of this integrated approach.

  4. Preservation of Geometrical Integrity of Supersolidus-Liquid-Phase-Sintered SKD11 Tool Steels Prepared with Powder Injection Molding

    NASA Astrophysics Data System (ADS)

    Chuang, K. H.; Hwang, K. S.

    2011-07-01

    The powder injection molded SKD11 tool steels often manifest shape retention problems during supersolidus liquid phase sintering due to the difficulties in controlling the amount of liquid phase. The typical temperature range for the sintering of SKD11 is only 10 K, between 1503 and 1513 K (1230 and 1240 °C), and this narrow sintering range demands a special furnace with very uniform temperature distribution. Through the addition of carbides, in particular TiC, this problem is resolved by enlarging the liquid + γ + carbide region in the phase diagram and by impeding the grain growth with the carbides. The resulting sintering window is broadened to 40 K, between 1513 and 1553 K (1240 and 1280 °C). The relevant mechanisms on the improvement of shape retention are discussed with a focus on the effect of carbide addition on the changes in the phase diagram and the microstructure. A guideline for the selection of effective carbides is also proposed based on the experimental results and the phase diagram analyses.

  5. Characterization of thermoplastic polyurethane/polylactic acid (TPU/PLA) tissue engineering scaffolds fabricated by microcellular injection molding.

    PubMed

    Mi, Hao-Yang; Salick, Max R; Jing, Xin; Jacques, Brianna R; Crone, Wendy C; Peng, Xiang-Fang; Turng, Lih-Sheng

    2013-12-01

    Polylactic acid (PLA) and thermoplastic polyurethane (TPU) are two kinds of biocompatible and biodegradable polymers that can be used in biomedical applications. PLA has rigid mechanical properties while TPU possesses flexible mechanical properties. Blended TPU/PLA tissue engineering scaffolds at different ratios for tunable properties were fabricated via twin screw extrusion and microcellular injection molding techniques for the first time. Multiple test methods were used to characterize these materials. Fourier transform infrared spectroscopy (FTIR) confirmed the existence of the two components in the blends; differential scanning calorimetry (DSC) and dynamic mechanical analysis (DMA) confirmed the immiscibility between the TPU and PLA. Scanning electron microscopy (SEM) images verified that, at the composition ratios studied, PLA was dispersed as spheres or islands inside the TPU matrix and that this phase morphology further influenced the scaffold's microstructure and surface roughness. The blends exhibited a large range of mechanical properties that covered several human tissue requirements. 3T3 fibroblast cell culture showed that the scaffolds supported cell proliferation and migration properly. Most importantly, this study demonstrated the feasibility of mass producing biocompatible PLA/TPU scaffolds with tunable microstructures, surface roughnesses, and mechanical properties that have the potential to be used as artificial scaffolds in multiple tissue engineering applications. PMID:24094186

  6. Characterization of thermoplastic polyurethane/polylactic acid (TPU/PLA) tissue engineering scaffolds fabricated by microcellular injection molding

    PubMed Central

    Mi, Hao-Yang; Salick, Max R.; Jing, Xin; Jacques, Brianna R.; Crone, Wendy C.; Peng, Xiang-Fang; Turng, Lih-Sheng

    2015-01-01

    Polylactic acid (PLA) and thermoplastic polyurethane (TPU) are two kinds of biocompatible and biodegradable polymers that can be used in biomedical applications. PLA has rigid mechanical properties while TPU possesses flexible mechanical properties. Blended TPU/PLA tissue engineering scaffolds at different ratios for tunable properties were fabricated via twin screw extrusion and microcellular injection molding techniques for the first time. Multiple test methods were used to characterize these materials. Fourier transform infrared spectroscopy (FTIR) confirmed the existence of the two components in the blends; differential scanning calorimetry (DSC) and dynamic mechanical analysis (DMA) confirmed the immiscibility between the TPU and PLA. Scanning electron microscopy (SEM) images verified that, at the composition ratios studied, PLA was dispersed as spheres or islands inside the TPU matrix and that this phase morphology further influenced the scaffold’s microstructure and surface roughness. The blends exhibited a large range of mechanical properties that covered several human tissue requirements. 3T3 fibroblast cell culture showed that the scaffolds supported cell proliferation and migration properly. Most importantly, this study demonstrated the feasibility of mass producing biocompatible PLA/TPU scaffolds with tunable microstructures, surface roughnesses, and mechanical properties that have the potential to be used as artificial scaffolds in multiple tissue engineering applications. PMID:24094186

  7. Improvement of the Dimensional Stability of Powder Injection Molded Compacts by Adding Swelling Inhibitor into the Debinding Solvent

    NASA Astrophysics Data System (ADS)

    Fan, Yang-Liang; Hwang, Kuen-Shyang; Su, Shao-Chin

    2008-02-01

    Defects are frequently found in powder injection molded (PIM) compacts during solvent debinding due to the swelling of the binders. This problem can be alleviated by adjusting the composition of the debinding solvent. In this study, 10 vol pct swelling inhibitors were added into heptane, and the in-situ amounts of swelling and sagging of the specimen in the solvent were recorded using a noncontacting laser dilatometer. The results show that the addition of ethanol, 2-propanol, 1-butanol, and 1-pentanol reduced the amounts of swelling by 31, 21, 17, and 11 pct, respectively. This was because the small molecule alcohols, which do not dissolve paraffin wax (PW) or stearic acid (SA) in the binder system, could diffuse easily into the specimen and increased the portion of the swelling inhibitor inside. The amount of the extracted PW and SA also decreased, but only by 8.3, 6.1, 4.3, and 2.4 pct, respectively. The solubility parameters of 1-bromopropane (n-PB) and ethyl acetate (EA) are between those of heptane and alcohols, and they also yielded a slight reduction in the amounts of swelling by 6 and 11 pct, respectively. These results suggest that to reduce defects caused by binder swelling during solvent debinding, alcohols with high solubility parameters can be added into heptane without sacrificing significantly on the debinding rate.

  8. Metal injection molding as enabling technology for the production of metal prosthesis components: electrochemical and in vitro characterization.

    PubMed

    Melli, Virginia; Rondelli, Gianni; Sandrini, Enrico; Altomare, Lina; Bolelli, Giovanni; Bonferroni, Benedetta; Lusvarghi, Luca; Cigada, Alberto; De Nardo, Luigi

    2013-10-01

    Industrial manufacturing of prosthesis components could take significant advantage by the introduction of new, cost-effective manufacturing technologies with near net-shape capabilities, which have been developed during the last years to fulfill the needs of different technological sectors. Among them, metal injection molding (MIM) appears particularly promising for the production of orthopedic arthroplasty components with significant cost saving. These new manufacturing technologies, which have been developed, however, strongly affect the chemicophysical structure of processed materials and their resulting properties. In order to investigate this relationship, here we evaluated the effects on electrochemical properties, ion release, and in vitro response of medical grade CoCrMo alloy processed via MIM compared to conventional processes. MIM of the CoCrMo alloy resulted in coarser polygonal grains, with largely varying sizes; however, these microstructural differences between MIM and forged/cast CoCrMo alloys showed a negligible effect on electrochemical properties. Passive current densities values observed were 0.49 µA cm(-2) for MIM specimens and 0.51 µA cm(-2) for forged CoCrMo specimens, with slightly lower transpassive potential in the MIM case; open circuit potential and Rp stationary values showed no significant differences. Moreover, in vitro biocompatibility tests resulted in cell viability levels not significantly different for MIM and conventionally processed alloys. Although preliminary, these results support the potential of MIM technology for the production of CoCrMo components of implantable devices. PMID:23661502

  9. Mold Allergy

    MedlinePlus

    ... the Allergist Health Professionals Partners Media Donate Allergies Mold Allergy What Is a Mold Allergy? If you have an allergy that occurs ... or basement. What Are the Symptoms of a Mold Allergy? The symptoms of mold allergy are very ...

  10. Assessment of Current Process Modeling Approaches to Determine Their Limitations, Applicability and Developments Needed for Long-Fiber Thermoplastic Injection Molded Composites

    SciTech Connect

    Nguyen, Ba Nghiep; Holbery, Jim; Smith, Mark T.; Kunc, Vlastimil; Norris, Robert E.; Phelps, Jay; Tucker III, Charles L.

    2006-11-30

    This report describes the status of the current process modeling approaches to predict the behavior and flow of fiber-filled thermoplastics under injection molding conditions. Previously, models have been developed to simulate the injection molding of short-fiber thermoplastics, and an as-formed composite part or component can then be predicted that contains a microstructure resulting from the constituents’ material properties and characteristics as well as the processing parameters. Our objective is to assess these models in order to determine their capabilities and limitations, and the developments needed for long-fiber injection-molded thermoplastics (LFTs). First, the concentration regimes are summarized to facilitate the understanding of different types of fiber-fiber interaction that can occur for a given fiber volume fraction. After the formulation of the fiber suspension flow problem and the simplification leading to the Hele-Shaw approach, the interaction mechanisms are discussed. Next, the establishment of the rheological constitutive equation is presented that reflects the coupled flow/orientation nature. The decoupled flow/orientation approach is also discussed which constitutes a good simplification for many applications involving flows in thin cavities. Finally, before outlining the necessary developments for LFTs, some applications of the current orientation model and the so-called modified Folgar-Tucker model are illustrated through the fiber orientation predictions for selected LFT samples.

  11. Area 2 Bitcutter and Post-Shot Injection Wells Corrective Action Unit 90 Post-Closure Annual Report

    SciTech Connect

    Glen Richardson

    2002-09-01

    Area 2 Bitcutter and Post-Shot Containment Wells Corrective Action Unit (CAU) 90 Post-Closure Monitoring requirements are described in Section VII.B.8.b of the Nevada Test Site Resource Conservation and Recovery Act Permit for a Hazardous Waste Management Facility No. NEV HW009, Revision 4, reissued on November 20, 2000.

  12. Creating Drug Solubilization Compartments via Phase Separation in Multicomponent Buccal Patches Prepared by Direct Hot Melt Extrusion-Injection Molding.

    PubMed

    Alhijjaj, Muqdad; Bouman, Jacob; Wellner, Nikolaus; Belton, Peter; Qi, Sheng

    2015-12-01

    Creating in situ phase separation in solid dispersion based formulations to allow enhanced functionality of the dosage form, such as improving dissolution of poorly soluble model drug as well as being mucoadhesive, can significantly maximize the in vitro and in vivo performance of the dosage form. This formulation strategy can benefit a wide range of solid dosage forms for oral and alternative routes of delivery. This study using buccal patches as an example created separated phases in situ of the buccal patches by selecting the excipients with different miscibility with each other and the model drug. The quaternary dispersion based buccal patches containing PEG, PEO, Tween 80, and felodipine were prepared by direct hot melt extrusion-injection molding (HME-IM). The partial miscibility between Tween 80 and semicrystalline PEG-PEO led to the phase separation after extrusion. The Tween phases acted as drug solubilization compartments, and the PEG-PEO phase had the primary function of providing mucoadhesion and carrier controlled dissolution. As felodipine was preferably solubilized in the amorphous regions of PEG-PEO, the high crystallinity of PEG-PEO resulted in an overall low drug solubilizing capacity. Tween 80 was added to improve the solubilization capacity of the system as the model drug showed good solubility in Tween. Increasing the drug loading led to the supersaturation of drug in Tween compartments and crystalline drug dispersed in PEG-PEO phases. The spatial distribution of these phase-separated compartments was mapped using X-ray micro-CT, which revealed that the domain size and heterogeneity of the phase separation increased with increasing the drug loading. The outcome of this study provides new insights into the applicability of in situ formed phase separation as a formulation strategy for the delivery of poorly soluble drugs and demonstrated the basic principle of excipient selection for such technology. PMID:26551593

  13. Effect of reprocessing cycles on the degradation of polypropylene copolymer filled with talc or montmorillonite during injection molding process

    SciTech Connect

    Demori, R.; Mauler, R. S.; Ashton, E.; Weschenfelder, V. F.; Cândido, L. H. A.; Kindlein, W.

    2015-05-22

    Mechanical recycling of polymeric materials is a favorable technique resulting in economic and environmental benefits, especially in the case of polymers with a high production volume as the polypropylene copolymer (PP). However, recycling by reprocessing techniques can lead to thermal, mechanical or thermo-oxidative degradation that can affect the structure of the polymer and subsequently the material properties. PP filled with montmorillonite (MMT) or talc are widely produced and studied, however, its degradation reactions by reprocessing cycles are poorly studied so far. In this study, the effects of reprocessing cycles in the structure and in the properties of the PP/MMT and PP/Talc were evaluated. The samples were mixed with 5% talc or MMT Cloisite C15A in a twin-screw extrusion. After extrusion, this filled material was submitted to five reprocessing cycles through an injection molding process. In order to evaluate the changes induced by reprocessing techniques, the samples were characterized by DSC, FT-IR, Izod impact and tensile strength tests. The study showed that Young modulus, elongation at brake and Izod impact were not affected by reprocessing cycles, except when using talc. In this case, the elongation at brake reduced until the fourth cycle, showing rigidity increase. The DSC results showed that melting and crystallization temperature were not affected. A comparison of FT-IR spectra of the reprocessed indicated that in both samples, between the first and the fifth cycle, no noticeable change has occurred. Thus, there is no evidence of thermo oxidative degradation. In general, these results suggest that PP reprocessing cycles using MMT or talc does not change the material properties until the fifth cycle.

  14. Injection molded component

    SciTech Connect

    James, Allister W; Arrell, Douglas J

    2014-09-30

    An intermediate component includes a first wall member, a leachable material layer, and a precursor wall member. The first wall member has an outer surface and first connecting structure. The leachable material layer is provided on the first wall member outer surface. The precursor wall member is formed adjacent to the leachable material layer from a metal powder mixed with a binder material, and includes second connecting structure.

  15. Allergy shots

    MedlinePlus

    ... allergens include: Mold spores Dust mites Animal dander Pollen Insect venom A health care provider gives you ... for common allergens such as: Weed and tree pollen Grass Mold or fungus Animal dander Dust mites ...

  16. Effects of process parameters on the molding quality of the micro-needle array

    NASA Astrophysics Data System (ADS)

    Qiu, Z. J.; Ma, Z.; Gao, S.

    2016-07-01

    Micro-needle array, which is used in medical applications, is a kind of typical injection molded products with microstructures. Due to its tiny micro-features size and high aspect ratios, it is more likely to produce short shots defects, leading to poor molding quality. The injection molding process of the micro-needle array was studied in this paper to find the effects of the process parameters on the molding quality of the micro-needle array and to provide theoretical guidance for practical production of high-quality products. With the shrinkage ratio and warpage of micro needles as the evaluation indices of the molding quality, the orthogonal experiment was conducted and the analysis of variance was carried out. According to the results, the contribution rates were calculated to determine the influence of various process parameters on molding quality. The single parameter method was used to analyse the main process parameter. It was found that the contribution rate of the holding pressure on shrinkage ratio and warpage reached 83.55% and 94.71% respectively, far higher than that of the other parameters. The study revealed that the holding pressure is the main factor which affects the molding quality of micro-needle array so that it should be focused on in order to obtain plastic parts with high quality in the practical production.

  17. MOLDING APPARATUS

    DOEpatents

    Fleming, P.G.

    1963-10-01

    Molding apparatus capable of coating multiple elements each molding cycle is described. The apparatus comprises a centrally disposed reservoir penetrated by a plurality of circumferentially arranged and radially extending passageways. These passageways, in turn, communicate with passages in a separable annular member that retains selectively configured molds and mold seating arrangements. Each mold, which is readily removable from its respective seat, is adapted to retain an element therein in spaced relation to the interior of the mold by utilizing element positioning means within the mold seat and the mold so that coating material may flow about the entire outer surface of the element. (AEC)

  18. Energy-Saving Effect of the Add-on Energy Recovery System for Electric Motor Drive Systems in the Injection Molding Machine

    NASA Astrophysics Data System (ADS)

    Takahashi, Keisuke; Hiraki, Eiji; Tanaka, Toshihiko

    The regenerative energy from the motor drive systems used in the injection molding is consumed by resistors connected to the DC bus of the inverters. Recently the recovery systems of the regenerative energy with a bi-directional DC-DC converter and capacitors have been developed. In this paper a new control strategy of the EDLC based energy recovery system is proposed. The basic principle of the proposed control strategy and the power losses consumed in the energy recovery system are discussed in detail. The validity and practicability are confirmed by digital computer simulation.

  19. Rapid mold replication

    SciTech Connect

    Heestand, G.M.; Beeler, R.G. Jr.; Brown, D.L.

    1995-06-01

    The desire to reduce tooling costs have driven manufacturers to investigate new manufacturing methods and materials. In the plastics injection molding industry replicating molds to meet production needs is time consuming (up to 6 months) and costly in terms of lost business. We have recently completed a feasibility study demonstrating the capability of high rate Electron Beam Physical Vapor Deposition (EBPVD) in producing mold inserts in days, not months. In the current practice a graphite mandrel, in the shape of the insert`s negative image, was exposed to a jet of metal vapor atoms emanating from an electron beam heated source of an aluminum-bronze alloy. The condensation rate of the metal atoms on the mandrel was sufficient to allow the deposit to grow at over 30 {mu}m/min or 1.2 mils per minute. The vaporization process continued for approximately 14 hours after which the mandrel and deposit were removed from the EBPVD vacuum chamber. The mandrel and condensate were easily separated resulting in a fully dense aluminum-bronze mold insert about 2.5 cm or one inch thick. This mold was subsequently cleaned and drilled for water cooling passages and mounted on a fixture for operation in an actual injection molding machine. Results of the mold`s operation were extremely successful showing great promise for this technique. This paper describes the EBPVD feasibility demonstration in more detail and discusses future development work needed to bring this technique into practice.

  20. Area 2 Bitcutter and Post-Shot Injection Wells Corrective Action Unit 90 Post-Closure Inspection Annual Report

    SciTech Connect

    D. S. Tobiason

    2001-09-01

    Area 2 Bitcutter and Post-Shot Containment Wells Corrective Action Unit (CAU) 90 Post-Closure Monitoring requirements are described in {section} VIIB.8.b of the Nevada Test Site Resource Conservation and Recovery Act Permit for a Hazardous Waste Management Facility No. NEV HW009, reissued November 20, 2000, Revision 4. Post-closure care consists of the following: Semiannual inspections of the unit using an inspection checklist; photographic documentation; field note documentation; and preparation and submittal of an annual report. The report includes copies of the inspection checklist, photographs, and recommendations and conclusions. The Post-Closure Inspection Checklists are found in Attachment A, a copy of the field notes is found in Attachment B, and a copy of the inspection photographs is found in Attachment C.

  1. Study on Three-dimensional Structures in Injection-molded iPP/Poly(ethylene-co-octene) by Transmission Electron Microtomography

    NASA Astrophysics Data System (ADS)

    Ono, Michio; Nishioka, Hideo; Jinnai, Hiroshi; Nakajima, Ken; Nishi, Toshio

    A phase-separated structure of the injection-molded isotactic polypropylene (iPP)/poly(ethylene-co-octene) (EOR) binary blend was studied in three-dimension (3D) by transmission electron microtomography (TEMT). Highly oriented EOR domains along both flow- (FD) and transverse-to-flow (TD) directions resulting in stacking lamella-sheet like structures to normal direction (ND) were confirmed. Some irregularities in morphology and intervals between the EOR sheets, and thickness heterogeneity of the sheets, were observed more frequently in the TD rather than in the FD. Using the 3D information obtained by the TEMT, we have tried to elucidate massive anisotropy in linear thermal expansion coefficient (CLTE) along the injection directions in this blend. We found that the CLTE anisotropy was well correlated with the lamella-like sheets arrays and their irregularities.

  2. Use of acrylic sheet molds for elastomeric products

    NASA Technical Reports Server (NTRS)

    Heisman, R. M.; Koerner, A. E.; Messineo, S. M.

    1970-01-01

    Molds constructed of acrylic sheet are more easily machined than metal, are transparent to ensure complete filling during injection, and have smooth surfaces free of contamination. Technique eliminates flashing on molded parts and mold release agents.

  3. Plastic molds reduce cost of encapsulating electric cable connectors

    NASA Technical Reports Server (NTRS)

    Knott, D.

    1964-01-01

    Resin casting of the aluminum master pattern forms a plastic mold for encapsulating a cable connector. An elastomer is injected into the mold and cured. The mold is disassembled leaving an elastomeric encapsulation around the connector.

  4. Phenolic Molding Compounds

    NASA Astrophysics Data System (ADS)

    Koizumi, Koji; Charles, Ted; de Keyser, Hendrik

    Phenolic Molding Compounds continue to exhibit well balanced properties such as heat resistance, chemical resistance, dimensional stability, and creep resistance. They are widely applied in electrical, appliance, small engine, commutator, and automotive applications. As the focus of the automotive industry is weight reduction for greater fuel efficiency, phenolic molding compounds become appealing alternatives to metals. Current market volumes and trends, formulation components and its impact on properties, and a review of common manufacturing methods are presented. Molding processes as well as unique advanced techniques such as high temperature molding, live sprue, and injection/compression technique provide additional benefits in improving the performance characterisitics of phenolic molding compounds. Of special interest are descriptions of some of the latest innovations in automotive components, such as the phenolic intake manifold and valve block for dual clutch transmissions. The chapter also characterizes the most recent developments in new materials, including long glass phenolic molding compounds and carbon fiber reinforced phenolic molding compounds exhibiting a 10-20-fold increase in Charpy impact strength when compared to short fiber filled materials. The role of fatigue testing and fatigue fracture behavior presents some insight into long-term reliability and durability of glass-filled phenolic molding compounds. A section on new technology outlines the important factors to consider in modeling phenolic parts by finite element analysis and flow simulation.

  5. Kids Guide to Shots

    MedlinePlus

    ... that they usually don't get a very bad case of it. Milder cases mean fewer spots and less itching. Shots are given by injection with a needle. A syringe (say: seh-RINJ) holds the liquid vaccine, and the needle has a hole in it ...

  6. Microstructure and properties of nano-TiN modified Ti(C,N)-based cermets fabricated by powder injection molding and die pressing

    NASA Astrophysics Data System (ADS)

    Yi, Shan-jie; Yin, Hai-qing; Chen, Ke; Khan, Dil-Faraz; Zheng, Qing-jun; Qu, Xuan-hui

    2013-11-01

    Powder injection molding (PIM) and die pressing were employed to fabricate nano-TiN modified Ti(C,N)-based cermets. The shrinkage behavior, microstructure, porosity, and mechanical properties of the samples with and without nano-TiN addition fabricated by PIM and die pressing were analyzed. It is demonstrated that for either PIM or die pressing, the porosities are obviously reduced, the mechanical properties are significantly improved after adding nano-TiN, and the hard particles are refined; the rim phase thickness obviously becomes thinner, and the number of dimples in fracture also increases. Compared the samples fabricated by die pressing, it is difficult for PIM to obtain dense Ti(C,N)-based cermets. Due to the too much existence of pores and isolated carbon, the mechanical properties of the sintered samples by PIM are inferior to those of the sintered ones by die pressing.

  7. Allergy shots

    MedlinePlus

    ... include: Mold spores Dust mites Animal dander Pollen Insect venom A health care provider gives you the ... that allergies make worse Allergic rhinitis, allergic conjunctivitis Insect bite sensitivity Eczema , a skin condition that a ...

  8. Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites - FY 2014 First Quarterly Report

    SciTech Connect

    Nguyen, Ba Nghiep; Sanborn, Scott E.; Simmons, Kevin L.; Mathur, Raj N.; Sangid, Michael D.; Jin, Xiaoshi; Costa, Franco; Gandhi, Umesh N.; Mori, Steven; Tucker III, Charles L.

    2014-02-19

    The CRADA between PNNL, Autodesk, Toyota and Magna has been effective since October 28th, 2013. The whole team including CRADA and subcontract partners kicked off the project technically on November 1st, 2013. This report describes work performed during the first quarter of FY 2014. The following technical progresses have been made toward project milestones: 1) The project kickoff meeting was organized at PlastiComp, Inc. in Winona on November 13th, 2013 involving all the project partners. During this meeting the research plan and Gantt chart were discussed and refined. The coordination of the research activities among the partners was also discussed to ensure that the deliverables and timeline will be met. 2) Autodesk delivered a research version of ASMI to PNNL for process modeling using this tool under the project. PNNL installed this research version on a PNNL computer and tested it. Currently, PNNL is using ASMI to prepare the models for PlastiComp plaques. 3) PlastiComp has compounded long carbon-fiber reinforced polypropylene and polyamide 6,6 compounds for rheological and thermal characterization tests by the Autodesk laboratories in Melbourne, Australia. 4) Initial mold flow analysis was carried out by PlastiComp to confirm that the 3D complex part selected by Toyota as a representative automotive part is moldable. 5) Toyota, Magna, PlastiComp and PNNL finalized the planning for molding the Toyota 3D complex part. 6) Purdue University worked with PNNL to update and specify the test matrix for characterization of fiber length/orientation. 7) Purdue University developed tools to automate the data collection and analysis of fiber length and orientation measurements. 8) Purdue University designed and specified equipment to replace the need for equipment using the technology established by the University of Leeds at General Motors.

  9. Mold Cavity Roughness vs. Flow of Polymer

    NASA Astrophysics Data System (ADS)

    Stanek, Michal; Manas, Miroslav; Manas, David

    2009-07-01

    Injection molding represents such a way of polymer processing that requires injection of polymer melt into the mold cavity with very high injection rate. The fluidity of polymers is affected by many parameters (mold design, melt temperature, injection rate and pressure). The main objective of this paper is the study of influence of surface roughness of mold cavity of the polymer melts flow. Evaluation of set of data obtained by experiments where the testing conditions were widely changed shows that quality of cavity surface affects on the length of flow.

  10. Confine Clay in an Alternating Multilayered Structure through Injection Molding: A Simple and Efficient Route to Improve Barrier Performance of Polymeric Materials.

    PubMed

    Yu, Feilong; Deng, Hua; Bai, Hongwei; Zhang, Qin; Wang, Ke; Chen, Feng; Fu, Qiang

    2015-05-20

    Various methods have been devoted to trigger the formation of multilayered structure for wide range of applications. These methods are often complicated with low production efficiency or require complex equipment. Herein, we demonstrate a simple and efficient method for the fabrication of polymeric sheets containing multilayered structure with enhanced barrier property through high speed thin-wall injection molding (HSIM). To achieve this, montmorillonite (MMT) is added into PE first, then blended with PP to fabricate PE-MMT/PP ternary composites. It is demonstrated that alternating multilayer structure could be obtained in the ternary composites because of low interfacial tension and good viscosity match between different polymer components. MMT is selectively dispersed in PE phase with partial exfoliated/partial intercalated microstructure. 2D-WAXD analysis indicates that the clay tactoids in PE-MMT/PP exhibits an uniplanar-axial orientation with their surface parallel to the molded part surface, while the tactoids in binary PE-MMT composites with the same overall MMT contents illustrate less orientation. The enhanced orientation of nanoclay in PE-MMT/PP could be attributed to the confinement of alternating multilayer structure, which prohibits the tumbling and rotation of nanoplatelets. Therefore, the oxygen barrier property of PE-MMT/PP is superior to that of PE-MMT because of increased gas permeation pathway. Comparing with the results obtained for PE based composites in literature, outstanding barrier property performance (45.7% and 58.2% improvement with 1.5 and 2.5 wt % MMT content, respectively) is achieved in current study. Two issues are considered responsible for such improvement: enhanced MMT orientation caused by the confinement in layered structure, and higher local density of MMT in layered structure induced denser assembly. Finally, enhancement in barrier property by confining impermeable filler into alternating multilayer structure through such

  11. Fiber orientation structures and mechanical properties of injection molded short glass fiber-reinforced nylon ribbed plates

    SciTech Connect

    Wire, S.L.; Hine, P.J.; Duckett, R.A.; O`Gara, J.G.

    1996-12-31

    The work presented in this paper, sponsored by General Motors, describes a study of injection moulded ribbed plates of short glass fibre-reinforced Nylon. Ribs have been placed both parallel and perpendicular to the injection direction in an attempt to simulate the likely geometry of an actual automotive part. The complex orientation structures developed within these ribbed samples during injection moulding have been determined within both the parallel and perpendicular ribs, and for the regions between these structures using an automated image analysis system developed in-house by our colleagues at the University of Leeds Instrumentation Group. This system allows the rapid measurement of accurate fibre orientation data over large sample areas (mm {times} mm) enabling thousands of fibre images to be sampled. Mechanical properties both between and underneath the rib structures have been measured using the ultrasonic immersion technique, and these have been compared with theoretical predictions, determined using the measured fibre orientation averages and simple composite models developed within this laboratory. In general the agreement between theory and experiment is excellent.

  12. MOLD POLLUTION

    EPA Science Inventory

    Mold pollution is the growth of molds in a building resulting in a negative impact on the use of that structure. The negative impacts generally fall into two categories: destruction of the structure itself and adverse health impacts on the building's occupants. It is estimated...

  13. Mold Charlatans.

    ERIC Educational Resources Information Center

    Woody, Daniel

    2002-01-01

    Offers a primer on toxic mold and its removal, warning against ignorant or unethical mold remediation companies and offering five considerations (checking references, considering the big picture, sampling more than the air, considering release, and considering the source) when hiring such services. (EV)

  14. Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites - FY 2015 First Quarterly Report

    SciTech Connect

    Nguyen, Ba Nghiep; Fifield, Leonard S.; Kijewski, Seth A.; Sangid, Michael D.; Wang, Jin; Jin, Xiaoshi; Costa, Franco; Tucker, III, Charles L.; Mathur, Raj N.; Gandhi, Umesh N.; Mori, Steven

    2015-01-29

    plan for the project and submitted the established plan to DOE. 9) PNNL performed ASMI mid-plane analyses for the fast-fill center-gated 30wt% LCF/PP and 50wt% LCF/PA66 plaques and compared the predicted fiber orientations with the measured data provided by Purdue at Locations A, B, and C on these plaques. 10) Based on discussions with the University of Illinois and Autodesk, PNNL proposed a procedure to adjust fiber orientation data for Location A of the center-gated plaques so that the data can be expressed and interpreted in the flow/cross-flow direction coordinate system. 11) PNNL tested the new ASMI version received from Autodesk, examined and discussed 3D fiber orientation predictions for PlastiComp plaques. 12) PlastiComp, Inc. (PlastiComp), Toyota Research Institute North America (Toyota) and Magna Exteriors and Interiors Corp. (Magna) participated in discussions with team members on the go/no-go plan and the issues related to fiber length measurements. Toyota continued the discussion with Magna on tool modification for molding the complex part in order to achieve the target fiber length in the part.

  15. Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites - Second FY 2015 Quarterly Report

    SciTech Connect

    Nguyen, Ba Nghiep; Fifield, Leonard S.; Kijewski, Seth A.; Sangid, Michael D.; Wang, Jin; Costa, Franco; Tucker, III, Charles L.; Mathur, Raj N.; Gandhi, Umesh N.; Mori, Steven

    2015-05-19

    validation and compared the predicted fiber orientations with the measured data provided by Purdue at Locations A, B, and C on these plaques. The 15% accuracy criterion based on evaluation of tensile and bending stiffness was used to assess the accuracy in fiber orientation predictions. 9) PNNL completed ASMI mid-plane analyses for all the PlastiComp plaques defined on the go/no-go list for fiber length distribution (FLD) model validation and compared the predicted length distributions with the measured data provided by Purdue at Locations A, B, and C on these plaques. The 15% accuracy criterion based on evaluation of tensile and bending stiffness was used to assess the accuracy in fiber orientation predictions. 10) PNNL tested the new ASMI version received from Autodesk in March 2015, examined and discussed 3D fiber orientation predictions for PlastiComp plaques. 11) PlastiComp, Inc. (PlastiComp), Toyota Research Institute North America (Toyota) and Magna Exteriors and Interiors Corporation (Magna) participated in discussions with team members on the go/no-go plan. Toyota continued the discussion with Magna on tool modification for molding the complex part in order to achieve the target fiber length in the part.

  16. Fabrication of low-cost beta-type Ti-Mn alloys for biomedical applications by metal injection molding process and their mechanical properties.

    PubMed

    Santos, Pedro Fernandes; Niinomi, Mitsuo; Liu, Huihong; Cho, Ken; Nakai, Masaaki; Itoh, Yoshinori; Narushima, Takayuki; Ikeda, Masahiko

    2016-06-01

    Titanium and its alloys are suitable for biomedical applications owing to their good mechanical properties and biocompatibility. Beta-type Ti-Mn alloys (8-17 mass% Mn) were fabricated by metal injection molding (MIM) as a potential low cost material for use in biomedical applications. The microstructures and mechanical properties of the alloys were evaluated. For up to 13 mass% Mn, the tensile strength (1162-938MPa) and hardness (308-294HV) of the MIM fabricated alloys are comparable to those of Ti-Mn alloys fabricated by cold crucible levitation melting. Ti-9Mn exhibits the best balance of ultimate tensile strength (1046MPa) and elongation (4.7%) among the tested alloys, and has a Young's modulus of 89GPa. The observed low elongation of the alloys is attributed to the combined effects of high oxygen content, with the presence of interconnected pores and titanium carbides, the formation of which is due to carbon pickup during the debinding process. The elongation and tensile strength of the alloys decrease with increasing Mn content. The Ti-Mn alloys show good compressive properties, with Ti-17Mn showing a compressive 0.2% proof stress of 1034MPa, and a compressive strain of 50%. PMID:26999621

  17. Design, assembly, and optical bench testing of a high-numerical-aperture miniature injection-molded objective for fiber-optic confocal reflectance microscopy

    NASA Astrophysics Data System (ADS)

    Chidley, Matthew D.; Carlson, Kristen D.; Richards-Kortum, Rebecca R.; Descour, Michael R.

    2006-04-01

    The design, analysis, assembly methods, and optical-bench test results for a miniature injection-molded plastic objective lens used in a fiber-optic confocal reflectance microscope are presented. The five-lens plastic objective was tested as a stand-alone optical system before its integration into a confocal microscope for in vivo imaging of cells and tissue. Changing the spacing and rotation of the individual optical elements can compensate for fabrication inaccuracies and improve performance. The system performance of the miniature objective lens is measured by use of an industry-accepted slanted-edge modulation transfer function (MTF) metric. An estimated Strehl ratio of 0.61 and a MTF value of 0.66 at the fiber-optic bundle Nyquist frequency have been obtained. The optical bench testing system is configured to permit interactive optical alignment during testing to optimize performance. These results are part of an effort to demonstrate the manufacturability of low-cost, high-performance biomedical optics for high-resolution in vivo imaging. Disposable endoscopic microscope objectives could help in vivo confocal microscopy technology mature to permit wide-scale clinical screening and detection of early cancers and precancerous lesions.

  18. Cosintering of Powder Injection Molding Parts Made from Ultrafine WC-Co and 316L Stainless Steel Powders for Fabrication of Novel Composite Structures

    NASA Astrophysics Data System (ADS)

    Simchi, A.; Petzoldt, F.

    2010-01-01

    Sintering response and phase formation during sintering of WC-Co/316L stainless steel composites produced by assembling of powder injection molding (PIM) parts were studied. It is shown that during cosintering a significant mismatch strain (>4 pct) is developed in the temperature range of 1080 °C to 1350 °C. This mismatch strain induces biaxial stresses at the interface, leading to interface delamination. Experimental results revealed that sintering at a heating rate of 20 K/min could be used to decrease the mismatch strain to <2 pct. Meanwhile, WC is decomposed at the contact area and the diffusion of C and Co into the iron lattice results in the formation of a liquid and MC and M6C carbides at 1220 °C. Spreading of the liquid accelerates the reaction, affecting the dimensional stability of the PIM parts. To prevent the reaction, surface oxidation of the cemented carbide followed by hydrogen reduction during sintering was examined. Although the amount of mismatch strain increased, formation of a metallic interface consisting of a W-Co alloy (45 to 50 at. pct Co) and a Co-rich iron alloy (18 at. pct Co) prevented the decomposition of WC and melt formation. It is also shown that the deposition of a thin Ni layer after thermal debinding decreases the mismatch stresses through melt formation, although interlayer diffusion causes pore-band formation close to the steel part.

  19. On the failure mode in dry and hygrothermally aged short fiber-reinforced injection-molded polyarylamide composites by acoustic emission

    NASA Astrophysics Data System (ADS)

    Czigány, T.; Mohd Ishak, Z. A.; Karger-Kocsis, J.

    1995-09-01

    The failure mode in injection-molded short glass (GF) and carbon fiber (CF) reinforced polyarylamide (PAR) composites was studied on compact tension (CT) specimens in as-received (AR), hygrothermally aged (HA) and re-dried (RD) states, respectively, using acoustic emission (AE) and fractography. A significant difference was revealed in the failure manner characterized by the cumulative run, amplitude and energy distribution of the AE events as a function of the water content of the composites. Furthermore, a correlation was found between the cumulative AE events up to the maximum load and the fracture toughness of the composites. It was shown that the fracture response and thus the failure behavior of the water-saturated PAR composites can be restored by drying. This fact indicates that the water absorption and desorption are of a purely physical nature, i.e. they are reversible processes. It was established that chopped fiber-reinforced PAR composites fail by matrix deformation along with fiber/matrix debonding in the crack initiation, whereas fiber pull-out becomes dominant in the crack propagation range. Water uptake shifts both the AE amplitude and energy curves toward lower values, a phenomenon attributed to plastification of the PAR matrix by water.

  20. Development and evaluation of P/M processing techniques to improve and control the mechanical properties of metal injection molded parts

    NASA Astrophysics Data System (ADS)

    Sago, James Alan

    Metal Injection Molding (MIM) is one of the most rapidly growing areas of powder metallurgy (P/M) but the growth of MIM into new markets and more demanding applications is limited by two fundamental barriers, the availability of low cost metal powders and a lack of knowledge and understanding of how mechanical properties, especially toughness, are affected by the many parameters in the MIM process. The goals of this study were to investigate solutions to these challenges for MIM. Mechanical alloying (MA) is a technique which can produce a wide variety of powder compositions in a size range suited to MIM and in smaller batches. However MA typically suffers from low production volumes and long milling times. This study will show that a saucer mill can produce sizable volumes of MA powders in times typically less than an hour. The MA process was also used to produce powders of 17-4PH stainless steel and the NiTi shape memory alloy for a MIM feedstock. This study shows that the MA powder characteristics led to successful MIM processing of parts. Previous studies have shown that the toughness of individual MIM parts can vary widely within a single production run and from one producer to another. In the last part of the study a Design of Experiments (DOE) approach was used to evaluate the effects of MIM processing parameters on the mechanical properties. Analysis of Variance produced mathematical models for Charpy impact toughness, hardness, density, and carbon content. Tensile properties did not produce a good model due to processing problems. The models and recommendations for improving both toughness and reproducibility of toughness are presented.

  1. Effects of Cr and B Contents on Volume Fraction of (Cr,Fe)2B and Hardness in Fe-Based Alloys Used for Powder Injection Molding

    NASA Astrophysics Data System (ADS)

    Do, Jeonghyeon; Lee, Hyuk-Joong; Jeon, Changwoo; Ha, Dae Jin; Kim, Choongnyun Paul; Lee, Byeong-Joo; Lee, Sunghak; Shin, Yang Su

    2012-07-01

    In the current study, Fe-based alloys were used for powder injection molding (PIM) parts with various qualities and hardness ranges by varying chemical compositions according to thermodynamically calculated phase diagrams. Their microstructure and hardness values were analyzed and compared with those of the PIM specimens made from conventional Fe-based alloy powders or stainless steel powders. The Cr-to-B ratio ( X Cr/ X B) and the sum of Fe, Cr, and B content ( X Fe+ X Cr+ X B) were varied to design nine Fe-based alloy compositions based on the composition of Armacor "M" alloy powders (Liquidmetal Technologies, Lake Forest, CA). According to the microstructural analysis results of the cast and heat-treated Fe-based alloys, large amounts of (Cr,Fe)2B were formed in the tempered martensite matrix. The volume fraction of (Cr,Fe)2B was varied from 42 pct to 91 pct with alloy compositions, and these results were well matched with the thermodynamically calculated volume fractions of (Cr,Fe)2B. The hardness of the fabricated alloys was varied from 300 VHN to 1600 VHN with alloy compositions, and this value increased linearly with the increasing volume fraction of (Cr,Fe)2B. From the correlation data between the volume fraction of (Cr,Fe)2B and hardness, the high-temperature equilibrium phase diagram, which could be used for the design of Fe-based alloys with various fractions and hardness values of (Cr,Fe)2B, was made.

  2. Allergies, asthma, and molds

    MedlinePlus

    Allergic rhinitis - mold ... make allergies or asthma worse are called triggers. Mold is a common trigger. When your asthma or allergies become worse due to mold, you are said to have a mold allergy. ...

  3. INGOT MOLD

    DOEpatents

    Mangold, A.J. Jr.; MaHaffey, J.W.; Reese, S.L.

    1958-04-29

    An improved ingot-mold assembly is described, consisting of a body having a cavity and a recess extending through to the bottom of the body from the cavity, and the bottom of the cavity having an internal shoulder extending downward and a plug having an external shoulder. The plug extends above the shoulders and below the bottom of the body.

  4. Mold Infections of the Central Nervous System

    PubMed Central

    McCarthy, Matthew; Rosengart, Axel; Schuetz, Audrey N.; Kontoyiannis, Dimitrios P.; Walsh, Thomas J.

    2016-01-01

    The recent outbreak of exserohilum rostratum meningitis linked to epidural injections of methylprednisolone acetate has brought renewed attention to mold infections of the central nervous system (CNS).1 Although uncommon, these infections are often devastating and difficult to treat. This focused review of the epidemiologic aspects, clinical characteristics, and treatment of mold infections of the CNS covers a group of common pathogens: aspergillus, fusarium, and scedosporium species, molds in the order Mucorales, and dematiaceous molds. Infections caused by these pathogen groups have distinctive epidemiologic profiles, clinical manifestations, microbiologic characteristics, and therapeutic implications, all of which clinicians should understand. PMID:25006721

  5. Organic materials for ceramic molding processes

    NASA Technical Reports Server (NTRS)

    Saito, K.

    1984-01-01

    Ceramic molding processes are examined. Binders, wetting agents, lubricants, plasticizers, surface active agents, dispersants, etc., for pressing, rubber pressing, sip casting, injection casting, taping, extrusion, etc., are described, together with forming machines.

  6. Improved compression molding process

    NASA Technical Reports Server (NTRS)

    Heier, W. C.

    1967-01-01

    Modified compression molding process produces plastic molding compounds that are strong, homogeneous, free of residual stresses, and have improved ablative characteristics. The conventional method is modified by applying a vacuum to the mold during the molding cycle, using a volatile sink, and exercising precise control of the mold closure limits.

  7. Babies and shots

    MedlinePlus

    ... article discusses how to ease the pain of shots for babies. ... Parents often wonder how to make shots less painful for their babies. Nearly all immunizations (also called vaccinations) need to be given into the muscle or under the skin ...

  8. Allergy Shots (For Parents)

    MedlinePlus

    ... Shots Help Allergy shots help the body build immunity to specific allergens, thus eventually preventing or lessening ... the immune system to safely adjust and build immunity to the allergens. This is called the buildup ...

  9. Hip joint injection

    MedlinePlus

    ... this page: //medlineplus.gov/ency/article/007633.htm Hip joint injection To use the sharing features on this ... injection is a shot of medicine into the hip joint. The medicine helps relieve pain and inflammation. It ...

  10. Get Important Shots

    MedlinePlus

    ... a Plan Keep a Record The Basics The Basics: Overview Adults need to get shots (vaccines) just like kids do. ... Previous section Overview 2 of 5 sections The Basics: Other Shots Do I need any other shots to help me stay healthy? ...

  11. Babies and shots

    MedlinePlus

    ... next one less scary. Some doctors use a pain-relieving spray or cream before giving the shot. WHEN THE SHOT IS BEING GIVEN Put pressure on the area before the shot is given. Stay calm and do not let the child see if ...

  12. Birth Control Shot

    MedlinePlus

    ... to a year after they stop getting the birth control shot. However, the shot does not cause permanent loss of fertility and most women can get pregnant once they stop getting the shot. previous continue Who Uses It? Every method of birth control should be considered in light of what works ...

  13. Flow behavior in liquid molding

    NASA Technical Reports Server (NTRS)

    Hunston, D.; Phelan, F.; Parnas, R.

    1992-01-01

    The liquid molding (LM) process for manufacturing polymer composites with structural properties has the potential to significantly lower fabrication costs and increase production rates. LM includes both resin transfer molding and structural reaction injection molding. To achieve this potential, however, the underlying science base must be improved to facilitate effective process optimization and implementation of on-line process control. The National Institute of Standards and Technology (NIST) has a major program in LM that includes materials characterization, process simulation models, on-line process monitoring and control, and the fabrication of test specimens. The results of this program are applied to real parts through cooperative projects with industry. The key feature in the effort is a comprehensive and integrated approach to the processing science aspects of LM. This paper briefly outlines the NIST program and uses several examples to illustrate the work.

  14. Thermoset matched die molding

    NASA Astrophysics Data System (ADS)

    Young, P. R.

    Reinforced molding compounds, mat molding, preform molding, cold press molding, and various other molding processes are discussed. Particular attention is given to the bulk molding compound (BMC) and the sheet molding compound (SMC) (both of which are reinforced molding compounds) as there is an increasing use of these compounds. SMC can employ a wider range of fiber lengths and fiber content than BMC, while preserving strength. The dimensional stability of BMC and SMC is unexcelled, and their corrosion resistance is generally excellent. Both compounds are composed of resins (10-2500 poises), reinforcements (BMC-glass, asbestos, sisal; SMC-soluble binder chopped strand mat), and fillers from four chemical groups (silica and silicates, carbonates, sulfates, and oxides). Molding press designs are included.

  15. Applying simulation to optimize plastic molded optical parts

    NASA Astrophysics Data System (ADS)

    Jaworski, Matthew; Bakharev, Alexander; Costa, Franco; Friedl, Chris

    2012-10-01

    Optical injection molded parts are used in many different industries including electronics, consumer, medical and automotive due to their cost and performance advantages compared to alternative materials such as glass. The injection molding process, however, induces elastic (residual stress) and viscoelastic (flow orientation stress) deformation into the molded article which alters the material's refractive index to be anisotropic in different directions. Being able to predict and correct optical performance issues associated with birefringence early in the design phase is a huge competitive advantage. This paper reviews how to apply simulation analysis of the entire molding process to optimize manufacturability and part performance.

  16. Omalizumab Injection

    MedlinePlus

    ... and pharmacist what other prescription and nonprescription medications, vitamins, nutritional supplements, and herbal products you are taking or plan to take. Be sure to mention any of the following: allergy shots (a series of injections given regularly to prevent the body from developing ...

  17. Molds in the Environment

    MedlinePlus

    ... Program in Brief Related Issues Resources Quick Links Air Pollution & Respiratory Health Air Quality Asthma Mold What's New ... ng Việt [PDF - 273 KB] Quick Links Air Pollution & Respiratory Health Air Quality Asthma Mold What's New ...

  18. Pyrotechnic filled molding powder

    DOEpatents

    Hartzel, Lawrence W.; Kettling, George E.

    1978-01-01

    The disclosure relates to thermosetting molding compounds and more particularly to a pyrotechnic filled thermosetting compound comprising a blend of unfilled diallyl phthalate molding powder and a pyrotechnic mixture.

  19. QUANTIFYING INDOOR MOLDS

    EPA Science Inventory

    There is growing awareness that indoor molds/fungi may be connected to such conditions as asthma, allergies, hemorrhaging, chronic rhinosinusitis, memory loss, and a symptom complex called sick-building-syndrome. In addition, molds cause frequently fatal nosocomical infections. ...

  20. Allergies, asthma, and molds

    MedlinePlus

    ... in damp places. Outdoors, mold lives in the soil, on compost, and on plants that are damp. Keeping your house and yard drier will help control mold growth. Central heating and air-conditioning systems can help control mold. Change furnace and ...

  1. Molds for cable dielectrics

    DOEpatents

    Roose, L.D.

    1996-12-10

    Molds for use in making end moldings for high-voltage cables are described wherein the dielectric insulator of a cable is heated and molded to conform to a desired shape. As a consequence, high quality substantially bubble-free cable connectors suitable for mating to premanufactured fittings are made. 5 figs.

  2. Molds for cable dielectrics

    DOEpatents

    Roose, Lars D.

    1996-01-01

    Molds for use in making end moldings for high-voltage cables are described wherein the dielectric insulator of a cable is heated and molded to conform to a desired shape. As a consequence, high quality substantially bubble-free cable connectors suitable for mating to premanufactured fittings are made.

  3. Mold and Children's Health.

    ERIC Educational Resources Information Center

    Tuscano, Antoinette

    1998-01-01

    Mold can seriously affect the health of children with asthma or allergies. Indoor air problems related to mold can be difficult to identify, but when several students who spend time in the same classroom area show allergic symptoms, it is important to consider mold and air quality. Failure to respond promptly can have serious consequences. (SM)

  4. Mold-Resistant Construction.

    ERIC Educational Resources Information Center

    Huckabee, Christopher

    2003-01-01

    Asserts that one of the surest ways to prevent indoor air quality and mold issues is to use preventive construction materials, discussing typical resistance to dealing with mold problems (usually budget-related) and describing mold-resistant construction, which uses concrete masonry, brick, and stone and is intended to withstand inevitable…

  5. Bleach Neutralizes Mold Allergens

    ERIC Educational Resources Information Center

    Science Teacher, 2005

    2005-01-01

    Researchers at National Jewish Medical and Research Center have demonstrated that dilute bleach not only kills common household mold, but may also neutralize the mold allergens that cause most mold-related health complaints. The study, published in the Journal of Allergy and Clinical Immunology, is the first to test the effect on allergic…

  6. Preliminary concepts for high-temperature mold heating and cooling

    SciTech Connect

    Larson, J.P.

    1990-12-01

    The feasibility and limitations of various methods for mold heating and cooling were investigated. Two methods were chosen for evaluation: electrical heating and water cooling, and electrical heating and heat pipe conduction cooling. A model mold of each method was built. Test results indicated that the electrical heating and circulated water cooling was the better method. An injection mold utilizing this method was fabricated and temperature-cycled between 300 and 770{degree}F. 1 ref., 2 figs., 7 tabs.

  7. Shot-put kinematics

    NASA Astrophysics Data System (ADS)

    DeLuca, R.

    2005-11-01

    The problem of the optimum throw in the shot-put discipline is analysed by relaxing the assumption that the height H, from which the athlete releases the shot, does not depend on the angle θ which the arm of the putter makes with the horizontal axis. In this context, the kinematics of the shot-put is studied and results are compared with the traditional analysis, which considers the height H, the angle θ and the modulus V0 of the initial velocity of the metal sphere as independent parameters.

  8. Shots for Safety

    MedlinePlus

    ... and Aging Shots For Safety Flu Pneumococcal Disease Tetanus and Diphtheria Shingles Measles, Mumps, and Rubella Side ... may need a second one to stay protected. Tetanus and Diphtheria Tetanus (sometimes called lockjaw) is caused ...

  9. 53. PRODUCTION MOLDS. THESE MOLDS ARE COPIES OF THE ORIGINAL ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    53. PRODUCTION MOLDS. THESE MOLDS ARE COPIES OF THE ORIGINAL MOLDS IN THE MORAVIAN POTTERY AND TILE WORKS COLLECTION, AND ARE USED TO PRESS TILES. THE FACTORY KEEPS TEN PRODUCTION MOLDS FOR EACH IMAGE. THE ORIGINAL MOLDS ARE NOT USED IN PRODUCTION. - Moravian Pottery & Tile Works, Southwest side of State Route 313 (Swamp Road), Northwest of East Court Street, Doylestown, Bucks County, PA

  10. Comparative sampling molds evaluation

    SciTech Connect

    Pierrard, L.; Jarry, P.; Charbonnier, J.; Rigaut, C.

    1996-10-01

    The metallurgical industry needs to cast alloys with narrow tolerances in their chemical composition in order to reduce variability of their use properties. Therefore appropriate sampling practices and analytical methods are required. Both accuracy and precision of the analytical results are limited by the non-homogeneity of as-cast disk or cylinder samples, which results from macrosegregation phenomenon. This paper presents a comparison between six commonly used molds: four molds recommended by ASTM standards (center-pour molds type B and vacuum mold), mushroom shaped and cylinder molds. Two complementary approaches are exhibited for the different molds designs: (1) solidification modeling in order to predict macrosegregation localization using the Simulor software; (2) experimental characterization. Radial and axial segregation profiles are determined by Analytical Scanning Electron Microscopy in addition to analytical precision evaluation by spark optical emission and X-Ray fluorescence spectrometries for a given machining depth.

  11. Development of processes and techniques for molding thermally stable, fire-retardant, low-smoke-emitting polymeric materials

    NASA Technical Reports Server (NTRS)

    Silverman, B.

    1979-01-01

    All available newly developed nonmetallic thermally stable polymers were examined for the development of processes and techniques by compression molding, injection molding, or thermoforming cabin interior parts. Efforts were directed toward developing molding techniques of new polymers to economically produce usable nonmetallic molded parts. Data on the flame resistant characteristics of the materials were generated from pilot plant batches. Preliminary information on the molding characteristics of the various thermoplastic materials was obtained by producing actual parts.

  12. Molded Magnetic Article

    NASA Technical Reports Server (NTRS)

    Bryant, Robert G. (Inventor); Namkung, Min (Inventor); Wincheski, Russell A. (Inventor); Fulton, James P. (Inventor); Fox, Robert L. (Inventor)

    2000-01-01

    A molded magnetic article and fabrication method are provided. Particles of ferromagnetic material embedded in a polymer binder are molded under heat and pressure into a geometric shape. Each particle is an oblate spheroid having a radius-to-thickness aspect ratio approximately in the range of 15-30. Each oblate spheroid has flattened poles that are substantially in perpendicular alignment to a direction of the molding pressure throughout the geometric shape.

  13. Guide to Molds at School.

    ERIC Educational Resources Information Center

    Healthy Schools Network, Inc., Albany, NY.

    Asserting that molds growing in schools can be harmful to children's health and learning, this guide offers information about the issue. It provides an overview of the basics, then addresses testing, types of molds, molds and health, monitoring schools for mold, mold prevention and clean-up tips for schools, and what parents should do if they…

  14. Effects of Process Parameters on Replication Accuracy of Microinjection Molded Cyclic Olefins Copolymers Parts

    NASA Astrophysics Data System (ADS)

    Lin, Hsuan-Liang; Chen, Chun-Sheng; Lee, Ruey-Tsung; Chen, Shia-Chung; Chien, Rean-Der; Jeng, Ming-Chang; Hwang, Jiun-Ren

    2013-04-01

    In this study, the effects of various processing parameters of microinjection molding on the replication accuracy of the micro featured fluidic platform used for DNA/RNA tests are investigated. LIGA-like processes were utilized to prepare a silicon-based SU-8 photoresist, followed by electroforming to make a Ni-Co-based stamp. A cyclic olefin copolymer (COC) was used as the injection molding material. The molding parameters associated with the replication accuracy of micro channel parts were investigated. It was found that for microinjection molded devices, the replication accuracies of the imprint width and depth increase with increasing of mold temperature, melt temperature, injection velocity, and packing pressure.

  15. BRITISH MOLDING MACHINE, PBQ AUTOMATIC COPE AND DRAG MOLDING MACHINE ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    BRITISH MOLDING MACHINE, PBQ AUTOMATIC COPE AND DRAG MOLDING MACHINE MAKES BOTH MOLD HALVES INDIVIDUALLY WHICH ARE LATER ROTATED, ASSEMBLED, AND LOWERED TO POURING CONVEYORS BY ASSISTING MACHINES. - Southern Ductile Casting Company, Casting, 2217 Carolina Avenue, Bessemer, Jefferson County, AL

  16. Implications of diamond-turned versus diamond-ground mold fabrication techniques on precision-molded optics

    NASA Astrophysics Data System (ADS)

    Mertus, Lou; Symmons, Alan

    2012-10-01

    In recent years, the trend within the molded optics community has been an overall advancement in the capability to diamond grind molds using a variety of grinding techniques. Improvements in grinding equipment, materials and tooling have enabled higher quality ceramic and carbide molds and thereby lenses. Diamond turned molds from ductile metals are still used prevalently throughout the molding industry. Each technology presents a unique set of advantages and disadvantages whether used for precision injection molding of plastic optics or precision glass molding. This paper reviews the manufacturing techniques for each approach and applicable molding process. The advantages and disadvantages of each are compared and analyzed. The subtle differences that exist in optics molded from each technique and the impact they have on the performance in various applications is reviewed. Differences stemming from tooling material properties, material-specific minor defects, as well as cutting and grinding process-induced artifacts are described in detail as well as their influence on the roughness, waviness, and form errors present on the molded surface. A comparison with results between similar surfaces for both diamond grinding and diamond turning is presented.

  17. Manufacturing injection-moleded Fresnel lens parquets for point-focus concentrating photovoltaic systems

    SciTech Connect

    Peters, E.M.; Masso, J.D.

    1995-10-01

    This project involved the manufacturing of curved-faceted, injection-molded, four-element Fresnel lens parquets for concentrating photovoltaic arrays. Previous efforts showed that high-efficiency (greater than 82%) Fresnel concentrators could be injection molded. This report encompasses the mold design, molding, and physical testing of a four-lens parquet for a solar photovoltaic concentrator system.

  18. Silicon micro-mold

    DOEpatents

    Morales, Alfredo M.

    2006-10-24

    The present invention describes a method for rapidly fabricating a robust 3-dimensional silicon-mold for use in preparing complex metal micro-components. The process begins by depositing a conductive metal layer onto one surface of a silicon wafer. A thin photoresist and a standard lithographic mask are then used to transfer a trace image pattern onto the opposite surface of the wafer by exposing and developing the resist. The exposed portion of the silicon substrate is anisotropically etched through the wafer thickness down to conductive metal layer to provide an etched pattern consisting of a series of rectilinear channels and recesses in the silicon which serve as the silicon micro-mold. Microcomponents are prepared with this mold by first filling the mold channels and recesses with a metal deposit, typically by electroplating, and then removing the silicon micro-mold by chemical etching.

  19. Silicone plesiotherapy molds

    SciTech Connect

    Karolis, C.; Reay-Young, P.S.; Walsh, W.; Velautham, G.

    1983-04-01

    Plesiotherapy, the treatment of superficial lesions by radioactive molds has largely been replaced by teletherapy techniques involving high energy photon and electron beams. There are, however, situations for which a short distance type treatment, in one form or another, is superior to any other presently available. Traditionally, molds have taken the form of rigid devices incorporating clamps to attach them to the patient. This ensures a reproducible geometry about a localized region since the molds are applied on a daily basis. To make such devices requires considerable skill and patience. This article describes an alternative method that eliminates the use of cumbersome devices in many situations. Silicone molds made from a plaster cast model have been found suitable for the treatment of surface lesions and especially for lesions in the oral and nasal cavities. With the use of radioactive gold seeds the molds may be left in place for a few days without fear of them moving.

  20. Glass molding process with mold lubrication

    DOEpatents

    Davey, Richard G.

    1978-06-27

    Improvements are provided in glass forming processes of the type wherein hot metal blank molds are employed by using the complementary action of a solid film lubricant layer, of graphite dispersed in a cured thermoset organopolysiloxane, along with an overspray of a lubricating oil.

  1. Integrally cored ceramic investment casting mold fabricated by ceramic stereolithography

    NASA Astrophysics Data System (ADS)

    Bae, Chang-Jun

    Superalloy airfoils are produced by investment casting (IC), which uses ceramic cores and wax patterns with ceramic shell molds. Hollow cored superalloy airfoils in a gas turbine engine are an example of complex IC parts. The complex internal hollow cavities of the airfoil are designed to conduct cooling air through one or more passageways. These complex internal passageways have been fabricated by a lost wax process requiring several processing steps; core preparation, injection molding for wax pattern, and dipping process for ceramic shell molds. Several steps generate problems such as high cost and decreased accuracy of the ceramic mold. For example, costly tooling and production delay are required to produce mold dies for complex cores and wax patterns used in injection molding, resulting in a big obstacle for prototypes and smaller production runs. Rather than using separate cores, patterns, and shell molds, it would be advantageous to directly produce a mold that has the casting cavity and the ceramic core by one process. Ceramic stereolithography (CerSLA) can be used to directly fabricate the integrally cored ceramic casting mold (ICCM). CerSLA builds ceramic green objects from CAD files from many thin liquid layers of powder in monomer, which are solidified by polymerization with a UV laser, thereby "writing" the design for each slice. This dissertation addresses the integrally cored casting ceramic mold (ICCM), the ceramic core with a ceramic mold shell in a single patternless construction, fabricated by ceramic stereolithography (CerSLA). CerSLA is considered as an alternative method to replace lost wax processes, for small production runs or designs too complex for conventional cores and patterns. The main topic is the development of methods to successfully fabricate an ICCM by CerSLA from refractory silica, as well as related issues. The related issues are the segregation of coarse fused silica powders in a layer, the degree of segregation parameter to

  2. Resin film infusion mold tooling and molding method

    NASA Technical Reports Server (NTRS)

    Burgess, Roger (Inventor); Grossheim, Brian (Inventor); Mouradian, Karbis (Inventor); Thrash, Patrick J. (Inventor)

    1999-01-01

    A mold apparatus and method for resin film infusion molding including an outer mold tool having a facing sheet adapted to support a resin film and preform assembly. The facing sheet includes attachment features extending therefrom. An inner mold tool is positioned on the facing sheet to enclose the resin film and preform assembly for resin film infusion molding. The inner mold tool includes a plurality of mandrels positioned for engagement with the resin film and preform assembly. Each mandrel includes a slot formed therein. A plurality of locating bars cooperate with the slots and with the attachment features for locating the mandrels longitudinally on the outer mold tool.

  3. 92. PRODUCTION MOLDS. THESE MOLDS ARE COPIES OF THE ORIGINAL ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    92. PRODUCTION MOLDS. THESE MOLDS ARE COPIES OF THE ORIGINAL MOLDS IN THE MORAVIAN POTTERY AND TILE WORKS COLLECTION, AND ARE USED TO PRESS TILES. THE FACTORY KEEPS TEN PRODUCTION MOLDS FOR EACH IMAGE. THE ORIGINAL MOLDS ARE NOT USED IN PRODUCTION. SAME VIEW AS PA-107-53. - Moravian Pottery & Tile Works, Southwest side of State Route 313 (Swamp Road), Northwest of East Court Street, Doylestown, Bucks County, PA

  4. Mold After a Disaster

    MedlinePlus

    ... Health Matters What's New Preparation & Planning Disasters & Severe Weather Earthquakes Extreme Heat Floods Hurricanes Landslides Tornadoes Tsunamis ... Disaster Mold Removal After a Disaster Disasters & Severe Weather Earthquakes Extreme Heat Floods Hurricanes Landslides Tornadoes Tsunamis ...

  5. Breaking the Mold.

    ERIC Educational Resources Information Center

    Huckabee, Christopher

    2003-01-01

    Using the example of a Texas elementary school, describes how to eliminate mold and mildew from school facilities, including discovering the problem, responding quickly, reconstructing the area, and crisis planning and prevention. (EV)

  6. Newborn head molding

    MedlinePlus

    ... molding. In: Graham JM, Sanchez-Lara PA, eds. Smiths' Recognizable Patterns of Human Deformation . 4th ed. Philadelphia, PA: Elsevier; 2016:chap 35. Smith J. Initial evaluation. In: Gleason CA, Devaskar SU, ...

  7. MOLDS FOR CASTING PLUTONIUM

    DOEpatents

    Anderson, J.W.; Miley, F.; Pritchard, W.C.

    1962-02-27

    A coated mold for casting plutonium comprises a mold base portion of a material which remains solid and stable at temperatures as high as the pouring temperature of the metal to be cast and having a thin coating of the order of 0.005 inch thick on the interior thereof. The coating is composed of finely divided calcium fluoride having a particle size of about 149 microns. (AEC)

  8. ZAPP shot summary

    SciTech Connect

    Loisel, Guillaume Pascal

    2015-10-01

    This was the second Z Astrophysical Plasma Properties (ZAPP) fundamental science shot series of 2015. ZAPP experiments measure fundamental properties of atoms in plasmas to solve the following important astrophysical puzzles: Why can’t we accurately model the opacity of Fe at the convection zone boundary in the Sun? How accurate are the photoionization models used to interpret data from xray satellite observations? and Why doesn’t spectral fitting provide the correct properties for White Dwarfs?

  9. Multilevel micro-structuring of glassy carbon molds for precision glass molding

    NASA Astrophysics Data System (ADS)

    Prater, Karin; Dukwen, Julia; Scharf, Toralf; Herzig, Hans Peter; Plöger, Sven; Hermerschmidt, Andreas

    2015-09-01

    Replication techniques for diffractive optical elements (DOEs) in soft materials such as plastic injection molding are state of the art. For precision glass molding in glasses with high transition temperatures, molds with extreme thermal resistivity, low chemical reactivity and high mechanical strength are needed. Glassy Carbon can be operated up to 2000°C making it possible to mold almost all glasses including Fused Silica with a transition temperatures above 1060°C. For the structuring of Glassy Carbon wafers photolithography and a RIE process is used. We have developed a process using Si as a hard mask material. If the flow rates of the etching gases O2 and SF6 are chosen properly, high selectivity of GC to Si 19:1 can be achieved, which provides excellent conditions to realize high resolution elements with feature size down to 1 micron and fulfills requirements for optical applications. We fabricated several multilevel GC molds with 8 levels of structuring. Two different optical functionalities were implemented: 6x6 array beamsplitter and 1x4 linear beamsplitter. The molds were applied for precision glass molding of a low Tg glass L-BAL 42 (from Ohara) with a transition temperature of 565°C. Their optical performance was measured. A more detailed analysis of the impact of mold fabrication defects on optical performance is done. Rigorous coupled wave analysis simulations are performed, where we included fabrication constrains such as duty cycle, edge depth errors, wall verticality and misalignment errors. We will compare the results with the design specifications and discuss the influence of fabrication errors introduced during the different process steps.

  10. Replication of optical microlens array using photoresist coated molds.

    PubMed

    Chakrabarti, M; Dam-Hansen, C; Stubager, J; Pedersen, T F; Pedersen, H C

    2016-05-01

    A cost reduced method of producing injection molding tools is reported and demonstrated for the fabrication of optical microlens arrays. A standard computer-numerical-control (CNC) milling machine was used to make a rough mold in steel. Surface treatment of the steel mold by spray coating with photoresist is used to smooth the mold surface providing good optical quality. The tool and process are demonstrated for the fabrication of an ø50 mm beam homogenizer for a color mixing LED light engine. The acceptance angle of the microlens array is optimized, in order to maximize the optical efficiency from the light engine. Polymer injection molded microlens arrays were produced from both the rough and coated molds and have been characterized for lenslet parameters, surface quality, light scattering, and acceptance angle. The surface roughness (Ra) is improved approximately by a factor of two after the coating process and the light scattering is reduced so that the molded microlens array can be used for the color mixing application. The measured accepted angle of the microlens array is 40° which is in agreement with simulations. PMID:27137566

  11. Mold deflection effects on the prediction of packing pressure decay and shrinkage of semi-crystalline polymers

    NASA Astrophysics Data System (ADS)

    Costa, Franco S.; Yuan, Zhongshuang

    2015-05-01

    The beneficial effect of considering mold deflection and mold spring-back on the prediction of packing pressure decay and part shrinkage of amorphous polymers has already been demonstrated. In this paper, a similar mold deflection effect is added to the recently developed flow-induced crystallization modeling of semi-crystalline materials during injection molding. The combined effect of improved solidification rate from the crystallization modeling and improved pressure decay due to the mold deflection effect results in improved part shrink and warp predictions. Simulation results are validated against molding data of cavity pressure and shrinkage for a range of polymers.

  12. Lead shot toxicity to passerines

    USGS Publications Warehouse

    Vyas, N.B.; Spann, J.W.; Heinz, G.H.

    2001-01-01

    This study evaluated the toxicity of a single size 7.5 lead shot to passerines. No mortalities or signs of plumbism were observed in dosed cowbirds (Molothrus ater) fed a commercial diet, but when given a more natural diet, three of 10 dosed birds died within 1 day. For all survivors from which shot were recovered, all but one excreted the shot within 24 h of dosing, whereas, the dead birds retained their shot. Shot erosion was significantly greater (P < 0.05) when weathered shot were ingested compared to new shot, and the greatest erosion was observed in those birds that died (2.2-9.7%). Blood lead concentrations of birds dosed with new shot were not significantly different (P=0.14) from those of birds exposed to weathered shot. Liver lead concentrations of birds that died ranged from 71 to 137 ppm, dry weight. Despite the short amount of time the shot was retained, songbirds may absorb sufficient lead to compromise their survival.

  13. A review on the importance of surface coating of micro/nano-mold in micro/nano-molding processes

    NASA Astrophysics Data System (ADS)

    Saha, Biswajit; Toh, Wei Quan; Liu, Erjia; Beng Tor, Shu; Hardt, David E.; Lee, Junghoon

    2016-01-01

    Micro/nano hot-embossing and injection molding are two promising manufacturing processes for the mass production of workpieces bearing micro/nanoscale features. However, both the workpiece and micro/nano-mold are susceptive to structural damage due to high thermal stress, adhesion and friction, which occur at the interface between the workpiece and the mold during these processes. Hence, major constraints of micro/nano-molds are mainly attributed to improper replication and their inability to withstand a prolonged sliding surface contact because of high sidewall friction and/or high adhesion. Consequently, there is a need for proper surface coating as it can improve the surface properties of micro/nano-molds such as having a low friction coefficient, low adhesion and low wear rate. This review deals with the physical, mechanical and tribological properties of various surface coatings and their impact on the replication efficiency and lifetime of micro/nano-molds that are used in micro/nano hot-embossing and injection molding processes.

  14. TENDING THE MOLD, DURING THE TRANSFER FROM TUNDISH TO MOLD ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    TENDING THE MOLD, DURING THE TRANSFER FROM TUNDISH TO MOLD TO CONTAINMENT CHAMBER IS CONTINUOUS CASTING OPERATOR, CALVIN ANDERS. - U.S. Steel, Fairfield Works, Continuous Caster, Fairfield, Jefferson County, AL

  15. Pressure molding of powdered materials improved by rubber mold insert

    NASA Technical Reports Server (NTRS)

    1964-01-01

    Pressure molding tungsten microspheres is accomplished by applying hydraulic pressure to a silicone rubber mold insert with several barrel shaped chambers which is placed in a steel die cavity. This technique eliminates castings containing shear fractures.

  16. FILLING MOLDS MADE ON THE BRITISH MOLDING MACHINE, AUTOMATIC COPE ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    FILLING MOLDS MADE ON THE BRITISH MOLDING MACHINE, AUTOMATIC COPE AND DRAG (BMM) FROM MOBILE LADLE. EMPTY BULL LADLE IN FOREGROUND. - Southern Ductile Casting Company, Casting, 2217 Carolina Avenue, Bessemer, Jefferson County, AL

  17. The Physics of Shot Towers

    ERIC Educational Resources Information Center

    Lipscombe, Trevor C.; Mungan, Carl E.

    2012-01-01

    In the late 18th and throughout the 19th century, lead shot for muskets was prepared by use of a shot tower. Molten lead was poured from the top of a tower and, during its fall, the drops became spherical under the action of surface tension. In this article, we ask and answer the question: "How does the size of the lead shot depend on the height…

  18. Lead shot poisons bald eagles

    SciTech Connect

    Cohn, J.P.

    1985-09-01

    This article describes the controversy between the US Fish and Wildlife Service, the National Wildlife Federation and the increased mortality of bald eagles. The eagles are being poisoned by preying on waterfowl which have ingested lead shot or have been wounded by shot and not recovered. The controversy has resulted in the establishment of new criteria for so-called non-toxic shot waterfowl hunting.

  19. Bag molding processes

    NASA Astrophysics Data System (ADS)

    Slobodzinsky, A.

    Features, materials, and techniques of vacuum, pressure, and autoclave FRP bag molding processes are described. The bags are used in sealed environments, inflated to flexibly force a curing FRP laminate to conform to a stiff mold form which defines the shape of the finished product. Densification is achieved as the bag presses out the voids and excess resin from the laminate, and consolidation occurs as the plies and adherends are bonded by the bag pressure. Curing techniques nominally involved room temperature or high temperature, and investigations of alternative techniques, such as induction, dielectric, microwave, xenon flash, UV, electron beam, and gamma radiation heating are proceeding. Polysulfone is the most common thermoplastic. Details are given of mold preparations, peel plies or release films and fabrics, bagging techniques, and reusable venting blankets and silicone rubber bags.

  20. The Physics of Shot Towers

    NASA Astrophysics Data System (ADS)

    Lipscombe, Trevor C.; Mungan, Carl E.

    2012-04-01

    In the late 18th and throughout the 19th century, lead shot for muskets was prepared by use of a shot tower. Molten lead was poured from the top of a tower and, during its fall, the drops became spherical under the action of surface tension. In this article, we ask and answer the question: How does the size of the lead shot depend on the height of the tower? In the process, we explain the basic technology underlying an important historical invention (the shot tower) and use simple physics (Newtonian mechanics and the thermodynamic laws of cooling) to model its operation.

  1. System for Image-Processing-Based Inspection of a Screw Hole on a Molded Plastic Frame

    NASA Astrophysics Data System (ADS)

    Satoh, Hironobu; Takeda, Fumiaki

    A screw hole is incorrectly molded if the pin on the mold is broken when the plastic is molded by injection molding. Sampling inspection is carried out manually to identify the incorrectly molded screw hole. In the sampling inspection, the incorrectly molded screw hole on the molded plastic frame is rarely overlooked. Therefore, the development of a system for the high-precision identification of the incorrectly molded screw hole is required. The purpose of this study is to develop a screw-hole inspection system that distinguishes between a correctly molded screw hole and an incorrectly molded one. In this paper, a screw-hole inspection system is proposed. There is a need to capture clearly the screw hole on an uneven plastic frame and therefore, a multi-camera system is used. The proposed system consists of several Web cameras with the individual adjustable focus. Moreover, the inspection of the screw holes is performed using an inspection algorithm that is developed for a multi-camera system. When 2548 correctly molded screw holes and 2940 incorrectly molded screw holes were inspected by the proposed system, the inspection success rate was 100.0%. Finally, we have verified its effectiveness by performing an experiment.

  2. Centrifugal shot blast system

    SciTech Connect

    1998-02-01

    This report describes a demonstration of Concrete cleaning, Inc., modified centrifugal shot blast technology to remove the paint coating from concrete flooring. This demonstration is part of the Chicago Pile-5 (CP-5) Large-Scale Demonstration Project (LSDP) sponsored by the US Department of Energy (DOE), office of Science and Technology (OST), Deactivation and Decommissioning Focus Area (DDFA). The objective of the LSDP is to select and demonstrate potentially beneficial technologies at the Argonne National Laboratory-East (ANL) CP-5 Research Reactor. The purpose of the LSDP is to demonstrate that using innovative and improved decontamination and decommissioning (D and D) technologies from various sources can result in significant benefits, such as decreased cost and increased health and safety, as compared with baseline D and D technologies. Potential markets exist for the innovative centrifugal shot blast system at the following sites: Fernald Environmental Management Project, Los Alamos, Nevada, Oak Ridge Y-12 and K-25, Paducah, Portsmouth Gaseous Diffusion site, and the Savannah River Site. This information is based on a revision to the OST Linkage Tables dated August 4, 1997.

  3. Chemorheology of in-mold coating for compression molded SMC applications

    NASA Astrophysics Data System (ADS)

    Ko, Seunghyun; Straus, Elliott J.; Castro, Jose M.

    2015-05-01

    In-mold coating (IMC) is applied to compression molded sheet molding compound (SMC) exterior automotive or truck body panels as an environmentally friendly alternative to make the surface conductive for subsequent electrostatic painting operations. The coating is a thermosetting liquid that when injected onto the surface of the part cures and bonds to provide a smooth conductive surface. In order to optimize the IMC process, it is essential to predict the time available for flow, that is the time before the thermosetting reaction starts (inhibition time) as well as the time when the coating has enough structural integrity so that the mold can be opened without damaging the part surface (cure time). To predict both the inhibition time and the cure time, it is critical to study the chemorheology of IMC. In this paper, we study the chemorheology for a typical commercial IMC system, and show its relevance to both the flow and cure time for the IMC stage during SMC compression molding.

  4. Shot Planning and Analysis Tools

    SciTech Connect

    Casey, A; Beeler, R; Conder, A; Fallejo, R; Flegel, M; Hutton, M; Jancaitis, K; Lakamsani, V; Potter, D; Reisdorf, S; Tappero, J; Whitman, P; Carr, W; Liao, Z

    2011-07-25

    Shot planning and analysis tools (SPLAT) integrate components necessary to help achieve a high over-all operational efficiency of the National Ignition Facility (NIF) by combining near and long-term shot planning, final optics demand and supply loops, target diagnostics planning, and target fabrication requirements. Currently, the SPLAT project is comprised of two primary tool suites for shot planning and optics demand. The shot planning component provides a web-based interface to selecting and building a sequence of proposed shots for the NIF. These shot sequences, or 'lanes' as they are referred to by shot planners, provide for planning both near-term shots in the Facility and long-term 'campaigns' in the months and years to come. The shot planning capabilities integrate with the Configuration Management Tool (CMT) for experiment details and the NIF calendar for availability. Future enhancements will additionally integrate with target diagnostics planning and target fabrication requirements tools. The optics demand component is built upon predictive modelling of maintenance requirements on the final optics as a result of the proposed shots assembled during shot planning. The predictive models integrate energetics from a Laser Performance Operations Model (LPOM), the status of the deployed optics as provided by the online Final Optics Inspection system, and physics-based mathematical 'rules' that predict optic flaw growth and new flaw initiations. These models are then run on an analytical cluster comprised of forty-eight Linux-based compute nodes. Results from the predictive models are used to produce decision-support reports in the areas of optics inspection planning, optics maintenance exchanges, and optics beam blocker placement advisories. Over time, the SPLAT project will evolve to provide a variety of decision-support and operation optimization tools.

  5. End moldings for cable dielectrics

    DOEpatents

    Roose, Lars D.

    2000-01-01

    End moldings for high-voltage cables are described wherein the dielectric insulator of the cable is heated and molded to conform to a desired shape. As a consequence, high quality substantially bubble-free cable connectors suitable for mating to premanufactured fittings are made. Disclosed is a method for making the cable connectors either in the field or in a factory, molds suitable for use with the method, and the molded cable connectors, themselves.

  6. Molding process for imidazopyrrolone polymers

    NASA Technical Reports Server (NTRS)

    Johnson, C. L. (Inventor)

    1973-01-01

    A process is described for producing shaped articles of imidazopyrrolone polymers comprising molding imidazopyrrolone polymer molding power under pressure and at a temperature greater than 475 C. Moderate pressures may be employed. Preferably, prior to molding, a preform is prepared by isostatic compression. The preform may be molded at a relatively low initial pressure and temperature; as the temperature is increased to a value greater than 475 C., the pressure is also increased.

  7. REFRACTORY COATING FOR GRAPHITE MOLDS

    DOEpatents

    Stoddard, S.D.

    1958-06-24

    Refractory coating for graphite molds used in the casting of uranium is described. The coating is an alumino-silicate refractory composition which may be used as a mold surface in solid form or as a coating applied to the graphite mold. The composition consists of a mixture of ball clay, kaolin, alumina cement, alumina, water, sodium silicate, and sodium carbonate.

  8. MOLDED SEALING ELEMENT

    DOEpatents

    Bradford, B.W.; Skinner, W.J.

    1959-03-24

    Molded sealing elements suitable for use under conditions involving exposure to uranium hexafluoride vapor are described. Such sealing elements are made by subjecting graphitic carbons to a preliminary treatment with uranium hexafluoride vapor, and then incorporating polytetrafluorethylene in them. The resulting composition has good wear resistant and frictional properties and is resistant to disintegration by uranium hexafluoride over long periods of exposure.

  9. White Mold of Chickpea

    Technology Transfer Automated Retrieval System (TEKTRAN)

    White mold of chickpea can occur at either seedling stage or at flowering and pod filling stages. At seedling stage, the disease occurs at the base of the stem causing symptoms like collar rot. Often white mycelial growth around the stem on soil surface is visible. Affected plants wilt and die. ...

  10. Nonpost mold cure compound

    NASA Astrophysics Data System (ADS)

    Hirata, Akihiro

    1997-08-01

    The recent low price trend of electronic products has made IC manufacturing efficiency a top priority in the semiconductor industry. Post mold cure (PMC) process, which generally involves heating the packages in the oven at 175 C for 4 to 8 hours, takes up much longer time than most other assembly processes. If this PMC process can be reduced or eliminated, semiconductor makers will be rewarded with a much higher cost merit. We define the purpose of Non-PMC as 'to get high reliability with suitable physical and electrical properties without PMC'. We compared carious properties of molding compound before and after PMC. We found that curing reaction has almost complete through DSC and C-NMR measurement, but several properties have not stabilized yet, and that not all properties after PMC were better than before PMC. We developed new grade of molding compound considering these facts. And we found that main factors to accomplish non-PMC compound are curability and flowability, and more, increasing of fundamental properties. To accomplish non-PMC, at first, molding compound need to have very high curability. Generally speaking, too high curability causes low flowability, and causes incomplete filing, wire sweep, pad shift, and weak adhesion to inner parts of IC packages. To prevent these failures, various compound properties were studied, and we achieved in adding good flowability to very high curable molding compound. Finally, anti-popcorn property was improved by adding low moisture, high adhesion, high Tg, and high flexural strengths at high temperature. Through this study, we developed new compound grade for various package, especially large QFP using standard ECN resin.

  11. Moon shots for management.

    PubMed

    Hamel, Gary

    2009-02-01

    In May 2008, a group of management scholars and senior executives worked to define an agenda for management during the next 100 years. The so-called renegade brigade, led by Gary Hamel, included academics, such as C.K. Prahalad, Peter Senge, and Jeffrey Pfeffer; new-age thinkers, like James Surowiecki; and progressive CEOs, such as Whole Foods' John Mackey, W.L. Gore's Terri Kelly, and IDEO's Tim Brown. What drew them together was a set of shared beliefs about the importance of management and a sense of urgency about reinventing it for a new era. The group's first task was to compile a roster of challenges that would focus the energies of management innovators around the world. Accordingly, in this article, Hamel (who has set up the Management Lab, a research organization devoted to management innovation) outlines 25 "moon shots"--ambitious goals that managers should strive to achieve and in the process create Management 2.0. Topping the list is the imperative of extending management's responsibilities beyond just creating shareholder value. To do so will require both reconstructing the field's philosophical foundations so that work serves a higher purpose and fully embedding the ideas of community and citizenship into organizations. A number of challenges focus on ameliorating the toxic effects of hierarchy. Others focus on better ways to unleash creativity and capitalize on employees' passions. Still others seek to transcend the limitations of traditional patterns of management thinking. Not all the moon shots are new, but many tackle issues that are endemic in large organizations. Their purpose is to inspire new solutions to long-simmering problems by making every company as genuinely human as the people who work there. PMID:19266704

  12. High Cost/High Risk Components to Chalcogenide Molded Lens Model: Molding Preforms and Mold Technology

    SciTech Connect

    Bernacki, Bruce E.

    2012-10-05

    This brief report contains a critique of two key components of FiveFocal's cost model for glass compression molding of chalcogenide lenses for infrared applications. Molding preforms and mold technology have the greatest influence on the ultimate cost of the product and help determine the volumes needed to select glass molding over conventional single-point diamond turning or grinding and polishing. This brief report highlights key areas of both technologies with recommendations for further study.

  13. Fabrication of microinjection-molded miniature freeform Alvarez lenses.

    PubMed

    Li, Likai; Raasch, Thomas W; Sieber, Ingo; Beckert, Erik; Steinkopf, Ralf; Gengenbach, Ulrich; Yi, Allen Y

    2014-07-01

    Microinjection molding is a mass production method to fabricate affordable optical components. However, the intense nature of this process often results in part deformation and uneven refractive index distribution. These two factors limit the precision of replicated optics. In order to understand the influences of injection molding on freeform optical devices, in this study, finite element method (FEM) was employed to investigate the miniature microinjection-molded Alvarez lenses. In addition, an innovative metrology setup was proposed to evaluate the optical wavefront patterns in the molded lenses using an interferometer-based wavefront measurement system. This measurement setup utilized an optical matching liquid to reduce or eliminate the lenses' surface power such that the wavefront pattern with large deviation from the freeform lenses can be measured by a regular wavefront setup. The FEM simulation results were also used to explain the differences between the nominal and experimentally measured wavefront patterns of the microinjection-molded Alvarez lenses. In summary, the proposed method combining simulation and wavefront measurements is shown to be an effective approach for studying injection molding of freeform optics. PMID:25089987

  14. Mold Heating and Cooling Pump Package Operator Interface Controls Upgrade

    SciTech Connect

    Josh A. Salmond

    2009-08-07

    The modernization of the Mold Heating and Cooling Pump Package Operator Interface (MHC PP OI) consisted of upgrading the antiquated single board computer with a proprietary operating system to off-the-shelf hardware and off-the-shelf software with customizable software options. The pump package is the machine interface between a central heating and cooling system that pumps heat transfer fluid through an injection or compression mold base on a local plastic molding machine. The operator interface provides the intelligent means of controlling this pumping process. Strict temperature control of a mold allows the production of high quality parts with tight tolerances and low residual stresses. The products fabricated are used on multiple programs.

  15. Analysis of shot-to-shot variability in post-disruption runaway electron currents for diverted DIII-D discharges

    NASA Astrophysics Data System (ADS)

    Izzo, V. A.; Humphreys, D. A.; Kornbluth, M.

    2012-09-01

    In DIII-D experiments, rapid termination by Ar-pellet injection sometimes produces a post-termination runaway electron (RE) current plateau, but this effect is highly non-reproducible on a shot-to-shot basis, particularly for diverted target plasmas. A set of DIII-D discharges is analyzed with two MHD codes to understand the relationship between the current profile of the target plasma and the amplitude of the RE current plateau. Using the linear stability code GATO, a correlation between the radial profile of the unstable n = 1 mode just after Ar-pellet injection and the observed appearance of an RE plateau is identified. Nonlinear NIMROD simulations with RE test-particle calculations directly predict RE confinement times during the disruption. With one exception, NIMROD predicts better RE confinement for shots in which higher RE currents were observed in DIII-D. But, the variation in confinement is primarily connected to the saturated n = 1 mode amplitude and not its radial profile. Still, both sets of analyses support the hypothesis that RE deconfinement by MHD fluctuations is a major factor in the shot-to-shot variability of RE plateaus, though additional factors such as seed current amplitude cannot be ruled out.

  16. Improved plastic molding technology for magneto-optical disk substrate

    NASA Astrophysics Data System (ADS)

    Galic, George J.

    1991-03-01

    A patented new injection-molding technology which already has been coninercially licensed nonexclusively to worldleading plastic magnetooptical (MO) mediamakers gives very high moldpacking pressures (needed for maximum microsurface replication) without high birefringence (minimized by reducing constrictiveness during fill) even with high viscosity plastics. I . " STATFMENT OF ThE PROBLIM" FOB ERASABLE OPTICALDI 5K MOLDINQ Al though gl ass and new cross 1 inkabl e p1 as t i cs are cont ending wi th polycarbonate and other injection moldable thermoplastics for this new market polycarbonate has prevailed as " first generation" erasable media substrate (although product life considerations may require added barrier coat to the MO coating stacks thereof). If performance of all these substrate contenders were equal the injection moldable thermoplastics will be preferred due to lowest cost and most automatable production If molded thermoplastics don''t ultimately win out a main reason will have been that these disk products require a long narrow mold cavity to be filled by the thermoplastic of choice then packed at double the pressures used for digital audio compact disks (CDs) in order to force the molten thermoplastic against the staner microsurface until detailed microreplication is assured yet only very low moldedin stresses can be tolerated (typically 1/2 to 1/5 those of audio CDs) 1. 1 Fillrelated Molding Problems M-O disks typically are 130am or 86nin in diameter and as molded thickness of a single

  17. Ultra-short Pulse Laser Structuring of Molding Tools

    NASA Astrophysics Data System (ADS)

    Conrad, Daniel; Richter, Lars

    The machining of highly filled abrasive polymer plastics in injection molding processes determines high resistant tools in the industrial production. One of the most important points is a long durability of the molding tools to reduce the costs of production. Thus, the adhesion force and abrasion will be reduced with the help of defined surface properties. To achieve appropriate surface conditions, an ultra-short pulse laser is used for a micro structuring. Additional a laser polishing of the micro-structured surfaces to optimize the frictional properties is presented. This paper shows the research results of investigations on the laser modification of steel surfaces, to generate high-quality and wear-resistant surfaces for injection molding tools.

  18. SunShot Identity Video

    SciTech Connect

    Le, Minh; Resch, Rhone

    2014-05-19

    Highlights of the SunShot program, the national targets for the program, and the "all of the above" approach to achieving those goals through research, tech transfer, permitting, tax incentives, and a comprehensive approach to installation.

  19. SunShot Identity Video

    ScienceCinema

    Le, Minh; Resch, Rhone

    2014-06-05

    Highlights of the SunShot program, the national targets for the program, and the "all of the above" approach to achieving those goals through research, tech transfer, permitting, tax incentives, and a comprehensive approach to installation.

  20. Innovative molding technologies for the fabrication of components for microsystems

    NASA Astrophysics Data System (ADS)

    Piotter, Volker; Benzler, Tobias; Hanemann, Thomas; Woellmer, Heinz; Ruprecht, Robert; Hausselt, Juergen H.

    1999-03-01

    Economic success of microsystems technology requires a wide range of materials as well as the related manufacturing processes. A suitable technology for medium/large scale production is micro injection molding which actually allows the manufacturing of plastic microstructures with 20 microns minimum thickness, structural details of approximately 0.2 microns or maximum aspect ratios of more than 20. These microstructures are, for example, applied as components in micro optics, micro fluidics or minimally invasive surgery. This is demonstrated by microparts that are currently available or will be available soon. For higher economic efficiency and cost reduction, fully electrical injection modeling machines of higher accuracy have been applied. Also, micro insert injection molding reduces mounting costs. Manufacturing of metal or ceramic microparts by powder injection modeling allows large-scale production of complex shaped microstructures with a wide range of materials. Typical examples are sintered structured like stepped LIGA- gear wheels with minimal dimensions of 50 microns in different metal and ceramic materials. Micro Precision Casting originating from conventional investment casting is a suitable process for small/medium-scale production. Examples are microturbine housings made of precious metal alloys. An approach similar to rapid prototyping applies photocurable reactive resins. Photoinduced molding of low viscous resins under ambient conditions leads to significantly reduced cycle times. Additionally, rapid testing of new composite materials can be performed easily. Microcomponents molded from polymers and different composites like dyes with nonlinear optical properties and nanosized ceramic powders will be presented.

  1. Spin-dependent shot noise in semiconductor and graphene nanostructures

    NASA Astrophysics Data System (ADS)

    Dragomirova, Ralitsa L.

    Shot noise is the name given to the time-dependent non-equilibrium current (or voltage) fluctuations which persist down to zero temperature and are fundamentally related to the discrete nature of the electron charge. Over the past two decades it has become a major tool for gathering information about microscopic mechanisms of transport and correlations between charges which cannot be extracted from traditional conductance measurements. Recently a handful of theoretical and experimental studies have suggested that shot noise in systems with spin-dependent interactions provides a sensitive probe to differentiate between scattering from magnetic impurities, spin-flip scattering, and continuous spin precession effects on semiclassical or quantum transport of injected spin-polarized currents. This is due to the fact that any spin flip converts spin-↑ subsystem particle into a spin-↓ subsystem particle, where the two subsystems differ when spin degeneracy is lifted. Thus, the nonconservation of the number of particles in each subsystem generates additional source of current fluctuations. Here we generalize the scattering theory of quantum shot noise to include the full spin-density matrix of electrons. This formalism yields the spin-resolved shot noise power applicable for a generic spintronic device where partially polarized charge current or even pure spin current is injected from a spin-filtering or ferromagnetic electrode into a quantum-coherent nanostructure governed by arbitrary spin-dependent interactions. The developed formalism [2, 5] is applied in Chapter 5 to diffusive multichannel quantum wires with the Rashba spin-orbit (SO) coupling sandwiched between ferromagnetic source and ferromagnetic or normal drain electrodes. The crucial role played by the SO interactions in all-electrical control of spin in semiconductor nanostructures has ignited recent studies of their signatures on the shot noise. We investigate what is the effect of the Rahsba SO coupling

  2. Fabrication of Molded Magnetic Article

    NASA Technical Reports Server (NTRS)

    Bryant, Robert G. (Inventor); Namkung, Min (Inventor); Wincheski, Russell A. (Inventor); Fox, Robert L. (Inventor)

    2001-01-01

    A molded magnetic article and fabrication method are provided. Particles of ferromagnetic material embedded in a polymer binder are molded under heat and pressure into a geometric shape. Each particle is an oblate spheroid having a radius-to-thickness aspect ratio approximately in the range of 15-30. Each oblate spheroid has flattened poles that are substantially in perpendicular alignment to a direction of the molding pressure throughout the geometric shape.

  3. Microminiature molding techniques for cochlear electrode arrays.

    PubMed

    Loeb, G E; Peck, R A; Smith, D W

    1995-12-01

    We provide a general method for producing a variety of small, complex electrode arrays based on injection molds produced using computer-aided drafting and machining (CAD-CAM) procedures and a novel method for connecting to the very fine electrical leads associated with the individual contacts of such arrays. Cat-sized cochlear electrode arrays with up to eight contacts were built according to these methods and their electrical contacts were characterized in vitro by impedance spectroscopy and in vivo by monitoring impedance for over 1 year of intermittent stimulation in chronically instrumented animals. PMID:8788052

  4. Method for molding ceramic powders

    DOEpatents

    Janney, M.A.

    1990-01-16

    A method for molding ceramic powders comprises forming a slurry mixture including ceramic powder, a dispersant for the metal-containing powder, and a monomer solution. The monomer solution includes at least one multifunctional monomer, a free-radical initiator, and an organic solvent. The slurry mixture is transferred to a mold, and the mold containing the slurry mixture is heated to polymerize and crosslink the monomer and form a firm polymer-solvent gel matrix. The solid product may be removed from the mold and heated to first remove the solvent and subsequently remove the polymer, where after the product may be sintered.

  5. Method for molding ceramic powders

    DOEpatents

    Janney, Mark A.

    1990-01-01

    A method for molding ceramic powders comprises forming a slurry mixture including ceramic powder, a dispersant for the metal-containing powder, and a monomer solution. The monomer solution includes at least one multifunctional monomer, a free-radical initiator, and an organic solvent. The slurry mixture is transferred to a mold, and the mold containing the slurry mixture is heated to polymerize and crosslink the monomer and form a firm polymer-solvent gel matrix. The solid product may be removed from the mold and heated to first remove the solvent and subsequently remove the polymer, whereafter the product may be sintered.

  6. 76 FR 59421 - Proposed Information Collection; Approval Procedures for Nontoxic Shot and Shot Coatings

    Federal Register 2010, 2011, 2012, 2013, 2014

    2011-09-26

    ... Shot Coatings AGENCY: Fish and Wildlife Service, Interior. ACTION: Notice; request for comments... Procedures for Nontoxic Shot and Shot Coatings, 50 CFR 20.134. Service Form Number(s): None. Type of Request... market approved nontoxic shot types or nontoxic shot coatings. Respondent's Obligation: Required...

  7. An in-mold packaging process for plastic fluidic devices.

    PubMed

    Yoo, Y E; Lee, K H; Je, T J; Choi, D S; Kim, S K

    2011-01-01

    Micro or nanofluidic devices have many channel shapes to deliver chemical solutions, body fluids or any fluids. The channels in these devices should be covered to prevent the fluids from overflowing or leaking. A typical method to fabricate an enclosed channel is to bond or weld a cover plate to a channel plate. This solid-to-solid bonding process, however, takes a considerable amount of time for mass production. In this study, a new process for molding a cover layer that can enclose open micro or nanochannels without solid-to-solid bonding is proposed and its feasibility is estimated. First, based on the design of a model microchannel, a brass microchannel master core was machined and a plastic microchannel platform was injection-molded. Using this molded platform, a series of experiments was performed for four process or mold design parameters. Some feasible conditions were successfully found to enclosed channels without filling the microchannels for the injection molding of a cover layer over the plastic microchannel platform. In addition, the bond strength and seal performance were estimated in a comparison with those done by conventional bonding or welding processes. PMID:21446432

  8. Fabrication of large-area hydrophobic surfaces with femtosecond-laser-structured molds

    NASA Astrophysics Data System (ADS)

    Wu, P. H.; Cheng, C. W.; Chang, C. P.; Wu, T. M.; Wang, J. K.

    2011-11-01

    Fast replication of large-area femtosecond-laser-induced surface micro/nanostructures on plastic parts by injection molding is demonstrated. An STAVAX steel mold insert is irradiated by femtosecond laser pulses with linear or circular polarization to form periodic-like nanostructures or nanostructure-covered conical microstructures. It was then used for the process of thermal injection molding. The process provides high-volume manufacturing means to generate hydrophobic enhanced plastic parts, which is expected to be widely used in consumables and chemical/biomedical device industries.

  9. 8. VIEW OF A MOLD FOR PRECISION CASTING. THE MOLD ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    8. VIEW OF A MOLD FOR PRECISION CASTING. THE MOLD WAS USED IN FOUNDRY OPERATIONS THAT CAST PLUTONIUM EITHER AS INGOTS SUITABLE FOR ROLLING AND FURTHER WROUGHT PROCESSING OR INTO SHAPES AMENABLE TO DIRECT MACHINING OPERATIONS. (5/6/59) - Rocky Flats Plant, Plutonium Fabrication, Central section of Plant, Golden, Jefferson County, CO

  10. MOLD SPECIFIC QUANTITATIVE PCR: THE EMERGING STANDARD IN MOLD ANALYSIS

    EPA Science Inventory

    Today I will talk about the use of quantitative or Real time PCR for the standardized identification and quantification of molds. There are probably at least 100,000 species of molds or fungi. But there are actually about 100 typically found indoors. Some pose a threat to human...

  11. Mold Materials For Permanent Molding of Aluminum Alloys

    SciTech Connect

    John F Wallace; David Schwam; Wen Hong dxs11@po.cwru.edu

    2001-09-14

    A test that involves immersion of the potential mod materials for permanent molds has been developed that provides a thermal cycle that is similar to the experienced during casting of aluminum in permanent molds. This test has been employed to determine the relative thermal fatigue resistance of several different types of mold materials. Four commercial mold coatings have been evaluated for their insulating ability, wear resistance and roughness. The results indicate that composition and structure of the mold materials have considerable effect on their thermal fatigue cracking behavior. Irons with a gray iron structure are the most prone to thermal fatigue cracking followed by compacted graphite irons with the least thermal fatigue cracking of the cast irons experienced by ductile iron. The composition of these various irons affects their behavior.

  12. Laser-induced breakdown spectroscopy of bacterial spores, molds, pollens, and protein: initial studies of discrimination potential

    NASA Astrophysics Data System (ADS)

    Samuels, Alan C.; Delucia, Frank C.; McNesby, Kevin L.; Miziolek, Andrzej W.

    2003-10-01

    Laser-induced breakdown spectroscopy (LIBS) has been used to study bacterial spores, molds, pollens, and proteins. Biosamples were prepared and deposited onto porous silver substrates. LIBS data from the individual laser shots were analyzed by principal-components analysis and were found to contain adequate information to afford discrimination among the different biomaterials. Additional discrimination within the three bacilli studied appears feasible.

  13. Processing studies in sheet molding compound compression molding

    NASA Astrophysics Data System (ADS)

    Abrams, Lisa Marie

    Due to its high strength to weight ratio, corrosion resistance, and low cost. Sheet Molding Compound (SMC) production offers great potential for growth in the automotive and trucking industry. Much attention is now being given to improving the economy of SMC compression molding by reducing the cycle time required to produce acceptable parts in steady production. One of the fastest growing applications of Sheet Molding Compound (SMC) compression molding panels is the manufacture of truck body panels. Due to their large size, the molding forces developed are substantial and have a major influence in the molding cycle. The relevant process models for SMC flow are reviewed and a procedure is developed that can be used to obtain the closing force and calculate the needed material parameters. Experiments were done using commercially made SMC varying quantities of glass, filler, and thickener to verify the validity of this model and the compression force was predicted for commercially made automotive hoods. It was found that glass and filler had a significant impact on the material parameters. When the amount of glass was increased, both material parameters m/deltan and eta increased. Similar trends were seen when increasing the amount of filler. For the thickener used in this research (magnesium oxide), it was found that it had minimal effect on the material parameters. Molding conditions and initial SMC charge configurations were also varied to see their effects on molding force and material parameters. Initial charge dimensions and volume as well as mold closing speed showed no effect on material parameters, while molding temperature showed a minimal effect. Material parameters were calculated for each SMC composition. These parameters were used to predict the compression force for the Corvette hood and Fiero hood. These predictions were compared with actual Corvette and Fiero hoods manufactured in industry. They predicted the commercially made parts quite well.

  14. Twistable mold for helicopter blades

    NASA Technical Reports Server (NTRS)

    Carter, E. S.; Kiely, E. F.

    1972-01-01

    Design is described of mold for fabrication of blades composed of sets of aerodynamic shells having same airfoil section characteristics but different distributions. Mold consists of opposing stacks of thin templates held together by long bolts. When bolts are loosened, templates can be set at different positions with respect to each other and then locked in place.

  15. Thermophilic molds: Biology and applications.

    PubMed

    Singh, Bijender; Poças-Fonseca, Marcio J; Johri, B N; Satyanarayana, Tulasi

    2016-11-01

    Thermophilic molds thrive in a variety of natural habitats including soils, composts, wood chip piles, nesting materials of birds and other animals, municipal refuse and others, and ubiquitous in their distribution. These molds grow in simple media containing carbon and nitrogen sources and mineral salts. Polyamines are synthesized in these molds and the composition of lipids varies considerably, predominantly containing palmitic, oleic and linoleic acids with low levels of lauric, palmiotoleic and stearic acids. Thermophilic molds are capable of efficiently degrading organic materials by secreting thermostable enzymes, which are useful in the bioremediation of industrial wastes and effluents that are rich in oil, heavy metals, anti-nutritional factors such as phytic acid and polysaccharides. Thermophilic molds synthesize several antimicrobial substances and biotechnologically useful miscellaneous enzymes. The analysis of genomes of thermophilic molds reveals high G:C contents, shorter introns and intergenic regions with lesser repetitive sequences, and further confirms their ability to degrade agro-residues efficiently. Genetic engineering has aided in ameliorating the characteristics of the enzymes of thermophilic molds. This review is aimed at focusing on the biology of thermophilic molds with emphasis on recent developments in the analysis of genomes, genetic engineering and potential applications. PMID:26777293

  16. STANDARDIZED MOLD IDENTIFICATION AND ENUMERATION

    EPA Science Inventory

    There are probably at least 100,000 species of molds or fungi. But there are actually about 100 typically found indoors. Some pose a threat to humans and animals and others don't. We need to know what molds are present indoors and their concentrations. The older methods of cult...

  17. INDOOR MOLDS AND ALLERGIC POTENTIAL

    EPA Science Inventory

    Rationale: Damp/moldy environments have been associated with asthma exacerbation, but mold¿s role in allergic asthma induction is less clear. Recently, 5 molds were statistically associated with water-damaged asthmatic homes in the Cleveland area. The asthma exacerbation...

  18. Shot-noise Fano factor

    NASA Astrophysics Data System (ADS)

    Rajdl, Kamil; Lansky, Petr

    2015-11-01

    A variability measure of the times of uniform events based on a shot-noise process is proposed and studied. The measure is inspired by the Fano factor, which we generalize by considering the time-weighted influence of the events given by a shot-noise response function. The sequence of events is assumed to be an equilibrium renewal process, and based on this assumption we present formulas describing the behavior of the variability measure. The formulas are derived for a general response function, restricted only by some natural conditions, but the main focus is given to the shot noise with exponential decrease. The proposed measure is analyzed and compared with the Fano factor.

  19. Shot-noise Fano factor.

    PubMed

    Rajdl, Kamil; Lansky, Petr

    2015-11-01

    A variability measure of the times of uniform events based on a shot-noise process is proposed and studied. The measure is inspired by the Fano factor, which we generalize by considering the time-weighted influence of the events given by a shot-noise response function. The sequence of events is assumed to be an equilibrium renewal process, and based on this assumption we present formulas describing the behavior of the variability measure. The formulas are derived for a general response function, restricted only by some natural conditions, but the main focus is given to the shot noise with exponential decrease. The proposed measure is analyzed and compared with the Fano factor. PMID:26651674

  20. Intravitreal injection

    MedlinePlus

    Retinal vein occlusion-intravitreal injection; Triamcinolone-intravitreal injection; Dexamethasone-intravitreal injection; Lucentis-intravitreal injection; Avastin-intravitreal injection; Bevacizumab-intravitreal injection; Ranibizumab- ...

  1. Current status of mold immunotherapy.

    PubMed

    Dhillon, M

    1991-05-01

    There is evidence to suggest that molds can cause IgE-mediated upper respiratory tract disorders and immunotherapy is efficacious in a select group. The environmental sampling studies show a remarkably small numbers of molds accounting for a majority of the mold load in various diverse locations. These are Cladosporium, Basidiospores, Aspergillus, and Alternaria-Penicillin families. Basidiospores have been underreported in the older studies because of difficulties in their identification. Whether the absolute mold level is the most important factor leading to IgE formation and induction of upper respiratory tract symptoms is uncertain. Certainly, the majority of the studies are based on the assumption that the absolute level of mold in the environment is the most important factor leading to the development of symptoms, but this is not based on strong evidence. A major problem in the majority of the studies is a lack of standardization of extracts which may lead to false negatives on skin testing and thus produce variable data in population evaluations comparing the prevalence of mold to its ability to induce IgE production and symptoms. The best current trials to document the efficacy of mold immunotherapy have been with the standardized Cladosporium extract. Unfortunately, these results cannot be extrapolated to the commercially available mold extracts available in the United States either for immunotherapy or for skin testing. These extracts are highly variable in their potency, prone to high false negative rates, and at best serve as poor skin testing reagents and possibly even worse immunotherapy reagents. Adequately standardized mold reagents are urgently needed to determine whether the Cladosporium data can be extrapolated to them in any meaningful way. PMID:2035901

  2. Enhanced shot noise in carbon nanotube field-effect transistors

    SciTech Connect

    Betti, A.; Fiori, G.; Iannaccone, G.

    2009-12-21

    We predict shot noise enhancement in defect-free carbon nanotube field-effect transistors through a numerical investigation based on the self-consistent solution of the Poisson and Schroedinger equations within the nonequilibrium Green's functions formalism, and on a Monte Carlo approach to reproduce injection statistics. Noise enhancement is due to the correlation between trapping of holes from the drain into quasibound states in the channel and thermionic injection of electrons from the source, and can lead to an appreciable Fano factor of 1.22 at room temperature.

  3. With Flu Shot, Timing May Be Everything

    MedlinePlus

    ... nih.gov/medlineplus/news/fullstory_158514.html With Flu Shot, Timing May Be Everything Vaccination seems to ... 26, 2016 TUESDAY, April 26, 2016 (HealthDay News) -- Flu shots may be more effective when people get ...

  4. Should I Get a Flu Shot?

    MedlinePlus

    ... Text Size Should People With Cancer Get a Flu Shot? Getting a flu shot is recommended for ... need for the flu season. What types of flu vaccines are recommended for people with cancer? People ...

  5. Flu Shot Might Cut Stillbirth Risk

    MedlinePlus

    ... nlm.nih.gov/medlineplus/news/fullstory_158080.html Flu Shot Might Cut Stillbirth Risk Australian researchers find ... THURSDAY, March 31, 2016 (HealthDay News) -- A seasonal flu shot may reduce a pregnant woman's risk of ...

  6. With Flu Shot, Timing May Be Everything

    MedlinePlus

    ... https://medlineplus.gov/news/fullstory_158514.html With Flu Shot, Timing May Be Everything Vaccination seems to ... 26, 2016 TUESDAY, April 26, 2016 (HealthDay News) -- Flu shots may be more effective when people get ...

  7. Transfer molding of PMR-15 polyimide resin

    NASA Technical Reports Server (NTRS)

    Reardon, J. P.; Moyer, D. W.; Nowak, B. E.

    1985-01-01

    Transfer molding is an economically viable method of producing small shapes of PMR-15 polyimide. It is shown that with regard to flexural, compressive, and tribological properties transfer-molded PMR-15 polyimide is essentially equivalent to PMR-15 polyimide produced by the more common method of compression molding. Minor variations in anisotropy are predictable effects of molding design and secondary finishing operations.

  8. ILLUSTRATED HANDBOOK OF SOME COMMON MOLDS.

    ERIC Educational Resources Information Center

    CHANDLER, MARION N.

    THIS DOCUMENT IS A PICTURE GUIDE FOR THE IDENTIFICATION OF TEN COMMON MOLDS. IT IS DESIGNED FOR USE WITH THE ELEMENTARY SCIENCE STUDY UNIT "MICROGARDENING" AND IS SUGGESTED FOR UPPER ELEMENTARY GRADES. INCLUDED FOR EACH MOLD ARE COLOR PHOTOGRAPHS AND PHOTOMICROGRAPHS OF THE INTACT MOLD MASS AND OF THE MOLD'S SPORE PRODUCING STRUCTURES. ALSO…

  9. White mold of Jerusalem artichoke

    Technology Transfer Automated Retrieval System (TEKTRAN)

    Jerusalem artichoke (Helianthus tuberosus) is a Native American food plant closely related to the common sunflower (Helianthus annuus). Tubers of Jerusalem artichoke are increasingly available in retail grocery outlets. White mold (Sclerotinia stem rot), caused by the fungus, Sclerotinia sclerotioru...

  10. Shot Automation for the National Ignition Facility

    SciTech Connect

    Lagin, L J; Bettenhausen, R C; Beeler, R G; Bowers, G A; Carey, R; Casavant, D D; Cline, B D; Demaret, R D; Domyancic, D M; Elko, S D; Fisher, J M; Hermann, M R; Krammen, J E; Kohut, T R; Marshall, C D; Mathisen, D G; Ludwigsen, A P; Patterson, Jr., R W; Sanchez, R J; Stout, E A; Van Arsdall, P J; Van Wonterghem, B M

    2005-09-21

    A shot automation framework has been developed and deployed during the past year to automate shots performed on the National Ignition Facility (NIF) using the Integrated Computer Control System This framework automates a 4-8 hour shot sequence, that includes inputting shot goals from a physics model, set up of the laser and diagnostics, automatic alignment of laser beams and verification of status. This sequence consists of set of preparatory verification shots, leading to amplified system shots using a 4-minute countdown, triggering during the last 2 seconds using a high-precision timing system, followed by post-shot analysis and archiving. The framework provides for a flexible, model-based execution driven of scriptable automation called macro steps. The framework is driven by high-level shot director software that provides a restricted set of shot life cycle state transitions to 25 collaboration supervisors that automate 8-laser beams (bundles) and a common set of shared resources. Each collaboration supervisor commands approximately 10 subsystem shot supervisors that perform automated control and status verification. Collaboration supervisors translate shot life cycle state commands from the shot director into sequences of ''macro steps'' to be distributed to each of its shot supervisors. Each Shot supervisor maintains order of macro steps for each subsystem and supports collaboration between macro steps. They also manage failure, restarts and rejoining into the shot cycle (if necessary) and manage auto/manual macro step execution and collaborations between other collaboration supervisors. Shot supervisors execute macro step shot functions commanded by collaboration supervisors. Each macro step has database-driven verification phases and a scripted perform phase. This provides for a highly flexible methodology for performing a variety of NIF shot types. Database tables define the order of work and dependencies (workflow) of macro steps to be performed for a

  11. Toxicity of experimental lead-iron shot versus commercial lead shot in mallards

    USGS Publications Warehouse

    Finley, M.T.; Dieter, M.P.

    1978-01-01

    The toxicity of an experimental lead-iron shot containing 38.1 percent lead was compared with commercial lead shot in mallard ducks (Anas platyrhynchos) fed corn for 14 weeks. Significantly higher mortality occurred in ducks dosed with commercial lead shot compared to ducks given lead-iron shot containing comparable amounts of lead. Loss of body weight was indicative of the difference in toxicity of the 2 types of shot. Mortality was dose related in ducks given commercial lead shot; one # 8 shot (73 mg lead) caused 35 percent mortality with higher amounts of lead causing 80 to 100 percent mortality. Ingestion of up to 2 #4 lead-iron shot (111 mg lead) caused no significant weight loss and only 5 percent mortality. However, ducks dosed with 5 lead-iron shot suffered 45 percent mortality and those given 16 shot 50 percent mortality.

  12. Molded polymer solar water heater

    DOEpatents

    Bourne, Richard C.; Lee, Brian E.

    2004-11-09

    A solar water heater has a rotationally-molded water box and a glazing subassembly disposed over the water box that enhances solar gain and provides an insulating air space between the outside environment and the water box. When used with a pressurized water system, an internal heat exchanger is integrally molded within the water box. Mounting and connection hardware is included to provide a rapid and secure method of installation.

  13. Rotary peening with captive shot

    SciTech Connect

    1998-02-01

    Roto Peen with captive shot removes coatings and surface contamination from concrete floors. The objective of treating radioactively contaminated concrete floors during the Deactivation and Decommissioning (D and D) process is to reduce the surface contamination levels to meet regulatory criteria for unrestricted use. The US Department of Energy (DOE) Chicago Operations office and DOE`s Federal Energy Technology Center (FETC) jointly sponsored a Large-Scale Demonstration Project (LSDP) at the Chicago Pile-5 Research Reactor (CP-5) at Argonne National Laboratory-East (ANL). The objective of the LSDP is to demonstrate potentially beneficial D and D technologies in comparison with current baseline technologies. As part of the LSDP, roto Peen with captive shot was demonstrated March 17--20, 1997, to treat a 20 x 25 ft area of radioactively contaminated concrete floor on the service level of the CP-5 building.

  14. The Problem of Shot Selection in Basketball

    PubMed Central

    Skinner, Brian

    2012-01-01

    In basketball, every time the offense produces a shot opportunity the player with the ball must decide whether the shot is worth taking. In this article, I explore the question of when a team should shoot and when they should pass up the shot by considering a simple theoretical model of the shot selection process, in which the quality of shot opportunities generated by the offense is assumed to fall randomly within a uniform distribution. Within this model I derive an answer to the question “how likely must the shot be to go in before the player should take it?” and I show that this lower cutoff for shot quality depends crucially on the number of shot opportunities remaining (say, before the shot clock expires), with larger demanding that only higher-quality shots should be taken. The function is also derived in the presence of a finite turnover rate and used to predict the shooting rate of an optimal-shooting team as a function of time. The theoretical prediction for the optimal shooting rate is compared to data from the National Basketball Association (NBA). The comparison highlights some limitations of the theoretical model, while also suggesting that NBA teams may be overly reluctant to shoot the ball early in the shot clock. PMID:22295109

  15. The problem of shot selection in basketball.

    PubMed

    Skinner, Brian

    2012-01-01

    In basketball, every time the offense produces a shot opportunity the player with the ball must decide whether the shot is worth taking. In this article, I explore the question of when a team should shoot and when they should pass up the shot by considering a simple theoretical model of the shot selection process, in which the quality of shot opportunities generated by the offense is assumed to fall randomly within a uniform distribution. Within this model I derive an answer to the question "how likely must the shot be to go in before the player should take it?" and I show that this lower cutoff for shot quality f depends crucially on the number n of shot opportunities remaining (say, before the shot clock expires), with larger n demanding that only higher-quality shots should be taken. The function f(n) is also derived in the presence of a finite turnover rate and used to predict the shooting rate of an optimal-shooting team as a function of time. The theoretical prediction for the optimal shooting rate is compared to data from the National Basketball Association (NBA). The comparison highlights some limitations of the theoretical model, while also suggesting that NBA teams may be overly reluctant to shoot the ball early in the shot clock. PMID:22295109

  16. Residue stress analysis of molding aspherical plastic lens

    NASA Astrophysics Data System (ADS)

    Hsu, Ming-Ying; Cheng, Yuan-Chieh; Chang, Shenq-Tsong; Huang, Ting-Ming

    2015-09-01

    The aspherical plastic lens is widely used in commercial optical products. Warpage and residue stress are two important factors that influence wavefront error. Several investigators have discussed warpage. We propose a methodology to study the effect of residue stress on wavefront error. Mold flow software was adopted to calculate the residue stress in injection processes. Optical software was used to find optical ray paths through the lens. Corresponding Optical Path Different (OPD) in each ray path was simulated by self-developed software. A 50-mm diameter plastic lens was used in this study. The mild- and high-frequency wavefront errors and the stress OPD effect at the injection area were found to be a result of the molding process. The proposed methodology was found to be very suitable for finding the effect of residue stress on wavefront error in plastic lenses.

  17. SnapShot: Multiple Myeloma.

    PubMed

    Braggio, Esteban; Kortüm, K Martin; Stewart, A Keith

    2015-11-01

    Multiple myeloma (MM) is a plasma cell malignancy characterized by a heterogeneous clinical presentation. Genetic abnormalities are not only key events in the origin and progression of the disease but are also useful tools for prognosis, risk stratification, and therapeutic decision making. Although still incurable, a revolution in the treatment of MM is currently ongoing, leading to a significant improvement of clinical outcome and survival. To view this SnapShot, open or download the PDF. PMID:26555176

  18. Incidence of lead shot in canvasbacks

    USGS Publications Warehouse

    Perry, M.C.

    1976-01-01

    During 1975 and 1976, 2,544 canvasbacks (Aythya valisineria) from North Dakota, Wisconsin, Illinois, and Maryland were flouroscoped to determine the incidence of body shot. A significant increase from west to east was detected in the incidence of shot for immatures from the four states. The incidence of shot in immatures after the 1975-76 hunting season was 18 percent in Maryland and 20 percent in Illinois. In Wisconsin no difference in the incidence of shot could be detected between areas trapped or time periods when trapping was conducted. In Maryland a significant decrease in the incidence of body shot was detected in adults, but not immatures, between 1975 and 1976. shot was located throughout the body of canvasbacks. Frequency varied from one to nine shot per bird and averaged 2.0 for adults and 1.5 for immatures.

  19. Rotationally Molded Liquid Crystalline Polymers

    NASA Technical Reports Server (NTRS)

    Rogers, Martin; Stevenson, Paige; Scribben, Eric; Baird, Donald; Hulcher, Bruce

    2002-01-01

    Rotational molding is a unique process for producing hollow plastic parts. Rotational molding offers advantages of low cost tooling and can produce very large parts with complicated shapes. Products made by rotational molding include water tanks with capacities up to 20,000 gallons, truck bed liners, playground equipment, air ducts, Nylon fuel tanks, pipes, toys, stretchers, kayaks, pallets, and many others. Thermotropic liquid crystalline polymers are an important class of engineering resins employed in a wide variety of applications. Thermotropic liquid crystalline polymers resins are composed of semi-rigid, nearly linear polymeric chains resulting in an ordered mesomorphic phase between the crystalline solid and the isotropic liquid. Ordering of the rigid rod-like polymers in the melt phase yields microfibrous, self-reinforcing polymer structures with outstanding mechanical and thermal properties. Rotational molding of liquid crystalline polymer resins results in high strength and high temperature hollow structures useful in a variety of applications. Various fillers and reinforcements can potentially be added to improve properties of the hollow structures. This paper focuses on the process and properties of rotationally molded liquid crystalline polymers.

  20. Rotationally Molded Liquid Crystalline Polymers

    NASA Technical Reports Server (NTRS)

    Rogers, Martin; Scribben, Eric; Baird, Donald; Hulcher, Bruce

    2002-01-01

    Rotational molding is a unique process for producing hollow plastic parts. Rotational molding offers low cost tooling and can produce very large parts with complicated shapes. Products made by rotational molding include water tanks with capacities up to 20,000 gallons, truck bed liners, playground equipment, air ducts, Nylon fuel tanks, pipes, toys, stretchers, kayaks, pallets, and many others. Thermotropic liquid crystalline polymers are an important class of engineering resins employed in a wide variety of applications. Thermotropic liquid crystalline polymers resins are composed of semirigid, nearly linear polymeric chains resulting in an ordered mesomorphic phase between the crystalline solid and the isotropic liquid. Ordering of the rigid rod-like polymers in the melt phase yields microfibrous, self-reinforcing polymer structures with outstanding mechanical and thermal properties. Rotational molding of liquid crystalline polymer resins results in high strength and high temperature hollow structures useful in a variety of applications. Various fillers and reinforcements can potentially be added to improve properties of the hollow structures. This paper focuses on the process and properties of rotationally molded liquid crystalline polymers. This paper will also highlight the interactions between academia and small businesses in developing new products and processes.

  1. Semantic Shot Classification in Sports Video

    NASA Astrophysics Data System (ADS)

    Duan, Ling-Yu; Xu, Min; Tian, Qi

    2003-01-01

    In this paper, we present a unified framework for semantic shot classification in sports videos. Unlike previous approaches, which focus on clustering by aggregating shots with similar low-level features, the proposed scheme makes use of domain knowledge of a specific sport to perform a top-down video shot classification, including identification of video shot classes for each sport, and supervised learning and classification of the given sports video with low-level and middle-level features extracted from the sports video. It is observed that for each sport we can predefine a small number of semantic shot classes, about 5~10, which covers 90~95% of sports broadcasting video. With the supervised learning method, we can map the low-level features to middle-level semantic video shot attributes such as dominant object motion (a player), camera motion patterns, and court shape, etc. On the basis of the appropriate fusion of those middle-level shot classes, we classify video shots into the predefined video shot classes, each of which has a clear semantic meaning. The proposed method has been tested over 4 types of sports videos: tennis, basketball, volleyball and soccer. Good classification accuracy of 85~95% has been achieved. With correctly classified sports video shots, further structural and temporal analysis, such as event detection, video skimming, table of content, etc, will be greatly facilitated.

  2. Experimental study of glass molding process and transcription characteristics of mold surface in molding of aspheric glass lenses

    NASA Astrophysics Data System (ADS)

    Cha, Du Hwan; Park, Heung Su; Hwang, Yeon; Kim, Jeong-Ho; Kim, Hye-Jeong

    2011-03-01

    The effects of the process parameters in the molding of aspheric glass lenses for camera phone modules have been investigated experimentally and the surface topographies of the mold and the molded lens were compared to ascertain the transcription characteristics. The molding conditions were optimized with respect to the form error (PV) (the response variable) of the molded lens. The experimental conditions were obtained by employing a factorial design method. From the analysis of variance (ANOVA) and P-value (significance level), the slow cooling rate was found to affect the response variable most significantly. For the form topography, the lens molded under the optimum molding condition showed a transcription ratio of 93.4% against the mold.

  3. Staged mold for encapsulating hazardous wastes

    DOEpatents

    Unger, Samuel L.; Telles, Rodney W.; Lubowitz, Hyman R.

    1988-01-01

    A staged mold for stabilizing hazardous wastes for final disposal by molding an agglomerate of the hazardous wastes and encapsulating the agglomerate. Three stages are employed in the process. In the first stage, a first mold body is positioned on a first mold base, a mixture of the hazardous wastes and a thermosetting plastic is loaded into the mold, the mixture is mechanically compressed, heat is applied to cure the mixture to form a rigid agglomerate, and the first mold body is removed leaving the agglomerate sitting on the first mold base. In the second stage, a clamshell second mold body is positioned around the agglomerate and the first mold base, a powdered thermoplastic resin is poured on top of the agglomerate and in the gap between the sides of the agglomerate and the second mold body, the thermoplastic is compressed, heat is applied to melt the thermoplastic, and the plastic is cooled jacketing the agglomerate on the top and sides. In the third stage, the mold with the jacketed agglomerate is inverted, the first mold base is removed exposing the former bottom of the agglomerate, powdered thermoplastic is poured over the former bottom, the first mold base is replaced to compress the thermoplastic, heat is applied to melt the new thermoplastic and the top part of the jacket on the sides, the plastic is cooled jacketing the bottom and fusing with the jacketing on the sides to complete the seamless encapsulation of the agglomerate.

  4. Staged mold for encapsulating hazardous wastes

    DOEpatents

    Unger, Samuel L.; Telles, Rodney W.; Lubowitz, Hyman R.

    1990-01-01

    A staged mold for stabilizing hazardous wastes for final disposal by molding an agglomerate of the hazardous wastes and encapsulating the agglomerate. Three stages are employed in the process. In the first stage, a first mold body is positioned on a first mold base, a mixture of the hazardous wastes and a thermosetting plastic is loaded into the mold, the mixture is mechanically compressed, heat is applied to cure the mixture to form a rigid agglomerate, and the first mold body is removed leaving the agglomerate sitting on the first mold base. In the second stage, a clamshell second mold body is positioned around the agglomerate and the first mold base, a powdered thermoplastic resin is poured on top of the agglomerate and in the gap between the sides of the agglomerate and the second mold body, the thermoplastic is compressed, heat is applied to melt the thermoplastic, and the plastic is cooled jacketing the agglomerate on the top and sides. In the third stage, the mold with the jacketed agglomerate is inverted, the first mold base is removed exposing the former bottom of the agglomerate, powdered thermoplastic is poured over the former bottom, the first mold base is replaced to compress the thermoplastic, heat is applied to melt the new thermoplastic and the top part of the jacket on the sides, the plastic is cooled jacketing the bottom and fusing with the jacketing on the sides to complete the seamless encapsulation of the agglomerate.

  5. Shot noise in ballistic graphene.

    PubMed

    Danneau, R; Wu, F; Craciun, M F; Russo, S; Tomi, M Y; Salmilehto, J; Morpurgo, A F; Hakonen, P J

    2008-05-16

    We have investigated shot noise in graphene field effect devices in the temperature range of 4.2-30 K at low frequency (f=600-850 MHz). We find that for our graphene samples with a large width over length ratio W/L, the Fano factor F reaches a maximum F ~ 1/3 at the Dirac point and that it decreases strongly with increasing charge density. For smaller W/L, the Fano factor at Dirac point is significantly lower. Our results are in good agreement with the theory describing that transport at the Dirac point in clean graphene arises from evanescent electronic states. PMID:18518472

  6. Facts about Stachybotrys chartarum and Other Molds

    MedlinePlus

    ... Program in Brief Related Issues Resources Quick Links Air Pollution & Respiratory Health Air Quality Asthma Mold What's New ... be removed. Â Top of Page Quick Links Air Pollution & Respiratory Health Air Quality Asthma Mold What's New ...

  7. Contamination Barrier For Contour-Molding Material

    NASA Technical Reports Server (NTRS)

    Adams, James F.

    1988-01-01

    Release agent prevents molding compound from adhering to or contaminating surface. Cleaning agent, Turco 4215 NCLT, forms barrier preventing silicone molding compound from sticking to surface and leaving contaminating residue. Also see MFS-29243.

  8. MOLD-SPECIFIC QUANTITATIVE PCR: THE EMERGING STANDARD IN MOLD ANALYSIS

    EPA Science Inventory

    Molds can cause health problems like infections and allergies, destroy crops, and contaminate our food or pharmaceuticals. We can't avoid molds. Molds are essential players in the biological processes on earth, but we can now identify and quantify the molds that will be most pr...

  9. Blow molding of melt processible rubber

    SciTech Connect

    Abell, W.R.; Stuart, R.E.; Myrick, R.E.

    1991-07-01

    This article discusses the advantages of making hollow rubber parts by blow molding thermoplastic elastomers (TPEs) versus conventional rubber processing. It describes the various types of blow molding processes and it provides some insight into the rheological properties of melt processible rubber (MPR) and how MPR should be molded by each of these processes. A number of blow molded applications for MPR are also discussed.

  10. Making Internal Molds Of Long, Curved Tubes

    NASA Technical Reports Server (NTRS)

    Burley, Richard K.

    1989-01-01

    Mold material carried to internal weld joint and removed after impression taken. Remotely operated device makes impression mold of interior surface of tube at weld joint. Mold provides indication of extent of mismatch between members at joint. Maneuvered to weld inspected through curved tube 3 in. in diameter by 50 in. long. Readily adapted to making molds to measure depth of corrosion in boiler tubes or other pipes.

  11. The Mold that Almost Ate the Principal

    ERIC Educational Resources Information Center

    Barry, Wayne; Bishop, Chuck; Byars, Jennifer

    2006-01-01

    New-building mold was a bane for many home construction companies and new homeowners during the 1990s. It was not unusual to read or watch the news and see the tragedy played out in one's local community. Untold, however, is the story of the toll new-building mold can take on school systems and their principals, especially as these mold problems…

  12. Attack of the Killer Mold Spores.

    ERIC Educational Resources Information Center

    Moore, Mary

    1999-01-01

    Describes experiences at the Arkansas State University at Jonesboro library when mold was discovered in a large portion of the monograph collection. Discusses causes of mold formation, equipment needed, news media coverage, staff involvement in the cleanup, and possible health hazards from mold. (LRW)

  13. Gray Mold or Botrytis Blight

    Technology Transfer Automated Retrieval System (TEKTRAN)

    Gray mold, caused by Botrytis cinerea can cause an intermittent decay of leaves or seed production organs of beet. The disease is not usually economically important on sugar beet, but can be severe enough to need control on swiss chard. This chapter describes the disease and pathogen and mentions ...

  14. ALLERGIC POTENTIAL OF INDOOR MOLDS

    EPA Science Inventory

    Many fungi have been associated with allergic lung disease, but few are well studied and even fewer allergens of fungal origin are well characterized. Exposure to damp moldy environments has been associated with the exacerbation of asthma, but the role of molds in the induction o...

  15. ANIMAL MODELS OF MOLD ALLERGY

    EPA Science Inventory

    The concept of molds as causative agents for allergy/asthma is not new. In fact many fungal genera have been associated with allergic lung disease, but only a few fungi are well studied and even fewer fungal allergens well characterized. The complexity and variety of fungal pro...

  16. Molded Concrete Center Mine Wall

    NASA Technical Reports Server (NTRS)

    Lewis, E. V.

    1987-01-01

    Proposed semiautomatic system forms concrete-foam wall along middle of coal-mine passage. Wall helps support roof and divides passage into two conduits needed for ventilation of coal face. Mobile mold and concrete-foam generator form sections of wall in place.

  17. Is Mold the New Asbestos?

    ERIC Educational Resources Information Center

    Colgan, Craig

    2003-01-01

    Mold and indoor air quality (IAQ) are matters of major concern to architects and their educational clients. The Environmental Protection Agency's Indoor Air Quality Tools for Schools program offers help to districts seeking to tackle IAQ issues. Strengthening community relations is one way to be ready in case of a bad environmental or IAQ report.…

  18. Effect of fast mold surface temperature evolution on iPP part morphology gradients

    NASA Astrophysics Data System (ADS)

    Liparoti, Sara; Sorrentino, Andrea; Guzman, Gustavo; Cakmak, Mukerrem; Titomanlio, Giuseppe

    2016-03-01

    The control of mold surface temperature is an important factor that affects the sample surface morphology as well as the structural gradients (orientation crystal size, and type) as well as cooling stresses. The frozen layer thickness formed during the filling stage also has a very significant effect on the flow resistance and thus on the resulting pressure drop and flow length in thin wall parts. The possibility to have a hot mold during filling and a quick cooling soon afterward is a significant process enhancement particularly for specialized applications such as micro injection molding and for the reproduction of micro structured surfaces. Up to now, several methods (electromagnetic, infrared, hot vapor fleshing etc,) were tried to achieve fast temperature evolution of the mold. Unfortunately, all these methods require a complex balance between thermal and mechanical problems, equipment cost, energy consumption, safety, molding cycle time and part quality achievable. In this work, a thin electrical resistance was designed and used to generate a fast and confined temperature variation on mold surface (by joule effect). Since the whole temperature evolution can take place in a few seconds, one can couple the advantages of a high surface temperature during filling with the advantages of a low mold temperature, fast cooling and low heating dissipation. Some experiments were performed with a commercial iPP resin. The effects of the surface temperature and of the heating time (under constant electric power) on surface finishing and on the final morphology (thickness and structure of the different layers) are explored and discussed.

  19. Testing of molded high temperature plastic actuator road seals for use in advanced aircraft hydraulic systems

    NASA Technical Reports Server (NTRS)

    Waterman, A. W.; Huxford, R. L.; Nelson, W. G.

    1976-01-01

    Molded high temperature plastic first and second stage rod seal elements were evaluated in seal assemblies to determine performance characteristics. These characteristics were compared with the performance of machined seal elements. The 6.35 cm second stage Chevron seal assembly was tested using molded Chevrons fabricated from five molding materials. Impulse screening tests conducted over a range of 311 K to 478 K revealed thermal setting deficiencies in the aromatic polyimide molding materials. Seal elements fabricated from aromatic copolyester materials structurally failed during impulse cycle calibration. Endurance testing of 3.85 million cycles at 450 K using MIL-H-83283 fluid showed poorer seal performance with the unfilled aromatic polyimide material than had been attained with seals machined from Vespel SP-21 material. The 6.35 cm first stage step-cut compression loaded seal ring fabricated from copolyester injection molding material failed structurally during impulse cycle calibration. Molding of complex shape rod seals was shown to be a potentially controllable technique, but additional molding material property testing is recommended.

  20. HIGH TEMPERATURE REFRACTORY COATING FOR GRAPHITE MOLDS

    DOEpatents

    Stoddard, S.D.

    1958-10-21

    An improved foundry mold coating for use with graphite molds used in the casting of uranium is presented. The refractory mold coating serves to keep the molten uranium from contact with graphite of the mold and thus prevents carbon pickup by the molten metal. The refractory coating is made by dry mixing certain specific amounts of aluminum oxide, bentonite, Tennessee ball clay, and a soluble silicate salt. Water is then added to the mixture and the suspension thus formed is applied by spraying onto the mold.

  1. 7 CFR 51.904 - Shot berries.

    Code of Federal Regulations, 2010 CFR

    2010-01-01

    ... 7 Agriculture 2 2010-01-01 2010-01-01 false Shot berries. 51.904 Section 51.904 Agriculture Regulations of the Department of Agriculture AGRICULTURAL MARKETING SERVICE (Standards, Inspections, Marketing... Standards for Grades of Table Grapes (European or Vinifera Type) 1 Definitions § 51.904 Shot berries....

  2. SunShot Initiative Portfolio Book 2014

    SciTech Connect

    Solar Energy Technologies Office

    2014-05-01

    The 2014 SunShot Initiative Portfolio Book outlines the progress towards the goals outlined in the SunShot Vision Study. Contents include overviews of each of SunShot’s five subprogram areas, as well as a description of every active project in the SunShot’s project portfolio as of May 2014.

  3. SnapShot: Renal Cell Carcinoma.

    PubMed

    Turajlic, Samra; Larkin, James; Swanton, Charles

    2015-12-01

    This SnapShot summarizes current knowledge about the key features in mutational landscape, major pathways, and tumor evolution and heterogeneity in renal cell carcinoma, as well as the most recent advances in therapeutic development. To view this SnapShot, open or download the PDF. PMID:26638079

  4. The killing efficiency of soft iron shot

    USGS Publications Warehouse

    Andrews, R.; Longcore, J.R.

    1969-01-01

    A cooperative research effort between the ammunition industry and the Bureau of Sport Fisheries and Wildlife is aimed at finding a suitable non-toxic substitute for lead shot. A contract study by an independent research organization evaluated ways of coating or detoxifying lead shot or replacing it with another metal. As a result of that study, the only promising candidate is soft iron. Previous tests of hard iron shot had suggested that its killing effectiveness was poor at longer ranges due to the lower density. In addition, its hardness caused excessive damage to shotgun barrels. A unique, automated shooting facility was constructed at the Patuxent Wildlife Research Center to test the killing effectiveness of soft iron shot under controlled conditions. Tethered game-farm mallards were transported across a shooting point in a manner simulating free flight. A microswitch triggered a mounted shotgun so that each shot was 'perfect.' A soft iron shot, in Number 4 size, was produced by the ammunition industry and loaded in 12-gauge shells to give optimum ballistic performance. Commercial loads of lead shot in both Number 4 and Number 6 size were used for comparison. A total of 2,010 ducks were shot at ranges of 30 to 65 yards and at broadside and head-on angles in a statistically designed procedure. The following data were recorded for each duck: time until death, broken wing or leg bones, and number of embedded shot. Those ducks not killed outright were held for 10 days. From these data, ducks were categorized as 'probably bagged,' 'probably lost cripples,' or survivors. The test revealed that the killing effectiveness of this soft iron shot was superior to its anticipated performance and close to that obtained with commercial lead loads containing an equal number of pellets. Bagging a duck, in terms of rapid death or broken wing, was primarily dependent on the probability of a shot striking that vital area, and therefore a function of range. There was no indication

  5. Advanced manufacturing methods for chalcogenide molded optics

    NASA Astrophysics Data System (ADS)

    Cogburn, Gabriel

    2011-06-01

    As Chalcogenide glass and Precision Molded Optics (PMO) have developed and matured to a point of being accepted as replacements for Germanium Single Point Diamond Turned (SPDT) optics; technological research is being dedicated to developing infrared PMO that can be used in a broader application base. These include laser arrays, large aperture molded chalcogenide optics, and molded in mount infrared optics. This paper presents applications for infrared laser arrays and the corresponding optics that must be closely mechanically mounted to avoid clipping the beams. Different molding and mounting techniques will be discussed to solve this issue which include; dicing chalcogenide optic lenses, molded in mount chalcogenide optics and stepped optic shape molding for mounting purposes. Accompanying the research and discussion of these techniques will be experiments and molded chalcogenide glass lenses showing the results and application for each lens type.

  6. Shot-size reduction of photoresist formulations

    NASA Astrophysics Data System (ADS)

    Moreau, Wayne M.; Cornett, Kathleen M.; Fahey, James T.; Linehan, Leo L.; Montgomery, Warren; Plat, Marina V.; Smith, Randolph S.; Wood, Robert L.

    1995-06-01

    The cost of expendable chemicals in the resist process is increasing and with this the economic impetus to conserve usage. The volume of liquid resist dispensed (shot size) determines the consumption rate and disposal volumes of liquid resist. The choice of resist solvent can influence the shot volume. Three formulation factors influence the shot size: (1) the surface tension of the resist and the interfacial energy of the coating surface, (2) the viscosity of the resist formulation, and (3) the evaporation rate of the solvent. The suitable resist formulation and subsequent solvent choice should be of the lowest surface tension and lowest viscosity and be balanced by an evaporation rate which allows a minimum shot volume to be spread on the surface without significant solvent loss. Of all the solvents examined, ethyl 3-ethoxy propionate (EEP) gave the lowest shot size relative to the old resist solvent standard of 2- ethoxy ethyl acetate (ECA).

  7. Billion shot flashlamp for spaceborne lasers

    NASA Technical Reports Server (NTRS)

    Richter, Linda; Schuda, Felix; Degnan, John

    1990-01-01

    A billion-shot flashlamp developed under a NASA contract for spaceborne laser missions is presented. Lifetime-limiting mechanisms are identified and addressed. Two energy loadings of 15 and 44 Joules were selected for the initial accelerated life testing. A fluorescence-efficiency test station was used for measuring the useful-light output degradation of the lamps. The design characteristics meeting NASA specifications are outlined. Attention is focused on the physical properties of tungsten-matrix cathodes, the chemistry of dispenser cathodes, and anode degradation. It is reported that out of the total 83 lamps tested in the program, 4 lamps reached a billion shots and one lamp is beyond 1.7 billion shots, while at 44 Joules, 4 lamps went beyond 100 million shots and one lamp reached 500 million shots.

  8. A review on the basketball jump shot.

    PubMed

    Okazaki, Victor H A; Rodacki, André L F; Satern, Miriam N

    2015-06-01

    The ability to shoot an effective jump shot in the sport of basketball is critical to a player's success. In an attempt to better understand the aspects related to expert performance, researchers have investigated successful free throws and jump shots of various basketball players and identified movement variables that contribute to their success. The purpose of this study was to complete a systematic review of the scientific literature on the basketball free throw and jump shot for the purpose of revealing the critical components of shooting that coaches, teachers, and players should focus on when teaching, learning, practising, and performing a jump shot. The results of this review are presented in three sections: (a) variables that affect ball trajectory, (b) phases of the jump shot, and PMID:26102462

  9. Adults Don't Need Tetanus Shot Every Decade

    MedlinePlus

    ... fullstory_157980.html Adults Don't Need Tetanus Shot Every Decade: Study Booster shot every 30 years would protect as well as ... have always been told to get a tetanus shot every 10 years, but actually, there is very ...

  10. Incipient flocculation molding: A new ceramic-forming technique

    NASA Astrophysics Data System (ADS)

    Arrasmith, Steven Reade

    Incipient Flocculation Molding (IFM) was conceived as a new near-net-shape forming technique for ceramic components. It was hypothesized that the development of a temperature-dependent deflocculant would result in a forming technique that is flexible, efficient, and capable of producing a superior microstructure with improved mechanical properties from highly reactive, submicron ceramic powders. IFM utilizes a concentrated, nonaqueous, sterically stabilized ceramic powder and/or colloidal suspension which is injected into a non-porous mold. The suspension is then flocculated by destabilizing the suspension by lowering the temperature. Flocculation is both rapid and reversible. Cooling to -20°C produces a green body with sufficient strength for removal from the mold. The solvent is removed from the green body by evaporation. The dried green body is subsequently sintered to form a dense ceramic monolith. This is the first ceramic forming method based upon the manipulation of a sterically-stabilized suspension. To demonstrate IFM, the process of grafting polyethylene glycol (PEG), with molecular weights from 600 to 8000, to alumina powders was investigated. The maximum grafted amounts were achieved by the technique of dispersing the alumina powders in molten polymer at 195°C. The ungrafted PEG was then removed by repeated centrifuging and redispersion in fresh distilled water. The rheological behavior of suspensions of the PEG-grafted powders in water, 2-propanol and 2-butanol were characterized. All of the aqueous suspensions were shear thinning. The PEG 4600-grafted alumina powder aqueous suspensions were the most fluid. Sample rods and bars were molded from 52 vol% PEG-grafted alumina suspensions in 2-butanol. The best results were obtained with a preheated aluminum mold lubricated with a fluorinated oil mold-release. The samples were dried, sintered, and their microstructure and density were compared with sintered samples dry pressed from the same alumina powder

  11. Influence of mold length and mold heat transfer on horizontal continuous casting of nonferrous alloy rods

    NASA Astrophysics Data System (ADS)

    Verwijs, J. P.; Weckman, D. C.

    1988-04-01

    The influence of mold length and mold heat transfer on the conventional hot-top D.C. continuous casting process was studied through numerical simulations and experiments with horizontally cast 20 mm diameter lead and zinc rods. The minimum casting speed was found to be a nonlinear function of the mold length. For short molds, an inverse relationship between mold length and minimum casting speed was observed. However, the minimum casting speed for zinc cast from molds longer than 12 mm was constant at 2.5 mm/s. For lead cast in molds longer than 12 mm, the minimum observed casting speed was constant at 4.0 mm/s. The observed nonlinear relationship between minimum casting speed and mold length was predicted using a numerical model of the process. For this, an analytical expression for the mold boundary conditions was derived which included the influence of gas gap formation between the rod and the mold due to thermoelastic deformations of both the rod and the mold. Correlation between observed and predicted behavior was demonstrated for both the lead and zinc rods. Maximum casting speed was observed to increase with increased mold length; however, this speed was found to be critically dependent on process attributes such as mold and pinch wheel alignment and mold lubrication.

  12. Precision compression molding of chalcogenide glass optical elements

    NASA Astrophysics Data System (ADS)

    Qi, Chaowei; Ma, Tao; Chen, Fan

    2013-12-01

    Precision glass molding process (GMP) is a promising process to manufacture small precision optical elements in large volume. In this paper, we report on the fabrication of a molded chalcogenide glass lens as an optical element. A set of mold was designed and manufactured with silicon carbide material for the molding test. The structure of the mold set was semi-closed and detachable which can make the molded lens easy releasing with non-invasion. The surfaces of the mold cores are coated with thin protecting DLC film to relieve adhesion problem and increase the working life. Experiments were also performed using a precision glass molding machine Toshiba GMP-311V to determine the molding parameters i.e. molding temperature, pressure and cooling rate. The glass lens breakage during precision molding process was analyzed according to the glass property and the molding parameters. By modifying the mold design and optimization the processing parameters, ultimately achieve the desired molded lens.

  13. High Temperature Transfer Molding Resins

    NASA Technical Reports Server (NTRS)

    Connell, John W. (Inventor); Smith, Joseph G., Jr. (Inventor); Hergenrother, Paul M. (Inventor)

    2000-01-01

    High temperature resins containing phenylethynyl groups that are processable by transfer molding have been prepared. These phenylethynyl containing oligomers were prepared from aromatic diamines containing phenylethynyl groups and various ratios of phthalic anhydride and 4-phenylethynlphthalic anhydride in glacial acetic acid to form a mixture of imide compounds in one step. This synthetic approach is advantageous since the products are a mixture of compounds and consequently exhibit a relatively low melting temperature. In addition, these materials exhibit low melt viscosities which are stable for several hours at 210-275 C, and since the thermal reaction of the phenylethynyl group does not occur to any appreciable extent at temperatures below 300 C, these materials have a broad processing window. Upon thermal cure at approximately 300-350 C, the phenylethynyl groups react to provide a crosslinked resin system. These new materials exhibit excellent properties and are potentially useful as adhesives, coatings, films, moldings and composite matrices.

  14. Compression molding of aerogel microspheres

    DOEpatents

    Pekala, R.W.; Hrubesh, L.W.

    1998-03-24

    An aerogel composite material produced by compression molding of aerogel microspheres (powders) mixed together with a small percentage of polymer binder to form monolithic shapes in a cost-effective manner is disclosed. The aerogel composites are formed by mixing aerogel microspheres with a polymer binder, placing the mixture in a mold and heating under pressure, which results in a composite with a density of 50--800 kg/m{sup 3} (0.05--0.80 g/cc). The thermal conductivity of the thus formed aerogel composite is below that of air, but higher than the thermal conductivity of monolithic aerogels. The resulting aerogel composites are attractive for applications such as thermal insulation since fabrication thereof does not require large and expensive processing equipment. In addition to thermal insulation, the aerogel composites may be utilized for filtration, ICF target, double layer capacitors, and capacitive deionization. 4 figs.

  15. Compression molding of aerogel microspheres

    DOEpatents

    Pekala, Richard W.; Hrubesh, Lawrence W.

    1998-03-24

    An aerogel composite material produced by compression molding of aerogel microspheres (powders) mixed together with a small percentage of polymer binder to form monolithic shapes in a cost-effective manner. The aerogel composites are formed by mixing aerogel microspheres with a polymer binder, placing the mixture in a mold and heating under pressure, which results in a composite with a density of 50-800 kg/m.sup.3 (0.05-0.80 g/cc). The thermal conductivity of the thus formed aerogel composite is below that of air, but higher than the thermal conductivity of monolithic aerogels. The resulting aerogel composites are attractive for applications such as thermal insulation since fabrication thereof does not require large and expensive processing equipment. In addition to thermal insulation, the aerogel composites may be utilized for filtration, ICF target, double layer capacitors, and capacitive deionization.

  16. Onychomycosis due to opportunistic molds*

    PubMed Central

    Martínez-Herrera, Erick Obed; Arroyo-Camarena, Stefanie; Tejada-García, Diana Luz; Porras-López, Carlos Francisco; Arenas, Roberto

    2015-01-01

    BACKGROUND: Onychomycosis are caused by dermatophytes and Candida, but rarely by non- dermatophyte molds. These opportunistic agents are filamentous fungi found as soil and plant pathogens. OBJECTIVES: To determine the frequency of opportunistic molds in onychomycosis. METHODS: A retrospective analysis of 4,220 cases with onychomycosis, diagnosed in a 39-month period at the Institute of Dermatology and Skin surgery "Prof. Dr. Fernando A. Cordero C." in Guatemala City, and confirmed with a positive KOH test and culture. RESULTS: 32 cases (0.76%) of onychomycosis caused by opportunistic molds were confirmed. The most affected age group ranged from 41 to 65 years (15 patients, 46.9%) and females were more commonly affected (21 cases, 65.6%) than males. Lateral and distal subungual onychomycosis (OSD-L) was detected in 20 cases (62.5%). The microscopic examination with KOH showed filaments in 19 cases (59.4%), dermatophytoma in 9 cases (28.1%), spores in 2 cases (6.25%), and filaments and spores in 2 cases (6.25%). Etiologic agents: Aspergillus sp., 11 cases (34.4%); Scopulariopsis brevicaulis, 8 cases (25.0%); Cladosporium sp., 3 cases (9.4%); Acremonium sp., 2 cases (6.25%); Paecilomyces sp., 2 cases (6.25%); Tritirachium oryzae, 2 cases (6.25%); Fusarium sp., Phialophora sp., Rhizopus sp. and Alternaria alternate, 1 case (3.1%) each. CONCLUSIONS: We found onychomycosis by opportunistic molds in 0.76% of the cases and DLSO was present in 62.5%. The most frequent isolated etiological agents were: Aspergillus sp. and Scopulariopsis brevicaulis. PMID:26131862

  17. Basketball shot types and shot success in different levels of competitive basketball.

    PubMed

    Erčulj, Frane; Štrumbelj, Erik

    2015-01-01

    The purpose of our research was to investigate the relative frequencies of different types of basketball shots (above head, hook shot, layup, dunk, tip-in), some details about their technical execution (one-legged, two-legged, drive, cut, …), and shot success in different levels of basketball competitions. We analysed video footage and categorized 5024 basketball shots from 40 basketball games and 5 different levels of competitive basketball (National Basketball Association (NBA), Euroleague, Slovenian 1st Division, and two Youth basketball competitions). Statistical analysis with hierarchical multinomial logistic regression models reveals that there are substantial differences between competitions. However, most differences decrease or disappear entirely after we adjust for differences in situations that arise in different competitions (shot location, player type, and attacks in transition). Differences after adjustment are mostly between the Senior and Youth competitions: more shots executed jumping or standing on one leg, more uncategorised shot types, and more dribbling or cutting to the basket in the Youth competitions, which can all be attributed to lesser technical and physical ability of developing basketball players. The two discernible differences within the Senior competitions are that, in the NBA, dunks are more frequent and hook shots are less frequent compared to European basketball, which can be attributed to better athleticism of NBA players. The effect situational variables have on shot types and shot success are found to be very similar for all competitions. PMID:26038836

  18. Basketball Shot Types and Shot Success in Different Levels of Competitive Basketball

    PubMed Central

    2015-01-01

    The purpose of our research was to investigate the relative frequencies of different types of basketball shots (above head, hook shot, layup, dunk, tip-in), some details about their technical execution (one-legged, two-legged, drive, cut, …), and shot success in different levels of basketball competitions. We analysed video footage and categorized 5024 basketball shots from 40 basketball games and 5 different levels of competitive basketball (National Basketball Association (NBA), Euroleague, Slovenian 1st Division, and two Youth basketball competitions). Statistical analysis with hierarchical multinomial logistic regression models reveals that there are substantial differences between competitions. However, most differences decrease or disappear entirely after we adjust for differences in situations that arise in different competitions (shot location, player type, and attacks in transition). Differences after adjustment are mostly between the Senior and Youth competitions: more shots executed jumping or standing on one leg, more uncategorised shot types, and more dribbling or cutting to the basket in the Youth competitions, which can all be attributed to lesser technical and physical ability of developing basketball players. The two discernible differences within the Senior competitions are that, in the NBA, dunks are more frequent and hook shots are less frequent compared to European basketball, which can be attributed to better athleticism of NBA players. The effect situational variables have on shot types and shot success are found to be very similar for all competitions. PMID:26038836

  19. On the nonlinear modeling of shot noise

    PubMed Central

    Eliazar, Iddo; Klafter, Joseph

    2005-01-01

    We introduced a nonlinear shot-noise model, a natural generalization of the “classic” shot-noise model, which differs markedly from the existing linear shot-noise models. This model produces a wide spectrum of stationary noise processes. Because of its intrinsic nonlinearity, the model's resulting noise processes are capable of displaying a rich variety of both amplitudal and temporal statistical behaviors. Surprisingly, the nonlinear model is amenable to mathematical analysis and yields closed-form formulae for the characterizing statistics of its resulting noise processes. PMID:16172376

  20. Between Shots TRANSP Web Service

    NASA Astrophysics Data System (ADS)

    Feibush, E.; Andre, R.; Ludescher-Furth, C.; Kaye, S.; McCune, D.

    2008-11-01

    Running TRANSP between NSTX shots requires rapid data preparation and job submittal. A web service with a graphical user interface and data visualization has been developed to meet these goals. The underlying data preparation system has a command line interface written in Python and runs on a PPPL compute server. The display client is a Java program (ElVis) that sends requests to the data preparation system. As the run data is prepared, graphs are created and sent to the client for display. Flux surface plots are displayed and animated over time. The most commonly used control options are implemented in the UI as buttons and text fields. A time slice or time dependent run can be prepared. The command line interface is available in the client program for expert users to apply advanced settings, to prototype new UI buttons, and to run scripts. The client program contains a simple text editor for modifying the TRANSP namelist. When data preparation is complete the run is submitted to the TRANSP production system. The initial version has been deployed and is being tested in the control room setting. Results will be discussed in the poster presentation. Work performed at PPPL under the auspices of U.S. DOE Contract DE-AC02-76CH03073.

  1. Education's Shot in the Arm

    ERIC Educational Resources Information Center

    Butler, Kevin

    2009-01-01

    The federal stimulus package provides badly needed aid to school districts, allowing them to avoid massive staff and teacher layoffs and injecting them with a healthy dose of funds for many programs ranging from technology to renovation work. The American Recovery and Reinvestment Act (ARRA), which President Barack Obama signed on Feb.17, provides…

  2. Success in chess mediated by mental molds.

    PubMed

    Hernández Hernández, Pedro; Rodríguez Mateo, Heriberto

    2006-11-01

    Research has revealed the impact of cognitive-affective strategies (Molds of the Mind) on subjective well-being, interpersonal relationships, or school achievement. However, it seems odd that such strategies could influence the success of chess players, because this game is usually considered to be influenced mainly by technical and cognitive skills. To examine the influence of cognitive-affective molds, 53 chess players, ages from 9 to 16 years old, enrolled in sport competitions, were assigned to two groups, high and low success. They responded to the MOLDES, designed to evaluate individuals' molds. The results show that the "Mental Molds" of the most successful players are more realistic, positive and regulators of the emotions, while the molds of the less successful players are more evasive, magical, defensive and inoperative. PMID:17296106

  3. Gating of Permanent Molds for ALuminum Casting

    SciTech Connect

    David Schwam; John F. Wallace; Tom Engle; Qingming Chang

    2004-03-30

    This report summarizes a two-year project, DE-FC07-01ID13983 that concerns the gating of aluminum castings in permanent molds. The main goal of the project is to improve the quality of aluminum castings produced in permanent molds. The approach taken was determine how the vertical type gating systems used for permanent mold castings can be designed to fill the mold cavity with a minimum of damage to the quality of the resulting casting. It is evident that somewhat different systems are preferred for different shapes and sizes of aluminum castings. The main problems caused by improper gating are entrained aluminum oxide films and entrapped gas. The project highlights the characteristic features of gating systems used in permanent mold aluminum foundries and recommends gating procedures designed to avoid common defects. The study also provides direct evidence on the filling pattern and heat flow behavior in permanent mold castings.

  4. Amorphous materials molded IR lens progress report

    NASA Astrophysics Data System (ADS)

    Hilton, A. R., Sr.; McCord, James; Timm, Ronald; Le Blanc, R. A.

    2008-04-01

    Amorphous Materials began in 2000 a joint program with Lockheed Martin in Orlando to develop molding technology required to produce infrared lenses from chalcogenide glasses. Preliminary results were reported at this SPIE meeting by Amy Graham1 in 2003. The program ended in 2004. Since that time, AMI has concentrated on improving results from two low softening glasses, Amtir 4&5. Both glasses have been fully characterized and antireflection coatings have been developed for each. Lenses have been molded from both glasses, from Amtir 6 and from C1 Core glass. A Zygo unit is used to evaluate the results of each molded lens as a guide to improving the molding process. Expansion into a larger building has provided room for five production molding units. Molded lens sizes have ranged from 8 mm to 136 mm in diameter. Recent results will be presented

  5. Intelligent process development of foam molding for the Thermal Protection System (TPS) of the space shuttle external tank

    NASA Technical Reports Server (NTRS)

    Bharwani, S. S.; Walls, J. T.; Jackson, M. E.

    1987-01-01

    A knowledge based system to assist process engineers in evaluating the processability and moldability of poly-isocyanurate (PIR) formulations for the thermal protection system of the Space Shuttle external tank (ET) is discussed. The Reaction Injection Molding- Process Development Advisor (RIM-PDA) is a coupled system which takes advantage of both symbolic and numeric processing techniques. This system will aid the process engineer in identifying a startup set of mold schedules and in refining the mold schedules to remedy specific process problems diagnosed by the system.

  6. Modeling and control of flow during impregnation of heterogeneous porous media, with application to composite mold-filling processes

    NASA Astrophysics Data System (ADS)

    Bickerton, Simon

    cavities. The molds applied in this study have required careful consideration of cavity thickness variations. Any effects on mold filling due to corner radii have been overshadowed by those due to preform compression. While numerical tools are available to study actively controlled mold filling in a virtual environment, some development is required for the physical equipment to implement this in practice. A versatile, multiple line fluid injection system is developed here. The equipment and control algorithms employed have provided servo control of flow rate, or injection pressure, and have been tested under very challenging conditions. The single injection line developed is expanded to a multiple line system, and shows great potential for application to actual resin systems. A case study is presented, demonstrating design and implementation of a simple actively controlled injection scheme. The experimental facility developed provides an excellent testbed for application of actively controlled mold filling concepts, an area that is providing great promise for the advancement of LCM processes.

  7. POST-SHOT RADIATION ENVIRONMENT FOLLOWING LOW-YIELD SHOTS INSIDE THE NATIONAL IGNITION FACILITY

    SciTech Connect

    Sitaraman, S; Brereton, S; Dauffy, L; Hall, J; Hansen, L; Khater, H; Kim, S; Pohl, B; Verbeke, J

    2010-10-29

    A detailed model of the Target Bay (TB) at the National Ignition Facility (NIF) has been developed to estimate the post-shot radiation environment inside the facility. The model includes large number of structures and diagnostic instruments present inside the TB. These structures and instruments are activated by the few nanosecond pulse of neutrons generated during a shot and the resultant gamma dose rates are estimated at various decay times following the shot. The results presented in this paper are based on a low-yield D-T shot of 10{sup 16} neutrons. General environment dose rates drop to below 3 mrem/h within three hours following a shot with higher dose rates observed at contact with some of the components. Dose rate maps of the different TB levels were generated to aid in estimating worker stay-out times following a shot before entry is permitted into the TB.

  8. Mold For Casting Radius-Inspection Specimens

    NASA Technical Reports Server (NTRS)

    Ball, Robert N.

    1988-01-01

    Thin replicas viewed on comparator without sectioning. New mold machined from piece of transparent poly(methyl methacrylate). Fits around base of post. Two slots machined into inner surface form channels for casting inspection sections. Bottom of mold fits flush against surface around bottom of post. When surface slanted, mold automatically aligns in proper orientation. Time required to inspect elliptical radii located at bottoms of series of small posts reduced from 18 hours to 3 hours.

  9. Mold in My School: What Do I Do?

    ERIC Educational Resources Information Center

    National Clearinghouse for Educational Facilities, Washington, DC.

    This publication provides information on the most important indoor mold-related health concerns and discusses how school districts can keep school facilities mold-free and avoid these problems. The document addresses when to be concerned, how molds cause health problems, symptoms caused by mold allergies, indoor molds that form toxins, who is most…

  10. Pregnant Women Need a Flu Shot

    MedlinePlus

    ... antibodies after getting flu vaccine. Talk to your doctor, nurse, or clinic about getting vaccinated as soon as ... have already had a flu shot--call your doctor, nurse, or clinic right away. Doctors can prescribe medicine ...

  11. Expectant Mom's Flu Shot Protects 2

    MedlinePlus

    ... infant records. Information was available for nine flu seasons from December 2005 through March 2014. Only about ... shot during any trimester of pregnancy during flu season, Tan said. The new study found that 97 ...

  12. Whooping Cough Shot Safe for Pregnant Women

    MedlinePlus

    ... fullstory_158983.html Whooping Cough Shot Safe for Pregnant Women It also offers short-term protection to ... News) -- The whooping cough vaccine is safe for pregnant women, a new study indicates. The researchers also ...

  13. Whooping Cough Shot Safe for Pregnant Women

    MedlinePlus

    ... nih.gov/medlineplus/news/fullstory_158983.html Whooping Cough Shot Safe for Pregnant Women It also offers ... MONDAY, May 23, 2016 (HealthDay News) -- The whooping cough vaccine is safe for pregnant women, a new ...

  14. The Hardest Straight-in Pool Shot

    ERIC Educational Resources Information Center

    Mabry, Rick

    2010-01-01

    When playing pool or billiards, a player often has the opportunity to make a "straight-in" shot, that is, one in which the cue ball, the object ball, and the target (e.g., a pocket) are collinear. With the distance from the cue ball to the target assumed fixed, the relative difficulty is here explored of shots taken at varying positions of the…

  15. Two-part silicone mold. A new tool for flexible ureteroscopy surgical training

    PubMed Central

    Marroig, Bruno; Fortes, Marco Antonio Q. R.; Pereira-Sampaio, Marco; Sampaio, Francisco J. B.; Favorito, Luciano A.

    2016-01-01

    ABSTRACT Introduction and objectives: Flexible ureteroscopy is a common procedure nowadays. Most of the training programs use virtual reality simulators. The aim of this study was to standardize the building of a three-dimensional silicone mold (cavity) of the collecting system, on the basis of polyester resin endocasts, which can be used in surgical training programs. Materials and Methods: A yellow polyester resin was injected into the ureter to fill the collecting system of 24 cadaveric fresh human kidneys. After setting off the resin, the kidneys were immersed in hydrochloric acid until total corrosion of the organic matter was achieved and the collecting system endocasts obtained. The endocasts were used to prepare white color two-part silicone molds, which after endocasts withdrawn, enabled a ureteroscope insertion into the collecting system molds (cavities). Also, the minor calices were painted with different colors in order to map the access to the different caliceal groups. The cost of the materials used in the molds is $30.00 and two days are needed to build them. Results: Flexible ureteroscope could be inserted into all molds and the entire collecting system could be examined. Since some anatomical features, as infundular length, acute angle, and perpendicular minor calices may difficult the access to some minor calices, especially in the lower caliceal group, surgical training in models leads to better surgical results. Conclusions: The two-part silicone mold is feasible, cheap and allows its use for flexible ureteroscopy surgical training. PMID:27564302

  16. Golimumab Injection

    MedlinePlus

    ... it.Golimumab injection comes in prefilled syringes and auto-injection devices for subcutaneous injection. Use each syringe ... method.Do not remove the cap from the auto-injection device or the cover from the prefilled ...

  17. Indoor mold and Children's health

    PubMed

    Etzel; Rylander

    1999-06-01

    Reactive airways disease in children is increasing in many countries around the world. The clinical diagnosis of asthma or reactive airways disease includes a variable airflow and an increased sensitivity in the airways. This condition can develop after an augmented reaction to a specific agent (allergen) and may cause a life-threatening situation within a very short period of exposure. It can also develop after a long-term exposure to irritating agents that cause an inflammation in the airways in the absence of an allergen. (paragraph) Several environmental agents have been shown to be associated with the increased incidence of childhood asthma. They include allergens, cat dander, outdoor as well as indoor air pollution, cooking fumes, and infections. There is, however, increasing evidence that mold growth indoors in damp buildings is an important risk factor. About 30 investigations from various countries around the world have demonstrated a close relationship between living in damp homes or homes with mold growth, and the extent of adverse respiratory symptoms in children. Some studies show a relation between dampness/mold and objective measures of lung function. Apart from airways symptoms, some studies demonstrate the presence of general symptoms that include fatigue and headache and symptoms from the central nervous system. At excessive exposures, an increased risk for hemorraghic pneumonia and death among infants has been reported. (paragraph) The described effects may have important consequences for children in the early years of life. A child's immune system is developing from birth to adolescence and requires a natural, physiologic stimulation with antigens as well as inflammatory agents. Any disturbances of this normal maturing process will increase the risk for abnormal reactions to inhaled antigens and inflammagenic agents in the environment. (paragraph) The knowledge about health risks due to mold exposure is not widespread and health authorities in

  18. Use of SoloShot autodestruct syringes compared with disposable syringes, in a national immunization campaign in Indonesia.

    PubMed Central

    Nelson, C. M.; Sutanto, A.; Suradana, I. G.

    1999-01-01

    Autodestruct syringes can reduce the improper reuse of syringes, which present a significant risk in the transmission of bloodborne pathogens in developing countries, especially during immunization campaigns owing to the high number of injections given per session. SoloShot is an autodestruct syringe, distributed by UNICEF, which has been shown to be safer and easier to use than standard syringes. This study analyses the accuracy and dose-efficiency of SoloShot, compared with disposable syringes, during a national tetanus toxoid immunization campaign on the Indonesian island of Lombok. Observation and dose measurements revealed that SoloShot syringes delivered more precise and consistent doses and 15% more doses per vial than disposable syringes. Vaccine savings may partially be offset by the higher price of SoloShot. Vaccinators preferred SoloShot, describing it as easier to use, faster, and more accurate than the disposable syringe. The study indicates that SoloShot is highly appropriate for use in immunization campaigns by reducing vaccine wastage and improving injection safety. PMID:10063658

  19. Molding procedure for casting a variety of alloys

    NASA Technical Reports Server (NTRS)

    Fontes, M. J.; Kourtides, D.; Leibfritz, E. R.

    1970-01-01

    General procedure and molding sand composition for preparing molds usable for casting variety of alloys are developed. Molds are prepared from mixture of sand, sodium silicate binder, and organic liquid ester. Castings of radiographic quality are produced from various alloys.

  20. 1. INTERIOR VIEW OF MOLDING ROOM, NO. 2 WORKS, SHOWING ...

    Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

    1. INTERIOR VIEW OF MOLDING ROOM, NO. 2 WORKS, SHOWING BUCKET LINE FEEDING MOLDING MACHINES - Harbison-Walker Refractories Company, Molding Room, West end of Shirley Street, Mount Union, Huntingdon County, PA