Evolution of Constitution, Structure, and Morphology in FeCo-Based Multicomponent Alloys

NASA Astrophysics Data System (ADS)

Li, R.; Stoica, M.; Liu, G.; Eckert, J.

2010-07-01

Constituent phases, melting behaviors, and microstructure of multicomponent (Fe0.5Co0.5) x (Mo0.1C0.2B0.5Si0.2)100- x alloys ( x = 95, 90, 85, 80, and 70) produced by copper mold casting were evaluated by various analysis techniques, i.e., X-ray diffractometry, scanning electronic microscopy with energy dispersive X-ray spectrometry, and differential scanning calorimetry. Metastable Fe3C- and Cr23C6-type phases were identified in the chill-cast alloys. A schematic illustration was proposed to explain the evolution of constituent phases and microstructure for the alloys with x = 95, 90, and 85 during the solidification process, which could be applicable to controlling microstructural formation of other multicomponent alloys with similar microstructures by artificially adjusting the composition.

Micromolded thick PZT sol gel composite structures for ultrasound transducer devices operating at high frequencies

NASA Astrophysics Data System (ADS)

Pang, Guofeng

The objective of this work has been to design and develop a micromolding technique useful for batch fabrication to microfabricate 3D ceramic structures for device purposes using a sol gel composite processing technique and deep photolithography (UV LIGA). These structures may be the elements of ultrasound transducers, the structures associated with electronic packaging, or microstructures for microfluidic applications. To demonstrate the technique, the project has focused on the design and fabrication of annular and linear arrays for high frequency (>20 MHz) ultrasound imaging applications, particularly where an electronically steered imaging modality is employed. Other typical micromolded structures have been demonstrated to show the potential for micromolding. The transferability of the technique for industrial purposes is proposed. Using a sol gel composite process, the critical components in this technique are mold making, mold filling, material-processing, demolding, top electrode and essential material characterization. Two types of molds have been created using UV LIGA and/or electroplating. A purely organic mold made of Su-8 epoxy based photo-resist has shown tremendous performance for micromolding. The transducer packaging process has also been designed and evaluated at the laboratory level. A Su-8 micro bridge and bond pad has been used for wire bonding purposes. A 5-element annular array transducer has been fabricated by this technique and fully packaged. The micromolded piezoceramic structures have been characterized. The pulse echo performance of each element and the focusing performance of 5 elements of a packaged transducer array have been evaluated using a coaxial cable and a cable delay system.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Huang, Tianyu; Xu, Hongyi; Chen, Wei

Fiber-reinforced polymer composites are strong candidates for structural materials to replace steel and light alloys in lightweight vehicle design because of their low density and relatively high strength. In the integrated computational materials engineering (ICME) development of carbon fiber composites, microstructure reconstruction algorithms are needed to generate material microstructure representative volume element (RVE) based on the material processing information. The microstructure RVE reconstruction enables the material property prediction by finite element analysis (FEA)This paper presents an algorithm to reconstruct the microstructure of a chopped carbon fiber/epoxy laminate material system produced by compression molding, normally known as sheet molding compounds (SMC).more » The algorithm takes the result from material’s manufacturing process as inputs, such as the orientation tensor of fibers, the chopped fiber sheet geometry, and the fiber volume fraction. The chopped fiber sheets are treated as deformable rectangle chips and a random packing algorithm is developed to pack these chips into a square plate. The RVE is built in a layer-by-layer fashion until the desired number of lamina is reached, then a fine tuning process is applied to finalize the reconstruction. Compared to the previous methods, this new approach has the ability to model bended fibers by allowing limited amount of overlaps of rectangle chips. Furthermore, the method does not need SMC microstructure images, for which the image-based characterization techniques have not been mature enough, as inputs. Case studies are performed and the results show that the statistics of the reconstructed microstructures generated by the algorithm matches well with the target input parameters from processing.« less

Precision glass molding of high-resolution diffractive optical elements

NASA Astrophysics Data System (ADS)

Prater, Karin; Dukwen, Julia; Scharf, Toralf; Herzig, Hans P.; Plöger, Sven; Hermerschmidt, Andreas

2016-04-01

The demand of high resolution diffractive optical elements (DOE) is growing. Smaller critical dimensions allow higher deflection angles and can fulfill more demanding requirements, which can only be met by using electron-beam lithography. Replication techniques are more economical, since the high cost of the master can be distributed among a larger number of replicas. The lack of a suitable mold material for precision glass molding has so far prevented an industrial use. Glassy Carbon (GC) offers a high mechanical strength and high thermal strength. No anti-adhesion coatings are required in molding processes. This is clearly an advantage for high resolution, high aspect ratio microstructures, where a coating with a thickness between 10 nm and 200 nm would cause a noticeable rounding of the features. Electron-beam lithography was used to fabricate GC molds with highest precision and feature sizes from 250 nm to 2 μm. The master stamps were used for precision glass molding of a low Tg glass L-BAL42 from OHARA. The profile of the replicated glass is compared to the mold with the help of SEM images. This allows discussion of the max. aspect-ratio and min. feature size. To characterize optical performances, beamsplitting elements are fabricated and their characteristics were investigated, which are in excellent agreement to theory.

Bioinspired polydimethylsiloxane-based composites with high shear resistance against wet tissue.

PubMed

Fischer, Sarah C L; Levy, Oren; Kroner, Elmar; Hensel, René; Karp, Jeffrey M; Arzt, Eduard

2016-08-01

Patterned microstructures represent a potential approach for improving current wound closure strategies. Microstructures can be fabricated by multiple techniques including replica molding of soft polymer-based materials. However, polymeric microstructures often lack the required shear resistance with tissue needed for wound closure. In this work, scalable microstructures made from composites based on polydimethylsiloxane (PDMS) were explored to enhance the shear resistance with wet tissue. To achieve suitable mechanical properties, PDMS was reinforced by incorporation of polyethylene (PE) particles into the pre-polymer and by coating PE particle reinforced substrates with parylene. The reinforced microstructures showed a 6-fold enhancement, the coated structures even a 13-fold enhancement in Young׳s modulus over pure PDMS. Shear tests of mushroom-shaped microstructures (diameter 450µm, length 1mm) against chicken muscle tissue demonstrate first correlations that will be useful for future design of wound closure or stabilization implants. Copyright © 2016 The Authors. Published by Elsevier Ltd.. All rights reserved.

Effect of modified mold shell on the microstructure and tensile fracture morphology of single-crystal nickel-base superalloy

NASA Astrophysics Data System (ADS)

Xu, Weitai; Zhao, Yutao; Sun, Shaochun; Liu, Manping; Ma, Dexin; Liang, Xiangfeng; Wang, Cunlong; Tao, Ran

2018-04-01

The mold shell used for single-crystal turbine blades preparation was modified from conventional process to fiber reinforcement technology. The wall thickness was decreased by 32.3 percent (pct) than the conventional process. Then these two mold shells were used to produce single crystal samples of nickel-base superalloy in a Bridgman furnace. The local temperature curves were recorded in the process. The results show that the modified mold shell can increase the temperature gradient in the mushy zone than the conventional mold shell. The primary and secondary dendrite arm space were reduced by 8 pct and 12 pct, respectively. Moreover, both the area fraction and mean size of the γ‧/γ eutectic were declined, as well as the dendritic segregation tendency. Therefore it contributed to the lower residual eutectic and micro-porosity in the heat-treated microstructure. Further, fracture surface of the samples made by modified mold shell exhibited smaller facets and more uniform dimples in the size and shape.

New alnico magnets fabricated from pre-alloyed gas-atomized powder through diverse consolidation techniques

DOE Office of Scientific and Technical Information (OSTI.GOV)

Tang, W.; Zhou, L.; Kassen, A. G.

2015-05-25

Fine Alnico 8 spherical powder produced by gas atomization was consolidated through hot pressing (HP), hot isostatic pressing (HIP), and compression molding and subsequent sintering (CMS) techniques. The effects of different fabrication techniques and processing parameters on microstructure and magnetic properties were analyzed and compared. The HP, HIP, and CMS magnets exhibited different features in microstructures and magnetic properties. Magnetically annealed at 840°C for 10 min and subsequently tempered at 650°C for 5h and 580°C for 15h, the HIP sample achieved the best coercivity (H cj =1845 Oe) due to spinodally decomposed (SD) phases with uniform and well-faceted mosaic morphology.more » As a result, the CMS sample had a lower Hcj than HIP and HP samples, but a higher remanence and thus the best energy product (6.5 MGOe) due to preferential grain alignment induced by abnormal grain growth.« less

Direct micropatterning of polymer materials by ice mold

NASA Astrophysics Data System (ADS)

Yu, Xinhong; Xing, Rubo; Luan, Shifang; Wang, Zhe; Han, Yanchun

2006-10-01

Micropatterning of functional polymer materials by micromolding in capillaries (MIMIC) with ice mold is reported in this paper. Ice mold was selected due to its thaw or sublimation. Thus, the mold can be easily removed. Furthermore, the polymer solution did not react with, swell, or adhere to the ice mold, so the method is suitable for many kinds of materials (such as P3HT, PMMA Alq 3/PVK, PEDOT: PSS, PS, P2VP, etc.). Freestanding polymer microstructures, binary polymer pattern, and microchannels have been fabricated by the use of ice mold freely.

Tracing the Origin of Non-ferrous Oxides in Lamination Defects on Hot-Rolled Coils: Mold Slag Entrainment vs Submerged Entry Nozzle Reaction Products

NASA Astrophysics Data System (ADS)

Sengo, Sabri; Romano Triguero, Patricia; Zinngrebe, Enno; Mensonides, Fokko

2017-06-01

In this work, lamination defects (slivers) on hot-rolled coils of Ca-treated steel were investigated for microstructure and composition using optical and scanning electron microscopy combined with microanalysis (SEM/EDS). The goal was to identify possible origins for the observed defects which contain a complex assemblage of phases, such as different types of calcium aluminates (CA, CA2, CA6), melilite (C2AS), spinel (MA), and a newly identified phase, CNA2. Mold slag similar to that employed during the cast was absent. Analysis of the bulk composition of some of the defects indicated these to be too rich in alumina to be derived from mold slag through steel-slag redox exchange. In contrast, microstructural observation of the inner side of the submerged entry nozzles (SEN) used during casting showed deposits with compositions comparable to those of the defect material. Based on an estimation of the chemical evolution of mold slag interacting with steel, it is found that the defects are not likely to be entrained mold slag but remobilized SEN deposits, as supported by several microstructural and trace phase criteria. However, it should be noted that extensive reduction of mold slag by steel can lead to compositions rich in sodic-calcic aluminates (CNA2). Therefore, differentiation between specific locations of the defect materials within a casting system requires detailed analysis from the potential sources of origin as well as from the materials found in the defects.

Microstructures, mechanical properties, and fracture behaviors of metal-injection molded 17-4PH stainless steel

NASA Astrophysics Data System (ADS)

Wu, Ming-Wei; Huang, Zeng-Kai; Tseng, Chun-Feng; Hwang, Kuen-Shyang

2015-05-01

Metal injection molding (MIM) is a versatile technique for economically manufacturing various metal parts with complicated shapes and excellent properties. The objective of this study was to clarify the effects of powder type (water-atomized and gas-atomized powders) and various heat treatments (sintering, solutioning, H900, and H1100) on the microstructures, mechanical properties, and fracture behaviors of MIM 17-4PH stainless steels. The results showed that better mechanical properties of MIM 17-4PH can be achieved with gas-atomized powder than with water-atomized powder due mainly to the lower silicon and oxygen contents and fewer SiO2 inclusions in the steels. The presence of 10 vol% δ ferrite does not impair the UTS or elongation of MIM 17-4PH stainless steels. The δ ferrite did not fracture, even though the neighboring martensitic matrix was severely cracked. Moreover, H900 treatment produces the highest hardness and UTS, along with moderate elongation. H1100 treatment produces the best elongation, along with moderate hardness and UTS.

Highly oriented carbon fiber–polymer composites via additive manufacturing

DOE PAGES

Tekinalp, Halil L.; Kunc, Vlastimil; Velez-Garcia, Gregorio M.; ...

2014-10-16

Additive manufacturing, diverging from traditional manufacturing techniques, such as casting and machining materials, can handle complex shapes with great design flexibility without the typical waste. Although this technique has been mainly used for rapid prototyping, interest is growing in using this method to directly manufacture actual parts of complex shape. To use 3D-printing additive manufacturing in wide spread applications, the technique and the feedstock materials require improvements to meet the mechanical requirements of load-bearing components. Thus, we investigated the short fiber (0.2 mm to 0.4 mm) reinforced acrylonitrile-butadiene-styrene composites as a feedstock for 3D-printing in terms of their processibility, microstructuremore » and mechanical performance; and also provided comparison with traditional compression molded composites. The tensile strength and modulus of 3D-printed samples increased ~115% and ~700%, respectively. 3D-printer yielded samples with very high fiber orientation in printing direction (up to 91.5 %), whereas, compression molding process yielded samples with significantly less fiber orientation. Microstructure-mechanical property relationships revealed that although the relatively high porosity is observed in the 3D-printed composites as compared to those produced by the conventional compression molding technique, they both exhibited comparable tensile strength and modulus. Furthermore, this phenomena is explained based on the changes in fiber orientation, dispersion and void formation.« less

Processing-microstructure models for short- and long-fiber thermoplastic composites

NASA Astrophysics Data System (ADS)

Phelps, Jay H.

The research for this thesis has explored the important microstructural variables for injection-molded thermoplastic composites with discontinuous fiber reinforcement. Two variables, the distributions of fiber orientation and fiber length after processing, have proven to be not only important for correct material property prediction but also difficult to predict using currently available modeling and simulation techniques. In this work, we develop new models for the prediction of these two microstructural variables. Previously, the Folgar-Tucker model has been widely used to predict fiber orientation in injection molded SFT composites. This model accounts for the effects of both hydrodynamics and fiber-fiber interactions in order to give a prediction for a tensorial measure of fiber orientation. However, when applied to at least some classes of LFTs, this model does not match all components of experimental fiber orientation tensor data. In order to address this shortcoming of the model, we hypothesize that Folgar and Tucker's phenomenological treatment of the effects of fiber-fiber interactions with an isotropic rotary diffusion contribution to the rate of change of orientation is insufficient for materials with longer fibers. Instead, this work develops a fiber orientation model that incorporates anisotropic rotary diffusion (ARD). From kinetic theory we derive a general family of evolution equations for the second-order orientation tensor, correcting errors in earlier treatments, and identify a specific equation that is useful for predicting orientation in LFTs. The amount of diffusivity in this model used to approximate the effect of fiber-fiber interactions in each direction is assumed to depend on a second-order space tensor, which is taken to be a function of the orientation state and the rate of deformation. Also, concentrated fiber suspensions align more slowly with respect to strain than the Folgar-Tucker model predicts. Here, we borrow the technique of Wang et al. (2008) to incorporate this behavior in an objective fashion in this new model. Model parameters are selected by matching the experimental steady-state orientation in simple shear flow, and by requiring stable steady states and physically realizable solutions. Utilizing two separate techniques, we identify model parameters for three different materials. We then show that once a set of parameters that meets all previously established criteria has been identified, the differences in model behavior are negligible within that set of parameters. The final model with the proper parameter set is suitable for use in mold filling and other flow simulations, and does give improved predictions of fiber orientation for injection molded LFTs. Although significant fiber length degradation in LFTs has been observed both in literature and in this work, there are no quantitative fiber breakage models to predict either fiber length distributions or average fiber length measures. This work reviews the suspected causes of fiber breakage during the processing of discontinuously-reinforced thermoplastics, specifically LFTs, and introduces a phenomenological fiber breakage model based on the buckling force in a hydrodynamically loaded fiber. This breakage model is incorporated into a conservation equation for total fiber length, and a phenomenological model for the evolution of the fiber length distribution is developed. From this model, we also develop separate, approximate models for the evolution of both the number-average and weight-average fiber length measures. By applying these models to both a simple numerical example and a more complex mold-filling simulation, a qualitative agreement between experiment and prediction is observed. Although these results are promising, the breakage models have only been applied to the mold cavity in injection molding simulation. Both a literature review and our experimental data strongly suggest that the majority of fiber length degradation occurs in the earlier stages of injection molding, in the screw nozzle, runners, and gate. A better understanding of the melting and flow conditions upstream of the mold cavity, the simulation of which is beyond the scope of this work, is needed before these breakage models can be properly applied to the entire injection molding process. (Abstract shortened by UMI.)

Fabrication of a negative PMMA master mold for soft-lithography by MeV ion beam lithography

NASA Astrophysics Data System (ADS)

Puttaraksa, Nitipon; Unai, Somrit; Rhodes, Michael W.; Singkarat, Kanda; Whitlow, Harry J.; Singkarat, Somsorn

2012-02-01

In this study, poly(methyl methacrylate) (PMMA) was investigated as a negative resist by irradiation with a high-fluence 2 MeV proton beam. The beam from a 1.7 MV Tandetron accelerator at the Plasma and Beam Physics Research Facility (PBP) of Chiang Mai University is shaped by a pair of computer-controlled L-shaped apertures which are used to expose rectangular pattern elements with 1-1000 μm side length. Repeated exposure of rectangular pattern elements allows a complex pattern to be built up. After subsequent development, the negative PMMA microstructure was used as a master mold for casting poly(dimethylsiloxane) (PDMS) following a standard soft-lithography process. The PDMS chip fabricated by this technique was demonstrated to be a microfluidic device.

Topographic design and application of hierarchical polymer surfaces replicated by microinjection compression molding

NASA Astrophysics Data System (ADS)

Guan, Wei-Sheng; Huang, Han-Xiong; Wang, Bin

2013-10-01

In recent years, the fast growing demand for biomimetic surfaces featuring unique wettability and functionality in various fields highlights the necessity of developing a reliable technique for mass production. In this work, hierarchical topography designs of templates were applied to prepare superhydrophobic surfaces via microinjection compression molding, comprehensively considering the feasibility of mechanical demolding and the superhydrophobicity and mechanical robustness of the molded polypropylene parts. Mimicking the wettability of a lotus leaf or rose petal, superhydrophobic surfaces were replicated. An unstable wetting state formed on the surface exhibiting the petal effect. On such a surface, the increased water pressure could cause water penetration into the micro gaps between the hierarchical asperities featuring low-roughness sidewalls and bottom surface; the resultant water membrane led to drastically increased water adhesion of the surface. Moreover, the low-adhesion superhydrophobicity of the molded surface was changed into superhydrophilicity, by means of introducing carbonyl groups via ultraviolet/ozone treatment and the subsequent water membrane preserved in microstructures via the pre-wetting process. Patterning the superhydrophilic micro channel on the superhydrophobic surface developed the surface microfluidic devices for micro-liter fluid pumping and mixing processes driven by surface tension.

Development of the Electromagnetic Continuous Casting Technology for of Magnesium Alloys

NASA Astrophysics Data System (ADS)

Park, Joon-Pyo; Kim, Myoung-Gyun; Kim, Jong-Ho; Lee, Gyu-Chang

Currently, magnesium billets produced by ingot casting or direct chill casting process, result in low-quality surfaces and low productivity, Continuous casting technology to solve these problem has not only high-quality surface billets with fine-grained and homogeneous microstructure but also cost down. The latent heat of fusion per weight (J/g) of magnesium is similar to other metals, however, considering the heat emitted to the mold surface during continuous casting in meniscus region and converting it to the latent heat of fusion per volume, magnesium will be rapidly solidified in the mold during continuous casting, which induces subsequent surface defect formation. In this study, electromagnetic casting and stirring (EMC and EMS) techniques are proposed to control solidification process conveniently by compensating the low latent heat of solidification by volume and to fabricate magnesium billet with high-quality surface. This technique was extended to large scale billets up to 300 mm diameter and continuous casting was successfully conducted. Then magnesium billet was used for the fabrication of prototype automobile pulley.

Novel Real-Time Temperature Diagnosis of Conventional Hot-Embossing Process Using an Ultrasonic Transducer

PubMed Central

Cheng, Chin-Chi; Yang, Sen-Yeu; Lee, Dasheng

2014-01-01

This paper presents an integrated high temperature ultrasonic transducer (HTUT) on a sensor insert and its application for real-time diagnostics of the conventional hot embossing process to fabricate V-cut patterns. The sensor was directly deposited onto the sensor insert of the hot embossing mold by using a sol-gel spray technique. It could operate at temperatures higher than 400 °C and uses an ultrasonic pulse-echo technique. The ultrasonic velocity could indicate the three statuses of the hot embossing process and also evaluate the replication of V-cut patterns on a plastic plate under various processing conditions. The progression of the process, including mold closure, plastic plate softening, cooling and plate detachment inside the mold, was clearly observed using ultrasound. For an ultrasonic velocity range from 2197.4 to 2435.9 m/s, the height of the V-cut pattern decreased from 23.0 to 3.2 μm linearly, with a ratio of −0.078 μm/(m/s). The incompleteness of the replication of the V-cut patterns could be indirectly observed by the ultrasonic signals. This study demonstrates the effectiveness of the ultrasonic sensors and technology for diagnosing the replicating condition of microstructures during the conventional hot embossing process. PMID:25330051

Impact toughness of cellulose-fiber reinforced polypropylene : influence of microstructure in laminates and injection molded composites

Treesearch

Craig Clemons; Daniel Caulfield; A. Jeffrey Giacomin

2003-01-01

Unlike their glass reinforced counterparts, microstructure and dynamic fracture behavior of natural fiber-reinforced thermoplastics have hardly been investigated. Here, we characterize the microstructure of cellulose fiber-reinforced polypropylene and determined its effect on impact toughness. Fiber lengths were reduced by one-half when compounded in a high-intensity...

Improved silicon nitride for advanced heat engines

NASA Technical Reports Server (NTRS)

Yeh, Harry C.; Fang, Ho T.

1991-01-01

The results of a four year program to improve the strength and reliability of injection-molded silicon nitride are summarized. Statistically designed processing experiments were performed to identify and optimize critical processing parameters and compositions. Process improvements were monitored by strength testing at room and elevated temperatures, and microstructural characterization by optical, scanning electron microscopes, and scanning transmission electron microscope. Processing modifications resulted in a 20 percent strength and 72 percent Weibull slope improvement of the baseline material. Additional sintering aids screening and optimization experiments succeeded in developing a new composition (GN-10) capable of 581.2 MPa at 1399 C. A SiC whisker toughened composite using this material as a matrix achieved a room temperature toughness of 6.9 MPa m(exp .5) by the Chevron notched bar technique. Exploratory experiments were conducted on injection molding of turbocharger rotors.

Rapid and low-cost hot-embossing of polycaprolactone microfluidic devices

NASA Astrophysics Data System (ADS)

Fan, Yiqiang; Liu, Shicheng; He, Jianyun; Gao, Kexin; Zhang, Yajun

2018-01-01

Polycaprolactone (PCL) is a low-cost biocompatible and biodegradable material which is highly suitable for the short-live applications like microfluidics in the biological and medical field. In this study, a rapid and low-cost microfabrication technique for PCL-based microfluidic devices is proposed, the SU-8 mold fabricated on the silicon substrate was used for the hot-embossing of microstructures on PCL. Since PCL after the molding process is optically non-transparent, to improve the visibility of the fluid in the microfluidic device and enclosing the microchannel, a transparency adhesive film which originally used for the sealing of PCR well-plate is used for the sealing of the microchannels embossed on PCL substrate. The profile of the fabricated microchannels was carefully characterized, the bonding strength is tested and several PCL-based microfluidic devices were also fabricated and tested for demonstration.

Effect of Reclamation on the Skin Layer of Ductile Iron Cast in Furan Molds

NASA Astrophysics Data System (ADS)

Dańko, R.; Holtzer, M.; Górny, M.; Żymankowska-Kumon, S.

2013-11-01

The paper presents the results of investigations of the influence of the quality of molding sand with furan resin hardened by paratoluenesulfonic acid, on the formation of microstructure and surface quality of ductile iron castings. Within the studies different molding sands were used: molding sand prepared with fresh sand and molding sands prepared with reclaimed sands of a different purification degree, determined by the ignition loss value. Various concentrations of sulfur and nitrogen in the sand molds as a function of the ignition loss were shown in the paper. A series of experimental melts of ductile iron in molds made of molding sand characterized by different levels of surface-active elements (e.g., sulfur) and different gas evolution rates were performed. It was shown that there exists a significant effect of the quality of the sand on the formation of the graphite degeneration layer.

Surface 3D Micro Free Forms: Multifunctional Microstructured Mesoporous α-Alumina by in Situ Slip Casting Using Excimer Laser Ablated Polycarbonate Molds.

PubMed

Rowthu, Sriharitha; Böhlen, Karl; Bowen, Paul; Hoffmann, Patrik

2015-11-11

Ceramic surface microstructuring is a rapidly growing field with a variety of applications in tribology, wetting, biology, and so on. However, there are limitations to large-area microstructuring and fabrication of three-dimensional (3D) micro free forms. Here, we present a route to obtain intricate surface structures through in situ slip casting using polydimethylsiloxane (PDMS) negative molds which are replicated from excimer laser ablated polycarbonate (PC) master molds. PC sheets are ablated with a nanosecond KrF (λ = 248 nm) excimer laser mask projection system to obtain micron-scale 3D surface features over a large area of up to 3 m(2). Complex surface structures that include 3D free forms such as 3D topography of Switzerland, shallow structures such as diffractive optical elements (60 nm step) and conical micropillars have been obtained. The samples are defect-free produced with thicknesses of up to 10 mm and 120 mm diameter. The drying process of the slip cast alumina slurry takes place as a one-dimensional process, through surface evaporation and water permeation through the PDMS membrane. This allows homogeneous one-dimensional shrinkage during the drying process, independent of the sample's lateral dimensions. A linear mass diffusion model has been proposed to predict and explain the drying process of these ceramic colloidal suspensions. The calculated drying time is linearly proportional to the height of the slurry and the thickness of the negatively structured PDMS and is validated by the experimental results. An experimentally observed optimum Sylgard PDMS thickness range of ∼400 μm to 1 mm has achieved the best quality microstructured green compacts. Further, the model predicts that the drying time is independent of the microstructured areas and was validated using experimental observations carried out with microstructured areas of 300 mm(2), 1200 mm(2), and 120 cm(2). Therefore, in principle, the structures can be further replicated in areas up to 3 m(2) with the same drying time for the same slurry height. The surface-structured ceramics display interesting wetting properties, for example, eicosane-coated mesoporous microstructured alumina shows superhydrophobic behavior. Additionally, ceramic bulk samples could be further used as second-generation very hard and low-wear molds for further microfabrication.

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.

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. © 2013.

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

Influence of injection molding process parameters on fiber concentration distribution in long glass fiber reinforced polypropylene

NASA Astrophysics Data System (ADS)

Scantamburlo, Andrea; Gazzola, Luca; Sorgato, Marco; Lucchetta, Giovanni

2018-05-01

In parts manufactured by injection molding of long glass fiber reinforced polypropylene, the local fiber orientation, fiber concentration and fiber length distribution varies along both the thickness direction and the flow path. This heterogeneous microstructure significantly influences the mechanical properties variability in the molded parts. The aim of this work is to investigate the influence of the matrix viscosity, the injection speed and the mold geometry on the fiber concentration distribution. In particular, the factors involved in fiber-matrix separation and fiber pull-out during the injection phases were analyzed in order to understand the phenomenon.

Rapid fabrication of surface-relief plastic diffusers by ultrasonic embossing

NASA Astrophysics Data System (ADS)

Liu, Shih-Jung; Huang, Yu-Chin; Yang, Sen-Yeu; Hsieh, Kuo-Huang

2010-07-01

This paper discusses an innovative and effective ultrasonic embossing process, which enables the rapid fabrication of surface-relief plastic diffusers. The metallic mold bearing the microstructures is fabricated using a tungsten carbide turning machine. A 1500-W ultrasonic vibrator with an output frequency of 20 kHz was used to replicate the microstructure onto 1-mm-thick PMMA plates in the experiments. During ultrasonic embossing, the ultrasonic energy is converted into heat through intermolecular friction at the master mold/plastic plate interface due to asperities to melt the thermoplastic at the interface and thereby to replicate the microstructure. Under the proper processing conditions, high-performance plastic diffusers have been successfully fabricated. The cycle time required to successfully fabricate a diffuser is less than 2 s. The experimental results suggest that ultrasonic embossing could provide an effective way of fabricating high-performance plastic diffusers with a high throughput.

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

Nguyen, Ba Nghiep; Bapanapalli, Satish K.; Smith, Mark T.

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 amore » 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.« less

Effects of size reduction on deformation, microstructure, and surface roughness of micro components for micro metal injection molding

NASA Astrophysics Data System (ADS)

Liu, Lin; Wang, Xin-da; Li, Xiang; Qi, Xiao-tong; Qu, Xuan-hui

2017-09-01

The fabrication of 17-4PH micro spool mandrils by micro metal injection molding was described here. The effects of size reduction on deformation, microstructure and surface roughness were studied by comparing a ϕ500 μm micro post and a ϕ1.7 mm cylinder after debinding and sintering. Experimental results show that slumping of the micro posts occurred due to a dramatic increase in outlet vapor pressure initiated at the thermal degradation onset temperature and the moment of gravity. Asymmetrical stress distribution within the micro component formed during the cooling stage may cause warping. Prior solvent debinding and adjustment in a thermal debinding scheme were useful for preventing the deformation of the micro components. Smaller grain size and higher micro hardness due to impeded grain growth were observed for the micro posts compared with the ϕ1.7 mm cylinder. Surface roughness increased with distance from the gate of the micro spool mandril due to melt front advancement during mold filling and the ensuing pressure distribution. At each position, surface roughness was dictated by injection molding and increased slightly after sintering.

Development of Semicrystalline Morphology of Poly(L-lactic acid) During Processing of a Vascular Scaffold

NASA Astrophysics Data System (ADS)

Ailianou, Artemis

New and promising treatments for coronary heart disease are enabled by vascular scaffolds made of poly(L-lactic acid) (PLLA), as demonstrated by Abbott Vascular's bioresorbable vascular scaffold. PLLA is a semicrystalline polymer whose degree of crystallinity and crystalline microstructure depend on the thermal and deformation history during processing. In turn, the semicrystalline morphology determines scaffold strength and biodegradation time. However, spatially-resolved information about the resulting material structure (crystallinity and crystal orientation) is needed to interpret in vivo observations. The first manufacturing step of the scaffold is tube expansion in a process similar to injection blow molding. Spatial uniformity of the tube microstructure is essential for the consistent production and performance of the final scaffold. For implantation into the artery, solid-state deformation below the glass transition temperature is imposed on a laser-cut subassembly to crimp it into a small diameter. Regions of localized strain during crimping are implicated in deployment behavior. To examine the semicrystalline microstructure development of the scaffold, we employed complementary techniques of scanning electron and polarized light microscopy, wide-angle X-ray scattering, and X-ray microdiffraction. These techniques enabled us to assess the microstructure at the micro and nano length scale. The results show that the expanded tube is very uniform in the azimuthal and axial directions and that radial variations are more pronounced. The crimping step dramatically changes the microstructure of the subassembly by imposing extreme elongation and compression. Spatial information on the degree and direction of chain orientation from X-ray microdiffraction data gives insight into the mechanism by which the PLLA dissipates the stresses during crimping, without fracture. Finally, analysis of the microstructure after deployment shows that it is inherited from the crimping step and contributes to the scaffold's successful implantation in vivo.

Controle de la morphologie d'hydrogels poreux a partir de structures polymeres

NASA Astrophysics Data System (ADS)

Esquirol, Anne-Laure

This master thesis presents a new fabrication method to prepare hydrogels with fully interconnected and tunable macropore networks prepared with co-continuous polymer blends. The main contributions are: (1) a hydrogel fabrication process providing a high control over the average pore size diameter, their volume fraction and their interconnectivity; (2) the microstructural characterization of porous hydrogels with new techniques such as X-ray microtomography and (3) the preparation of porous gels with industrial equipment such as extruders and injection molding presses. The development and improvement of methods and techniques to prepare porous polymers and porous gels have been intensive areas of research in materials science over the past 20 years because of their potential use in fields as diverse as high performance membranes and filtration devices, supports for catalysis and biochemical reactions, encapsulating devices for drug release, and scaffolds for cells seeding and proliferation. For this last application, in tissue engineering, some typical parameters related to porosity must be rigorously controlled: (1) the average pore size diameter; (2) the pore volume fraction; (3) the pore interconnectivity. Porous hydrogels are excellent candidates due to their similarities with the extracellular matrix (composition, mechanical properties and diffusion properties). A certain number of methods and techniques have been developed and studied to prepare gels comprising microstructured 3-D networks of (more or less) interconnected pores (also called sometimes microfluidic gels or (macro)porous gels). Poly(L-lactide) (PLA) porous materials were realized from immiscible and co-continuous binary blends of polystyrene/poly(L-lactide) (PS/PLA) at 50/50 %vol prepared by different methods : (1) internal mixer (cubic samples with 0.8 mm sides) and (2) extrusion followed by injection molding which allows the fabrication of bars with superior dimensions (0.95 cm x 1.25 cm x 6.3 cm). Quiescent annealing of the binary blends was performed at 190 °C to tune the characteristic dimensions of the co-continuous morphology: (1) 0, 10, 30, 60 and 90 min for cubic samples and (2) 0, 10, 20 and 30 min for bars. Afterwards, the PLA phase has been isolated by a specific solvent extraction of the PS phase to obtain porous PLA molds. Gravimetric analysis have demonstrated a co-continuity superior to 95% for cubic samples and superior to 85% for the bars. This morphology was analyzed by scanning electron microscopy (SEM) for each annealing time (for the cubic samples). Image analysis performed on the SEM micrographs have demonstrated that the average pore diameter can range from 3 mum to over 400 mum and that the specific interfacial area ranges from 5800 cm-1 to 45 cm-1, for annealing times going from 0 min to 90 min). The porosity of the bars was observed by X-ray microtomography and shows that the average pore diameter ranges from 10 mum to 500 mum (annealing from 10 min to 30 min). Solutions of agar or alginate were subsequently injected into the PLA porous molds by using a manual injection system, followed by an in situ gelification. Visual inspections and optical microscope observations show a complete injection for molds with average pore sizes over 20 mum (cubic samples) and over 300 mum (for bars). These assumptions are also supported by the gels morphology characterization. The second polymer phase (PLA) was subsequently dissolved using a second selective solvent, leaving only the porous gel structures. X-ray microtomography analysis, which provide 2-D and 3-D images, have demonstrated that the morphologies of the porous gels are similar to the PLA molds microstructures. For example, porous gels prepared with cubic PLA molds annealed during 60 min, show an average pore size of about 285 mum (as compared to 200 mum for the PLA molds) and a specific interfacial area of 70 cm -1 (as compared to 100 cm-1 for the PLA molds). Similar results were obtained for the porous gels prepared with the porous PLA bars (qualitative observation). The effectiveness of two sterilization methods has been proven on nutrient agar (NA) and "Brain Heart Infusion" (BHI) with no bacterial colonies apparition. The first method is the freeze-drying followed by an oven treatment at 120 °C in a sterile environment. The porous gel morphology was characterized by X-ray microtomography before and after freeze-drying, and after rehydration, demonstrating the conservation of the macroscopic dimensions of the gels, of their morphologies and porosities. The second method is the successive baths in an ethanol solution. Finally mechanical compression tests have shown that porous gels, as can be expected, have a lower compressive resistance as compared to non-porous hydrogels. (Abstract shortened by UMI.).

Effect of boron addition on injection molded 316L stainless steel: mechanical, corrosion properties and in vitro bioactivity.

PubMed

Bayraktaroglu, Esra; Gulsoy, H Ozkan; Gulsoy, Nagihan; Er, Ozay; Kilic, Hasan

2012-01-01

The research was investigated the effect of boron additions on sintering characteristics, mechanical, corrosion properties and biocompatibility of injection molded austenitic grade 316L stainless steel. Addition of boron is promoted to get high density of sintered 316L stainless steels. The amount of boron plays a role in determining the sintered microstructure and all properties. In this study, 316L stainless steel powders have been used with the elemental NiB 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 temperature. The debinded samples were sintered at different temperature for 60 min. Mechanical property, microstructural characterization and electrochemical property of the sintered samples were performed using tensile testing, hardness, optical, scanning electron microscopy and electrochemical corrosion experiments. 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. Results of study showed that sintered 316L and 316L with NiB addition samples exhibited high mechanical and corrosion properties in a physiological environment. Especially, 316L with NiB addition can be used in some bioapplications.

Microstructure and High Temperature Oxidation Property of Fe-Cr-B Based Metal/Ceramic Composite Manufactured by Powder Injection Molding Process

NASA Astrophysics Data System (ADS)

Joo, Yeun-Ah; Kim, Young-Kyun; Yoon, Tae-Sik; Lee, Kee-Ahn

2018-03-01

This study investigated the microstructure and high temperature oxidation property of Fe-Cr-B metal/ceramic composite manufactured using powder injection molding process. Observations of initial microstructure showed a unique structure where α-Fe and (Cr, Fe)2B form a continuous three-dimensional network. High temperature oxidation tests were performed at 900, 1000 and 1100 °C, for 24 h, and the oxidation weight gain according to each temperature condition was 0.13, 0.84 and 6.4 mg/cm2, respectively. The oxidation results according to time at 900 and 1000 °C conditions represented parabolic curves, and at 1100 °C condition formed a rectilinear curve. Observation and phase analysis results of the oxides identified Cr2O3 and SiO2 at 900 and 1000 °C. In addition to Cr2O3 and SiO2, CrBO3 and FeCr2O4 formed due to phase decomposition of boride were identified at 1100 °C. Based on the findings above, this study suggested the high temperature oxidation mechanism of Fe-Cr-B metal/ceramic composite manufactured using powder injection molding, and the possibility of its application as a high temperature component material was also discussed.

Processing-microstructure relationships in thermotropic liquid crystalline polymers: Experimental and numerical modeling studies

NASA Astrophysics Data System (ADS)

Fang, Jun

Thermotropic liquid crystalline polymers (TLCPs) are a class of promising engineering materials for high-demanding structural applications. Their excellent mechanical properties are highly correlated to the underlying molecular orientation states, which may be affected by complex flow fields during melt processing. Thus, understanding and eventually predicting how processing flows impact molecular orientation is a critical step towards rational design work in order to achieve favorable, balanced physical properties in finished products. This thesis aims to develop deeper understanding of orientation development in commercial TLCPs during processing by coordinating extensive experimental measurements with numerical computations. In situ measurements of orientation development of LCPs during processing are a focal point of this thesis. An x-ray capable injection molding apparatus is enhanced and utilized for time-resolved measurements of orientation development in multiple commercial TLCPs during injection molding. Ex situ wide angle x-ray scattering is also employed for more thorough characterization of molecular orientation distributions in molded plaques. Incompletely injection molded plaques ("short shots") are studied to gain further insights into the intermediate orientation states during mold filling. Finally, two surface orientation characterization techniques, near edge x-ray absorption fine structure (NEXAFS) and infrared attenuated total reflectance (FTIR-ATR) are combined to investigate the surface orientation distribution of injection molded plaques. Surface orientation states are found to be vastly different from their bulk counterparts due to different kinematics involved in mold filling. In general, complex distributions of orientation in molded plaques reflect the spatially varying competition between shear and extension during mold filling. To complement these experimental measurements, numerical calculations based on the Larson-Doi polydomain model are performed. The implementation of the Larson-Doi in complex processing flows is performed using a commercial process modeling software suite (MOLDFLOWRTM), exploiting a nearly exact analogy between the Larson-Doi model and a fiber orientation model that has been widely used in composites processing simulations. The modeling scheme is first verified by predicting many qualitative and quantitative features of molecular orientation distributions in isothermal extrusion-fed channel flows. In coordination with experiments, the model predictions are found to capture many qualitative features observed in injection molded plaques (including short shots). The final, stringent test of Larson-Doi model performance is prediction of in situ transient orientation data collected during mold filling. The model yields satisfactory results, though certain numerical approximations limit performance near the mold front.

Characterization of nuclear graphite elastic properties using laser ultrasonic methods

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zeng, Fan W; Han, Karen; Olasov, Lauren R

2015-01-01

Laser ultrasonic methods have been used to characterize the elastic behaviors of commercially-available and legacy nuclear graphites. Since ultrasonic techniques are sensitive to various aspects of graphite microstructure including preferred grain orientation, microcrack orientation and porosity, laser ultrasonics is a candidate technique for monitoring graphite degradation and structural integrity in environments expected in high-temperature, gas-cooled nuclear reactors. Aspects of materials texture can be assessed by studying ultrasonic wavespeeds as a function of propagation direction and polarization. Shear wave birefringence measurements, in particular, can be used to evaluate elastic anisotropy. In this work, laser ultrasonic measurements of graphite moduli have beenmore » made to provide insight into the relationship between the microstructures and the macroscopic stiffnesses of these materials. In particular, laser ultrasonic measurements have been made using laser line sources to produce shear waves with specific polarizations. By varying the line orientation relative to the sample, shear wave birefringence measurements have been recorded. Results from shear wave birefringence measurements show that an isostatically molded graphite, such as PCIB, behaves isotropically, while an extruded graphite, such as H-451, displays significant ultrasonic texture. Graphites have complicated microstructures that depend on the manufacturing processes used, and ultrasonic texture in these materials could originate from grain orientation and preferred microcrack alignment. Effects on material isotropy due to service related microstructural changes are possible and the ultimate aim of this work is to determine the degree to which these changes can be assessed nondestructively using laser ultrasonics measurements« less

Dynamic fracture toughness of cellulose-fiber-reinforced polypropylene : preliminary investigation of microstructural effects

Treesearch

Craig M. Clemons; Daniel F. Caulfield; A. Jeffrey Giacomin

1999-10-01

In this study, the microstructure of injection-molded polypropylene reinforced with cellulose fiber was investigated. Scanning electron microscopy of the fracture surfaces and X-ray diffraction were used to investigate fiber orientation. The polypropylene matrix was removed by solvent extraction, and the lengths of the residual fibers were optically determined. Fiber...

Data characterizing tensile behavior of cenosphere/HDPE syntactic foam.

PubMed

Kumar, B R Bharath; Doddamani, Mrityunjay; Zeltmann, Steven E; Gupta, Nikhil; Ramakrishna, Seeram

2016-03-01

The data set presented is related to the tensile behavior of cenosphere reinforced high density polyethylene syntactic foam composites "Processing of cenosphere/HDPE syntactic foams using an industrial scale polymer injection molding machine" (Bharath et al., 2016) [1]. The focus of the work is on determining the feasibility of using an industrial scale polymer injection molding (PIM) machine for fabricating syntactic foams. The fabricated syntactic foams are investigated for microstructure and tensile properties. The data presented in this article is related to optimization of the PIM process for syntactic foam manufacture, equations and procedures to develop theoretical estimates for properties of cenospheres, and microstructure of syntactic foams before and after failure. Included dataset contains values obtained from the theoretical model.

Data characterizing tensile behavior of cenosphere/HDPE syntactic foam

PubMed Central

Kumar, B.R. Bharath; Doddamani, Mrityunjay; Zeltmann, Steven E.; Gupta, Nikhil; Ramakrishna, Seeram

2016-01-01

The data set presented is related to the tensile behavior of cenosphere reinforced high density polyethylene syntactic foam composites “Processing of cenosphere/HDPE syntactic foams using an industrial scale polymer injection molding machine” (Bharath et al., 2016) [1]. The focus of the work is on determining the feasibility of using an industrial scale polymer injection molding (PIM) machine for fabricating syntactic foams. The fabricated syntactic foams are investigated for microstructure and tensile properties. The data presented in this article is related to optimization of the PIM process for syntactic foam manufacture, equations and procedures to develop theoretical estimates for properties of cenospheres, and microstructure of syntactic foams before and after failure. Included dataset contains values obtained from the theoretical model. PMID:26937472

Cell-micropatterning by micromolding in capillary technique based on UV polymerization

NASA Astrophysics Data System (ADS)

Park, Min J.; Choi, Won M.; Park, O. O.

2006-01-01

Although optical lithography or photolithography is one of the most well-established techniques for micro, nano-fabrication, its usage with proteins and cells is restricted by steps that must be carried out in harsh organic solvents. Here, we present simple methods for cell-micropatterning using poly(dimethylsiloxane) (PDMS) as a mold. Cell non-adhesive surface or nonfouling surface providing a physico-chemical barrier to cell attachment was introduced for biomaterial pattering, where cells fail to interact with the surface over desired periods of time determined by each application. Poly(ethylene glycol) (PEG) was selected as nonfouling material to inhibit protein adsorption from biological media. The fouling resistance of PEG polymer is often explained by a steric repulsion interaction, resulting from the compression of PEG chains as proteins approach the surface. We also chose fibronectin to direct cell attachment because it is an extracellular matrix protein that is involved in the adhesion and spreading of anchorage-dependent cells. In our experiment, we propose two methods by application of micromolding in capillary (MIMIC) method based on UV polymerization to obtain a surface of alternating PEG and fibronectin. First to fabricate PEG microstructure via MIMIC method, a pre-patterned PDMS mold is placed on a desired substrate, and then the relief structure in the mold forms a network of empty channels. A drop of ethylene glycol monomer solution containing initiator for UV polymerization is placed at the open ends of the network of channels, which is then polymerized by exposure to UV light at room temperature. Once PEG microstructure is fabricated, incubation of the patterned surface in a fibronectin-containing solution allows back-filling of only the bare regions with fibronectin via adsorption. In the alternative method, a substrate is first incubated in a fibronectin-containing solution, leading to the adsorption of fibronectin over the entire surface, and the fibronectin-adsorbed substrate is then micropatterned with the PEG by MIMIC based on UV polymerization. Both methods create reproducible alternating PEG and fibronectin patterns applicable to cell-surface interactions on the microscale.

Route to one-step microstructure mold fabrication for PDMS microfluidic chip

NASA Astrophysics Data System (ADS)

Lv, Xiaoqing; Geng, Zhaoxin; Fan, Zhiyuan; Wang, Shicai; Su, Yue; Fang, Weihao; Pei, Weihua; Chen, Hongda

2018-04-01

The microstructure mold fabrication for PDMS microfluidic chip remains complex and time-consuming process requiring special equipment and protocols: photolithography and etching. Thus, a rapid and cost-effective method is highly needed. Comparing with the traditional microfluidic chip fabricating process based on the micro-electromechanical system (MEMS), this method is simple and easy to implement, and the whole fabrication process only requires 1-2 h. Different size of microstructure from 100 to 1000 μm was fabricated, and used to culture four kinds of breast cancer cell lines. Cell viability and morphology was assessed when they were cultured in the micro straight channels, micro square holes and the bonding PDMS-glass microfluidic chip. The experimental results indicate that the microfluidic chip is good and meet the experimental requirements. This method can greatly reduce the process time and cost of the microfluidic chip, and provide a simple and effective way for the structure design and in the field of biological microfabrications and microfluidic chips.

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.

Differences in time-dependent mechanical properties between extruded and molded hydrogels

PubMed Central

Ersumo, N; Witherel, CE; Spiller, KL

2016-01-01

The mechanical properties of hydrogels used in biomaterials and tissue engineering applications are critical determinants of their functionality. Despite the recent rise of additive manufacturing, and specifically extrusion-based bioprinting, as a prominent biofabrication method, comprehensive studies investigating the mechanical behavior of extruded constructs remain lacking. To address this gap in knowledge, we compared the mechanical properties and swelling properties of crosslinked gelatin-based hydrogels prepared by conventional molding techniques or by 3D bioprinting using a BioBots Beta pneumatic extruder. A preliminary characterization of the impact of bioprinting parameters on construct properties revealed that both Young's modulus and optimal extruding pressure increased with polymer content, and that printing resolution increased with both printing speed and nozzle gauge. High viability (>95%) of encapsulated NIH 3T3 fibroblasts confirmed the cytocompatibility of the construct preparation process. Interestingly, the Young's moduli of extruded and molded constructs were not different, but extruded constructs did show increases in both the rate and extent of time-dependent mechanical behavior observed in creep. Despite similar polymer densities, extruded hydrogels showed greater swelling over time compared to molded hydrogels, suggesting that differences in creep behavior derived from differences in microstructure and fluid flow. Because of the crucial roles of time-dependent mechanical properties, fluid flow, and swelling properties on tissue and cell behavior, these findings highlight the need for greater consideration of the effects of the extrusion process on hydrogel properties. PMID:27550945

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.

Permanent Mold Casting of JIS-AC4C Aluminum Alloy Using a Low-Temperature Mold

DOE Office of Scientific and Technical Information (OSTI.GOV)

Yamagata, Hiroshi; Nikawa, Makoto

2011-01-17

Permanent mold casting using mold temperatures below 200 deg. C was conducted to obtain a high-strength, thin-walled casting. Al-7.36 mass% Si -0.18 Cu- 0.27Mg-0.34Fe alloy JIS-AC4C was cast using a bottom pouring cast plan. The product had a rectangular tube shape (70 mm W x 68 mm D x 180 mm H) with wall thicknesses of 1, 3 and 5 mm. The effect of heat insulation at the melt path was compared when using a sand runner insert and when using a steel runner insert as well as a powder mold release agent. Fine microstructures were observed in the casting.more » The smaller the thickness, the higher the hardness with smaller secondary dendrite arm spacing (SDAS). However, the hardness and the SDAS were unaffected by the mold temperature. It was proposed that the avoidance of the formation of primary {alpha} dendrite at the melt path generates a higher strength casting with adequate mold filling.« less

A Review of Metal Injection Molding- Process, Optimization, Defects and Microwave Sintering on WC-Co Cemented Carbide

NASA Astrophysics Data System (ADS)

Shahbudin, S. N. A.; Othman, M. H.; Amin, Sri Yulis M.; Ibrahim, M. H. I.

2017-08-01

This article is about a review of optimization of metal injection molding and microwave sintering process on tungsten cemented carbide produce by metal injection molding process. In this study, the process parameters for the metal injection molding were optimized using Taguchi method. Taguchi methods have been used widely in engineering analysis to optimize the performance characteristics through the setting of design parameters. Microwave sintering is a process generally being used in powder metallurgy over the conventional method. It has typical characteristics such as accelerated heating rate, shortened processing cycle, high energy efficiency, fine and homogeneous microstructure, and enhanced mechanical performance, which is beneficial to prepare nanostructured cemented carbides in metal injection molding. Besides that, with an advanced and promising technology, metal injection molding has proven that can produce cemented carbides. Cemented tungsten carbide hard metal has been used widely in various applications due to its desirable combination of mechanical, physical, and chemical properties. Moreover, areas of study include common defects in metal injection molding and application of microwave sintering itself has been discussed in this paper.

A Comparative Study on Permanent Mold Cast and Powder Thixoforming 6061 Aluminum Alloy and Sicp/6061Al Composite: Microstructures and Mechanical Properties.

PubMed

Zhang, Xuezheng; Chen, Tijun; Qin, He; Wang, Chong

2016-05-24

Microstructural and mechanical characterization of 10 vol% SiC particles (SiC p ) reinforced 6061 Al-based composite fabricated by powder thixoforming (PTF) was investigated in comparison with the PTF and permanent mold cast (PMC) 6061 monolithic alloys. The results reveal that the microstructure of the PMC alloy consists of coarse and equiaxed α dendrites and interdendritic net-like eutectic phases. However, the microstructure of the PTF composite, similar to that of the PTF alloy, consists of near-spheroidal primary particles and intergranular secondarily solidified structures except SiC p , which are distributed in the secondarily solidified structures. The eutectics amount in the PTF materials is distinctly lower than that in the PMC alloy, and the microstructures of the former materials are quite compact while that of the latter alloy is porous. Therefore, the PTF alloy shows better tensile properties than the PMC alloy. Owing to the existence of the SiC reinforcing particles, the PTF composite attains an ultimate tensile strength and yield strength of 230 MPa and 128 MPa, representing an enhancement of 27.8% and 29.3% than those (180 MPa and 99 MPa) of the PTF alloy. A modified model based on three strengthening mechanisms was proposed to calculate the yield strength of the PTF composite. The obtained theoretical results were quite consistent with the experimental data.

Effect of volatile removal during molding on the properties of two phenolic-fiber composites

NASA Technical Reports Server (NTRS)

Price, H. L.; Lucy, M. H.

1974-01-01

A comparison has been made of the effect of three volatile-removing techniques during molding on the properties of phenolic-fiber composites. The first technique involved heating the molding compound from one side, initiating the volatile-producing reactions, and driving these volatiles through the compound toward the cooler side. The second technique involved the application of a vacuum to the molding cavity before and during the cure cycle. The third technique was a combination of the first two. These techniques were used in the compression molding of phenolic-asbestos and phenolic-glass composites. The effects of both the individual and combined techniques on the mechanical, thermal, and sorption properties of the composites are reported.

Microstructure and High Temperature Mechanical Property of Fe-Cr-B Based Metal/Ceramic Composite Manufactured by Metal Injection Molding Process

NASA Astrophysics Data System (ADS)

Lee, Kee-Ahn; Gwon, Jin-Han; Yoon, Tae-Sik

2018-03-01

This study investigated the microstructure and the room and high temperature mechanical properties of Fe-Cr-B alloy manufactured by metal injection molding. In addition, hot isostatic pressing was performed to increase the density of the material, and a comparison of properties was made. Microstructural observation confirmed a bi-continuous structure composed of a three-dimensional network of α-Fe phase and (Cr,Fe)2B phase. The HIPed specimen featured a well-formed adhesion between the α-Fe phase and boride, and the number of fine pores was significantly reduced. The tensile results confirmed that the HIPed specimen (RT to 900 °C) had higher strengths compared to the as-sintered specimen, and the change of elongation starting from 700 °C was significantly greater in the HIPed specimen. Fractography suggested that cracks propagated mostly along the interface between the α-Fe matrix and boride in the as-sintered specimen, while direct fracture of boride was observed in addition to interface separation in the HIPed specimen.

Evaluation of Three Different Processing Techniques in the Fabrication of Complete Dentures

PubMed Central

Chintalacheruvu, Vamsi Krishna; Balraj, Rajasekaran Uttukuli; Putchala, Lavanya Sireesha; Pachalla, Sreelekha

2017-01-01

Aims and Objectives: The objective of the present study is to compare the effectiveness of three different processing techniques and to find out the accuracy of processing techniques through number of occlusal interferences and increase in vertical dimension after denture processing. Materials and Methods: A cross-sectional study was conducted on a sample of 18 patients indicated for complete denture fabrication was selected for the study and they were divided into three subgroups. Three processing techniques, compression molding and injection molding using prepolymerized resin and unpolymerized resin, were used to fabricate dentures for each of the groups. After processing, laboratory-remounted dentures were evaluated for number of occlusal interferences in centric and eccentric relations and change in vertical dimension through vertical pin rise in articulator. Data were analyzed using statistical test ANOVA and SPSS software version 19.0 by IBM was used. Results: Data obtained from three groups were subjected to one-way ANOVA test. After ANOVA test, results with significant variations were subjected to post hoc test. Number of occlusal interferences with compression molding technique was reported to be more in both centric and eccentric positions as compared to the two injection molding techniques with statistical significance in centric, protrusive, right lateral nonworking, and left lateral working positions (P < 0.05). Mean vertical pin rise (0.52 mm) was reported to more in compression molding technique as compared to injection molding techniques, which is statistically significant (P < 0.001). Conclusions: Within the limitations of this study, injection molding techniques exhibited less processing errors as compared to compression molding technique with statistical significance. There was no statistically significant difference in processing errors reported within two injection molding systems. PMID:28713763

Evaluation of Three Different Processing Techniques in the Fabrication of Complete Dentures.

PubMed

Chintalacheruvu, Vamsi Krishna; Balraj, Rajasekaran Uttukuli; Putchala, Lavanya Sireesha; Pachalla, Sreelekha

2017-06-01

The objective of the present study is to compare the effectiveness of three different processing techniques and to find out the accuracy of processing techniques through number of occlusal interferences and increase in vertical dimension after denture processing. A cross-sectional study was conducted on a sample of 18 patients indicated for complete denture fabrication was selected for the study and they were divided into three subgroups. Three processing techniques, compression molding and injection molding using prepolymerized resin and unpolymerized resin, were used to fabricate dentures for each of the groups. After processing, laboratory-remounted dentures were evaluated for number of occlusal interferences in centric and eccentric relations and change in vertical dimension through vertical pin rise in articulator. Data were analyzed using statistical test ANOVA and SPSS software version 19.0 by IBM was used. Data obtained from three groups were subjected to one-way ANOVA test. After ANOVA test, results with significant variations were subjected to post hoc test. Number of occlusal interferences with compression molding technique was reported to be more in both centric and eccentric positions as compared to the two injection molding techniques with statistical significance in centric, protrusive, right lateral nonworking, and left lateral working positions ( P < 0.05). Mean vertical pin rise (0.52 mm) was reported to more in compression molding technique as compared to injection molding techniques, which is statistically significant ( P < 0.001). Within the limitations of this study, injection molding techniques exhibited less processing errors as compared to compression molding technique with statistical significance. There was no statistically significant difference in processing errors reported within two injection molding systems.

Modeling and Simulation of Compression Molding Process for Sheet Molding Compound (SMC) of Chopped Carbon Fiber Composites

DOE PAGES

Li, Yang; Chen, Zhangxing; Xu, Hongyi; ...

2017-01-02

Compression molded SMC composed of chopped carbon fiber and resin polymer which balances the mechanical performance and manufacturing cost presents a promising solution for vehicle lightweight strategy. However, the performance of the SMC molded parts highly depends on the compression molding process and local microstructure, which greatly increases the cost for the part level performance testing and elongates the design cycle. ICME (Integrated Computational Material Engineering) approaches are thus necessary tools to reduce the number of experiments required during part design and speed up the deployment of the SMC materials. As the fundamental stage of the ICME workflow, commercial softwaremore » packages for SMC compression molding exist yet remain not fully validated especially for chopped fiber systems. In this study, SMC plaques are prepared through compression molding process. The corresponding simulation models are built in Autodesk Moldflow with the same part geometry and processing conditions as in the molding tests. The output variables of the compression molding simulations, including press force history and fiber orientation of the part, are compared with experimental data. Influence of the processing conditions to the fiber orientation of the SMC plaque is also discussed. It is found that generally Autodesk Moldflow can achieve a good simulation of the compression molding process for chopped carbon fiber SMC, yet quantitative discrepancies still remain between predicted variables and experimental results.« less

Modeling and Simulation of Compression Molding Process for Sheet Molding Compound (SMC) of Chopped Carbon Fiber Composites

DOE Office of Scientific and Technical Information (OSTI.GOV)

Li, Yang; Chen, Zhangxing; Xu, Hongyi

Compression molded SMC composed of chopped carbon fiber and resin polymer which balances the mechanical performance and manufacturing cost presents a promising solution for vehicle lightweight strategy. However, the performance of the SMC molded parts highly depends on the compression molding process and local microstructure, which greatly increases the cost for the part level performance testing and elongates the design cycle. ICME (Integrated Computational Material Engineering) approaches are thus necessary tools to reduce the number of experiments required during part design and speed up the deployment of the SMC materials. As the fundamental stage of the ICME workflow, commercial softwaremore » packages for SMC compression molding exist yet remain not fully validated especially for chopped fiber systems. In this study, SMC plaques are prepared through compression molding process. The corresponding simulation models are built in Autodesk Moldflow with the same part geometry and processing conditions as in the molding tests. The output variables of the compression molding simulations, including press force history and fiber orientation of the part, are compared with experimental data. Influence of the processing conditions to the fiber orientation of the SMC plaque is also discussed. It is found that generally Autodesk Moldflow can achieve a good simulation of the compression molding process for chopped carbon fiber SMC, yet quantitative discrepancies still remain between predicted variables and experimental results.« less

Comparative evaluation of border molding using two different techniques in maxillary edentulous arches: A clinical study

PubMed Central

Qanungo, Anchal; Aras, Meena Ajay; Chitre, Vidya; Coutinho, Ivy; Rajagopal, Praveen; Mysore, Ashwin

2016-01-01

Purpose: The aim of this in vivo study was to compare the single-step border molding technique using injectable heavy viscosity addition silicone with sectional border molding technique using low fusing impression compound by evaluating the retention of heat cure trial denture bases. Materials and Methods: Ten completely edentulous patients in need of prostheses were included in this study. Two border molding techniques, single-step (Group 1) and sectional (Group 2), were compared for retention. Both border molding techniques were performed in each patient. In both techniques, definitive wash impression was made with light viscosity addition silicone. The final results were analyzed using paired t-test to determine whether significant differences existed between the groups. Results: The t-value (3.031) infers that there was a significant difference between Group 1 and Group 2 (P = 0.014). The retention obtained in Group 2 (mean = 9.05 kgf) was significantly higher than that of Group 1 (mean = 8.26 kgf). Conclusion: Sectional border molding technique proved to be more retentive as compared to single-step border molding although clinically the retention appeared comparable. PMID:27746597

Comparison of two nasoalveolar molding techniques in unilateral complete cleft lip patients: a randomized, prospective, single-blind trial to compare nasal outcomes.

PubMed

Chang, Chun-Shin; Wallace, Christopher Glenn; Pai, Betty Chien-Jung; Chiu, Yu-Ting; Hsieh, Yuh-Jia; Chen, I-Ju; Liao, Yu-Fang; Liou, Eric Jen-Wein; Chen, Philip Kuo-Ting

2014-08-01

Nasoalveolar molding became increasingly popular in the 1990s as a means of easing surgery and improving nasal outcomes for cleft lip repairs. In the late 1990s, three orthodontists from our center underwent nasoalveolar molding training: two at the Rush Craniofacial Center, in Chicago; and one at New York University Craniofacial Center. They brought two different nasoalveolar molding techniques back to Chang Gung Craniofacial Center: the modified Figueroa and the modified Grayson techniques. Outcomes following use of these techniques have not previously been compared prospectively. Between May of 2010 and March of 2013, a randomized, prospective, single-blind trial was conducted to compare the number of clinical visits, total costs, complications, and nasal symmetry between the two nasoalveolar molding techniques in 30 patients with unilateral complete cleft lip. There were no differences between nasoalveolar molding techniques in the number of clinical visits, total costs, nostril height, or nostril area ratio. Preoperatively but after nasoalveolar molding, the nostril width ratio was wider for the Figueroa group than for the Grayson group. Six months after surgical correction, there were no differences in nostril height, nostril width, nasal sill height, or nostril area ratio between nasoalveolar molding methods. Alveolar ulceration occurred more frequently in the Grayson group. The modified Grayson technique reduced nostril width more efficiently, but alveolar ulceration was more frequent and no differences in nostril width were found following surgery. Overall, the two nasoalveolar molding techniques produced similar nasal outcomes. Therapeutic, II.

Micro-structure and Air-tightness of Squeeze Casting Motor housing for New Energy Vehicle

NASA Astrophysics Data System (ADS)

Jiang, Y. F.; Kang, Z. Q.; Jiang, W. F.; Wang, K. W.; Sha, D. L.; Li, M. L.; Sun, J.

2018-05-01

In order to improve the performance of automobile parts, the influence of squeeze casting process parameters on casting defects, material structure and air-tightness of aluminum alloy motor housing for new energy vehicle was studied. The results show that the density of the castings increases with the increase in pressure and mold temperature. With increase in pouring temperature, it increases first and then decreases. Pressure has the greatest influence on the density of the castings. Under a certain pressure, with moderate increase in casting temperature and mold temperature, the grain growth begins to increase; the dendrites become less, the new α - Al grains are spherical and granular, the micro-structure is uniform. Also, with increase in pressure, this effect is more pronounced, the air-tightness of castings improve. In conclusion, when the pressure is 110MPa, pouring temperature is 680° C, mold temperature is 280° C, pressure holding for 30s, and punch speed of 0.1m/s, there is no clear shrinkage in the casting, the structure is uniform, the qualified rate of air-tightness of production reaches 86%, and the performance is excellent.

INEL Spray-forming Research

NASA Technical Reports Server (NTRS)

Mchugh, Kevin M.; Key, James F.

1993-01-01

Spray forming is a near-net-shape fabrication technology in which a spray of finely atomized liquid droplets is deposited onto a suitably shaped substrate or mold to produce a coherent solid. The technology offers unique opportunities for simplifying materials processing without sacrificing, and oftentimes substantially improving, product quality. Spray forming can be performed with a wide range of metals and nonmetals, and offers property improvements resulting from rapid solidification (e.g., refined microstructures, extended solid solubilities and reduced segregation). Economic benefits result from process simplification and the elimination of unit operations. Researchers at the Idaho National Engineering Laboratory (INEL) are developing spray-forming technology for producing near-net-shape solids and coatings of a variety of metals, polymers, and composite materials. Results from several spray forming programs are presented to illustrate the range of capabilities of the technique as well as the accompanying technical and economic benefits. Low-carbon steel strip greater than 0.75 mm thick and polymer membranes for gas/gas and liquid/liquid separations that were spray formed are discussed; recent advances in spray forming molds, dies, and other tooling using low-melting-point metals are described.

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.

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

2014-06-27

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.

Using femtosecond laser to fabricate highly precise interior three-dimensional microstructures in polymeric flow chip

PubMed Central

Lee, Chia-Yu; Chang, Ting-Chou; Wang, Shau-Chun; Chien, Chih-Wei; Cheng, Chung-Wei

2010-01-01

This paper reports using femtosecond laser marker to fabricate the three-dimensional interior microstructures in one closed flow channel of plastic substrate. Strip-like slots in the dimensions of 800 μm×400 μm×65 μm were ablated with pulse Ti:sapphire laser at 800 nm (pulse duration of ∼120 fs with 1 kHz repetition rate) on acrylic slide. After ablation, defocused beams were used to finish the surface of microstructures. Having finally polished with sonication, the laser fabricated structures are highly precise with the arithmetic roughness of 1.5 and 4.5 nm. Fabricating such highly precise microstructures cannot be accomplished with nanosecond laser marking or other mechanical drilling methods. In addition, since laser ablation can directly engrave interior microstructures in one closed chip, glue smearing problems to damage molded microstructures possibly to occur during the chip sealing procedures can be avoided too. PMID:21079695

Using femtosecond laser to fabricate highly precise interior three-dimensional microstructures in polymeric flow chip.

PubMed

Lee, Chia-Yu; Chang, Ting-Chou; Wang, Shau-Chun; Chien, Chih-Wei; Cheng, Chung-Wei

2010-10-18

This paper reports using femtosecond laser marker to fabricate the three-dimensional interior microstructures in one closed flow channel of plastic substrate. Strip-like slots in the dimensions of 800 μm×400 μm×65 μm were ablated with pulse Ti:sapphire laser at 800 nm (pulse duration of ∼120 fs with 1 kHz repetition rate) on acrylic slide. After ablation, defocused beams were used to finish the surface of microstructures. Having finally polished with sonication, the laser fabricated structures are highly precise with the arithmetic roughness of 1.5 and 4.5 nm. Fabricating such highly precise microstructures cannot be accomplished with nanosecond laser marking or other mechanical drilling methods. In addition, since laser ablation can directly engrave interior microstructures in one closed chip, glue smearing problems to damage molded microstructures possibly to occur during the chip sealing procedures can be avoided too.

Relationship between microstructure and ductility of investment cast ASTM F-75 implant alloy.

PubMed

Gómez, M; Mancha, H; Salinas, A; Rodríguez, J L; Escobedo, J; Castro, M; Méndez, M

1997-02-01

Hip replacement implants fabricated using the ASTM F-75 alloy sometimes fail in a sudden catastrophic way. In general, fractures start at microstructural defects subjected to stress-corrosion under chemical attack by body fluids. In this paper the results of a study on the effect of casting parameters on the microstructure of ASTM F-75 are presented. The preheating mold temperature and the liquid temperature were varied between 900 and 1000 degrees C, and 1410 and 1470 degrees C, respectively. Optimum static strength and ductility were obtained when shrinkage microporosity and the volume fraction of M23C6 "eutectic" carbides precipitated at grain boundaries were minimized by increasing the preheating mold temperature to 1000 degrees C and by using intermediate pouring temperatures of 1455 degrees C. Under these casting conditions, however, the solidification rates are low, leading to large grain sizes, which, in turn, reduce the strength of the material under dynamic loading conditions. The volume fraction of the M23C6 "blocky" carbides appears to be independent of the casting conditions; however, their size and spatial distributions determine the strength of the as-cast alloys.

Effect of Rotating Mold Speed on Microstructure of Al LM6 Hollow Cylinder Fabricated Using Centrifugal Method

NASA Astrophysics Data System (ADS)

Kohnizio Mahli, Maximus; Jamian, Saifulnizan; Ismail, Al Emran; Nor, Nik Hisyamudin Muhd; Nor, Mohd Khir Mohd; Azhar Kamarudin, Kamarul

2017-10-01

Al LM6 hollow cylinder is fabricated using horizontal centrifugal casting which produce a very fine grain on the outer surface of the structure. In this study, the effect of motor speed and pouring temperature on the microstructure of Al LM6 hollow cylinder is determined. The speed of the motor used during casting are 1300rpm, 1500rpm and 1700rpm and the pouring temperature are 690°C, 710°C and 725°C. The Al LM6 hollow cylinder is produced by pouring the molten Al LM6 into a cylindrical casting mold which is connected with a shaft and it is rotated by motor until it is solidified. Then, the cross-section is observed using OM and SEM/EDS. From the microstructure observation, the distributions of Si are more concentrated at the inner parts and the size of Si is bigger at the inner parts. The result shows that the Si particles at the inner part which is fabricated at the highest motor speed (1700rpm) have the most Si particles compared with the Si particles that are casted with other motor speeds.

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.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Vu-khanh, T.; Denault, J.

The effects of the conditions of the processing of PEEK/carbon prepregs and comingled fabric on the microstructure and mechanical characteristics of the resulting composites were investigated. Results showed that, in the comingled fabric system, the fiber/matrix adhesion depends on the molding temperature, the residence time at the melt temperature, and the cooling rate. Too high molding temperature resulted in degradation of the PEEK matrix, which affected the crystallization behavior of the composites, the fiber/matrix adhesion, and the matrix properties. This effect was most important in the case of comingled systems containing sized carbon fibers. 17 refs.

Nanostructured Diamond Device for Biomedical Applications.

PubMed

Fijalkowski, M; Karczemska, A; Lysko, J M; Zybala, R; KozaneckI, M; Filipczak, P; Ralchenko, V; Walock, M; Stanishevsky, A; Mitura, S

2015-02-01

Diamond is increasingly used in biomedical applications because of its unique properties such as the highest thermal conductivity, good optical properties, high electrical breakdown voltage as well as excellent biocompatibility and chemical resistance. Diamond has also been introduced as an excellent substrate to make the functional microchip structures for electrophoresis, which is the most popular separation technique for the determination of analytes. In this investigation, a diamond electrophoretic chip was manufactured by a replica method using a silicon mold. A polycrystalline 300 micron-thick diamond layer was grown by the microwave plasma-assisted CVD (MPCVD) technique onto a patterned silicon substrate followed by the removal of the substrate. The geometry of microstructure, chemical composition, thermal and optical properties of the resulting free-standing diamond electrophoretic microchip structure were examined by CLSM, SFE, UV-Vis, Raman, XRD and X-ray Photoelectron Spectroscopy, and by a modified laser flash method for thermal property measurements.

Progress in Titanium Metal Powder Injection Molding.

PubMed

German, Randall M

2013-08-20

Metal powder injection molding is a shaping technology that has achieved solid scientific underpinnings. It is from this science base that recent progress has occurred in titanium powder injection molding. Much of the progress awaited development of the required particles with specific characteristics of particle size, particle shape, and purity. The production of titanium components by injection molding is stabilized by a good understanding of how each process variable impacts density and impurity level. As summarized here, recent research has isolated the four critical success factors in titanium metal powder injection molding (Ti-MIM) that must be simultaneously satisfied-density, purity, alloying, and microstructure. The critical role of density and impurities, and the inability to remove impurities with sintering, compels attention to starting Ti-MIM with high quality alloy powders. This article addresses the four critical success factors to rationalize Ti-MIM processing conditions to the requirements for demanding applications in aerospace and medical fields. Based on extensive research, a baseline process is identified and reported here with attention to linking mechanical properties to the four critical success factors.

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. Copyright © 2015 Elsevier Ltd. All rights reserved.

Progress in Titanium Metal Powder Injection Molding

PubMed Central

German, Randall M.

2013-01-01

Metal powder injection molding is a shaping technology that has achieved solid scientific underpinnings. It is from this science base that recent progress has occurred in titanium powder injection molding. Much of the progress awaited development of the required particles with specific characteristics of particle size, particle shape, and purity. The production of titanium components by injection molding is stabilized by a good understanding of how each process variable impacts density and impurity level. As summarized here, recent research has isolated the four critical success factors in titanium metal powder injection molding (Ti-MIM) that must be simultaneously satisfied—density, purity, alloying, and microstructure. The critical role of density and impurities, and the inability to remove impurities with sintering, compels attention to starting Ti-MIM with high quality alloy powders. This article addresses the four critical success factors to rationalize Ti-MIM processing conditions to the requirements for demanding applications in aerospace and medical fields. Based on extensive research, a baseline process is identified and reported here with attention to linking mechanical properties to the four critical success factors. PMID:28811458

Retention of denture bases fabricated by three different processing techniques – An in vivo study

PubMed Central

Chalapathi Kumar, V. H.; Surapaneni, Hemchand; Ravikiran, V.; Chandra, B. Sarat; Balusu, Srilatha; Reddy, V. Naveen

2016-01-01

Aim: Distortion due to Polymerization shrinkage compromises the retention. To evaluate the amount of retention of denture bases fabricated by conventional, anchorized, and injection molding polymerization techniques. Materials and Methods: Ten completely edentulous patients were selected, impressions were made, and master cast obtained was duplicated to fabricate denture bases by three polymerization techniques. Loop was attached to the finished denture bases to estimate the force required to dislodge them by retention apparatus. Readings were subjected to nonparametric Friedman two-way analysis of variance followed by Bonferroni correction methods and Wilcoxon matched-pairs signed-ranks test. Results: Denture bases fabricated by injection molding (3740 g), anchorized techniques (2913 g) recorded greater retention values than conventional technique (2468 g). Significant difference was seen between these techniques. Conclusions: Denture bases obtained by injection molding polymerization technique exhibited maximum retention, followed by anchorized technique, and least retention was seen in conventional molding technique. PMID:27382542

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

Peri-implant bone formation and surface characteristics of rough surface zirconia implants manufactured by powder injection molding technique in rabbit tibiae.

PubMed

Park, Young-Seok; Chung, Shin-Hye; Shon, Won-Jun

2013-05-01

To evaluate osseointegration in rabbit tibiae and to investigate surface characteristics of novel zirconia implants made by powder injection molding (PIM) technique, using molds with and without roughened inner surfaces. A total of 20 rabbits received three types of external hex implants with identical geometry on the tibiae: machined titanium implants, PIM zirconia implants without mold etching, and PIM zirconia implants with mold etching. Surface characteristics of the three types of implant were evaluated. Removal torque tests and histomorphometric analyses were performed. The roughness of PIM zirconia implants was higher than that of machined titanium implants. The PIM zirconia implants exhibited significantly higher bone-implant contact and removal torque values than the machined titanium implants (P < 0.001). The PIM zirconia implants using roughened mold showed significantly higher removal torque values than PIM zirconia implants without using roughened mold (P < 0.001). It is concluded that the osseointegration of PIM zirconia implant is promising and PIM using roughened mold etching technique can produce substantially rough surfaces on zirconia implants. © 2012 John Wiley & Sons A/S.

Mold Flux Crystallization and Mold Thermal Behavior

NASA Astrophysics Data System (ADS)

Peterson, Elizabeth Irene

Mold flux plays a small but critical role in the continuous casting of steel. The carbon-coated powder is added at the top of the water-cooled copper mold, over time it melts and infiltrates the gap between the copper mold and the solidifying steel strand. Mold powders serve five primary functions: (1) chemical insulation, (2) thermal insulation, (3) lubrication between the steel strand and mold, (4) absorption of inclusions, and (5) promotion of even heat flux. All five functions are critical to slab casting, but surface defect prevention is primarily controlled through even heat flux. Glassy fluxes have high heat transfer and result in a thicker steel shell. Steels with large volumetric shrinkage on cooling must have a crystalline flux to reduce the radiative heat transfer and avoid the formation of cracks in the shell. Crystallinity plays a critical role in steel shell formation, therefore it is important to study the thermal conditions that promote each phase and its morphology. Laboratory tests were performed to generate continuous cooling transformation (CCT) and time-temperature-transformation (TTT) diagrams. Continuous cooling transformation tests were performed in an instrumented eight cell step chill mold. Results showed that cuspidine was the only phase formed in conventional fluxes and all observed structures were dendritic. An isothermal tin bath quench method was also developed to isothermally age glassy samples. Isothermal tests yielded different microstructures and different phases than those observed by continuous cooling. Comparison of aged tests with industrial flux films indicates similar faceted structures along the mold wall, suggesting that mold flux first solidifies as a glass along the mold wall, but the elevated temperature devitrifies the glassy structure forming crystals that cannot form by continuous cooling.

The Effect of Li Additions on Wear Properties of Al-Mg2Si Cast In-situ Composites

NASA Astrophysics Data System (ADS)

Ghorbani, M. R.; Emamy, M.; Ghiasinejad, J.; Malekan, A.

2010-06-01

Wear rate of a modified Al-Mg2Si composite was studied by the use of a conventional pin-on-disc technique. In-situ Al-Mg2Si composites (15, 20, 25 wt.%) were cast in a simple cylindrical mold. 0.3 wt.% Li was added into the molten composite to modify its microstructure. It has been found that Li addition decreases the mean size of primary Mg2Si particles. The wear behavior of different composites at different rates revealed that Li addition increases the wear properties of Al-15%Mg2Si to some extent but it did not have any significant influence on wear properties of two other composites.

The effect of aging treatment on the fracture toughness and impact strength of injection molded Ni-625 superalloy parts

DOE Office of Scientific and Technical Information (OSTI.GOV)

Özgün, Özgür, E-mail: oozgun@bingol.edu.tr; Yılmaz, Ramazan; Özkan Gülsoy, H.

In this study, the effect of aging heat treatment on fracture toughness and impact strength of Ni-625 superalloy fabricated by using powder injection molding (PIM) method was examined. After a feedstock was prepared by mixing the prealloyed Ni-625 superalloy powder, which was fabricated by gas atomisation, with a polymeric binder system and then it was granulated, it was shaped through the use of injection. The molded specimens were sintered at 1300 °C for 3 h after a two-stage debinding process. Once the sintered specimens were treated in the solution at 1150 °C for 2 h, they were quenched. Aging treatmentmore » was performed by keeping specimens at 745 °C for 22 h. Fracture toughness and impact tests were performed on sintered and aged specimens. Microstructure examinations were performed by using optical microscope, scanning electron microscope, and transmission electron microscope. The results revealed that aging heat treatment led to the formation of some carbides and intermetallic phases in the microstructure. While the hardness of the aged specimens increased due to these phases, their fracture toughness and impact strength values decreased. - Highlights: • Ni-625 superalloy components were produced by means of powder injection molding. • The produced components were subjected to aging treatment. • Aging process provided approximately 50% increase in the hardness of components. • Intermetallic precipitates, carbides and TCP phases occurred within the aged parts. • Fracture toughness and impact strength values decreased due to the hard phases.« less

Experimental studies on a novel roll-to-roll powder hot embossing for large-area fabrication of micropyramid arrays on polymers

NASA Astrophysics Data System (ADS)

Yi, Peiyun; Deng, Yujun; Shu, Yunyi; Peng, Linfa

2018-08-01

Roll-to-roll (R2R) hot embossing is regarded as a cost-effective replication technology to fabricate microstructures on polymer films. However, the characteristics of continuous and fast forming for the R2R hot embossing process limits material flow during the filling stage and results in significant springback during the demolding stage. To resolve this issue, this study proposed a novel R2R powder hot embossing process, which combines the merits of the continuous fabrication of R2R hot embossing and near-net-shape forming of powder sintering and also decreases the whole cycle of the fabrication from films to microstructures. First, the relation between the molten layer thickness and processing parameters was discussed and an analytical model was established to predict the feed of the polymeric powder during R2R powder hot embossing. Then, with the use of a micro-pyramid array mold, the impact of the process parameters including mold temperature, feeding speed and applied force on the geometrical dimension of the patterned microstructures was discussed. Last, based on the response surface analysis, a process window, in terms of the mold temperature of 132 °C –145 °C, feeding speed of 0.1–1.4 m min‑1 and applied force of 15–50 kgf was determined for the continuous fabrication of completely-filled micropyramid arrays with the R2R powder hot embossing process. This research demonstrated the feasibility and superiority of the proposed R2R powder hot embossing process in continuously fabricating micropatterned structures on polymeric films.

Modeling and characterization of through-the-thickness properties of 3D woven composites

NASA Technical Reports Server (NTRS)

Hartranft, Dru; Pravizi-Majidi, Azar; Chou, Tsu-Wei

1995-01-01

The through-the-thickness properties of three-dimensionally (3D) woven carbon/epoxy composites have been studied. The investigation aimed at the evaluation and development of test methodologies for the property characterization in the thickness direction, and the establishment of fiber architectures were studied: layer-to-layer Angle Interlock, through-the-thickness Orthogonal woven preform with surface pile was also designed and manufactured for the fabrication of tensile test coupons with integrated grips. All the preforms were infiltrated by the resin transfer molding technique. The microstructures of the composites were characterized along the warp and fill (weft) directions to determine the degree of yarn undulations, yarn cross-sectional shapes, and microstructural dimensions. These parameters were correlated to the fiber architecture. Specimens were designed and tested for the direct measurement of the through-the-thickness tensile, compressive and shear properties of the composites. Design optimization was conducted through the analysis of the stress fields within the specimen coupled with experimental verification. The experimentally-derived elastic properties in the thickness direction compared well with analytical predictions obtained from a volume averaging model.

Study on temperature and near-infrared driving characteristics of hydrogel actuator fabricated via molding and 3D printing.

PubMed

Zhao, Qian; Liang, Yunhong; Ren, Lei; Qiu, Feng; Zhang, Zhihui; Ren, Luquan

2018-02-01

A hydrogel material system which was fit for molding and 3D printing was developed to fabricate bilayer hydrogel actuators with controllable temperature and near infrared laser responses. Polymerization on interface boundary of layered structure enhanced the bonding strength of hydrogel actuators. By utilizing anisotropic of microstructure along with thickness direction, bilayer hydrogel actuators fabricated via molding realized intelligent bending/shrinking responses, which guided the preparation of hydrogel ink for 3D printing. In-situ free radical polymerization under vacuum realized the solidification of printed hydrogel actuators with graphene oxide. Based on anisotropic swelling/deswelling behaviors of precise structure fabricated via 3D printing, the printed bilayer hydrogel actuators achieved temperature and near infrared laser responsive deformation. Changes of programmable printing path effectively resulted in corresponding deformation patterns. Combination of advantages of molding and 3D printing can promote the design and fabrication of hydrogel actuators with high mechanical strength, response speed and deformation ability. Copyright © 2017 Elsevier Ltd. All rights reserved.

Optimization of the injection molding process for development of high performance calcium oxide -based ceramic cores

NASA Astrophysics Data System (ADS)

Zhou, P. P.; Wu, G. Q.; Tao, Y.; Cheng, X.; Zhao, J. Q.; Nan, H.

2018-02-01

The binder composition used for ceramic injection molding plays a crucial role on the final properties of sintered ceramic and to avoid defects on green parts. In this study, the effects of binder compositions on the rheological, microstructures and the mechanical properties of CaO based ceramic cores were investigated. It was found that the optimized formulation for dispersant, solid loading was 1.5 wt% and 84 wt%, respectively. The microstructures, such as porosity, pore size distribution and grain boundary density were closely related to the plasticizer contents. The decrease of plasticizer contents can enhance the strength of the ceramic cores but with decreased shrinkage. Meanwhile, the creep resistance of ceramic cores was enhanced by decreasing of plasticizer contents. The flexural strength of the core was found to decrease with the increase of the porosity, the improvement of creep resistance is closely related to the decrease of porosity and grain boundary density.

Dimensional changes of acrylic resin denture bases: conventional versus injection-molding technique.

PubMed

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

2014-07-01

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. 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. 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. 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.

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

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.

Modeling and optimization of the hot embossing process for micro- and nanocomponent fabrication

NASA Astrophysics Data System (ADS)

Worgull, M.; Heckele, Mathias P.; Hétu, J. F.; Kabanemi, K. K.

2006-01-01

Hot embossing and injection molding belong to the established plastic molding processes in microengineering. Based on experimental findings, a variety of microstructures have been replicated using these processes. However, with increasing requirements regarding the embossing surface, and the simultaneous decrease of the structure size down into the nanorange, increasing know-how is needed to adapt hot embossing to industrial standards. To reach this objective, a German-Canadian cooperation project has been launched to study hot embossing theoretically by process simulation and experimentally. The present publication reports on the proceeding and present first results.

Warpage of QFN Package in Post Mold Cure Process of integrated circuit packaging

NASA Astrophysics Data System (ADS)

Sriwithoon, Nattha; Ugsornrat, Kessararat; Srisuwitthanon, Warayoot; Thonglor, Panakamon

2017-09-01

This research studied about warpage of QFN package in post mold cure process of integrated circuit (IC) packages using pre-plated (PPF) leadframe. For IC package, epoxy molding compound (EMC) are molded by cross linking of compound stiffness but incomplete crosslinked network and leading the fully cured thermoset by post mold cure (PMC) process. The cure temperature of PMC can change microstructure of EMC in term of stress inside the package and effect to warpage of the package due to coefficient of thermal expansion (CTE) between EMC and leadframe. In experiment, cure temperatures were varied to check the effect of internal stress due to different cure temperature after completed post mold cure for TDFN 2×3 8L. The cure temperature were varied with 180 °C, 170 °C, 160 °C, and 150°C with cure time 4 and 6 hours, respectively. For analysis, the TDFN 2×3 8L packages were analyzed the warpage by thickness gauge and scanning acoustic microscope (SAM) after take the test samples out from the oven cure. The results confirmed that effect of different CTE between EMC and leadframe due to different cure temperature resulting to warpage of the TDFN 2×3 8L packages.

Development and Demonstration of Adanced Tooling Alloys for Molds and Dies

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kevin M. McHugh; Enrique J. Lavernia

2006-01-01

This report summarizes research results in the project Development and Demonstration of Advanced Tooling Alloys for Molds and Dies. Molds, dies and related tooling are used to manufacture most of the plastic and metal products we use every day. Conventional fabrication of molds and dies involves a multiplicity of machining, benching and heat treatment unit operations. This approach is very expensive and time consuming. Rapid Solidifcation Process (RSP) Tooling is a spray-forming technology tailored for producing molds and dies. The appraoch combines rapid solidifcation processing and net-shape materials processing in a single step. An atomized spray of a tool-forming alloy,more » typically a tool steel, is deposited onto an easy-to-form tool pattern to replicate the pattern's shape and surface features. By so doing, the approach eliminates many machining operations in conventional mold making, significantly reducing cost, lead time and energy. Moreover, rapid solidification creates unique microstructural features by suppressing carbide precipitation and growth, and creating metastable phases. This can result in unique material properties following heat treatment. Spray-formed and aged tool steel dies have exhibited extended life compared to conventional dies in many forming operations such as forging, extrusion and die casting. RSP Tooling technolocy was commercialized with the formation of RSP Tooling, LLC in Solon, Oh.« less

Lost Mold Rapid Infiltration Forming of Mesoscale Ceramics: Part 1, Fabrication

PubMed Central

Antolino, Nicholas E.; Hayes, Gregory; Kirkpatrick, Rebecca; Muhlstein, Christopher L.; Frecker, Mary I.; Mockensturm, Eric M.; Adair, James H.

2009-01-01

Free-standing mesoscale (340 μm × 30 μm × 20 μm) bend bars with an aspect ratio over 15:1 and an edge resolution as fine as a single grain diameter (∼400 nm) have been fabricated in large numbers on refractory ceramic substrates by combining a novel powder processing approach with photoresist molds and an innovative lost-mold thermal process. The colloid and interfacial chemistry of the nanoscale zirconia particulates has been modeled and used to prepare highly concentrated suspensions. Engineering solutions to challenges in mold fabrication and casting have yielded free-standing, crack-free parts. Molds are fabricated using high-aspect-ratio photoresist on ceramic substrates. Green parts are formed using a rapid infiltration method that exploits the shear thinning behavior of the highly concentrated ceramic suspension in combination with gelcasting. The mold is thermally decomposed and the parts are sintered in place on the ceramic substrate. Chemically aided attrition milling disperses and concentrates the as-received 3Y-TZP powder to produce a dense, fine-grained sintered microstructure. Initial three-point bend strength data are comparable to that of conventional zirconia; however, geometric irregularities (e.g., trapezoidal cross sections) are present in this first generation and are discussed with respect to the distribution of bend strength. PMID:19809595

Improvement of Strength-Toughness-Hardness Balance in Large Cross-Section 718H Pre-Hardened Mold Steel

PubMed Central

Liu, Hanghang; Fu, Paixian; Liu, Hongwei; Li, Dianzhong

2018-01-01

The strength-toughness combination and hardness uniformity in large cross-section 718H pre-hardened mold steel from a 20 ton ingot were investigated with three different heat treatments for industrial applications. The different microstructures, including tempered martensite, lower bainite, and retained austenite, were obtained at equivalent hardness. The microstructures were characterized by using metallographic observations, scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray diffraction (XRD), and electron back-scattered diffraction (EBSD). The mechanical properties were compared by tensile, Charpy U-notch impact and hardness uniformity tests at room temperature. The results showed that the test steels after normalizing-quenching-tempering (N-QT) possessed the best strength-toughness combination and hardness uniformity compared with the conventional quenched-tempered (QT) steel. In addition, the test steel after austempering-tempering (A-T) demonstrated the worse hardness uniformity and lower yield strength while possessing relatively higher elongation (17%) compared with the samples after N-QT (14.5%) treatments. The better ductility of A-T steel mainly depended on the amount and morphology of retained austenite and thermal/deformation-induced twined martensite. This work elucidates the mechanisms of microstructure evolution during heat treatments and will highly improve the strength-toughness-hardness trade-off in large cross-section steels. PMID:29642642

Fast assembling microarrays of superparamagnetic Fe3O4@Au nanoparticle clusters as reproducible substrates for surface-enhanced Raman scattering

NASA Astrophysics Data System (ADS)

Ye, Min; Wei, Zewen; Hu, Fei; Wang, Jianxin; Ge, Guanglu; Hu, Zhiyuan; Shao, Mingwang; Lee, Shuit-Tong; Liu, Jian

2015-08-01

It is currently a very active research area to develop new types of substrates which integrate various nanomaterials for surface-enhanced Raman scattering (SERS) techniques. Here we report a unique approach to prepare SERS substrates with reproducible performance. It features silicon mold-assisted magnetic assembling of superparamagnetic Fe3O4@Au nanoparticle clusters (NCs) into arrayed microstructures on a wafer scale. This approach enables the fabrication of both silicon-based and hydrogel-based substrates in a sequential manner. We have demonstrated that strong SERS signals can be harvested from these substrates due to an efficient coupling effect between Fe3O4@Au NCs, with enhancement factors >106. These substrates have been confirmed to provide reproducible SERS signals, with low variations in different locations or batches of samples. We investigate the spatial distributions of electromagnetic field enhancement around Fe3O4@Au NCs assemblies using finite-difference-time-domain (FDTD) simulations. The procedure to prepare the substrates is straightforward and fast. The silicon mold can be easily cleaned out and refilled with Fe3O4@Au NCs assisted by a magnet, therefore being re-useable for many cycles. Our approach has integrated microarray technologies and provided a platform for thousands of independently addressable SERS detection, in order to meet the requirements of a rapid, robust, and high throughput performance.It is currently a very active research area to develop new types of substrates which integrate various nanomaterials for surface-enhanced Raman scattering (SERS) techniques. Here we report a unique approach to prepare SERS substrates with reproducible performance. It features silicon mold-assisted magnetic assembling of superparamagnetic Fe3O4@Au nanoparticle clusters (NCs) into arrayed microstructures on a wafer scale. This approach enables the fabrication of both silicon-based and hydrogel-based substrates in a sequential manner. We have demonstrated that strong SERS signals can be harvested from these substrates due to an efficient coupling effect between Fe3O4@Au NCs, with enhancement factors >106. These substrates have been confirmed to provide reproducible SERS signals, with low variations in different locations or batches of samples. We investigate the spatial distributions of electromagnetic field enhancement around Fe3O4@Au NCs assemblies using finite-difference-time-domain (FDTD) simulations. The procedure to prepare the substrates is straightforward and fast. The silicon mold can be easily cleaned out and refilled with Fe3O4@Au NCs assisted by a magnet, therefore being re-useable for many cycles. Our approach has integrated microarray technologies and provided a platform for thousands of independently addressable SERS detection, in order to meet the requirements of a rapid, robust, and high throughput performance. Electronic supplementary information (ESI) available: XRD, reflection spectra, zeta potential, TEM images, evaluations of reproducibility, EDS, tables of EF and RSD values of different substrates. See DOI: 10.1039/c5nr02491a

DOE Office of Scientific and Technical Information (OSTI.GOV)

Laguna, O.; Collar, E.P.; Taranco, J.

Observations are made about microstructural aspects from HDPE and LDPE homopolymers and their blends as virgin materials and also from urban plastic wastes. Micrographs were taken by SEM. Micrographs corresponding to the fracture surface from specimens tested in an impact test clearly show different microstructural features due to polymer which is more than 50%. Parts were injection molded. A discussion is given about crystallization behavior of those materials obtained by DSC. For all blends the same results have been found, i.e., two peaks owing to each of the two polymers which are present in the blends.

Obstetric balloon for treatment of foreshortened vagina using the McIndoe technique.

PubMed

Rauktys, Aubrey; Parikh, Pranay; Harmanli, Oz

2015-01-01

When conservative options such as the use of vaginal dilators fail, the McIndoe technique may be used in the surgical treatment of a foreshortened vagina. The McIndoe procedure, an approach commonly used for the treatment of vaginal agenesis, requires a mold over which a skin graft is sutured and placed inside the vagina. In most surgical descriptions, this mold is made from non-sterile foam, condoms, or gloves. Because makeshift molds can no longer be used in operating rooms owing to strict regulations, alternative methods must be employed. The obstetric balloon is a good choice for use as a soft and adjustable vaginal mold for a modified McIndoe procedure because it is readily available as an approved device in hospitals that provide obstetric services. This technique was successfully employed in a 54-year-old woman to treat foreshortened vagina. An obstetric balloon can be used effectively as a mold for vaginal reconstruction with the McIndoe technique.

Improved compression molding technology for continuous fiber reinforced composite laminates. Part 2: AS-4/Polyimidesulfone prepreg system

NASA Technical Reports Server (NTRS)

Baucom, Robert M.; Hou, Tan-Hung; Kidder, Paul W.; Reddy, Rakasi M.

1991-01-01

AS-4/polyimidesulfone (PISO2) composite prepreg was utilized for the improved compression molding technology investigation. This improved technique employed molding stops which advantageously facilitate the escape of volatile by-products during the B-stage curing step, and effectively minimize the neutralization of the consolidating pressure by intimate interply fiber-fiber contact within the laminate in the subsequent molding cycle. Without the modifying the resin matrix properties, composite panels with both unidirectional and angled plies with outstanding C-scans and mechanical properties were successfully molded using moderate molding conditions, i.e., 660 F and 500 psi, using this technique. The size of the panels molded were up to 6.00 x 6.00 x 0.07 in. A consolidation theory was proposed for the understanding and advancement of the processing science. Processing parameters such as vacuum, pressure cycle design, prepreg quality, etc. were explored.

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.

Wetting Behavior of Mold Flux Droplet on Steel Substrate With or Without Interfacial Reaction

NASA Astrophysics Data System (ADS)

Zhou, Lejun; Li, Jingwen; Wang, Wanlin; Sohn, Il

2017-08-01

The slag entrapment in mold tends to cause severe defects on the slab surface, especially for casting steels containing active alloy elements such as Al, Ti, and Mn. The wetting behavior of molten mold flux on the initial solidified shell is considered to be a key factor to determine the entrapment of mold slag on the shell surface. Therefore, the wetting behavior of mold flux droplet on the steel substrate with or without interfacial reaction was investigated by the sessile drop method. The results indicated that the melting process of mold flux has a significant influence on the variation of contact angle, and the final contact angle for Flux1 droplet on 20Mn23AlV is only 15 deg, which is lower than the other two cases due to the intensive interracial reactions occurring in this case. In addition, the thickness of the interaction layer for the case of Flux1 on 20Mn23AlV is 10- μm greater than the other two cases, which confirms that the most intensive reactions occurred at the interface area. The microstructure and element distribution at the interface analyzed by a scanning electron microscope (SEM) and energy dispersive spectrum (EDS) suggested that the increase of wettability of mold flux droplet on the steel substrate is caused by the migration of Al, Mn, and Si elements occurring in the vicinity of the interface. The results obtained in this article can reveal the mechanism of flux entrapment by hook or shell and provide theoretic guidance for mold flux design and optimization.

New methods and materials for molding and casting ice formations

NASA Technical Reports Server (NTRS)

Reehorst, Andrew L.; Richter, G. Paul

1987-01-01

This study was designed to find improved materials and techniques for molding and casting natural or simulated ice shapes that could replace the wax and plaster method. By utilizing modern molding and casting materials and techniques, a new methodology was developed that provides excellent reproduction, low-temperature capability, and reasonable turnaround time. The resulting casts are accurate and tough.

Rapid production of polymer microstructures

NASA Astrophysics Data System (ADS)

Nagarajan, Pratapkumar

The goal of this research is to develop an integrated polymer embossing module, with which difficult-to-emboss polymer microstructures and microparts can be fabricated in a cost-effective manner. In particular, the research addresses three major limitations of the hot embossing process, namely, long cycle time, difficulty in producing shell patterns, and difficulty in building up a high embossing pressure on thick substrates. To overcome these limitations, three new technical approaches - two-station embossing, rubber-assisted embossing, and through-thickness embossing - were developed and investigated. Fundamental understanding of these new embossing techniques were achieved through extensive experimental and theoretical studies involving parametric experiments, rheological characterization, surface investigation, mathematical modeling, and computer simulation. A two-station embossing process was developed to reduce the hot embossing cycle time, accomplished by decoupling the heating and cooling stations. For this purpose, the standard hot embossing mold was replaced by a shell type mold, and separate hot and cold stations were used to selectively heat and cool the shell mold during the process. With this method, microlens arrays and micro channels were fabricated onto ABS and HDPE substrates with a cycle time of approximately 10 s. Numerical simulations were performed to study the effect of different design parameters, including thermal contact resistance, shell material and shell thickness, on the thermal response at the mold surface. Furthermore, the polymer flow during the two-station embossing process for the microlens was numerically studied. The simulated filling behavior agreed with the experimental observation, and the predicted thermal and deformation history of the polymer offers a good explanation on the experimentally observed process characteristics. The second technique, rubber-assisted embossing, involving a rubber pad as a soft counter tool, was developed for precision embossing of shell structures. The rubber pad acted as a temporary negative during embossing and recovered to its original geometry after mold opening. With rubber-assisted embossing, a micro shell pattern with a characteristic size of 50 mum was successfully patterned on 25-mum thick polystyrene films. A focused study was undertaken on rubber-assisted isothermal embossing to establish the relationship between process parameters and pattern replication. It was found that the pattern replication and film uniformity were affected by the embossing temperature and the hardness of rubber. It was also found that adequate plasticity and higher stiffness of the deforming film were essential in achieving excellent pattern replication and uniformity in film thickness. The through-thickness embossing process was developed for embossing pressure buildup and fabrication of 3-D parts. The embossing tool includes a punching head and to-be-replicated features in the socket behind the punching head. The built-in punching head facilitates a through-thickness action and provides a close-die environment for embossing pressure buildup. The method was used to emboss multichannel millimeter waveguides which requires crispy edges and accurate dimensions. With a tool temperature of 140°C, an embossing time of 3 min and a total cycle time of 7 min, discrete 4-channel waveguides were successfully embossed from a room-temperature ABS substrate. A computer model was established to study the flow behavior during through-thickness embossing. It was found that nonisothermal embossing conditions helped to confine the polymer in the cavity and reduce the outflow into the surrounding region, thus achieving complete fill of the cavity.

Metal injection molding of titanium for medical and aerospace applications

NASA Astrophysics Data System (ADS)

Scharvogel, Matthias; Winkelmueller, Wendelin

2011-02-01

Mixing of titanium powder and thermoplastic binders creates a feedstock that is injection molded similar to plastic, has a chemical and thermal debinding process, and then is sintered to form a net-shape or near-net shape part. TiJet Medizintechnik GmbH (TiJet) developed and uses its own feedstock and powder processing technology to achieve desired mechanical properties. This paper explains the theory of the process and the possibilities that result from the development of this new powder processing technology, such as new alloys, design possibilities, etc. Discussed will be the microstructure, chemical composition, and mechanical properties of the manufactured parts.

Microengineering of Metals and Ceramics: Part I: Design, Tooling and Injection Molding; Volume 3: Advanced Micro & Nanosystems

NASA Astrophysics Data System (ADS)

Baltes, Henry; Brand, Oliver; Fedder, Gary K.; Hierold, Christofer; Korvink, Jan G.; Tabata, Osamu; Löhe, Detlef; Haußelt, Jürgen

2005-09-01

Microstructures, electronics, nanotechnology - these vast fields of research are growing together as the size gap narrows and many different materials are combined. Current research, engineering sucesses and newly commercialized products hint at the immense innovative potentials and future applications that open up once mankind controls shape and function from the atomic level right up to the visible world without any gaps. In this volume, authors from three major competence centres for microengineering illustrate step by step the process from designing and simulating microcomponents of metallic and ceramic materials to replicating micro-scale components by injection molding.

Microstructural Evolution of Al2O3-ZrO2 (Y2O3) Composites and its Correlation with Toughness

NASA Astrophysics Data System (ADS)

Kim, Hee Seung; Seo, Mi Young; Kim, Ik Jin

2008-02-01

The microstructure of zirconia (ZrO2) toughened alumina (Al2O3) ceramics was carefully controlled so as to obtain dense and fine-grained ceramics, thereby improving the properties and reliability of the ceramics for capillary applications in semiconductor bonding technology. Al2O3-ZrO2(Y2O3) composite was produced via Ceramic Injection Molding (CIM) technology, followed by Sinter-HIP process. Room temperature strength, hardness, Young's modulus, thermal expansion coefficient and toughness were determined, as well as surface strengthening induced by the fine grained homogenous microstructure and the thermal treatment. The changes in alumina/zirconia grain size, sintering condition and HIP treatment were found to be correlated.

Indirect three-dimensional printing of synthetic polymer scaffold based on thermal molding process.

PubMed

Park, Jeong Hun; Jung, Jin Woo; Kang, Hyun-Wook; Cho, Dong-Woo

2014-06-01

One of the major issues in tissue engineering has been the development of three-dimensional (3D) scaffolds, which serve as a structural template for cell growth and extracellular matrix formation. In scaffold-based tissue engineering, 3D printing (3DP) technology has been successfully applied for the fabrication of complex 3D scaffolds by using both direct and indirect techniques. In principle, direct 3DP techniques rely on the straightforward utilization of the final scaffold materials during the actual scaffold fabrication process. In contrast, indirect 3DP techniques use a negative mold based on a scaffold design, to which the desired biomaterial is cast and then sacrificed to obtain the final scaffold. Such indirect 3DP techniques generally impose a solvent-based process for scaffold fabrication, resulting in a considerable increase in the fabrication time and poor mechanical properties. In addition, the internal architecture of the resulting scaffold is affected by the properties of the biomaterial solution. In this study, we propose an advanced indirect 3DP technique using projection-based micro-stereolithography and an injection molding system (IMS) in order to address these challenges. The scaffold was fabricated by a thermal molding process using IMS to overcome the limitation of the solvent-based molding process in indirect 3DP techniques. The results indicate that the thermal molding process using an IMS has achieved a substantial reduction in scaffold fabrication time and has also provided the scaffold with higher mechanical modulus and strength. In addition, cell adhesion and proliferation studies have indicated no significant difference in cell activity between the scaffolds prepared by solvent-based and thermal molding processes.

A Study of the Oscillation Marks' Characteristics of Continuously Cast Incoloy Alloy 825 Blooms

NASA Astrophysics Data System (ADS)

Saleem, Saud; Vynnycky, Michael; Fredriksson, Hasse

2016-08-01

A comprehensive experimental study of oscillation mark (OM) formation and its characteristics during the solidification of Incoloy alloy 825 in the continuous casting of blooms is investigated by plant trials and metallographic study. The experiments involved two heats with the same casting and mold conditions and sampling at different locations across the strand. The metallographic study combined macro/micro-examinations of OMs and segregation analysis of Cr, Mn, Mo, Ni, and Si by microprobe analysis. The results show that OMs have widely different characteristics, such as mark type, depth, segregation, and accompanying microstructure. Furthermore, the mark pitch can vary considerably even for the similar casting conditions, leading to different conditions for the marks' formation in relation to the mold's cyclic movement. Finally, a mechanism for the OM formation is discussed and proposed. Possible solutions for minimizing the observed defects by optimizing the mold conditions are suggested.

A Knowledge Database on Thermal Control in Manufacturing Processes

NASA Astrophysics Data System (ADS)

Hirasawa, Shigeki; Satoh, Isao

A prototype version of a knowledge database on thermal control in manufacturing processes, specifically, molding, semiconductor manufacturing, and micro-scale manufacturing has been developed. The knowledge database has search functions for technical data, evaluated benchmark data, academic papers, and patents. The database also displays trends and future roadmaps for research topics. It has quick-calculation functions for basic design. This paper summarizes present research topics and future research on thermal control in manufacturing engineering to collate the information to the knowledge database. In the molding process, the initial mold and melt temperatures are very important parameters. In addition, thermal control is related to many semiconductor processes, and the main parameter is temperature variation in wafers. Accurate in-situ temperature measurment of wafers is important. And many technologies are being developed to manufacture micro-structures. Accordingly, the knowledge database will help further advance these technologies.

High-definition micropatterning method for hard, stiff and brittle polymers.

PubMed

Zhao, Yiping; Truckenmuller, Roman; Levers, Marloes; Hua, Wei-Shu; de Boer, Jan; Papenburg, Bernke

2017-02-01

Polystyrene (PS) is the most commonly used material in cell culture devices, such as Petri dishes, culture flasks and well plates. Micropatterning of cell culture substrates can significantly affect cell-material interactions leading to an increasing interest in the fabrication of topographically micro-structured PS surfaces. However, the high stiffness combined with brittleness of PS (elastic modulus 3-3.5GPa) makes high-quality patterning into PS difficult when standard hard molds, e.g. silicon and nickel, are used as templates. A new and robust scheme for easy processing of large-area high-density micro-patterning into PS film is established using nanoimprinting lithography and standard hot embossing techniques. Including an extra step through an intermediate PDMS mold alone does not result in faithful replication of the large area, high-density micropattern into PS. Here, we developed an approach using an additional intermediate mold out of OrmoStamp, which allows for high-quality and large-area micro-patterning into PS. OrmoStamp was originally developed for UV nanoimprint applications; this work demonstrates for the first time that OrmoStamp is a highly adequate material for micro-patterning of PS through hot embossing. Our proposed processing method achieves high-quality replication of micropatterns in PS, incorporating features with high aspect ratio (4:1, height:width), high density, and over a large pattern area. The proposed scheme can easily be adapted for other large-area and high-density micropatterns of PS, as well as other stiff and brittle polymers. Copyright © 2016 Elsevier B.V. All rights reserved.

Hierarchical Materials Design by Pattern Transfer Printing of Self-Assembled Binary Nanocrystal Superlattices

DOE Office of Scientific and Technical Information (OSTI.GOV)

Paik, Taejong; Yun, Hongseok; Fleury, Blaise

We demonstrate the fabrication of hierarchical materials by controlling the structure of highly ordered binary nanocrystal superlattices (BNSLs) on multiple length scales. Combinations of magnetic, plasmonic, semiconducting, and insulating colloidal nanocrystal (NC) building blocks are self-assembled into BNSL membranes via the liquid–interfacial assembly technique. Free-standing BNSL membranes are transferred onto topographically structured poly(dimethylsiloxane) molds via the Langmuir–Schaefer technique and then deposited in patterns onto substrates via transfer printing. BNSLs with different structural motifs are successfully patterned into various meso- and microstructures such as lines, circles, and even three-dimensional grids across large-area substrates. A combination of electron microscopy and grazing incidencemore » small-angle X-ray scattering (GISAXS) measurements confirm the ordering of NC building blocks in meso- and micropatterned BNSLs. This technique demonstrates structural diversity in the design of hierarchical materials by assembling BNSLs from NC building blocks of different composition and size by patterning BNSLs into various size and shape superstructures of interest for a broad range of applications.« less

Performance of disposable endoscopic forceps according to the manufacturing techniques.

PubMed

Kwon, Chang-Il; Kim, Gwangil; Moon, Jong Pil; Yun, Ho; Ko, Weon Jin; Cho, Joo Young; Hong, Sung Pyo

2018-03-05

Recently, to lower the production costs and risk of infection, new disposable biopsy forceps made using simple manufacturing techniques have been introduced. However, the effects of the manufacturing techniques are unclear. The aim of this study was to evaluate which types of biopsy forceps could obtain good-quality specimens according to the manufacturing techniques. By using an in vitro nitrile glove popping model, we compared the popping ability among eight different disposable biopsy forceps (one pair of biopsy forceps with cups made by a cutting method [cutting forceps], four pairs of biopsy forceps with cups made by a pressing method [pressing forceps], and three pairs of biopsy forceps with cups made using a injection molding method [molding forceps]). Using an in vivo swine model, we compared the penetration depth and quality of specimen among the biopsy forceps. In the in vitro model, the molding forceps provided a significantly higher popping rate than the other forceps (cutting forceps, 25.0%; pressing forceps, 17.5%; and molding forceps, 41.7%; p = 0.006). In the in vivo model, the cutting and pressing forceps did not provide larger specimens, deeper biopsy specimen, and higher specimen adequacy than those obtained using the molding forceps (p = 0.2631, p = 0.5875, and p = 0.2147, respectively). However, the molding forceps showed significantly more common crush artifact than the others (cutting forceps, 0%; pressing forceps, 5.0%; and molding forceps, 43.3%; p = 0.0007). The molding forceps provided lower performance than the cutting and pressing forceps in terms of crush artifact.

Processing of IN-718 Lattice Block Castings

NASA Technical Reports Server (NTRS)

Hebsur, Mohan G.

2002-01-01

Recently a low cost casting method known as lattice block casting has been developed by JAM Corporation, Wilmington, Massachusetts for engineering materials such as aluminum and stainless steels that has shown to provide very high stiffness and strength with only a fraction of density of the alloy. NASA Glenn Research Center has initiated research to investigate lattice block castings of high temperature Ni-base superalloys such as the model system Inconel-718 (IN-718) for lightweight nozzle applications. Although difficulties were encountered throughout the manufacturing process , a successful investment casting procedure was eventually developed. Wax formulation and pattern assembly, shell mold processing, and counter gravity casting techniques were developed. Ten IN-718 lattice block castings (each measuring 15-cm wide by 30-cm long by 1.2-cm thick) have been successfully produced by Hitchiner Gas Turbine Division, Milford, New Hampshire, using their patented counter gravity casting techniques. Details of the processing and resulting microstructures are discussed in this paper. Post casting processing and evaluation of system specific mechanical properties of these specimens are in progress.

A Novel General Chemistry Laboratory: Creation of Biomimetic Superhydrophobic Surfaces through Replica Molding

ERIC Educational Resources Information Center

Verbanic, Samuel; Brady, Owen; Sanda, Ahmed; Gustafson, Carolina; Donhauser, Zachary J.

2014-01-01

Biomimetic replicas of superhydrophobic lotus and taro leaf surfaces can be made using polydimethylsiloxane. These replicas faithfully reproduce the microstructures of the leaves' surface and can be analyzed using contact angle goniometry, self-cleaning experiments, and optical microscopy. These simple and adaptable experiments were used to…

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ahmed, A.; Chadwick, T.; Makhlouf, M.

This paper deals with the effects of various solidification variables such as cooling rate, temperature gradient, solidification rate, etc. on the microstructure and shrinkage defects in aluminum alloy (A356) castings. The effects are first predicted using commercial solidification modeling softwares and then verified experimentally. For this work, the authors are considering a rectangular bar cast in a sand mold. Simulation is performed using SIMULOR, a finite volume based casting simulation program. Microstructural variables such as dendritic arm spacing (DAS) and defects (percentage porosity) are calculated from the temperature fields, cooling rate, solidification time, etc. predicted by the computer softwares. Themore » same variables are then calculated experimentally in the foundry. The test piece is cast in a resin (Sodium Silicate) bonded sand mold and the DAS and porosity variables are calculated using Scanning Electron Microscopy and Image Analysis. The predictions from the software are compared with the experimental results. The results are presented and critically analyzed to determine the quality of the predicted results. The usefulness of the commercial solidification modeling softwares as a tool for the foundry are also discussed.« less

Nasoalveolar molding in cleft care: is it efficacious?

PubMed

Abbott, Megan M; Meara, John G

2012-09-01

In the era of evidence-based medicine, new treatment protocols and interventions should be routinely evaluated for their efficacy by reviewing the available evidence. In the cleft literature, nasoalveolar molding has garnered attention over the last decade as a new option for improving nasal form and symmetry before primary surgical repair. Systematic review of the evidence is, however, currently lacking. This review evaluates whether nasoalveolar molding can improve nasal symmetry and form toward the norm, as well as whether nasoalveolar molding demonstrates advantages over other protocols in achieving this goal. A literature search of five databases plus relevant reference lists retrieved 98 articles regarding nasoalveolar molding, 21 of which reported objective outcome measures of nasal symmetry and form, and six of which were able to be given evidence level ratings, all in the unilateral cleft population. Statistical analysis was not possible given the range of techniques and outcomes. Studies of bilateral cleft were not given evidence level ratings, given the inability to separate the effects of nasoalveolar molding from other primary nasal interventions in studies that would have otherwise been rated. In unilateral cleft lip-cleft palate, there was some evidence that nasoalveolar molding may improve nasal outcomes, though comparison with other techniques was limited. Despite a relative paucity of high-level evidence, nasoalveolar molding appears to be a promising technique that deserves further study.

Diagnosis of mold allergy by RAST and skin prick testing.

PubMed

Nordvall, S L; Agrell, B; Malling, H J; Dreborg, S

1990-11-01

Sera from 33 patients with mold allergy proven by bronchial provocation were analyzed for specific IgE against six mold species comparing an improved Phadebas RAST with four other techniques. The new method was more sensitive and gave significantly higher IgE antibody concentrations for all tested molds except Cladosporium herbarum.

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.

Manufacturing plastic injection optical molds

NASA Astrophysics Data System (ADS)

Bourque, David

2008-08-01

ABCO Tool & Die, Inc. is a mold manufacturer specializing in the manufacturing of plastic injection molds for molded optical parts. The purpose of this presentation is to explain the concepts and procedures required to build a mold that produces precision optical parts. Optical molds can produce a variety of molded parts ranging from safety eyewear to sophisticated military lens parts, which must meet precise optical specifications. The manufacturing of these molds begins with the design engineering of precision optical components. The mold design and the related optical inserts are determined based upon the specific optical criteria and optical surface geometry. The mold manufacturing techniques will be based upon the optical surface geometry requirements and specific details. Manufacturing processes used will be specific to prescribed geometrical surface requirements of the molded part. The combined efforts result in a robust optical mold which can produce molded parts that meet the most precise optical specifications.

Thermoplastics for aircraft interiors

NASA Technical Reports Server (NTRS)

Silverman, B.

1978-01-01

The goal for this contract is the development of processes and techniques for molding thermally stable, fire retardant, low smoke emitting polymeric materials. Outlined in this presentation are: (1) the typical molding types; (2) a program schedule; (3) physical properties of molding types with the test methods to be used; (4) general properties of injection molding materials; and (5) preliminary materials selection.

Hierarchically porous materials from layer-by-layer photopolymerization of high internal phase emulsions.

PubMed

Sušec, Maja; Ligon, Samuel Clark; Stampfl, Jürgen; Liska, Robert; Krajnc, Peter

2013-06-13

A combination of high internal phase emulsion (HIPE) templating and additive manufacturing technology (AMT) is applied for creating hierarchical porosity within an acrylate and acrylate/thiol-based polymer network. The photopolymerizable formulation is optimized to produce emulsions with a volume fraction of droplet phase greater than 80 vol%. Kinetic stability of the emulsions is sufficient enough to withstand in-mold curing or computer-controlled layer-by-layer stereolithography without phase separation. By including macroscale cellular cavities within the build file, a level of controlled porosity is created simultaneous to the formation of the porous microstructure of the polyHIPE. The hybrid HIPE-AMT technique thus provides hierarchically porous materials with mechanical properties tailored by the addition of thiol chain transfer agent. Copyright © 2013 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

A feasible injection molding technique for the manufacturing of large diameter aspheric plastic lenses

NASA Astrophysics Data System (ADS)

Shieh, Jen-Yu; Wang, Luke K.; Ke, Shih-Ying

2010-07-01

A computer aided engineering (CAE) tool-assisted technique, using Moldex3D and aspheric analysis utility (AAU) software in a polycarbonate injection molding design, is proposed to manufacture large diameter aspheric plastic lenses. An experiment is conducted to verify the applicability/feasibility of the proposed technique. Using the preceding two software tools, these crucial process parameters associated with the surface profile errors and birefringence of a molded lens can be attainable. The strategy adopted here is to use the actual quantity of shrinkage after an injection molding trial of an aspherical plastic lens as a reference to perform the core shaping job while keeping the coefficients of aspheric surface, radius, and conic constant unchanged. The design philosophy is characterized by using the CAE tool as a guideline to pursue the best symmetry condition, followed by injection molding trials, to accelerate a product’s developmental time. The advantages are less design complexity and shorter developmental time for a product.

High-Temperature Properties of Mold Flux Observed and Measured In Situ by Single/Double Hot-Thermocouple Technique

NASA Astrophysics Data System (ADS)

Wang, Wanlin; Lyu, Peisheng; Zhou, Lejun; Li, Huan; Zhang, Tongsheng

2018-05-01

Mold flux plays very important roles in the continuous casting process, and its high-temperature properties affect the quality of the final as-cast product greatly. Investigations on the melting, isothermal and nonisothermal crystallization, and phase evolution behaviors under a simulated temperature field for the mold flux system using the single/double hot-thermocouple technique (S/DHTT) were reviewed. Meanwhile, further in situ observations on the wetting behavior and heat transfer ability of the mold flux system were also carried out using the S/DHTT. The results summarized here provide a clear understanding of both the high-temperature properties of mold flux and the detailed application of advanced real-time visual high-temperature S/DHTT to this molten slag system.

Laser-Etched Designs for Molding Hydrogel-Based Engineered Tissues

PubMed Central

Munarin, Fabiola; Kaiser, Nicholas J.; Kim, Tae Yun; Choi, Bum-Rak

2017-01-01

Rapid prototyping and fabrication of elastomeric molds for sterile culture of engineered tissues allow for the development of tissue geometries that can be tailored to different in vitro applications and customized as implantable scaffolds for regenerative medicine. Commercially available molds offer minimal capabilities for adaptation to unique conditions or applications versus those for which they are specifically designed. Here we describe a replica molding method for the design and fabrication of poly(dimethylsiloxane) (PDMS) molds from laser-etched acrylic negative masters with ∼0.2 mm resolution. Examples of the variety of mold shapes, sizes, and patterns obtained from laser-etched designs are provided. We use the patterned PDMS molds for producing and culturing engineered cardiac tissues with cardiomyocytes derived from human-induced pluripotent stem cells. We demonstrate that tight control over tissue morphology and anisotropy results in modulation of cell alignment and tissue-level conduction properties, including the appearance and elimination of reentrant arrhythmias, or circular electrical activation patterns. Techniques for handling engineered cardiac tissues during implantation in vivo in a rat model of myocardial infarction have been developed and are presented herein to facilitate development and adoption of surgical techniques for use with hydrogel-based engineered tissues. In summary, the method presented herein for engineered tissue mold generation is straightforward and low cost, enabling rapid design iteration and adaptation to a variety of applications in tissue engineering. Furthermore, the burden of equipment and expertise is low, allowing the technique to be accessible to all. PMID:28457187

Homogeneous and heterogeneous micro-structuring of austenitic stainless steels by the low temperature plasma nitriding

NASA Astrophysics Data System (ADS)

Aizawa, T.; Yoshihara, S.-I.

2018-06-01

The austenitic stainless steels have been widely utilized as a structural component and member as well as a die and mold substrate for stamping. AISI316 dies and molds require for the surface treatment to accommodate the sufficient hardness and wear resistance to them. In addition, the candidate treatment methods must be free from toxicity, energy consumption and inefficiency. The low temperature plasma nitriding process has become one of the most promising methods to make solid-solution hardening by the nitrogen super-saturation. In the present paper, the high density RF/DC plasma nitriding process was applied to form the uniform nitrided layer in the AISI316 matrix and to describe the essential mechanism of inner nitriding in this low temperature nitriding process. In case of the nitrided AISI316 at 673 K for 14.4ks, the nitrided layer thickness became 60 μm with the surface hardness of 1700 HV and the surface nitrogen content of 7 mass %. This inner nitriding process is governed by the synergetic interrelation among the nitrogen super-saturation, the lattice expansion, the phase transformation, the plastic straining, the microstructure refinement and the acceleration of nitrogen diffusion. As far as this interrelation is sustained during the nitriding process, the original austenitic microstructure is homogeneously nitrided to have fine grains with the average size of 0.1 μm and the high crystallographic misorientation angles and to have two phase (γ + α’) structures with the plateau of nitrogen content by 5 mass%. Once this interrelation does not work anymore, the homogeneous microstructure changed itself to the heterogeneous one. The plastic straining took place in the selected coarse grains; they were partially refined into subgrains. This plastic localization accompanied the localized phase transformation.

Process optimization for ultrasonic vibration assisted polishing of micro-structured surfaces on super hard material

NASA Astrophysics Data System (ADS)

Sun, Zhiyuan; Guo, Bing; Rao, Zhimin; Zhao, Qingliang

2014-08-01

In consideration of the excellent property of SiC, the ground micro-structured surface quality is hard to meet the requirement - consequently the ultrasonic vibration assisted polishing (UVAP) of micro-structures of molds is proposed in this paper. Through the orthogonal experiment, the parameters of UVAP of micro-structures were optimized. The experimental results show that, abrasive polishing process, the effect of the workpiece feed rate on the surface roughness (Ra), groove tip radius (R) and material removal rate (MRR) of micro-structures is significant. While, the UVAP, the most significant effect factor for Ra, R and MRR is the ultrasonic amplitude of the ultrasonic vibration. In addition, within the scope of the polishing process parameters selected by preliminary experiments, ultrasonic amplitude of 2.5μm, polishing force of 0.5N, workpiece feed rate of 5 mm·min-1, polishing wheel rotational speed of 50rpm, polishing time of 35min, abrasive size of 100nm and the polishing liquid concentration of 15% is the best technology of UVAP of micro-structures. Under the optimal parameters, the ground traces on the micro-structured surface were removed efficiently and the integrity of the edges of the micro-structure after grinding was maintained efficiently.

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.

Improved ceramic slip casting technique. [application to aircraft model fabrication

NASA Technical Reports Server (NTRS)

Buck, Gregory M. (Inventor); Vasquez, Peter (Inventor)

1993-01-01

A primary concern in modern fluid dynamics research is the experimental verification of computational aerothermodynamic codes. This research requires high precision and detail in the test model employed. Ceramic materials are used for these models because of their low heat conductivity and their survivability at high temperatures. To fabricate such models, slip casting techniques were developed to provide net-form, precision casting capability for high-purity ceramic materials in aqueous solutions. In previous slip casting techniques, block, or flask molds made of plaster-of-paris were used to draw liquid from the slip material. Upon setting, parts were removed from the flask mold and cured in a kiln at high temperatures. Casting detail was usually limited with this technique -- detailed parts were frequently damaged upon separation from the flask mold, as the molded parts are extremely delicate in the uncured state, and the flask mold is inflexible. Ceramic surfaces were also marred by 'parting lines' caused by mold separation. This adversely affected the aerodynamic surface quality of the model as well. (Parting lines are invariably necessary on or near the leading edges of wings, nosetips, and fins for mold separation. These areas are also critical for flow boundary layer control.) Parting agents used in the casting process also affected surface quality. These agents eventually soaked into the mold, the model, or flaked off when releasing the case model. Different materials were tried, such as oils, paraffin, and even an algae. The algae released best, but some of it remained on the model and imparted an uneven texture and discoloration on the model surface when cured. According to the present invention, a wax pattern for a shell mold is provided, and an aqueous mixture of a calcium sulfate-bonded investment material is applied as a coating to the wax pattern. The coated wax pattern is then dried, followed by curing to vaporize the wax pattern and leave a shell mold of the calcium sulfate-bonded investment material. The shell mold is cooled to room temperature, and a ceramic slip is poured therein. After a ceramic shell of desired thickness has set up in the shell mold, excess ceramic slip is poured out. While still wet, the shell mold is peeled from the ceramic shell to expose any delicate or detailed parts, after which the ceramic shell is cured to provide a complete, detailed, precision ceramic article without parting lines.

21ST CENTURY MOLD ANALYSIS IN FOOD

EPA Science Inventory

Traditionally, the indoor air community has relied on mold analysis performed by either microscopic observations or the culturing of molds on various media to assess indoor air quality. These techniques were developed in the 19th century and are very laborious and time consumin...

Microfluidic devices fabricated in poly(methyl methacrylate) using hot-embossing with integrated sampling capillary and fiber optics for fluorescence detection.

PubMed

Qi, Shize; Liu, Xuezhu; Ford, Sean; Barrows, James; Thomas, Gloria; Kelly, Kevin; McCandless, Andrew; Lian, Kun; Goettert, Jost; Soper, Steven A

2002-05-01

High-aspect-ratio microstructures have been prepared using hot-embossing techniques in poly(methyl methacrylate) (PMMA) from Ni-based molding dies prepared using LIGA (Lithographie, Galvanoformung, Abformung). Due to the small amount of mask undercutting associated with X-ray lithography and the high energy X-ray beam used during photoresist patterning, deep structures with sharp and smooth sidewalls have been prepared. The Ni-electroforms produced devices with minimal replication errors using hot-embossing at a turn around time of approximately 5 min per device. In addition, several different polymers (with different glass transition temperatures) could be effectively molded with these Ni-electroforms and many devices (>300) molded with the same master without any noticeable degradation. The PMMA devices consisted of deep and narrow channels for insertion of a capillary for the automated electrokinetic loading of sample into the microfluidic device and also, a pair of optical fibers for shuttling laser light to the detection zone and collecting the resulting emission for fluorescence analysis. Electrophoretic separations of double-stranded DNA ladders Phi X174 digested with Hae III) were performed with fluorescence detection accomplished using near-IR excitation. It was found that the narrow width of the channels did not contribute significantly to electrophoretic zone broadening and the plate numbers generated in the extended length separation channel allowed sorting of the 271/281 base pair fragments associated with this sizing ladder when electrophoresed in methylcellulose entangled polymer solutions. The dual fiber detector produced sub-attomole detection limits with the entire detector, including laser source, electronics and photon transducer, situated in a single box measuring 3'' x 10" x 14".

40 CFR 63.5799 - How do I calculate my facility's organic HAP emissions on a tpy basis for purposes of determining...

Code of Federal Regulations, 2014 CFR

2014-07-01

... Calculating Organic Hap Emissions Factors for Open Molding and Centrifugal Casting § 63.5799 How do I.../casting operations, or a new facility that does not have any of the following operations: Open molding... coat is applied to an open centrifugal mold using open molding application techniques. Table 1 and the...

40 CFR 63.5799 - How do I calculate my facility's organic HAP emissions on a tpy basis for purposes of determining...

Code of Federal Regulations, 2013 CFR

2013-07-01

... Calculating Organic Hap Emissions Factors for Open Molding and Centrifugal Casting § 63.5799 How do I.../casting operations, or a new facility that does not have any of the following operations: Open molding... coat is applied to an open centrifugal mold using open molding application techniques. Table 1 and the...

Image-guided tissue engineering of anatomically shaped implants via MRI and micro-CT using injection molding.

PubMed

Ballyns, Jeffery J; Gleghorn, Jason P; Niebrzydowski, Vicki; Rawlinson, Jeremy J; Potter, Hollis G; Maher, Suzanne A; Wright, Timothy M; Bonassar, Lawrence J

2008-07-01

This study demonstrates for the first time the development of engineered tissues based on anatomic geometries derived from widely used medical imaging modalities such as computed tomography (CT) and magnetic resonance imaging (MRI). Computer-aided design and tissue injection molding techniques have demonstrated the ability to generate living implants of complex geometry. Due to its complex geometry, the meniscus of the knee was used as an example of this technique's capabilities. MRI and microcomputed tomography (microCT) were used to design custom-printed molds that enabled the generation of anatomically shaped constructs that retained shape throughout 8 weeks of culture. Engineered constructs showed progressive tissue formation indicated by increases in extracellular matrix content and mechanical properties. The paradigm of interfacing tissue injection molding technology can be applied to other medical imaging techniques that render 3D models of anatomy, demonstrating the potential to apply the current technique to engineering of many tissues and organs.

Replication fidelity improvement of PMMA microlens array based on weight evaluation and optimization

NASA Astrophysics Data System (ADS)

Jiang, Bing-yan; Shen, Long-jiang; Peng, Hua-jiang; Yin, Xiang-lin

2007-12-01

High replication fidelity is a prerequisite of high quality plastic microlens array in injection molding. But, there's not an economical and practical method to evaluate and improve the replication fidelity until now. Based on part weight evaluation and optimization, this paper presents a new method of replication fidelity improvement. Firstly, a simplified analysis model of PMMA micro columns arrays (5×16) with 200μm diameter was set up. And then, Flow (3D) module of Moldflow MPI6.0 based on Navier-Stokes equations was used to calculate the weight of the micro columns arrays in injection molding. The effects of processing parameters (melt temperature, mold temperature, injection time, packing pressure and packing time) on the part weight were investigated in the simulations. The simulation results showed that the mold temperature and the injection time have important effects on the filling of micro columns; the optimal mold temperature and injection time for better replication fidelity could be determined by the curves of mold temperature vs part weight and injection time vs part weight. At last, the effects of processing parameters on part weight of micro columns array were studied experimentally. The experimental results showed that the increase of melt temperature and mold temperature can make the packing pressure transfer to micro cavity more effectively through runner system, and increase the part weight. From the observation results of the image measuring apparatus, it was discovered that the higher the part weight, the better the filling of the microstructures. In conclusion, part weight can be used to evaluate the replication fidelity of micro-feature structured parts primarily; which is an economical and practical method to improve the replication fidelity of microlens arrays based on weight evaluation and optimization.

Development of improved asbestos reinforced phenolic insulating composites (optimization of physical properties as a function of molding technique and post cure conditions)

NASA Technical Reports Server (NTRS)

Hedges, L. M. (Editor)

1973-01-01

Detailed data are presented on phenolic-glass and phenolic-asbestos compounds which compare the effect of compression molding without degas to the effects of four variations of compression molding. These variations were designed to improve elimination of entrapped volatiles and the volatile products of the condensate reaction associated with the cure of phenolic resins. The utilization of conventional methods of degas plus degas by vacuum and directional heat flow methods are involved. Detailed data are also presented on these same compounds, comparing the effect of changes in post-bake time, and post-bake temperature for the five molding techniques.

Fabrication of PDMS architecture

NASA Astrophysics Data System (ADS)

Adam, Tijjani; Hashim, U.

2017-03-01

The study report novel, yet simple and flexible fabrication method for micro channel patterning PDMS thin mold on glass surfaces, the method allows microstructures with critical dimensions to be formed using PDMS. Micro channel production is a two-step process. First, soft photolithography methods are implemented to fabricate a reusable mold. The mold is then used to create the micro channel, which consists of SU8, PDMS and glass. The micro channel design was performed using AutoCAD and the fabrication begins by creating a replicable mold. The mold is created on a glass slide. by spin-coating speed between 500 to 1250rpm with an acceleration of 100 rpm/s for 100 and 15 second ramp up and down speed respectively. Channel flow rate based on concentration were measured by analyzing the recorded flow profiles which was collected from the high powered microscope at. 80µ, 70µm, 50µm for inlet channel 1, 2, 3 respectively the channel flow were compared for flow efficiency at different concentrations and Re. Thus, the simplicity of device structure and fabrication makes it feasible to miniaturize it for the development of point-of-care kits, facilitating its use in both clinical and non-clinical environments. With its simple geometric structure and potential for mass commercial fabrication, the device can be developed to become a portable photo detection sensor that can be use for both environmental and diagnostic application.

Fabrication of functional devices using soft lithography and unconventional micropatterning

NASA Astrophysics Data System (ADS)

Deng, Tao

In this thesis, I present part of our work in the fabrication of functional devices using soft lithography, and also describe unconventional micropatterning techniques involving photographic films. Soft lithography is a set of techniques that are complementary to photolithography, but not limited to planar patterning. It offers the capability of generating micro and nanostructures to a larger community than that familiar with conventional fabrication facilities. The first part of this thesis (chapter 1--4) focuses on the fabrication of microelectronic and micromagnetic devices. These successful demonstrations establish the compatibility of soft lithography with multilayer fabrication of functional devices, and open the door for the further development in these areas. Chapter 1 and 2 describe the use of microtransfer molding (muTM), micromolding in capillaries (MIMIC), and microcontact (muCP) for fabricating Schottky diodes and half-wave rectifier circuits. The fabrication processes involve multiple soft lithography steps and address the registrations between different layer of structures. Room temperature characteristics of these devices resemble those of diodes and rectifiers fabricated by photolithography. Chapter 3 and 4 demonstrate the fabrication of micromagnetic systems. In chapter 3, a one-dimensional bead motor is reported. Based on current-carrying wire systems, the bead motor can trap and transfer magnetic beads suspended in aqueous solutions. Chapter 4 shows a microfiltration system that uses arrays of nickel posts positioned in a polydimethylsiloxane (PDMS) microfluidic channel as the filtering elements. Turning on or off the magnetic field that is localized by these nickel posts can trap or release magnetic beads flowing by. The second part of this thesis (chapter 5--7) focuses on the development of unconventional microfabrication. The major objective underlying this work is to explore the simplest and most broadly available techniques that we could identify for forming patterns with features useful in functional microstructures. Chapter 5 and 6 describe the use of photographic films (microfiche and slide film) and transparencies printed using different printers as photomasks in the fabrication of PDMS stamps/molds for soft lithography. In chapter 6, we also compare different methods of generating microstructures using facilities readily and inexpensively available to chemistry and biology laboratories. Among the films and transparencies investigated, microfiche carries the highest resolution. It can generate structures as small as ˜10 mum in lateral dimensions. Chapter 7 shows a new rapid prototyping process for the fabrication of metallic microstructures using silver halide-based photographic film. The whole process, which involves photographic development and electrochemical deposition, only takes ˜2 hours, starting from a computer design file. It can generate electrically continuous structures with the smallest dimension of ˜30 mum in the plane of the film. The resulting structures---either supported on the film backing, or freed from it---are appropriate for use as passive, structural materials such as wire frames or meshes, and can also be used in microfluidic, microanalytical, and microelectromechanical systems (MEMS).

Comparative evaluation of border molding, using two different techniques in maxillary edentulous arches - An in vivo study

PubMed Central

Yarapatineni, Rameshbabu; Vilekar, Abhishek; Kumar, J Phani; Kumar, G Ajay; Aravind, Prasad; Kumar, P Anil

2013-01-01

Background: This study was undertaken to compare the retention between sectional border molding using low fusing greenstick compound and single step border molding using condensation silicone (putty) impression material in three stages- A. Immediately following border molding, B. After final impression and C. With the finished permanent denture base. Materials & Methods: In this study evaluation of retentive values of sectional border molding (Group I) (custom impression trays border molded with green stick compound ) and single step border molding (Group II) ( border molding with condensation silicone (putty) impression material ). In both techniques definitive wash impression were made with light body condensation silicone and permanent denture base with heat cure polymerization resin. Results: Group II was significantly higher (mean=8011.43) than Group I (mean=5777.43) in test-A. The t-value (1.5883) infers that there was significant difference between Group I and Group II (p =0.15). Group I was significantly higher (mean=6718.57) than Group II (mean=5224.29) in test -B. The t-value (1.6909) infers that there was significant difference between Group I and Group II (p=0.17). Group II was higher (mean=4025.14) than Group I (mean=3835.07) in test -C. The t-value was 0.1239. But it was found to be statistically insignificant (p=0.005). Conclusion: Within the limitation of this clinical study border molding custom tray with low fusing green stick compound provided similar retention as compared to custom impression tray with condensation silicone in permanent denture base. How to cite this article: Yarapatineni R, Vilekar A, Kumar JP, Kumar GA, Aravind P, Kumar PA. Comparative evaluation of border molding, using two different techniques in maxillary edentulous arches - An in vivo study. J Int Oral Health 2013; 5(6):82-7 . PMID:24453450

Influence of Heat Treatment on the Microstructure and Corrosion Resistance of 13 Wt Pct Cr-Type Martensitic Stainless Steel

NASA Astrophysics Data System (ADS)

Lu, Si-Yuan; Yao, Ke-Fu; Chen, Yun-Bo; Wang, Miao-Hui; Ge, Xue-Yuan

2015-12-01

The effect of heat treatment on the microstructure and the electrochemical properties of a typical corrosion-resistant plastic mold steel in Cl--containing solution were studied in this research. Through X-ray diffraction patterns, SEM and TEM analysis, it was found that the sequence of the precipitates in the steels tempered at 573 K, 773 K, and 923 K (300 °C, 500 °C, and 650 °C) was θ-M3C carbides, nano-sized Cr-rich M23C6 carbides, and micro/submicron-sized Cr-rich M23C6 carbides, respectively. The results of the electrochemical experiments showed that the pitting potential of the as-quenched martensitic stainless steels increased with the austenitizing temperature. However, the corrosion resistance of the steels would decreased after tempering, especially when tempered at 773 K (500 °C), no passivation regime could be found in the polarization curve of the MSSs and no effective passive film could be formed on the steels in Cl--containing environments. The present results suggested that the temperature around 773 K (500 °C) should be avoided for tempering process of MSS used as plastic molds.

EVALUATION OF POLLUTION PREVENTION TECHNIQUES TO REDUCE STYRENE EMISIONS FROM OPEN CONTACT MOLDING PROCESSES - VOLUME 1. FINAL REPORT

EPA Science Inventory

The report gives results of a study to evaluate several pollution prevention techniques that could be used to reduce styrene emissions from open molding processes in the fiberglass-reinforced
plastics/composites (FRP/C) and fiberglass boat building industries. Styrene emission...

EVALUATION OF POLLUTION PREVENTION TECHNIQUES TO REDUCE STYRENE EMISSIONS FROM OPEN CONTACT MOLDING PROCESSES - VOLUME 2. APPENDICES

EPA Science Inventory

The report gives results of a study to evaluate several pollution prevention techniques that could be used to reduce styrene emissions from open molding processes in the fiberglass-reinforced plastics/composites (FRP/C) and fiberglass boat building industries. Styrene emissions u...

The Temperature and Structure Dependence of Surface Tension of CaO-SiO2-Na2O-CaF2 Mold Fluxes

NASA Astrophysics Data System (ADS)

Gao, Qiang; Min, Yi; Jiang, Maofa

2018-06-01

The surface tension of mold flux is one of the most important properties and varies with the temperature from the top to the bottom of the mold, which influences the adhesion and lubrication between the liquid mold flux and the solidified shell, further influencing the quality of the continuous billet. In the present paper, the effect of temperature on the surface tension of CaO-SiO2-Na2O-CaF2 mold-flux melts with different CaO/SiO2 mass ratios was investigated using the maximum-pull method. Furthermore, the microstructure of mold fluxes was analyzed using FT-IR and Raman spectra to discuss the change mechanism of surface tension. The results indicated that the temperature dependence of surface tension was different with different CaO/SiO2 mass ratios, and agreed with the modification of melt structure. When the CaO/SiO2 mass ratio was 0.67 and 0.85, the change of surface tension with temperature was relatively stable, and the influence of temperature on the structure was small. When the CaO/SiO2 mass ratio was 1.03 and 1.16, with an increase of temperature, the surface tension decreased linearly and the changing amplitude was large; the degree of polymerization of melts and average radii of silicon-oxygen anions also decreased, which intensified the molecular thermal motion and weakened the intermolecular interaction, resulting in a decrease of surface tension of melts.

The Temperature and Structure Dependence of Surface Tension of CaO-SiO2-Na2O-CaF2 Mold Fluxes

NASA Astrophysics Data System (ADS)

Gao, Qiang; Min, Yi; Jiang, Maofa

2018-02-01

The surface tension of mold flux is one of the most important properties and varies with the temperature from the top to the bottom of the mold, which influences the adhesion and lubrication between the liquid mold flux and the solidified shell, further influencing the quality of the continuous billet. In the present paper, the effect of temperature on the surface tension of CaO-SiO2-Na2O-CaF2 mold-flux melts with different CaO/SiO2 mass ratios was investigated using the maximum-pull method. Furthermore, the microstructure of mold fluxes was analyzed using FT-IR and Raman spectra to discuss the change mechanism of surface tension. The results indicated that the temperature dependence of surface tension was different with different CaO/SiO2 mass ratios, and agreed with the modification of melt structure. When the CaO/SiO2 mass ratio was 0.67 and 0.85, the change of surface tension with temperature was relatively stable, and the influence of temperature on the structure was small. When the CaO/SiO2 mass ratio was 1.03 and 1.16, with an increase of temperature, the surface tension decreased linearly and the changing amplitude was large; the degree of polymerization of melts and average radii of silicon-oxygen anions also decreased, which intensified the molecular thermal motion and weakened the intermolecular interaction, resulting in a decrease of surface tension of melts.

Aluminum-fly ash metal matrix composites for automotive parts. [Reports for October 1 to December 31, 1999, and January 1 - to March 31, 2000

DOE Office of Scientific and Technical Information (OSTI.GOV)

Weiss, David; Purgert, Robert; Rhudy, Richard

2000-04-21

The highlights of this report are: (1) fly ash classified by less than 100 microns in size was mixed into a 300 lb melt of alloy 535 without the need of a magnesium additive; (2) a vibratory feeder fitted with a sieve was used as the means to minimize particle clustering while introducing fly ash into the aluminum alloy 535 melt; and (3) the industrial-size field test was successful in that sand mold castings and permanent mold castings of tensile bars, K mold bars, and ingots were made from aluminum alloy 535-fly ash mix. Use of aluminum alloy 535 containingmore » 7% magnesium precluded the need to introduce additional magnesium into the melt. The third round of sand mold castings as well as permanent mold castings produced components and ingots of alloy 535 instead of alloy 356. The ingots will be remelted and cast into parts to assess the improvement of flyash distribution which occurs through reheating and the solidification wetting process. Microstructure analysis continues on sand and permanent mold castings to study particle distribution in the components. A prototype sand cast intake manifold casting was found to be pressure tight which is a major performance requirement for this part. Another heat of pressure die cast brackets of A380-classified fly ash will be made to examine their strength and fly ash distribution. Ingots of A356-fly ash have been made at Eck for remelting at Thompson Aluminum for squeeze casting into motor mounts.« less

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.

Deflectometric analysis of high volume injection molds for production of occupational eye wear.

PubMed

Speck, Alexis; Zelzer, Benedikt; Speich, Marco; Börret, Rainer; Langenbucher, Achim; Eppig, Timo

2013-12-01

Most of the protective eye wear devices currently on the market are manufactured on simple polycarbonate shields, produced by injection molding techniques. Despite high importance of optical quality, injection molds are rarely inspected for surface quality before or during the manufacturing process. Quality degradation is mainly monitored by optical testing of the molded parts. The purpose of this work was to validate a non-contact deflectometric measurement technique for surface and shape analysis of injection molds to facilitate deterministic surface quality control and to monitor minor conformity of the injection mold with the design data. The system is based on phase-measuring deflectometry with a operating measurement field of 80×80 mm(2) (±18° slope), a lateral resolution of 60μm and a local sensitivity of some nanometers. The calibration was tested with a calibration normal and a reference sphere. The results were crosschecked against a measurement of the same object with a tactile coordinate measuring machine. Eight injection molds for production of safety goggles with radii of +58mm (convex) and -60mm (concave) were measured in this study. The molds were separated into two groups (cavity 1 and 2 of the tool with different polishing techniques) and measured to test whether the measurement tool could extract differences. The analysis was performed on difference height between the measured surface and the spherical model. The device could derive the surface change due to polishing and discriminate between both polishing techniques, on the basis of the measured data. The concave nozzle sides of the first group (cavity 1) showed good shape conformity. In comparison, the nozzle sides of the second group (cavity 2) showed local deviations from design data up to 14.4μm. Local form variations of about 5μm occurred in the field of view. All convex ejector sides of both groups (cavity 1 and 2) showed rotational symmetric errors and the molds were measured in general flatter than design data. We applied a deflectometric system for measuring and evaluating specular reflective injection molding tools to optimize the production process of occupational eye wear. The surface quality could be inline monitored in the production processes for actual spectacle models. Copyright © 2013. Published by Elsevier GmbH.

Fabrication mechanism of friction-induced selective etching on Si(100) surface

PubMed Central

2012-01-01

As a maskless nanofabrication technique, friction-induced selective etching can easily produce nanopatterns on a Si(100) surface. Experimental results indicated that the height of the nanopatterns increased with the KOH etching time, while their width increased with the scratching load. It has also found that a contact pressure of 6.3 GPa is enough to fabricate a mask layer on the Si(100) surface. To understand the mechanism involved, the cross-sectional microstructure of a scratched area was examined, and the mask ability of the tip-disturbed silicon layer was studied. Transmission electron microscope observation and scanning Auger nanoprobe analysis suggested that the scratched area was covered by a thin superficial oxidation layer followed by a thick distorted (amorphous and deformed) layer in the subsurface. After the surface oxidation layer was removed by HF etching, the residual amorphous and deformed silicon layer on the scratched area can still serve as an etching mask in KOH solution. The results may help to develop a low-destructive, low-cost, and flexible nanofabrication technique suitable for machining of micro-mold and prototype fabrication in micro-systems. PMID:22356699

Fabrication mechanism of friction-induced selective etching on Si(100) surface.

PubMed

Guo, Jian; Song, Chenfei; Li, Xiaoying; Yu, Bingjun; Dong, Hanshan; Qian, Linmao; Zhou, Zhongrong

2012-02-23

As a maskless nanofabrication technique, friction-induced selective etching can easily produce nanopatterns on a Si(100) surface. Experimental results indicated that the height of the nanopatterns increased with the KOH etching time, while their width increased with the scratching load. It has also found that a contact pressure of 6.3 GPa is enough to fabricate a mask layer on the Si(100) surface. To understand the mechanism involved, the cross-sectional microstructure of a scratched area was examined, and the mask ability of the tip-disturbed silicon layer was studied. Transmission electron microscope observation and scanning Auger nanoprobe analysis suggested that the scratched area was covered by a thin superficial oxidation layer followed by a thick distorted (amorphous and deformed) layer in the subsurface. After the surface oxidation layer was removed by HF etching, the residual amorphous and deformed silicon layer on the scratched area can still serve as an etching mask in KOH solution. The results may help to develop a low-destructive, low-cost, and flexible nanofabrication technique suitable for machining of micro-mold and prototype fabrication in micro-systems.

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

2013-10-07

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.

Precision lens molding of asphero diffractive surfaces in chalcogenide materials

NASA Astrophysics Data System (ADS)

Nelson, J.; Scordato, M.; Schwertz, K.; Bagwell, J.

2015-10-01

Finished lens molding, and the similar process of precision lens molding, have long been practiced for high volume, accurate replication of optical surfaces on oxide glass. The physics surrounding these processes are well understood, and the processes are capable of producing high quality optics with great fidelity. However, several limitations exist due to properties inherent with oxide glasses. Tooling materials that can withstand the severe environmental conditions of oxide glass molding cannot easily be machined to produce complex geometries such as diffractive surfaces, lens arrays, and off axis features. Current machining technologies coupled with a limited selection of tool materials greatly limits the type of structures that can be molded into the finished optic. Tooling for chalcogenide glasses are not bound by these restrictions since the molding temperatures required are much lower than for oxide glasses. Innovations in tooling materials and manufacturing techniques have enabled the production of complex geometries to optical quality specifications and have demonstrated the viability of creating tools for molding diffractive surfaces, off axis features, datums, and arrays. Applications for optics having these features are found in automotive, defense, security, medical, and industrial domains. This paper will discuss results achieved in the study of various molding techniques for the formation of positive diffractive features on a concave spherical surface molded from As2Se3 chalcogenide glass. Examples and results of molding with tools having CTE match with the glass and non CTE match will be reviewed. The formation of stress within the glass during molding will be discussed, and methods of stress management will also be demonstrated and discussed. Results of process development methods and production of good diffractive surfaces will be shown.

Study of parameters in precision optical glass molding

NASA Astrophysics Data System (ADS)

Ni, Ying; Wang, Qin-hua; Yu, Jing-chi

2010-10-01

Precision glass compression molding is an attractive approach to manufacture small precision optics in large volume over traditional manufacturing techniques because of its advantages such as lower cost, faster time to market and being environment friendly. In order to study the relationship between the surface figures of molded lenses and molding process parameters such as temperature, pressure, heating rate, cooling rate and so on, we present some glass compression molding experiments using same low Tg (transition temperature) glass material to produce two different kinds of aspheric lenses by different molding process parameters. Based on results from the experiments, we know the major factors influencing surface figure of molded lenses and the changing range of these parameters. From the knowledge we could easily catch proper molding parameters which are suitable for aspheric lenses with diameter from 10mm to 30mm.

Grinding aspheric and freeform micro-optical molds

NASA Astrophysics Data System (ADS)

Tohme, Yazid E.

2007-02-01

Fueled by the need for better performing optics, glass optics are now replacing plastic optics in many industrial and consumer electronic devices. One of these devices is the mobile phone camera. The optical sub-assembly in a mobile phone includes several micro lenses that are spherical and/or aspherical in shape and require form tolerances in the submicron range. These micro glass lenses are mass produced by a replication process known as glass press molding. The process entails the compression of a glass gob between two precise optical quality molds at an elevated temperature, usually near the transition temperature of the glass material. The elevated forces and temperatures required in the glass molding process limits the materials of the molds to very tough materials such as tungsten carbide or silicon carbide. These materials can withstand large pressing forces at high temperatures without any significant deformation. These materials offer great mechanical properties for glass press molding but they are also a challenge to machine to submicron accuracy. The work in this paper discusses a deterministic micro grinding manufacturing process referred to as wheel normal grinding, which is utilized to produce these optical quality molds. Wheel normal grinding is more accurate and more deterministic than most other grinding techniques and can produce molds to the form and finish tolerances required for optical molding. This method relies on the ability to recognize and compensate for grinding wheel wear and machine repeatable errors. Results will be presented to illustrate the accuracy of this micro grinding technique.

High resolution PFPE-based molding High resolution PFPE-based molding High resolution PFPE-based molding techniques for nanofabrication of high pattern density sub-20 nm features: A fundamental materials approach

DOE Office of Scientific and Technical Information (OSTI.GOV)

Williams, Stuart S; Samulski, Edward; Lopez, Renee

2010-01-01

ABSTRACT. Described herein is the development and investigation of PFPE-based elastomers for high resolution replica molding applications. The modulus of the elastomeric materials was increased through synthetic and additive approaches while maintaining relatively low surface energies (<25 mN/m). Using practically relevant large area master templates, we show that the resolution of the molds is strongly dependant upon the elastomeric mold modulus. A composite mold approach was used to form flexible molds out of stiff, high modulus materials that allow for replication of sub-20 nm post structures. Sub-100 nm line grating master templates, formed using e-beam lithography, were used to determinemore » the experimental stability of the molding materials. It was observed that as the feature spacing decreased, high modulus composite molds were able to effectively replicate the nano-grating structures without cracking or tear-out defects that typically occur with high modulus elastomers.« less

Improvement in current density of nano- and micro-structured Si solar cells by cost-effective elastomeric stamp process

NASA Astrophysics Data System (ADS)

Jeon, Kiseok; Jee, Hongsub; Lim, Sangwoo; Park, Min Joon; Jeong, Chaehwan

2018-03-01

Effective incident light should be controlled for improving the current density of solar cells by employing nano- and micro-structures on silicon surface. The elastomeric stamp process, which is more cost effective and simpler than conventional photolithography, was proposed for the fabrication of nano- and micro-structures. Polydimethylsiloxane (PDMS) was poured on a mother pattern with a diameter of 6 μm and a spacing of 2 μm; then, curing was performed to create a PDMS mold. The regular micropattern was stamped on a low-viscosity resin-coated silicon surface, followed by the simple reactive ion etching process. Nano-structures were formed using the Ag-based electroless etching process. As etching time was increased to 6 min, reflectance decreased to 4.53% and current density improved from 22.35 to 34.72 mA/cm2.

A Comparative study of two RVE modelling methods for chopped carbon fiber SMC

DOE Office of Scientific and Technical Information (OSTI.GOV)

Chen, Zhangxing; Li, Yi; Shao, Yimin

To achieve vehicle light-weighting, the chopped carbon fiber sheet molding compound (SMC) is identified as a promising material to replace metals. However, there are no effective tools and methods to predict the mechanical property of the chopped carbon fiber SMC due to the high complexity in microstructure features and the anisotropic properties. In this paper, the Representative Volume Element (RVE) approach is used to model the SMC microstructure. Two modeling methods, the Voronoi diagram-based method and the chip packing method, are developed for material RVE property prediction. The two methods are compared in terms of the predicted elastic modulus andmore » the predicted results are validated using the Digital Image Correlation (DIC) tensile test results. Furthermore, the advantages and shortcomings of these two methods are discussed in terms of the required input information and the convenience of use in the integrated processing-microstructure-property analysis.« less

Treatment of patients with a congenital transversal vaginal septum or a partial aplasia of the vagina. The vaginal pull-through versus the push-through technique.

PubMed

van Bijsterveldt, Chantal; Willemsen, Wim

2009-06-01

The aim of this study is to describe the different modalities of congenital obstructing vaginal malformations and the evaluation of techniques to solve the problem. A retrospective study. The University Hospital Nijmegen, the Netherlands. The medical records of 18 patients with congenital obstructive malformations of the vagina operated on by one gynecologist were retrospectively reviewed. The conditions were classified in three groups: group I with one uterus and vagina and with a transverse vaginal septum, group II with a partial vaginal agenesis and group III with a double genital system and a septum with occlusion of one vagina. Operating technique used, mold treatment after surgery, menstruation outflow, the possibility of having intercourse and the need for additional surgery. 18 patients were evaluated. Of 10 patients in group I, 8 patients were treated with the pull-through technique and 2 patients with the push-through technique. Four of the patients with a pull-through operation did not get mold treatment; of these patients, 3 needed repeat surgery because of the tendency for constriction. Of 4 patients in group II, 1 patient was treated with the pull-through technique and 3 with the push-through technique. The patient with the pull-through technique needed repeat surgery because of constriction. There was no mold treatment after the first procedure. Group III were 4 patients all treated with the pull-through technique. None of them received mold treatment, and none of these patients needed repeat surgery. The push-through method is a good surgical technique for the patients in whom problems of constriction after surgery are expected and for patients with difficulties during surgery. Mold treatment is recommended after surgery in patients with a thick transversal vaginal septum or a partial vaginal aplasia.

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.

Processing of alnico permanent magnets by advanced directional solidification methods

DOE PAGES

Zou, Min; Johnson, Francis; Zhang, Wanming; ...

2016-07-05

Advanced directional solidification methods have been used to produce large (>15 cm length) castings of Alnico permanent magnets with highly oriented columnar microstructures. In combination with subsequent thermomagnetic and draw thermal treatment, this method was used to enable the high coercivity, high-Titanium Alnico composition of 39% Co, 29.5% Fe, 14% Ni, 7.5% Ti, 7% Al, 3% Cu (wt%) to have an intrinsic coercivity (H ci) of 2.0 kOe, a remanence (B r) of 10.2 kG, and an energy product (BH) max of 10.9 MGOe. These properties compare favorably to typical properties for the commercial Alnico 9. Directional solidification of highermore » Ti compositions yielded anisotropic columnar grained microstructures if high heat extraction rates through the mold surface of at least 200 kW/m 2 were attained. This was achieved through the use of a thin walled (5 mm thick) high thermal conductivity SiC shell mold extracted from a molten Sn bath at a withdrawal rate of at least 200 mm/h. However, higher Ti compositions did not result in further increases in magnet performance. Images of the microstructures collected by scanning electron microscopy (SEM) reveal a majority α phase with inclusions of secondary αγ phase. Transmission electron microscopy (TEM) reveals that the α phase has a spinodally decomposed microstructure of FeCo-rich needles in a NiAl-rich matrix. In the 7.5% Ti composition the diameter distribution of the FeCo needles was bimodal with the majority having diameters of approximately 50 nm with a small fraction having diameters of approximately 10 nm. The needles formed a mosaic pattern and were elongated along one <001> crystal direction (parallel to the field used during magnetic annealing). Cu precipitates were observed between the needles. Regions of abnormal spinodal morphology appeared to correlate with secondary phase precipitates. The presence of these abnormalities did not prevent the material from displaying superior magnetic properties in the 7.5% Ti composition. As a result, higher Ti compositions did not display the preferred spinodal microstructure, explaining their inferior magnetic properties.« less

Controlled study of mold growth and cleaning procedure on treated and untreated wet gypsum wallboard in an indoor environment.

PubMed

Krause, Michael; Geer, William; Swenson, Lonie; Fallah, Payam; Robbins, Coreen

2006-08-01

The basis for some common gypsum wallboard mold remediation practices was examined. The bottom inch of several gypsum wallboard panels was immersed in bottled drinking water; some panels were coated and others were untreated. The panels were examined and tested for a period of 8 weeks. This study investigated: (a) whether mold growth, detectable visually or with tape lift samples, occurs within 1 week on wet gypsum wallboard; (b) the types, timing, and extent of mold growth on wet gypsum wallboard; (c) whether mold growth is present on gypsum wallboard surfaces 6 inches from visible mold growth; (d) whether some commonly used surface treatments affect the timing of occurrence and rate of mold growth; and (e) if moldy but dried gypsum wallboard can be cleaned with simple methods and then sealed with common surface treatments so that residual mold particles are undetectable with typical surface sampling techniques. Mold growth was not detected visually or with tape lift samples after 1 week on any of the wallboard panels, regardless of treatment, well beyond the 24-48 hours often mentioned as the incubation period. Growth was detected at 2 weeks on untreated gypsum. Penicillium, Cladosporium, and Acremonium were early colonizers of untreated panels. Aspergillus, Epicoccum, Alternaria, and Ulocladium appeared later. Stachybotrys was not found. Mold growth was not detected more than 6 inches beyond the margin of visible mold growth, suggesting that recommendations to remove gypsum wallboard more than 1 foot beyond visible mold are excessive. The surface treatments resulted in delayed mold growth and reduced the area of mold growth compared with untreated gypsum wallboard. Results showed that simple cleaning of moldy gypsum wallboard was possible to the extent that mold particles beyond "normal trapping" were not found on tape lift samples. Thus, cleaning is an option in some situations where removal is not feasible or desirable. In cases where conditions are not similar to those of this study, or where large areas may be affected, a sample area could be cleaned and tested to verify that the cleaning technique is sufficient to reduce levels to background or normal trapping. These results are generally in agreement with laboratory studies of mold growth on, and cleaning of, gypsum wallboard.

Advancing three-dimensional MEMS by complimentary laser micro manufacturing

NASA Astrophysics Data System (ADS)

Palmer, Jeremy A.; Williams, John D.; Lemp, Tom; Lehecka, Tom M.; Medina, Francisco; Wicker, Ryan B.

2006-01-01

This paper describes improvements that enable engineers to create three-dimensional MEMS in a variety of materials. It also provides a means for selectively adding three-dimensional, high aspect ratio features to pre-existing PMMA micro molds for subsequent LIGA processing. This complimentary method involves in situ construction of three-dimensional micro molds in a stand-alone configuration or directly adjacent to features formed by x-ray lithography. Three-dimensional micro molds are created by micro stereolithography (MSL), an additive rapid prototyping technology. Alternatively, three-dimensional features may be added by direct femtosecond laser micro machining. Parameters for optimal femtosecond laser micro machining of PMMA at 800 nanometers are presented. The technical discussion also includes strategies for enhancements in the context of material selection and post-process surface finish. This approach may lead to practical, cost-effective 3-D MEMS with the surface finish and throughput advantages of x-ray lithography. Accurate three-dimensional metal microstructures are demonstrated. Challenges remain in process planning for micro stereolithography and development of buried features following femtosecond laser micro machining.

Liquid-liquid phase separation and solidification behavior of Al55Bi36Cu9 monotectic alloy with different cooling rates

NASA Astrophysics Data System (ADS)

Bo, Lin; Li, Shanshan; Wang, Lin; Wu, Di; Zuo, Min; Zhao, Degang

2018-03-01

The cooling rate has a significant effect on the solidification behavior and microstructure of monotectic alloy. In this study, different cooling rate was designed through casting in the copper mold with different bore diameters. The effects of different cooling rate on the solidification behavior of Al55Bi36Cu9 (at.%) immiscible alloy have been investigated. The liquid-liquid phase separation of Al55Bi36Cu9 immiscible alloy melt was investigated by resistivity test. The solidification microstructure and phase analysis of Al55Bi36Cu9 immiscible alloy were performed by the SEM and XRD, respectively. The results showed that the liquid-liquid phase separation occurred in the solidification of Al55Bi36Cu9 monotectic melt from 917 °C to 653 °C. The monotectic temperature, liquid phase separation temperature and immiscibility zone of Al55Bi36Cu9 monotectic alloy was lower than those of Al-Bi binary monotectic alloy. The solidification morphology of Al55Bi36Cu9 monotectic alloy was very sensitive to the cooling rate. The Al/Bi core-shell structure formed when Al55Bi36Cu9 melt was cast in the copper mold with a 8 mm bore diameter.

Using template/hotwire cutting to demonstrate moldless composite fabrication

NASA Technical Reports Server (NTRS)

Coleman, J. Mario

1990-01-01

The objective of this experiment is to provide a simple, inexpensive composite fabrication technique which can be easily performed with a minimum of equipment and facilities. This process eliminates expensive female molds and uses only male molds which are easily formed from foam blocks. Once the mold is shaped, it is covered with fiberglass and becomes a structural component of the product.

Natural Fiber Composite Retting, Preform Manufacture and Molding (Project 18988/Agreement 16313)

DOE Office of Scientific and Technical Information (OSTI.GOV)

Simmons, Kevin L.; Howe, Daniel T.; Laddha, Sachin

2009-12-31

Plant-based natural fibers can be used in place of glass in fiber reinforced automotive composites to reduce weight, cost and provide environmental benefits. Current automotive applications use natural fibers in injection molded thermoplastics for interior, non-structural applications. Compression molded natural fiber reinforced thermosets have the opportunity to extend natural fiber composite applications to structural and semi-structural parts and exterior parts realizing further vehicle weight savings. The development of low cost molding and fiber processing techniques for large volumes of natural fibers has helped in understanding the barriers of non-aqueous retting. The retting process has a significant effect on the fibermore » quality and its processing ability that is related to the natural fiber composite mechanical properties. PNNL has developed a compression molded fiber reinforced composite system of which is the basis for future preforming activities and fiber treatment. We are using this process to develop preforming techniques and to validate fiber treatment methods relative to OEM provided application specifications. It is anticipated for next fiscal year that demonstration of larger quantities of SMC materials and molding of larger, more complex components with a more complete testing regimen in coordination with Tier suppliers under OEM guidance.« less

Magnetophoretic manipulation in microsystem using carbonyl iron-polydimethylsiloxane microstructures

PubMed Central

Faivre, Magalie; Gelszinnis, Renaud; Degouttes, Jérôme; Terrier, Nicolas; Rivière, Charlotte; Ferrigno, Rosaria; Deman, Anne-Laure

2014-01-01

This paper reports the use of a recent composite material, noted hereafter i-PDMS, made of carbonyl iron microparticles mixed in a PolyDiMethylSiloxane (PDMS) matrix, for magnetophoretic functions such as capture and separation of magnetic species. We demonstrated that this composite which combine the advantages of both components, can locally generate high gradients of magnetic field when placed between two permanent magnets. After evaluating the magnetic susceptibility of the material as a function of the doping ratio, we investigated the molding resolution offered by i-PDMS to obtain microstructures of various sizes and shapes. Then, we implemented 500 μm i-PDMS microstructures in a microfluidic channel and studied the influence of flow rate on the deviation and trapping of superparamagnetic beads flowing at the neighborhood of the composite material. We characterized the attraction of the magnetic composite by measuring the distance from the i-PDMS microstructure, at which the beads are either deviated or captured. Finally, we demonstrated the interest of i-PDMS to perform magnetophoretic functions in microsystems for biological applications by performing capture of magnetically labeled cells. PMID:25332740

Neonatal Ear Molding: Timing and Technique.

PubMed

Anstadt, Erin Elizabeth; Johns, Dana Nicole; Kwok, Alvin Chi-Ming; Siddiqi, Faizi; Gociman, Barbu

2016-03-01

The incidence of auricular deformities is believed to be ∼11.5 per 10,000 births, excluding children with microtia. Although not life-threatening, auricular deformities can cause undue distress for patients and their families. Although surgical procedures have traditionally been used to reconstruct congenital auricular deformities, ear molding has been gaining acceptance as an efficacious, noninvasive alternative for the treatment of newborns with ear deformations. We present the successful correction of bilateral Stahl's ear deformity in a newborn through a straightforward, nonsurgical method implemented on the first day of life. The aim of this report is to make pediatric practitioners aware of an effective and simple molding technique appropriate for correction of congenital auricular anomalies. In addition, it stresses the importance of very early initiation of ear cartilage molding for achieving the desired outcome. Copyright © 2016 by the American Academy of Pediatrics.

Use of DSC and DMA Techniques to Help Investigate a Material Anomaly for PTFE Used in Processing a Piston Cup for the Urine Processor Assembly (UPA) on International Space Station (ISS)

NASA Technical Reports Server (NTRS)

Wingard, Doug

2010-01-01

Human urine and flush water are eventually converted into drinking water with the Urine Processor Assembly (UPA) aboard the International Space Station (ISS). This conversion is made possible through the Distillation Assembly (DA) of the UPA. One component of the DA is a molded circular piston cup made of virgin polytetrafluoroethylene (PTFE). The piston cup is assembled to a titanium component using eight fasteners and washers. Molded PTFE produced for spare piston cups in the first quarter of 2010 was different in appearance and texture, and softer than material molded for previous cups. For the suspect newer PTFE material, cup fasteners were tightened to only one-half the required torque value, yet the washers embedded almost halfway into the material. The molded PTFE used in the DA piston cup should be Type II, based on AMS 3667D and ASTM D4894 specifications. The properties of molded PTFE are considerably different between Type I and II materials. Engineers working with the DA thought that if Type I PTFE was molded by mistake instead of Type II material, that could have resulted in the anomalous material properties. Typically, the vendor molds flat sheet PTFE from the same material lot used to mold the piston cups, and tensile testing as part of quality control should verify that the PTFE is Type II material. However, for this discrepant lot of material, such tensile data was not available. Differential scanning calorimetry (DSC) and dynamic mechanical analysis (DMA) were two of the testing techniques used at the NASA/Marshall Space Flight Center (MSFC) to investigate the anomaly for the PTFE material. Other techniques used on PTFE specimens were: Shore D hardness testing, tensile testing on dog bone specimens and a qualitative estimation of porosity by optical and scanning electron microscopy.

The "in situ molding technique: " an accurate and simple way to fix resorbable plates to the facial skeleton.

PubMed

Sadigh, Parviz Lionel; Chang, Li-Ren; Feng, Kuan-Ming; Jeng, Seng-Feng

2014-09-01

Bioabsorbable plates developed for use in the facial skeleton have become an integral part of the craniomaxillofacial surgeon's reconstructive armamentarium. They avoid the problems associated with the retention of metal plates and can be easily contoured when heated in a thermobath. The technical process of molding and securing these devices, often through small access incisions, to achieve rigid fixation of facial fractures can be difficult. In this article, we describe a simple, novel technique that we have developed, using hot water suction irrigation, to achieve in situ molding of resorbable plates during facial fracture fixation. We used this technique to fix 123 facial fractures in 110 patients over a 4-year period. No complications secondary to the use of hot water suction irrigation were encountered.

Soft Lithography

NASA Astrophysics Data System (ADS)

Xia, Younan; Whitesides, George M.

1998-08-01

Soft lithography represents a non-photolithographic strategy based on selfassembly and replica molding for carrying out micro- and nanofabrication. It provides a convenient, effective, and low-cost method for the formation and manufacturing of micro- and nanostructures. In soft lithography, an elastomeric stamp with patterned relief structures on its surface is used to generate patterns and structures with feature sizes ranging from 30 nm to 100 mum. Five techniques have been demonstrated: microcontact printing (muCP), replica molding (REM), microtransfer molding (muTM), micromolding in capillaries (MIMIC), and solvent-assisted micromolding (SAMIM). In this chapter we discuss the procedures for these techniques and their applications in micro- and nanofabrication, surface chemistry, materials science, optics, MEMS, and microelectronics.

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.

From micro- to nano-scale molding of metals : size effect during molding of single crystal Al with rectangular strip punches.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Chen, K.; Meng, W. J.; Mei, F.

2011-02-01

A single crystal Al specimen was molded at room temperature with long, rectangular, strip diamond punches. Quantitative molding response curves were obtained at a series of punch widths, ranging from 5 {micro}m to 550 nm. A significant size effect was observed, manifesting itself in terms of significantly increasing characteristic molding pressure as the punch width decreases to 1.5 {micro}m and below. A detailed comparison of the present strip punch molding results was made with Berkovich pyramidal indentation on the same single crystal Al specimen. The comparison reveals distinctly different dependence of the characteristic pressure on corresponding characteristic length. The presentmore » results show the feasibility of micro-/nano-scale compression molding as a micro-/nano-fabrication technique, and offer an experimental test case for size-dependent plasticity theories.« less

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

Application of heat pipe technology in permanent mold casting of nonferrous alloys

NASA Astrophysics Data System (ADS)

Elalem, Kaled

The issue of mold cooling is one, which presents a foundry with a dilemma. On the one hand; the use of air for cooling is safe and practical, however, it is not very effective and high cost. On the other hand, water-cooling can be very effective but it raises serious concerns about safety, especially with a metal such as magnesium. An alternative option that is being developed at McGill University uses heat pipe technology to carry out the cooling. The experimental program consisted of designing a permanent mold to produce AZ91E magnesium alloy and A356 aluminum alloy castings with shrinkage defects. Heat pipes were then used to reduce these defects. The heat pipes used in this work are novel and are patent pending. They are referred to as McGill Heat Pipes. Computer modeling was used extensively in designing the mold and the heat pipes. Final designs for the mold and the heat pipes were chosen based on the modeling results. Laboratory tests of the heat pipe were performed before conducting the actual experimental plan. The laboratory testing results verified the excellent performance of the heat pipes as anticipated by the model. An industrial mold made of H13 tool steel was constructed to cast nonferrous alloys. The heat pipes were installed and initial testing and actual industrial trials were conducted. This is the first time where a McGill heat pipe was used in an industrial permanent mold casting process for nonferrous alloys. The effects of cooling using heat pipes on AZ91E and A356 were evaluated using computer modeling and experimental trials. Microstructural analyses were conducted to measure the secondary dendrite arm spacing, SDAS, and the grain size to evaluate the cooling effects on the castings. The modeling and the experimental results agreed quite well. The metallurgical differences between AZ91E and A356 were investigated using modeling and experimental results. Selected results from modeling, laboratory and industrial trials are presented. The results show a promising future for heat pipe technology in cooling permanent molds for the casting of nonferrous alloys.

An in vitro study to compare the transverse strength of thermopressed and conventional compression-molded polymethylmethacrylate polymers.

PubMed

Raut, Anjana; Rao, Polsani Laxman; Vikas, B V J; Ravindranath, T; Paradkar, Archana; Malakondaiah, G

2013-01-01

Acrylic resins have been in the center stage of Prosthodontics for more than half a century. The flexural fatigue failure of denture base materials is the primary mode of clinical failure. Hence there is a need for superior physical and mechanical properties. This in vitro study compared the transverse strength of specimens of thermopressed injection-molded and conventional compression-molded polymethylmethacrylate polymers and examined the morphology and microstructure of fractured acrylic specimens. The following denture base resins were examined: Brecrystal (Thermopressed injection-molded, modified polymethylmethacrylate) and Pyrax (compression molded, control group). Specimens of each material were tested according to the American Society for Testing and Materials standard D790-03 for flexural strength testing of reinforced plastics and subsequently examined under SEM. The data was analyzed with Student unpaired t test. Flexural strength of Brecrystal (82.08 ± 1.27 MPa) was significantly higher than Pyrax (72.76 ± 0.97 MPa). The tested denture base materials fulfilled the requirements regarding flexural strength (>65 MPa). The scanning electron microscopy image of Brecrystal revealed a ductile fracture with crazing. The fracture pattern of control group specimens exhibited poorly defined crystallographic planes with a high degree of disorganization. Flexural strength of Brecrystal was significantly higher than the control group. Brecrystal showed a higher mean transverse strength value of 82.08 ± 1.27 MPa and a more homogenous pattern at microscopic level. Based on flexural strength properties and handling characteristics, Brecrystal may prove to be an useful alternative to conventional denture base resins.

Consolidation of Hierarchy-Structured Nanopowder Agglomerates and Its Application to Net-Shaping Nanopowder Materials

PubMed Central

Lee, Jai-Sung; Choi, Joon-Phil; Lee, Geon-Yong

2013-01-01

This paper provides an overview on our recent investigations on the consolidation of hierarchy-structured nanopowder agglomerates and related applications to net-shaping nanopowder materials. Understanding the nanopowder agglomerate sintering (NAS) process is essential to processing of net-shaped nanopowder materials and components with small and complex shape. The key concept of the NAS process is to enhance material transport through controlling the powder interface volume of nanopowder agglomerates. Based upon this concept, we have suggested a new idea of full density processing for fabricating micro-powder injection molded part using metal nanopowder agglomerates produced by hydrogen reduction of metal oxide powders. Studies on the full density sintering of die compacted- and powder injection molded iron base nano-agglomerate powders are introduced and discussed in terms of densification process and microstructure. PMID:28788317

Injection Molding and its application to drug delivery.

PubMed

Zema, Lucia; Loreti, Giulia; Melocchi, Alice; Maroni, Alessandra; Gazzaniga, Andrea

2012-05-10

Injection Molding (IM) consists in the injection, under high pressure conditions, of heat-induced softened materials into a mold cavity where they are shaped. The advantages the technique may offer in the development of drug products concern both production costs (no need for water or other solvents, continuous manufacturing, scalability, patentability) and technological/biopharmaceutical characteristics of the molded items (versatility of the design and composition, possibility of obtaining solid molecular dispersions/solutions of the active ingredient). In this article, process steps and formulation aspects relevant to IM are discussed, with emphasis on the issues and advantages connected with the transfer of this technique from the plastics industry to the production of conventional and controlled-release dosage forms. Moreover, its pharmaceutical applications thus far proposed in the primary literature, intended as either alternative manufacturing strategies for existing products or innovative systems with improved design and performance characteristics, are critically reviewed. Copyright © 2012 Elsevier B.V. All rights reserved.

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

Nguyen, Ba Nghiep; Holbery, Jim; Smith, Mark T.

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 understandingmore » 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.« less

Fabrication of an infrared Shack-Hartmann sensor by combining high-speed single-point diamond milling and precision compression molding processes.

PubMed

Zhang, Lin; Zhou, Wenchen; Naples, Neil J; Yi, Allen Y

2018-05-01

A novel fabrication method by combining high-speed single-point diamond milling and precision compression molding processes for fabrication of discontinuous freeform microlens arrays was proposed. Compared with slow tool servo diamond broaching, high-speed single-point diamond milling was selected for its flexibility in the fabrication of true 3D optical surfaces with discontinuous features. The advantage of single-point diamond milling is that the surface features can be constructed sequentially by spacing the axes of a virtual spindle at arbitrary positions based on the combination of rotational and translational motions of both the high-speed spindle and linear slides. By employing this method, each micro-lenslet was regarded as a microstructure cell by passing the axis of the virtual spindle through the vertex of each cell. An optimization arithmetic based on minimum-area fabrication was introduced to the machining process to further increase the machining efficiency. After the mold insert was machined, it was employed to replicate the microlens array onto chalcogenide glass. In the ensuing optical measurement, the self-built Shack-Hartmann wavefront sensor was proven to be accurate in detecting an infrared wavefront by both experiments and numerical simulation. The combined results showed that precision compression molding of chalcogenide glasses could be an economic and precision optical fabrication technology for high-volume production of infrared optics.

The influence of CF and TLCP co-reinforced on the mechanical properties of PA6-based composites

NASA Astrophysics Data System (ADS)

Zhang, Jing; Yin, Hong-Feng; Tang, Yun; Yuan, Hu-Die; Wei, Ying

2018-05-01

The purpose of this study was to investigate the effects of carbon fiber (CF) and thermotropic liquid crystal polymer (TLCP) as co-reinforcements on the mechanical properties of composites. The TLCP fibers were produced by melt exclusion. CF and TLCP co-reinforced PA6 composites (CF/TLCP/PA6) were prepared by the lamination molding method. The influence of molding temperature, TLCP content, compatibilizer, and pre-impregnation process on microstructure and mechanical properties of the CF/TLCP/PA6 composites were investigated with Electronic Microscopy and Mechanical tests (flexure and interlaminar shear) by Scanning Electron Microscope (SEM) and Universal Test Machine. It was found that the optimum molding temperature was 240 °C. The mechanical properties of the composites first increased and then decreased with an increase of TLCP content. The introduction of a compatibilizer obviously improved the mechanical properties of the composites. When the TLCP content was 15 wt%, the molding temperature was 240 °C, and 5 wt% compatibilizer was added, the comprehensive mechanical properties of the composites in terms of the flexural and interlaminar shear strengths were the best, which were 363.5 ± 4.4 MPa and 44.9 ± 2.9 MPa, respectively. The addition of TLCP fibers could prevent the propagation of microcracks in the composites, which further improved their mechanical properties due to the synergistic effect with CFs.

The Pursuit of a Scalable Nanofabrication Platform for Use in Material and Life Science Applications

PubMed Central

GRATTON, STEPHANIE E. A.; WILLIAMS, STUART S.; NAPIER, MARY E.; POHLHAUS, PATRICK D.; ZHOU, ZHILIAN; WILES, KENTON B.; MAYNOR, BENJAMIN W.; SHEN, CLIFTON; OLAFSEN, TOVE; SAMULSKI, EDWARD T.; DESIMONE, JOSEPH M.

2008-01-01

CONSPECTUS In this Account, we describe the use of perfluoropolyether (PFPE)-based materials that are able to accurately mold and replicate micro- and nanosized features using traditional techniques such as embossing as well as new techniques that we developed to exploit the exceptional surface characteristics of fluorinated substrates. Because of the unique partial wetting and nonwetting characteristics of PFPEs, we were able to go beyond the usual molding and imprint lithography approaches and have created a technique called PRINT (Particle [or Pattern] Replication In Nonwetting Templates). PRINT is a distinctive “top-down” fabrication technique capable of generating isolated particles, arrays of particles, and arrays of patterned features for a plethora of applications in both nanomedicine and materials science. A particular strength of the PRINT technology is the high-resolution molding of well-defined particles with precise control over size, shape, deformability, and surface chemistry. The level of replication obtained showcases some of the unique characteristics of PFPE molding materials. In particular, these materials arise from very low surface energy precursors with positive spreading coefficients, can be photocured at ambient temperature, and are minimally adhesive, nonswelling, and conformable. These distinctive features enable the molding of materials with unique attributes and nanometer resolution that have unprecedented scientific and technological value. For example, in nanomedicine, the use of PFPE materials with the PRINT technique allows us to design particles in which we can tailor key therapeutic parameters such as bioavailability, biodistribution, target-specific cell penetration, and controlled cargo release. Similarly, in materials science, we can fabricate optical films and lens arrays, replicate complex, naturally occurring objects such as adenovirus particles, and create 2D patterned arrays of inorganic oxides. PMID:18720952

The Effect of Chilling and Ce Addition on the Microstructure and Mechanical Properties of Al-23Si Alloy

NASA Astrophysics Data System (ADS)

Vijeesh, V.; Narayan Prabhu, K.

2017-01-01

The present work involves the study of the effect of varying concentration of Ce addition on microstructure and mechanical properties of Al-23%Si alloys. Melt-treated alloys were solidified in copper, brass, stainless steel molds to assess the effect of cooling rate. The effect on microstructure was assessed by measuring the fineness of primary silicon and eutectic silicon particle characteristics. The Ce melt treatment transformed the coarse and irregular primary silicon into refined polyhedral silicon crystals, and the effect was more significant at higher cooling rates. Although the melt treatment had refined the eutectic silicon at lower cooling rates, it did not show any considerable effect on the eutectic silicon at higher cooling rates. The mechanical properties of the alloy increased significantly with increase in cooling rates and cerium concentration. Analysis of the results and literature reveals that the refined primary silicon was formed as a result of an invariant reaction between Ce compounds and primary silicon at higher temperatures.

Microreplication of laser-fabricated surface and three-dimensional structures

NASA Astrophysics Data System (ADS)

Koroleva, Anastasia; Schlie, Sabrina; Fadeeva, Elena; Gittard, Shaun D.; Miller, Philip; Ovsianikov, Aleksandr; Koch, Jürgen; Narayan, Roger J.; Chichkov, Boris N.

2010-12-01

The fabrication of defined surface topographies and three-dimensional structures is a challenging process for various applications, e.g. in photonics and biomedicine. Laser-based technologies provide a promising approach for the production of such structures. The advantages of femtosecond laser ablation and two-photon polymerization for microstructuring are well known. However, these methods cannot be applied to all materials and are limited by their high cost and long production time. In this study, biomedical applications of an indirect rapid prototyping, molding microreplication of laser-fabricated two- and three-dimensional structures are examined. We demonstrate that by this method any laser-generated surface topography as well as three-dimensional structures can be replicated in various materials without losing the original geometry. The replication into multiple copies enables fast and perfect reproducibility of original microstructures for investigations of cell-surface interactions. Compared to unstructured materials, we observe that microstructures have strong influence on morphology and localization of fibroblasts, whereas neuroblastoma cells are not negatively affected.

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.

Forehead augmentation with a methyl methacrylate onlay implant using an injection-molding technique.

PubMed

Park, Dong Kwon; Song, Ingook; Lee, Jin Hyo; You, Young June

2013-09-01

The forehead, which occupies about one third of the face, is one of the major determinants of a feminine or masculine look. Various methods have been used for the augmentation of the forehead using autologous fat grafts or alloplastic materials. Methylmethacrylate (MMA) is the most appropriate material for augmentation of the forehead, and we have used an injection-molding technique with MMA to achieve satisfactory results. Under local anesthesia with intravenous (IV) sedation, an incision was made on the scalp and a meticulous and delicate subperiosteal dissection was then performed. MMA monomers and polymers were mixed, the dough was injected into the space created, and manual molding was performed along with direct inspection. This surgery was indicated for patients who wanted to correct an unattractive appearance by forehead augmentation. Every patient in this study visited our clinics 3 months after surgery to evaluate the results. We judged the postoperative results in terms of re-operation rates caused by the dissatisfaction of the patients and complications. During a 13-year period, 516 patients underwent forehead augmentation with MMA. With the injection-molding technique, the inner surface of the MMA implant is positioned close to the underlying frontal bone, which minimizes the gap between the implant and bone. The borders of the implant should be tapered sufficiently until no longer palpable or visible. Only 28 patients (5.4%) underwent a re-operation due to an undesirable postoperative appearance. The injection-molding technique using MMA is a simple, safe, and ideal method for the augmentation of the forehead.

Correction of Congenital Auricular Deformities Using the Ear-Molding Technique.

PubMed

Woo, Taeyong; Kim, Young Seok; Roh, Tai Suk; Lew, Dae Hyun; Yun, In Sik

2016-11-01

Studies of the ear-molding technique have emphasized the importance of initiating molding early to achieve the best results. In the present study, we describe the immediate effects and long-term outcomes of this technique, focusing on children who were older than the ideal age of treatment initiation. Patients who visited our institution from July 2014 to November 2015 were included. Medical charts were reviewed to collect data on demographics, the duration of treatment, the types of deformities, and the manner of recognition of the deformity and referral to our institution. Parents were surveyed to assess the degree of improvement, the level of procedural discomfort at the end of treatment, any changes in the shape of the molded auricle, and overall satisfaction 12 months after their last follow-up visits. A review of 28 ears in 18 patients was conducted, including the following types of deformities: constricted ear (64.2%), Stahl ear (21.4%), prominent ear (7.1%), and cryptotia (7.1%). The average score for the degree of improvement, rated on a 5-point scale (1, very poor; 5, excellent), was 3.5 at the end of treatment, with a score of 2.6 for procedural discomfort (1, very mild; 5, very severe). After 12 months, the shapes of all ears were well maintained. The average overall satisfaction score was 3.6 (1, very dissatisfied; 5, very satisfied). We had reasonable outcomes in older patients. After 1 year of follow-up, these outcomes were well maintained. Patients past the ideal age at presentation can still be candidates for the molding technique.

Forehead Augmentation with a Methyl Methacrylate Onlay Implant Using an Injection-Molding Technique

PubMed Central

Park, Dong Kwon; Song, Ingook; Lee, Jin Hyo

2013-01-01

Background The forehead, which occupies about one third of the face, is one of the major determinants of a feminine or masculine look. Various methods have been used for the augmentation of the forehead using autologous fat grafts or alloplastic materials. Methylmethacrylate (MMA) is the most appropriate material for augmentation of the forehead, and we have used an injection-molding technique with MMA to achieve satisfactory results. Methods Under local anesthesia with intravenous (IV) sedation, an incision was made on the scalp and a meticulous and delicate subperiosteal dissection was then performed. MMA monomers and polymers were mixed, the dough was injected into the space created, and manual molding was performed along with direct inspection. This surgery was indicated for patients who wanted to correct an unattractive appearance by forehead augmentation. Every patient in this study visited our clinics 3 months after surgery to evaluate the results. We judged the postoperative results in terms of re-operation rates caused by the dissatisfaction of the patients and complications. Results During a 13-year period, 516 patients underwent forehead augmentation with MMA. With the injection-molding technique, the inner surface of the MMA implant is positioned close to the underlying frontal bone, which minimizes the gap between the implant and bone. The borders of the implant should be tapered sufficiently until no longer palpable or visible. Only 28 patients (5.4%) underwent a re-operation due to an undesirable postoperative appearance. Conclusions The injection-molding technique using MMA is a simple, safe, and ideal method for the augmentation of the forehead. PMID:24086816

The Bark Myxomycetes--Their Collection, Culture and Identification

ERIC Educational Resources Information Center

Mitchell, David W.

1977-01-01

Describes a technique for isolating slime molds from tree bark and outlines projects for working with slime molds in the laboratory. Diagrams of 26 of the more common British species and a key to the Orders of Myxomcetes are given. (CS)

Progress on CD-DVD laser microfabrication method to develop cell culture scaffolds integrating biomimetic characteristics

NASA Astrophysics Data System (ADS)

Hautefeuille, Mathieu; Vázquez-Victorio, Genaro; Cruz-Ramírez, Aaron; Cabriales, Lucia; Jiménez-Diaz, Edgar; Escutia-Guadarrama, Lidia; López-Aparicio, Jehú; Pérez-Calixto, Daniel; Cano-Jorge, Mariel; Nieto-Rivera, Brenda; Sánchez-Olvera, Raúl

2018-02-01

The development of organ-on-chip and biological scaffolds is currently requiring simpler methods to microstructure biocompatible materials in three dimensions, fabricate structural and functional elements in biomaterials or modify the physicochemical properties of desired substrates. With the aim of creating simple, cost-effective alternatives to conventional existing techniques to produce such platforms with very specific properties, a low-power CD-DVD laser pickup head was recycled and mounted on a programmable three-axis micro-displacement system in order to modify the surface of polymeric materials in a local fashion. Thanks to a specially-designed method using a strongly absorbing additive coating the materials of interest, it has been possible to establish and precisely control processes useful in microtechnology for biomedical applications and normally restricted to much less affordable high-power lasers. In this work, we present our latest progress regarding the application of our fabrication technique to the development of organ-on-chip platforms thanks to the simple integration of several biomimetic characteristics typically achieved with traditional, less cost-effective microtechnology methods in one step or through replica-molding. Our straightforward approach indeed enables great control of local laser microablation for true on-demand biomimetic micropatterned designs in several transparent polymers and hydrogels of tunable stiffness and is allowing integration of microfluidics, microelectronics, optical waveguides, surface microstructuring and even transfer of superficial protein micropatterns on a variety of biocompatible materials. The results presented here were validated using hepatic and fibroblasts cell lines to demonstrate the viability of our procedure for organ-on-chip development and show the impact of such features in cell culture.

Evaluation of Additive Manufacturing for Composite Part Molds

DOE Office of Scientific and Technical Information (OSTI.GOV)

Duty, Chad E.; Springfield, Robert M.

2015-02-01

The ORNL Manufacturing Demonstration Facility (MDF) collaborated with Tru-Design to test the quality and durability of molds used for making fiber reinforced composites using additive manufacturing. The partners developed surface treatment techniques including epoxy coatings and machining to improve the quality of the surface finish. Test samples made using the printed and surface finished molds demonstrated life spans suitable for one-of-a-kind and low-volume applications, meeting the project objective.

Bioinspired, Mobile Robots With High Stability, Functionality and Low Cost

DTIC Science & Technology

2014-02-19

actuators with complex actuating modes (e.g., extending and multiple bending modes; Figure 5-3). Figure 5-1. (left panel) 3D printed molds...failure (e.g., cellulose , KevlarTM, polystyrene). We designed a two part mold (Figure 6-a) to pattern the exterior and interior pleating and then...variety of objects. The 3D molding technique used to fabricate this actuator, however, limits the pneumatic channel geometry. To achieve pneu-net

Applications of two- and three-dimensional microstructures formed by soft lithographic techniques

NASA Astrophysics Data System (ADS)

Jackman, Rebecca Jane

This thesis describes the development of several soft lithographic techniques. Each of these techniques has applications in two- and three-dimensional microfabrication or in the design of microreactor systems. All soft lithographic techniques make use of an elastomeric element that is formed by casting and curing a prepolymer against a planar substrate having three-dimensional (3D) relief. Chapters 1--3 (and Appendices I--VII) describe the use of a soft lithographic technique, microcontact printing (muCP), to produce patterns with micron-scale resolution on both planar and non-planar substrates. Electrodeposition transforms patterns produced by muCP into functional, 3D structures. It is an additive method that: (i) strengthens the metallic patterns; (ii) increases the conductivity of the structures; (iii) enables high-strain deformations to be performed on the structures; and (iv) welds non-connected structures. Applications for cylindrical microstructures, formed by the combination of muCP and electroplating, are presented. Some important classes of materials---biological macromolecules, gels, sol-gels, some polymers, low molecular weight organic and organometallic species---are often incompatible with conventional patterning techniques. Chapters 4 and 5 describe the use of elastomeric membranes as dry resists or as masks in dry lift-off to produce simple features as small as 5 mum from these and other materials on both planar and non-planar surfaces. These procedures are "dry" because the membranes conformed and sealed reversibly to surfaces without the use of solvents. This technique, for example, produced a simple electroluminescent device. By using two membranes simultaneously, multicolored, photoluminescent patterns of organic materials were created. Membranes were also used in sequential, dry-lift off steps to produce patterns with greater complexity. Chapter 6 (and Appendix XII) demonstrates that the ability to mold elastomers enables the fabrication of large (≤45 cm2) arrays of microwells (volumes ≥3 fL/well; densities ≤107 wells/cm2 ). These microwells can function as vessels for performing chemical reactions---"microreactors". Discontinuous dewetting is a technique that takes advantage of the interfacial properties of the elastomer and allows wells to be filled rapidly (typically ˜104 wells/second) and uniformly with a wide range of liquids. Several rudimentary strategies for addressing microwells are investigated including electroosmotic pumping and diffusion of gases.

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.

Novel high dose rate lip brachytherapy technique to improve dose homogeneity and reduce toxicity by customized mold.

PubMed

Feldman, Jon; Appelbaum, Limor; Sela, Mordechay; Voskoboinik, Ninel; Kadouri, Sarit; Weinberger, Jeffrey; Orion, Itzhak; Meirovitz, Amichay

2014-12-23

The purpose of this study is to describe a novel brachytherapy technique for lip Squamous Cell Carcinoma, utilizing a customized mold with embedded brachytherapy sleeves, which separates the lip from the mandible, and improves dose homogeneity. Seven patients with T2 lip cancer treated with a "sandwich" technique of High Dose Rate (HDR) brachytherapy to the lip, consisting of interstitial catheters and a customized mold with embedded catheters, were reviewed for dosimetry and outcome using 3D planning. Dosimetric comparison was made between the "sandwich" technique to "classic" - interstitial catheters only plan. We compared dose volume histograms for Clinical Tumor Volume (CTV), normal tissue "hot spots" and mandible dose. We are reporting according to the ICRU 58 and calculated the Conformal Index (COIN) to show the advantage of our technique. The seven patients (ages 36-81 years, male) had median follow-up of 47 months. Four patients received Brachytherapy and External Beam Radiation Therapy, 3 patients received brachytherapy alone. All achieved local control, with excellent esthetic and functional results. All patients are disease free. The Customized Mold Sandwich technique (CMS) reduced the high dose region receiving 150% (V150) by an average of 20% (range 1-47%), The low dose region (les then 90% of the prescribed dose) improved by 73% in average by using the CMS technique. The COIN value for the CMS was in average 0.92 as opposed to 0.88 for the interstitial catheter only. All differences (excluding the low dose region) were statistically significant. The CMS technique significantly reduces the high dose volume and increases treatment homogeneity. This may reduce the potential toxicity to the lip and adjacent mandible, and results in excellent tumor control, cosmetic and functionality.

Control of interaction strength in a network of the true slime mold by a microfabricated structure.

PubMed

Takamatsu, A; Fujii, T; Endo, I

2000-02-01

The plasmodium of the true slime mold, Physarum polycephalum, which shows various nonlinear oscillatory phenomena, for example, in its thickness, protoplasmic streaming and concentration of intracellular chemicals, can be regarded as a collective of nonlinear oscillators. The plasmodial oscillators are interconnected by microscale tubes whose dimensions can be closely related to the strength of interaction between the oscillators. Investigation of the collective behavior of the oscillators under the conditions in which the interaction strength can be systematically controlled gives significant information on the characteristics of the system. In this study, we proposed a living model system of a coupled oscillator system in the Physarum plasmodium. We patterned the geometry and dimensions of the microscale tube structure in the plasmodium by a microfabricated structure (microstructure). As the first step, we constructed a two-oscillator system for the plasmodium that has two wells (oscillator part) and a channel (coupling part). We investigated the oscillation behavior by monitoring the thickness oscillation of the plasmodium in the microstructure with various channel widths. It was found that the oscillation behavior of two oscillators dynamically changed depending on the channel width. Based on the results of measurements of the tube dimensions and the velocity of the protoplasmic streaming in the tube, we discuss how the channel width relates to the interaction strength of the coupled oscillator system.

Studies on the quantitative autoradiography. III. Quantitative comparison of a novel tissue-mold measurement technique "paste-mold method," to the semiquantitative whole body autoradiography (WBA), using the same animals.

PubMed

Motoji, N; Hamai, Y; Niikura, Y; Shigematsu, A

1995-01-01

A novel preparation technique, so called "Paste Mold," was devised for organ and tissue distribution studies. This is the most powerful by joining with autoradioluminography (ARLG), which was established and validated recently in the working group of Forum '93 of Japanese Society for study of xenobiotics. A small piece (10-50 mg) of each organ or tissue was available for measuring its radioactive concentration and it was sampled from the remains of frozen carcass used for macroautoradiography (MARG). The solubilization of the frozen pieces was performed with mixing a suitable volume of gelatine and strong alkaline solution prior to mild heating kept at 40 degrees C for a few hours. After that, the tissue paste was molded in template pattern to form the small plates. The molded plates were contacted with Imaging plate (IP) for recording their radioactive concentration. The recorded IP was processed by BAS2000. The molded plate was formed in thickness of 200 microns, so called infinit thickness against soft beta rays, and therefore the resulting relative intensities, represented by (PSL-BG)/S values, indicated practically responsible ratio of the radioactive concentration in organs and tissues, without any calibulation for beta-self absorption coefficiency. On the other hand, the left half body of the frozen carcass was used for making whole body autoradiography (WBA) before the Paste-Mold preparation. Comparison was performed for difference in (PSL-BG)/S values of organs and tissues between frozen and dried sections. A good concordance in relative intensities, (PSL-BG)/S by the Paste-Mold preparation was given with those by the frozen sections rather than dried sections.(ABSTRACT TRUNCATED AT 250 WORDS)

Mold growth on gypsum wallboard--a summary of three techniques.

PubMed

Menetrez, M Y; Foarde, K K; Webber, T D; Dean, T R; Betancourt, D A

2009-01-01

Reducing occupant exposure to mold growing on damp gypsum wallboard and controlling mold contamination in the indoor environment was studied through 1) delineation of environmental conditions required to promote and avoid mold growth and 2) efficacy testing of antimicrobial products, specifically cleaners and paints, on gypsum wallboard (GWB) surfaces. The effects of moisture and relative humidity (RH) on mold growth and transport are important in avoiding and eliminating problems. These effects have been demonstrated on GWB and are discussed in this article for use as control guidance. The authors discuss the efficacy of antimicrobial cleaners and paints to remove, eliminate, or control mold growth on GWB. Research to control Stachybotrys chartarum growth using 13 separate antimicrobial cleaners and nine varieties of antimicrobial paint on contaminated GWB was performed in laboratory testing. GWB surfaces were subjected to high RH. GWB control measures are summarized and combined, and the antimicrobial product results are explained.

Incidence of oronasal fistula formation after nasoalveolar molding and primary cleft repair.

PubMed

Dec, Wojciech; Shetye, Pradip R; Grayson, Barry H; Brecht, Lawrence E; Cutting, Court B; Warren, Stephen M

2013-01-01

The incidence of postoperative complications in cleft care is low. In this 19-year retrospective analysis of cleft lip and palate patients treated with preoperative nasoalveolar molding, we examine the incidence of postoperative oronasal fistulae. The charts of 178 patients who underwent preoperative nasoalveolar molding by the same orthodontist/prosthodontist team and primary cleft lip/palate repair by the same surgeon over a 19-year period were reviewed. Millard, Mohler, Cutting, or Mulliken-type techniques were used for cleft lip repairs. Oxford-, Bardach-, or von Langenbeck-type techniques were used for cleft palate repairs. One nasolabial fistula occurred after primary cleft lip repair (0.56% incidence) and was repaired surgically. Four palatal fistulae (3 at the junction between soft and hard palate and 1 at the right anterior palate near the incisive foramen) occurred, but 3 healed spontaneously. Only 1 palatal fistula (0.71%) required surgical repair. All 5 fistulae occurred within the first 8 years of the study period, with 4 (80%) of 5 occurring within the first 3 years. Although fistula rate may be related to surgeon experience and the evolution of presurgical techniques, nasoalveolar molding in conjunction with nasal floor closure contributes to a low incidence of oronasal fistulae.

A novel 2D silicon nano-mold fabrication technique for linear nanochannels over a 4 inch diameter substrate

PubMed Central

Yin, Zhifu; Qi, Liping; Zou, Helin; Sun, Lei

2016-01-01

A novel low-cost 2D silicon nano-mold fabrication technique was developed based on Cu inclined-deposition and Ar+ (argon ion) etching. With this technique, sub-100 nm 2D (two dimensional) nano-channels can be etched economically over the whole area of a 4 inch n-type <100> silicon wafer. The fabricating process consists of only 4 steps, UV (Ultraviolet) lithography, inclined Cu deposition, Ar+ sputter etching, and photoresist & Cu removing. During this nano-mold fabrication process, we investigated the influence of the deposition angle on the width of the nano-channels and the effect of Ar+ etching time on their depth. Post-etching measurements showed the accuracy of the nanochannels over the whole area: the variation in width is 10%, in depth it is 11%. However, post-etching measurements also showed the accuracy of the nanochannels between chips: the variation in width is 2%, in depth it is 5%. With this newly developed technology, low-cost and large scale 2D nano-molds can be fabricated, which allows commercial manufacturing of nano-components over large areas. PMID:26752559

Dimensional change in complete dentures fabricated by injection molding and microwave processing.

PubMed

Keenan, Phillip L J; Radford, David R; Clark, Robert K F

2003-01-01

Acrylic resin complete dentures undergo dimensional changes during polymerization. Techniques with injection molding and polymerization and microwave polymerization are reported to reduce these changes and thereby improve clinical fit. These dimensional changes need to be quantified. The purpose of this study was to compare differences in dimensional changes of simulated maxillary complete dentures during polymerization and storage in water after injection molding and conventional polymerization, or microwave polymerization against a control of conventionally packed and polymerized simulated maxillary complete dentures. Forty identical maxillary denture bases were prepared in dental wax with anatomic teeth. They were invested and the wax eliminated from the molds. Ten specimens each were randomly assigned to 1 of 4 groups. Group 1 was compression molded and conventionally polymerized; group 2 was injection molded and conventionally polymerized (Success); group 3 was injection molded and microwave polymerized (Acron MC); and group 4 was injection molded and microwave polymerized (Microbase). Intermolar width and changes in vertical dimension of occlusion, were determined after polymerization and after storage in water for 28 days. Measurements in triplicate were made between points scribed on the second molar teeth with a traveling microscope (accurate to 0.005 mm). Vertical dimension of occlusion was measured between points scribed on the upper and lower members of an articulator by use of an internal micrometer (accurate to 0.05 mm). Data were analyzed by use of a 1-way analysis of variance with Tukey post-hoc contrasts (P <.05). Polymerization contractions (intermolar widths) for each group were: group 1, -0.24%; group 2, -0.27%; group 3, -0.35%; and group 4, -0.37%. The Microbase specimens had greater shrinkage than conventionally polymerized specimens, but there were no significant differences between the groups. All injection methods had less postpolymerization increase in vertical dimension of occlusion (0.63 to 0.41 mm) than the conventional Trevalon control (0.74 mm), but only group 4 was significantly different (P<.004). After storage in water for 28 days, all specimens increased in vertical dimension of occlusion (0.10% to 0.16%) from polymerization techniques, but there were no significant differences between groups. Within the limitations of this study, injection molding resulted in a slightly less increase of vertical dimension of occlusion than conventional polymerization techniques, the difference being significant for Microbase compared with the conventional Trevalon control.

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.

Mail-Order Microfluidics: Evaluation of Stereolithography for the Production of Microfluidic Devices

PubMed Central

Au, Anthony K.; Lee, Wonjae; Folch, Albert

2015-01-01

The vast majority of microfluidic devices are developed in PDMS by molding (“soft lithography”) because PDMS is an inexpensive material, has physicochemical properties that are well suited for biomedical and physical sciences applications, and design cycle lengths are generally adequate for prototype development. However, PDMS molding is tediously slow and thus cannot provide the high- or medium-volume production required for the commercialization of devices. While high-throughput plastic molding techniques (e.g. injection molding) exist, the exorbitant cost of the molds and/or the equipment can be a serious obstacle for device commercialization, especially for small startups. High-volume production is not required to reach niche markets such as clinical trials, biomedical research supplies, customized research equipment, and classroom projects. Crucially, both PDMS and plastic molding are layer-by-layer techniques where each layer is produced as a result of physicochemical processes not specified in the initial photomask(s) and where the final device requires assembly by bonding, all resulting in a cost that is very hard to predict at the start of the project. By contrast, stereolithography (SL) is an automated fabrication technique that allows for the production of quasi-arbitrary 3D shapes in a single polymeric material at medium-volume throughputs (ranging from a single part to hundreds of parts). Importantly, SL devices can be designed between several groups using CAD tools, conveniently ordered by mail, and their cost precisely predicted via a web interface. Here we evaluate the resolution of an SL mail-order service and the main causes of resolution loss; the optical clarity of the devices and how to address the lack of clarity for imaging in the channels; and the future role that SL could play in the commercialization of microfluidic devices. PMID:24510161

Mail-order microfluidics: evaluation of stereolithography for the production of microfluidic devices.

PubMed

Au, Anthony K; Lee, Wonjae; Folch, Albert

2014-04-07

The vast majority of microfluidic devices are developed in PDMS by molding ("soft lithography") because PDMS is an inexpensive material, has physicochemical properties that are well suited for biomedical and physical sciences applications, and design cycle lengths are generally adequate for prototype development. However, PDMS molding is tediously slow and thus cannot provide the high- or medium-volume production required for the commercialization of devices. While high-throughput plastic molding techniques (e.g. injection molding) exist, the exorbitant cost of the molds and/or the equipment can be a serious obstacle for device commercialization, especially for small startups. High-volume production is not required to reach niche markets such as clinical trials, biomedical research supplies, customized research equipment, and classroom projects. Crucially, both PDMS and plastic molding are layer-by-layer techniques where each layer is produced as a result of physicochemical processes not specified in the initial photomask(s) and where the final device requires assembly by bonding, all resulting in a cost that is very hard to predict at the start of the project. By contrast, stereolithography (SL) is an automated fabrication technique that allows for the production of quasi-arbitrary 3D shapes in a single polymeric material at medium-volume throughputs (ranging from a single part to hundreds of parts). Importantly, SL devices can be designed between several groups using CAD tools, conveniently ordered by mail, and their cost precisely predicted via a web interface. Here we evaluate the resolution of an SL mail-order service and the main causes of resolution loss; the optical clarity of the devices and how to address the lack of clarity for imaging in the channels; and the future role that SL could play in the commercialization of microfluidic devices.

Plastic masters-rigid templates for soft lithography.

PubMed

Desai, Salil P; Freeman, Dennis M; Voldman, Joel

2009-06-07

We demonstrate a simple process for the fabrication of rigid plastic master molds for soft lithography directly from (poly)dimethysiloxane devices. Plastics masters (PMs) provide a cost-effective alternative to silicon-based masters and can be easily replicated without the need for cleanroom facilities. We have successfully demonstrated the use of plastics micromolding to generate both single and dual-layer plastic structures, and have characterized the fidelity of the molding process. Using the PM fabrication technique, world-to-chip connections can be integrated directly into the master enabling devices with robust, well-aligned fluidic ports directly after molding. PMs provide an easy technique for the fabrication of microfluidic devices and a simple route for the scaling-up of fabrication of robust masters for soft lithography.

Tensile strength of various nylon PA6 specimen modes

NASA Astrophysics Data System (ADS)

Raz, Karel; Zahalka, Martin

2017-05-01

This article explores the influence of production technique on the strength of nylon parts. Identical specimens were manufactured by various techniques. The material of specimens was nylon PA6. 3D printing and injection molding were used, with various orientations of printed layers, and various orientations of specimens in the working space of the 3D printer. The variants are described in detail. A special mold was used for the injection molding process in order to make specimens with and without a weld line. The effect of this weld line was evaluated. All specimens were tested using the standard tensile test configuration. The strength was compared. It was found that the same plastic material has very different mechanical properties depending on the production process.

Correction of nasal deformity in infants with unilateral cleft lip and palate using multiple digital techniques.

PubMed

Zheng, Yaqi; Zhang, Dapeng; Qin, Tian; Wu, Guofeng

2016-06-01

Presurgical correction of severe nasal deformities before cheiloplasty is often recommended for infants with cleft lip and palate. This article describes an approach for the computer-aided design and fabrication of a nasal molding stent. A 3-dimensional photogrammetric system was used to obtain the shape information of the nosewing that was then built as the nostril support for the nasal molding stent. The stent was fabricated automatically with a rapid prototyping machine. This technique may be an alternative approach to presurgical nasal molding in the clinic. Moreover, the patient's nasal morphology can be saved as clinical data for future study. Copyright © 2016 Editorial Council for the Journal of Prosthetic Dentistry. Published by Elsevier Inc. All rights reserved.

Analytical techniques for measuring hydrocarbon emissions from the manufacture of fiberglass-reinforced plastics. Report for June 1995--March 1997

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wright, R.S.; Kong, E.J.; Bahner, M.A.

The paper discusses several projects to measure hydrocarbon emissions associated with the manufacture of fiberglass-reinforced plastics. The main purpose of the projects was to evaluate pollution prevention techniques to reduce emissions by altering raw materials, application equipment, and operator technique. Analytical techniques were developed to reduce the cost of these emission measurements. Emissions from a small test mold in a temporary total enclosure (TTE) correlated with emissions from full-size production molds in a separate TTE. Gravimetric mass balance measurements inside the TTE generally agreed to within +/-30% with total hydrocarbon (THC) measurements in the TTE exhaust duct.

Benchtop Nanoscale Patterning Using Soft Lithography

ERIC Educational Resources Information Center

Meenakshi, Viswanathan; Babayan, Yelizaveta; Odom, Teri W.

2007-01-01

This paper outlines several benchtop nanoscale patterning experiments that can be incorporated into undergraduate laboratories or advanced high school chemistry curricula. The experiments, supplemented by an online video lab manual, are based on soft lithographic techniques such as replica molding, micro-molding in capillaries, and micro-contact…

Scalable Inkjet-Based Structural Color Printing by Molding Transparent Gratings on Multilayer Nanostructured Surfaces.

PubMed

Jiang, Hao; Kaminska, Bozena

2018-04-24

To enable customized manufacturing of structural colors for commercial applications, up-scalable, low-cost, rapid, and versatile printing techniques are highly demanded. In this paper, we introduce a viable strategy for scaling up production of custom-input images by patterning individual structural colors on separate layers, which are then vertically stacked and recombined into full-color images. By applying this strategy on molded-ink-on-nanostructured-surface printing, we present an industry-applicable inkjet structural color printing technique termed multilayer molded-ink-on-nanostructured-surface (M-MIONS) printing, in which structural color pixels are molded on multiple layers of nanostructured surfaces. Transparent colorless titanium dioxide nanoparticles were inkjet-printed onto three separate transparent polymer substrates, and each substrate surface has one specific subwavelength grating pattern for molding the deposited nanoparticles into structural color pixels of red, green, or blue primary color. After index-matching lamination, the three layers were vertically stacked and bonded to display a color image. Each primary color can be printed into a range of different shades controlled through a half-tone process, and full colors were achieved by mixing primary colors from three layers. In our experiments, an image size as big as 10 cm by 10 cm was effortlessly achieved, and even larger images can potentially be printed on recombined grating surfaces. In one application example, the M-MIONS technique was used for printing customizable transparent color optical variable devices for protecting personalized security documents. In another example, a transparent diffractive color image printed with the M-MIONS technique was pasted onto a transparent panel for overlaying colorful information onto one's view of reality.

Application of TRIZ Theory in Patternless Casting Manufacturing Technique

NASA Astrophysics Data System (ADS)

Yang, Weidong; Gan, Dequan; Jiang, Ping; Tian, Yumei

The ultimate goal of Patternless Casting Manufacturing (referred to as PCM) is how to obtain the casts by casting the sand mold directly. In the previous PCM, the resin content of sand mold is much higher than that required by traditional resin sand, so the casts obtained are difficult to be sound and qualified products, which limits the application of this technique greatly. In this paper, the TRIZ algorithm is introduced to the innovation process in PCM systematically.

Mimosa-inspired design of a flexible pressure sensor with touch sensitivity.

PubMed

Su, Bin; Gong, Shu; Ma, Zheng; Yap, Lim Wei; Cheng, Wenlong

2015-04-24

A bio-inspired flexible pressure sensor is generated with high sensitivity (50.17 kPa(-1)), quick responding time (<20 ms), and durable stability (negligible loading-unloading signal changes over 10 000 cycles). Notably, the key resource of surface microstructures upon sensor substrates results from the direct molding of natural mimosa leaves, presenting a simple, environment-friendly and easy scale-up fabrication process for these flexible pressure sensors. © 2014 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Effect of Slag-Steel Reaction on the Initial Solidification of Molten Steel during Continuous Casting

NASA Astrophysics Data System (ADS)

Wang, Wanlin; Lou, Zhican; Zhang, Haihui

2018-03-01

With the mold simulator technique, the effect of slag-steel reaction on the initial shell solidification as well as the heat transfer and lubrication behavior of the infiltrated mold/shell slag film was studied in this article. The results showed that the Al2O3 content, the CaO/SiO2 ratio, and the viscosity of mold flux were increased with the progress of the slag-steel reaction during casting. The slag-steel reaction has two major effects on the initial shell solidification: one is increasing the mold heat flux and shell thickness by the decrease of slag film thickness. The other is the reduction of mold heat flux by the increase of crystal fraction in slag film. Mold flux with a lower basicity, viscosity, and crystallization temperature would result in a larger liquid slag consumption and the uneven infiltration of slag into the mold and shell gap that eventually leads to the irregular solidification of initial shell with a poor surface quality, such as slag entrapment and depressions as well as glaciation marks. Conversely, mold flux with a higher viscosity, basicity, and crystallization temperature would result in a smaller liquid slag consumption, which would cause the poor mold lubrication, the longitudinal shell surface defects, and drag marks.

Effect of Slag-Steel Reaction on the Initial Solidification of Molten Steel during Continuous Casting

NASA Astrophysics Data System (ADS)

Wang, Wanlin; Lou, Zhican; Zhang, Haihui

2018-06-01

With the mold simulator technique, the effect of slag-steel reaction on the initial shell solidification as well as the heat transfer and lubrication behavior of the infiltrated mold/shell slag film was studied in this article. The results showed that the Al2O3 content, the CaO/SiO2 ratio, and the viscosity of mold flux were increased with the progress of the slag-steel reaction during casting. The slag-steel reaction has two major effects on the initial shell solidification: one is increasing the mold heat flux and shell thickness by the decrease of slag film thickness. The other is the reduction of mold heat flux by the increase of crystal fraction in slag film. Mold flux with a lower basicity, viscosity, and crystallization temperature would result in a larger liquid slag consumption and the uneven infiltration of slag into the mold and shell gap that eventually leads to the irregular solidification of initial shell with a poor surface quality, such as slag entrapment and depressions as well as glaciation marks. Conversely, mold flux with a higher viscosity, basicity, and crystallization temperature would result in a smaller liquid slag consumption, which would cause the poor mold lubrication, the longitudinal shell surface defects, and drag marks.

Magnet Assisted Composite Manufacturing: A Flexible New Technique for Achieving High Consolidation Pressure in Vacuum Bag/Lay-Up Processes.

PubMed

Pishvar, Maya; Amirkhosravi, Mehrad; Altan, M Cengiz

2018-05-17

This work demonstrates a protocol to improve the quality of composite laminates fabricated by wet lay-up vacuum bag processes using the recently developed magnet assisted composite manufacturing (MACM) technique. In this technique, permanent magnets are utilized to apply a sufficiently high consolidation pressure during the curing stage. To enhance the intensity of the magnetic field, and thus, to increase the magnetic compaction pressure, the magnets are placed on a magnetic top plate. First, the entire procedure of preparing the composite lay-up on a magnetic bottom steel plate using the conventional wet lay-up vacuum bag process is described. Second, placement of a set of Neodymium-Iron-Boron permanent magnets, arranged in alternating polarity, on the vacuum bag is illustrated. Next, the experimental procedures to measure the magnetic compaction pressure and volume fractions of the composite constituents are presented. Finally, methods used to characterize microstructure and mechanical properties of composite laminates are discussed in detail. The results prove the effectiveness of the MACM method in improving the quality of wet lay-up vacuum bag laminates. This method does not require large capital investment for tooling or equipment and can also be used to consolidate geometrically complex composite parts by placing the magnets on a matching top mold positioned on the vacuum bag.

Design and development of an injection-molded demultiplexer for optical communication systems in the visible range.

PubMed

Höll, S; Haupt, M; Fischer, U H P

2013-06-20

Optical simulation software based on the ray-tracing method offers easy and fast results in imaging optics. This method can also be applied in other fields of light propagation. For short distance communications, polymer optical fibers (POFs) are gradually gaining importance. This kind of fiber offers a larger core diameter, e.g., the step index POF features a core diameter of 980 μm. Consequently, POFs have a large number of modes (>3 million modes) in the visible range, and ray tracing could be used to simulate the propagation of light. This simulation method is applicable not only for the fiber itself but also for the key components of a complete POF network, e.g., couplers or other key elements of the transmission line. In this paper a demultiplexer designed and developed by means of ray tracing is presented. Compared to the classical optical design, requirements for optimal design differ particularly with regard to minimizing the insertion loss (IL). The basis of the presented key element is a WDM device using a Rowland spectrometer setup. In this approach the input fiber carries multiple wavelengths, which will be divided into multiple output fibers that transmit only one wavelength. To adapt the basic setup to POF, the guidance of light in this element has to be changed fundamentally. Here, a monolithic approach is presented with a blazed grating using an aspheric mirror to minimize most of the aberrations. In the simulations the POF is represented by an area light source, while the grating is analyzed for different orders and the highest possible efficiency. In general, the element should be designed in a way that it can be produced with a mass production technology like injection molding in order to offer a reasonable price. However, designing the elements with regard to injection molding leads to some inherent challenges. The microstructure of an optical grating and the thick-walled 3D molded parts both result in high demands on the injection molding process. This also requires complex machining of the molding tool. Therefore, different experiments are done to optimize the process parameter, find the best molding material, and find a suitable machining method for the molding tool. The paper will describe the development of the demultiplexer by means of ray-tracing simulations step by step. Also, the process steps and the realized solutions for the injection molding are described.

Diagnostics of glass fiber reinforced polymers and comparative analysis of their fabrication techniques with the use of acoustic emission

NASA Astrophysics Data System (ADS)

Bashkov, O. V.; Bryansky, A. A.; Panin, S. V.; Zaikov, V. I.

2016-11-01

Strength properties of the glass fiber reinforced polymers (GFRP) fabricated by vacuum and vacuum autoclave molding techniques were analyzed. Measurements of porosity of the GFRP parts manufactured by various molding techniques were conducted with the help of optical microscopy. On the basis of experimental data obtained by means of acoustic emission hardware/software setup, the technique for running diagnostics and forecasting the bearing capacity of polymeric composite materials based on the result of three-point bending tests has been developed. The operation principle of the technique is underlined by the evaluation of the power function index change which takes place on the dependence of the total acoustic emission counts versus the loading stress.

3D Representative Volume Element Reconstruction of Fiber Composites via Orientation Tensor and Substructure Features

DOE Office of Scientific and Technical Information (OSTI.GOV)

Li, Yi; Chen, Wei; Xu, Hongyi

To provide a seamless integration of manufacturing processing simulation and fiber microstructure modeling, two new stochastic 3D microstructure reconstruction methods are proposed for two types of random fiber composites: random short fiber composites, and Sheet Molding Compounds (SMC) chopped fiber composites. A Random Sequential Adsorption (RSA) algorithm is first developed to embed statistical orientation information into 3D RVE reconstruction of random short fiber composites. For the SMC composites, an optimized Voronoi diagram based approach is developed for capturing the substructure features of SMC chopped fiber composites. The proposed methods are distinguished from other reconstruction works by providing a way ofmore » integrating statistical information (fiber orientation tensor) obtained from material processing simulation, as well as capturing the multiscale substructures of the SMC composites.« less

Comparative study on the in vitro performance of blister molded and conventional lornoxicam immediate release liquitablets: accelerated stability study and anti-inflammatory and ulcerogenic effects.

PubMed

El-Setouhy, Doaa Ahmed; Gamiel, Alaa Abdel-Rahman; Badawi, Alia Abd El-Latif; Osman, Afaf Sayed; Labib, Dina Ahmed

2017-03-01

Lornoxicam is a potent non-steroidal anti-inflammatory drug (NSAID). It shows limited solubility in the gastric pH, delayed bioavailability and pharmacodynamic effects with aggravated gastric side effects (due to longer residence in the stomach wall). To enhance dissolution of lornoxicam in the gastric fluid and expectedly absorption and pharmacological action, with less ulcerogenic effects. Formulation of immediate release (IR) lornoxicam liquitablets containing both liquid and solid release modulators (wetting agent, solubilizers and microenvironmental pH modifiers). Beside the traditional direct compression technique employed for the preparation of liquitablets a new technique, blister molding, was also used. The effect of the two different manufacturing methods on the fast release characteristics (rapid disintegration and dissolution) was studied. Stability and pharmacological activity of the optimum formula were also explored. Similarity factor pointed out the superiority of molding technique in enhancing dissolution of lornoxicam owing to significant crystallinity reduction (XRD). Optimum formula showed negligible change in drug content and dissolution profiles over 12 weeks, significantly improved anti-inflammatory activity and significantly reduced gastric ulcerative effect over pure lornoxicam and commercial formula. Blister molded lornoxicam liquitablet of improved dissolution and pharmacological activity and less gastric erosion was successfully prepared.

Effects of substrate preheating during direct energy deposition on microstructure, hardness, tensile strength, and notch toughness

NASA Astrophysics Data System (ADS)

Baek, Gyeong Yun; Lee, Ki Yong; Park, Sang Hu; Shim, Do Sik

2017-11-01

This study examined the effects of substrate preheating for the hardfacing of cold-press dies using the high-speed tool steel AISI M4. The preheating of the substrate is a widely used technique for reducing the degree of thermal deformation and preventing crack formation. We investigated the changes in the metallurgical and mechanical properties of the high-speed tool steel M4 deposited on an AISI D2 substrate with changes in the substrate preheating temperature. Five preheating temperatures (100-500 °C; interval of 100 °C) were selected, and the changes in the temperature of the substrate during deposition were observed. As the preheating temperature of the substrate was increased, the temperature gradient between the melting layer and the substrate decreased; this prevented the formation of internal cracks, owing to thermal stress relief. Field-emission scanning electron microscopy showed that a dendritic structure was formed at the interface between the deposited layer and the substrate while a cellular microstructure was formed in the deposited layer. As the preheating temperature was increased, the sizes of the cells and precipitated carbides also increased. Furthermore, the hardness increased slightly while the strength and toughness decreased. Moreover, the tensile and impact properties deteriorated rapidly at excessively high preheating temperatures (greater than 500 °C). The results of this study can be used as preheating criteria for achieving the desired mechanical properties during the hardfacing of dies and molds.

Optimization of injection molding process parameters for a plastic cell phone housing component

NASA Astrophysics Data System (ADS)

Rajalingam, Sokkalingam; Vasant, Pandian; Khe, Cheng Seong; Merican, Zulkifli; Oo, Zeya

2016-11-01

To produce thin-walled plastic items, injection molding process is one of the most widely used application tools. However, to set optimal process parameters is difficult as it may cause to produce faulty items on injected mold like shrinkage. This study aims at to determine such an optimum injection molding process parameters which can reduce the fault of shrinkage on a plastic cell phone cover items. Currently used setting of machines process produced shrinkage and mis-specified length and with dimensions below the limit. Thus, for identification of optimum process parameters, maintaining closer targeted length and width setting magnitudes with minimal variations, more experiments are needed. The mold temperature, injection pressure and screw rotation speed are used as process parameters in this research. For optimal molding process parameters the Response Surface Methods (RSM) is applied. The major contributing factors influencing the responses were identified from analysis of variance (ANOVA) technique. Through verification runs it was found that the shrinkage defect can be minimized with the optimal setting found by RSM.

Modeling the investment casting of a titanium crown.

PubMed

Atwood, R C; Lee, P D; Curtis, R V; Maijer, D M

2007-01-01

The objective of this study was to apply computational modeling tools to assist in the design of titanium dental castings. The tools developed should incorporate state-of-the-art micromodels to predict the depth to which the mechanical properties of the crown are affected by contamination from the mold. The model should also be validated by comparison of macro- and micro-defects found in a typical investment cast titanium tooth crown. Crowns were hand-waxed and investment cast in commercial purity grade 1 (CP-1) titanium by a commercial dental laboratory. The castings were analyzed using X-ray microtomography (XMT). Following sectioning, analysis continued with optical and scanning electron microscopy, and microhardness testing. An in-house cellular-automata solidification and finite-difference diffusion program was coupled with a commercial casting program to model the investment casting process. A three-dimensional (3D) digital image generated by X-ray tomography was used to generate an accurate geometric representation of a molar crown casting. Previously reported work was significantly expanded upon by including transport of dissolved oxygen and impurity sources upon the arbitrarily shaped surface of the crown, and improved coupling of micro- and macro-scale simulations. Macroscale modeling was found to be sufficient to accurately predict the location of the large internal porosity. These are shrinkage pores located in the thick sections of the cusp. The model was used to determine the influence of sprue design on the size and location of these pores. Combining microscale with macroscale modeling allowed the microstructure and depth of contamination to be predicted qualitatively. This combined model predicted a surprising result--the dissolution of silicon from the mold into the molten titanium is sufficient to depress the freezing point of the liquid metal such that the crown solidifies the subsurface. Solidification then progresses inwards and back out to the surface through the silicon-enriched near-surface layer. The microstructure and compositional analysis of the near-surface region are consistent with this prediction. A multiscale model was developed and validated, which can be used to design CP-Ti dental castings to minimize both macro- and micro-defects, including shrinkage porosity, grain size and the extent of surface contamination due to reaction with the mold material. The model predicted the surprising result that the extent of Si contamination from the mold was sufficient to suppress the liquidus temperature to the extent that the surface (to a depth of approximately 100 microm) of the casting solidifies after the bulk. This significantly increases the oxygen pickup, thereby increasing the depth of formation of alpha casing. The trend towards mold materials with reduced Si in order to produce easier-to-finish titanium castings is a correct approach.

A new method of fabricating a blend scaffold using an indirect three-dimensional printing technique.

PubMed

Jung, Jin Woo; Lee, Hyungseok; Hong, Jung Min; Park, Jeong Hun; Shim, Jung Hee; Choi, Tae Hyun; Cho, Dong-Woo

2015-11-03

Due to its simplicity and effectiveness, the physical blending of polymers is considered to be a practical strategy for developing a versatile scaffold having desirable mechanical and biochemical properties. In the present work, an indirect three-dimensional (i3D) printing technique was proposed to fabricate a 3D free-form scaffold using a blend of immiscible materials, such as polycaprolactone (PCL) and gelatin. The i3D printing technique includes 3D printing of a mold and a sacrificial molding process. PCL/chloroform and gelatin/water were physically mixed to prepare the blend solution, which was subsequently injected into the cavity of a 3D printed mold. After solvent removal and gelatin cross-linking, the mold was dissolved to obtain a PCL-gelatin (PG) scaffold, with a specific 3D structure. Scanning electron microscopy and Fourier transform infrared spectroscopy analysis indicated that PCL masses and gelatin fibers in the PG scaffold homogenously coexisted without chemical bonding. Compression tests confirmed that gelatin incorporation into the PCL enhanced its mechanical flexibility and softness, to the point of being suitable for soft-tissue engineering, as opposed to pure PCL. Human adipose-derived stem cells, cultured on a PG scaffold, exhibited enhanced in vitro chondrogenic differentiation and tissue formation, compared with those on a PCL scaffold. The i3D printing technique can be used to blend a variety of materials, facilitating 3D scaffold fabrication for specific tissue regeneration. Furthermore, this convenient and versatile technique may lead to wider application of 3D printing in tissue engineering.

Nonaqueous slip casting of high temperature ceramic superconductors using an investment casting technique

NASA Technical Reports Server (NTRS)

Hooker, Matthew W. (Inventor); Taylor, Theodore D. (Inventor); Wise, Stephanie A. (Inventor); Buckley, John D. (Inventor); Vasquez, Peter (Inventor); Buck, Gregory M. (Inventor); Hicks, Lana P. (Inventor)

1993-01-01

A process for slip casting ceramic articles that does not employ parting agents and affords the casting of complete, detailed, precision articles that do not possess parting lines is presented. This process is especially useful for high temperature superconductors and water-sensitive ceramics. A wax pattern for a shell mold is provided, and an aqueous mixture of a calcium sulfate-bonded investment material is applied as a coating to the wax pattern. The coated wax pattern is then dried, followed by curing to vaporize the wax pattern and leave a shell mold of the calcium sulfate-bonded investment material. The shell mold is cooled to room temperature, and a ceramic slip, created by dispersing a ceramic powder in an organic liquid, is poured therein. After a ceramic shell of desired thickness or a solid article has set up in the shell mold, excess ceramic slip is poured out. The shell mold is misted with water and peeled away from the ceramic article, after which the ceramic is fired to provide a complete, detailed, precision, high temperature superconductive ceramic article without parting lines. The casting technique may take place in the presence of a magnetic field to orient the ceramic powders during the casting process.

Fourier Thermal Analysis of the Eutectic Formed in Pb-Sn Alloys

NASA Astrophysics Data System (ADS)

Cruz, H.; Ramírez-Argaez, M.; Juarez, A.; Garcia, A.; González-Rivera, C.

2009-06-01

The effect of the presence of two different primary phases on the microstructural characteristics and solidification kinetics of Pb-Sn eutectic was analyzed using Fourier thermal analysis method (FTA) and microstructural characterization. Three Pb-Sn alloys, a hypoeutectic, an eutectic, and a hypereutectic alloy, were melted in an electric furnace under an argon atmosphere and poured into sand molds. Cooling curves were obtained and numerically processed using FTA. Microstructural observations of the probes indicate a lamellar morphology for the eutectic microconstituent of the hypereutectic alloy; the eutectic alloy shows the presence of both lamellar and anomalous eutectic and the hypoeutectic alloy shows only the presence of anomalous eutectic. FTA results indicate that in the case of the probes showing the presence of anomalous eutectic, there is a primary eutectic formed during recalescence at high undercooling and a secondary eutectic yielded at low undercooling at the eutectic plateau temperature. This result shows that the cause behind the observed differences in the eutectic morphologies of the experimental alloys lies on the nucleating ability of the primary phase available as a potential substrate for nucleation of the eutectic microconstituent.

Microengineered Conductive Elastomeric Electrodes for Long-Term Electrophysiological Measurements with Consistent Impedance under Stretch

PubMed Central

Hu, Dinglong; Cheng, Tin Kei; Xie, Kai; Lam, Raymond H. W.

2015-01-01

In this research, we develop a micro-engineered conductive elastomeric electrode for measurements of human bio-potentials with the absence of conductive pastes. Mixing the biocompatible polydimethylsiloxane (PDMS) silicone with other biocompatible conductive nano-particles further provides the material with an electrical conductivity. We apply micro-replica mold casting for the micro-structures, which are arrays of micro-pillars embedded between two bulk conductive-PDMS layers. These micro-structures can reduce the micro-structural deformations along the direction of signal transmission; therefore the corresponding electrical impedance under the physical stretch by the movement of the human body can be maintained. Additionally, we conduct experiments to compare the electrical properties between the bulk conductive-PDMS material and the microengineered electrodes under stretch. We also demonstrate the working performance of these micro-engineered electrodes in the acquisition of the 12-lead electrocardiographs (ECG) of a healthy subject. Together, the presented gel-less microengineered electrodes can provide a more convenient and stable bio-potential measurement platform, making tele-medical care more achievable with reduced technical barriers for instrument installation performed by patients/users themselves. PMID:26512662

Effect of supercritical carbon dioxide pasteurization on natural microbiota, texture, and microstructure of fresh-cut coconut.

PubMed

Ferrentino, Giovanna; Balzan, Sara; Dorigato, Andrea; Pegoretti, Alessandro; Spilimbergo, Sara

2012-05-01

The objective of the present study was the evaluation of the effectiveness of supercritical carbon dioxide (SC-CO(2)) as a nonthermal technology for the pasteurization of fresh-cut coconut, as an example of ready-to-eat and minimally processed food. First, the inactivation kinetics of microbiota on coconut were determined using SC-CO(2) treatments (pressures at 8 and 12 MPa, temperatures from 24 to 45 °C, treatment times from 5 to 60 min). Second, the effects of SC-CO(2) on the hardness and microstructure of fresh-cut coconut processed at the optimal conditions for microbial reduction were investigated. SC-CO(2) treatment of 15 min at 45 °C and 12 MPa induced 4 log CFU/g reductions of mesophilic microorganisms, lactic acid bacteria, total coliforms, and yeasts and molds. The hardness of coconut was not affected by the treatment but the samples developed an irregular and disorderly microstructure. Results suggested the potential of SC-CO(2) in preserving fresh-cut fruits and ready-to-eat products. © 2012 Institute of Food Technologists®

Metallurgical characterization of orthodontic brackets produced by Metal Injection Molding (MIM).

PubMed

Zinelis, Spiros; Annousaki, Olga; Makou, Margarita; Eliades, Theodore

2005-11-01

The aim of this study was to investigate the bonding base surface morphology, alloy type, microstructure, and hardness of four types of orthodontic brackets produced by Metal Injection Molding technology (Discovery, Extremo, Freedom, and Topic). The bonding base morphology of the brackets was evaluated by scanning electron microscopy (SEM). Brackets from each manufacturer were embedded in epoxy resin, and after metallographic grinding, polishing and coating were analyzed by x-ray energy-dispersive spectroscopic (EDS) microanalysis to assess their elemental composition. Then, the brackets were subjected to metallographic etching to reveal their metallurgical structure. The same specimen surfaces were repolished and used for Vickers microhardness measurements. The results were statistically analyzed with one-way analysis of variance and Student-Newman-Keuls multiple comparison test at the 0.05 level of significance. The findings of SEM observations showed a great variability in the base morphology design among the brackets tested. The x-ray EDS analysis demonstrated that each bracket was manufactured from different ferrous or Co-based alloys. Metallographic analysis showed the presence of a large grain size for the Discovery, Freedom, and Topic brackets and a much finer grain size for the Extremo bracket. Vickers hardness showed great variations among the brackets (Topic: 287 +/- 16, Freedom: 248 +/- 13, Discovery: 214 +/- 12, and Extremo: 154 +/- 9). The results of this study showed that there are significant differences in the base morphology, composition, microstructure, and microhardness among the brackets tested, which may anticipate significant clinical implications.

Adaptive wettability-enhanced surfaces ordered on molded etched substrates using shrink film

NASA Astrophysics Data System (ADS)

Jayadev, Shreshta; Pegan, Jonathan; Dyer, David; McLane, Jolie; Lim, Jessica; Khine, Michelle

2013-01-01

Superhydrophobic surfaces in nature exhibit desirable properties including self-cleaning, bacterial resistance, and flight efficiency. However, creating such intricate multi-scale features with conventional fabrication approaches is difficult, expensive, and not scalable. By patterning photoresist on pre-stressed shrink-wrap film, which contracts by 95% in surface area when heated, such features over large areas can be obtained easily. Photoresist serves as a dry etch mask to create complex and high-aspect ratio microstructures in the film. Using a double-shrink process, we introduce adaptive wettability-enhanced surfaces ordered on molded etched (AWESOME) substrates. We first create a mask out of the children’s toy ‘Shrinky-Dinks’ by printing dots using a laserjet printer. Heating this thermoplastic sheet causes the printed dots to shrink to a fraction of their original size. We then lithographically transfer the inverse pattern onto photoresist-coated shrink-wrap polyolefin film. The film is then plasma etched. After shrinking, the film serves as a high-aspect ratio mold for polydimethylsiloxane, creating a superhydrophobic surface with water contact angles >150° and sliding angles <10°. We pattern a microarray of ‘sticky’ spots with a dramatically different sliding angle compared to that of the superhydrophobic region, enabling microtiter-plate type assays without the need for a well plate.

Microstamped opto-mechanical actuator for tactile displays

NASA Astrophysics Data System (ADS)

Camargo, Carlos J.; Torras, Núria; Campanella, Humberto; Marshall, Jean E.; Zinoviev, Kirill; Campo, Eva M.; Terentjev, Eugene M.; Esteve, Jaume

2011-10-01

Over the last few years, several technologies have been adapted for use in tactile displays, such as thermo-pneumatic actuators, piezoelectric polymers and dielectric elastomers. None of these approaches offers high-performance for refreshable Braille display system (RBDS), due to considerations of weight, power efficiency and response speed. Optical actuation offers an attractive alternative to solve limitations of current-art technologies, allowing electromechanical decoupling, elimination of actuation circuits and remote controllability. Creating these opticallydriven devices requires liquid crystal - carbon nanotube (LC-CNT) composites that show a reversible shape change in response to an applied light. This work thus reports on novel opto-actuated Braille dots based on LC-CNT composite and silicon mold microstamping. The manufacturing approach succeeds on producing blisters according to the Braille standard for the visually impaired, by taking shear-aligned LC-CNT films and silicon stamps. For this application, we need to define specifically-shaped structures. Some technologies have succeeded on elastomer microstructuring. Nevertheless, they are not applicable for LC-CNT molding because they do not consider the stretching of the polymer which is required for LC-CNT fabrication. Our process demonstrates that composites micro-molding and their 3-D structuring is feasible by silicon-based stamping. Its work principle involves the mechanical stretching, allowing the LC mesogens alignment.

Repurposing compact discs as master molds to fabricate high-performance organic nanowire field-effect transistors

NASA Astrophysics Data System (ADS)

Kim, Kyunghun; Cho, Jinhwi; Jhon, Heesauk; Jeon, Jongwook; Kang, Myounggon; Eon Park, Chan; Lee, Jihoon; An, Tae Kyu

2017-05-01

Organic field-effect transistors (OFETs) have been developed over the past few decades due to their potential applications in future electronics such as wearable and foldable electronics. As the electrical performance of OFETs has improved, patterning organic semiconducting crystals has become a key issue for their commercialization. However, conventional soft lithographic techniques have required the use of expensive processes to fabricate high-resolution master molds. In this study, we demonstrated a cost-effective method to prepare nanopatterned master molds for the fabrication of high-performance nanowire OFETs. We repurposed commercially available compact discs (CDs) as master molds because they already have linear nanopatterns on their surface. Flexible nanopatterned templates were replicated from the CDs using UV-imprint lithography. Subsequently, 6,13-bis-(triisopropylsilylethynyl) pentacene nanowires (NWs) were grown from the templates using a capillary force-assisted lithographic technique. The NW-based OFETs showed a high average field-effect mobility of 2.04 cm2 V-1 s-1. This result was attributed to the high crystallinity of the NWs and to their crystal orientation favorable for charge transport.

Inhomogeneity of Microstructure and Damping Capacity of a FC25 Disc-Brake Rotor and Their Interrelationship

NASA Astrophysics Data System (ADS)

Park, Jongbin; Han, Jeongho; Lee, Seung-Joon; Yi, Kyoungdon; Kwon, Chelwoong; Lee, Young-Kook

2016-08-01

The objective of the present study was to investigate the inhomogeneity of microstructure and damping capacity of a FC25 disc-brake rotor made of gray cast iron (GCI) and their interrelationship. The rotor had inhomogeneous microstructure due to different cooling rates caused by the position of inlets in a mold during casting. The volume fraction and size of graphite decreased with increasing cooling rate. A maximum deviation of the volume fraction of graphite within the rotor was approximately 2 pct, whereas that of the total perimeter of graphite per unit area was approximately 33 pct. Damping capacities measured at the first vibrational mode of both the real rotor and cantilever specimens, which were taken from four different regions within the rotor, depended on the location within the rotor. This result indicates that the damping capacity of the rotor is influenced by the inhomogeneous microstructure; particularly, the damping capacity was proportional to the total perimeter of graphite per unit area. Therefore, it was concluded that the damping of the GCI rotor used in the present study occurs primarily by the viscous or plastic flow at the interphase boundaries between the pearlite matrix and graphite particles at least at the frequencies of below 1140 Hz.

Effect of Zn addition on bulk microstructure of lead-free solder SN100C

NASA Astrophysics Data System (ADS)

Nur Nadirah M., K.; Nurulakmal M., S.

2017-12-01

This paper reports the effect of adding Zn (0.5 wt% Zn, 1.0 wt% Zn) to the bulk microstructure and intermetallic compound (IMC) formation of commercial SN100C (Sn-0.7Cu-0.05Ni+Ge) lead-free solder alloy. Solder alloys were prepared by melting SN100C ingot and Zn shots, and subsequently casted into steel mold. Samples were ground and polished for XRF, and polished samples were then etched for microstructure analysis. Microstructure of bulk solder and the IMC were observed using SEM equipped with EDX. SEM result showed the addition of 0.5 wt% Zn resulted in increased grain size of β-Sn matrix but further addition of Zn (1 wt%) reduced the size of β-Sn dendrites in the bulk solder. Several intermetallic compounds (IMCs) were observed distributed in the Sn matrix; Cu-Zn, Ni-Zn and Cu-Zn-Ni IMC but in relatively small percentage compared to Cu-Zn and Ni-Zn. These particles could be considered as effective nucleating agent that led to finer β-Sn grains. It is expected that the finer β-Sn will contribute towards higher solder strength and the various IMCs present could act as suppressant for Sn diffusion which will then tend to reduce the IMC growth during thermal aging.

Systems and Methods for Fabricating Structures Including Metallic Glass-Based Materials Using Low Pressure Casting

NASA Technical Reports Server (NTRS)

Hofmann, Douglas C. (Inventor); Kennett, Andrew (Inventor)

2018-01-01

Systems and methods to fabricate objects including metallic glass-based materials using low-pressure casting techniques are described. In one embodiment, a method of fabricating an object that includes a metallic glass-based material includes: introducing molten alloy into a mold cavity defined by a mold using a low enough pressure such that the molten alloy does not conform to features of the mold cavity that are smaller than 100 microns; and cooling the molten alloy such that it solidifies, the solid including a metallic glass-based material.

Study of the injection molding of a polarizing beam splitter.

PubMed

Jose de Carvalho, Edson; Braga, Edmundo da Silva; Cescato, Lucila H

2006-01-01

We describe the replication of a relief grating that behaves like a polarizing beam splitter by injection molding. Measurements of the grating master, nickel shim, and replica, performed by atomic force microscopy, allow establishing a limit for the injection molding technique (currently used in CD fabrication) to aspect ratios of approximately 0.15. Although this limit strongly reduces the diffraction efficiency of the elements as well as their polarizing properties, extinction ratios of approximately 10:1 were measured for the replicas in a large range of wavelengths.

Manufacturing Methods and Technology (MANTECH) Program Manufacturing Techniques for a Composite Tail Section for the Advanced Attack Helicopter.

DTIC Science & Technology

1981-10-01

Protection Resin Nomex Composite Structure Tooling Graphite Electrolysis Ballistic Survivability 24. AUMT ACT’ (Zim llea m di nemsy mitily by block minubr...angles required by the design. 105 , ~ ii i w d q 100 Aluminum male molds (Figure 69) are u~tri to lay up prepreg material to form the angles that attach...aluminum male mold shaped to the airfoil contour as Figure 78 indicates. The spars and ribs are laid up in matched metal molds with silicone rubber

Failure strengths of denture teeth fabricated on injection molded or compression molded denture base resins.

PubMed

Robison, Nathan E; Tantbirojn, Daranee; Versluis, Antheunis; Cagna, David R

2016-08-01

Denture tooth fracture or debonding remains a common problem in removable prosthodontics. The purpose of this in vitro study was to explore factors determining failure strengths for combinations of different denture tooth designs (shape, materials) and injection or compression molded denture base resins. Three central incisor denture tooth designs were tested: nanohybrid composite (NHC; Ivoclar Phonares II), interpenetrating network (IPN; Dentsply Portrait), and microfiller reinforced polyacrylic (MRP; VITA Physiodens). Denture teeth of each type were processed on an injection molded resin (IvoBase HI; Ivoclar Vivadent AG) or a compression molded resin (Lucitone 199; Dentsply Intl) (n=11 or 12). The denture teeth were loaded at 45 degrees on the incisal edge. The failure load was recorded and analyzed with 2-way ANOVA (α=.05), and the fracture mode was categorized from observed fracture surfaces as cohesive, adhesive, or mixed failure. The following failure loads (mean ±SD) were recorded: NHC/injection molded 280 ±52 N; IPN/injection molded 331 ±41 N; MRP/injection molded 247 ±23 N; NHC/compression molded 204 ±31 N; IPN/compression molded 184 ±17 N; MRP/compression molded 201 ±16 N. Injection molded resin yielded significantly higher failure strength for all denture teeth (P<.001), among which IPN had the highest strength. Failure was predominantly cohesive in the teeth, with the exception of mixed mode for the IPN/compression group. When good bonding was achieved, the strength of the structure (denture tooth/base resin combination) was determined by the strength of the denture teeth, which may be affected by the processing technique. Copyright © 2016 Editorial Council for the Journal of Prosthetic Dentistry. Published by Elsevier Inc. All rights reserved.

Hot-Tearing Assessment of Multicomponent Nongrain-Refined Al-Cu Alloys for Permanent Mold Castings Based on Load Measurements in a Constrained Mold

NASA Astrophysics Data System (ADS)

Sabau, Adrian S.; Mirmiran, Seyed; Glaspie, Christopher; Li, Shimin; Apelian, Diran; Shyam, Amit; Allen Haynes, J.; Rodriguez, Andres F.

2018-06-01

The hot-tearing resistance of multicomponent Al-Cu alloys during permanent mold casting was investigated using a constrained permanent mold in which the load and temperature were measured. The nominal Cu composition was varied from 5 to 8 wt pct. Casting experiments were conducted without adding any grain-refining inoculants. The following variables, which were obtained from the measured load data during casting, were considered to assess the hot-tearing resistance of the Al-Cu multicomponent alloys: "V"-like signature in the load rate variation, load at solidus point, and load rate average over the freezing range. In addition, a hot-tearing criterion based on the variation of the fraction of solid in the late stages of solidification was used. It was found that all criteria considered can accurately predict the alloys with the lowest and highest hot-tear resistance, respectively. It was found that the rate of measured load during casting could be used to indicate substantial hot tearing. However, the load rate variation could not be used to detect when small hot tears were present. Among all the criteria considered, the load at the solidus point shows an excellent agreement with experimentally observed hot-tearing resistance for all but one alloy. The poorly resistant hot-tearing alloys exhibited mainly coarse columnar grains while the most hot-tearing resistant alloys exhibited a much more refined grain microstructure. This is the first study in which good hot-tear resistance is demonstrated for multicomponent Al-Cu alloys with nominal Cu content greater than 7 wt pct.

EMTA-NLA

DOE Office of Scientific and Technical Information (OSTI.GOV)

2009-10-14

EMTA-NLA is a computer program for analyzing the nonlinear stiffness, strength, and thermo-elastic properties of discontinuous fiber composite materials. Discontinuous fiber composites are chopped-fiber reinforced polymer materials that are formed by injection molding or compression molding techniques. The fibers tend to align during forming as the composite flows and fills the mold. EMTA-NLA can read the fiber orientation data from the molding software, Autodesk Moldflow Plastics Insight, and calculate the local material properties for accurately analyzing the warpage, stiffness, and strength of the as-formed composite part using the commercial NLA software. Therefore, EMTA-NLA is a unique assembly of mathematical algorithmsmore » that provide a one-of-a-kind composites constitutive model that links these two powerful commercial software packages.« less

Biodegradable neural cell culture sheet made of poly(lactic-co-glycolic acid) thin film with micropatterns of Dulbecco’s phosphate-buffered saline (-) containing laminin layers

NASA Astrophysics Data System (ADS)

Nakamura, Yuki; Horiuchi, Shunpu; Nishioka, Yasushiro

2018-02-01

In the regenerative medicine field of nervous systems, techniques used to fabricate microstructures of neurons on flexible and biodegradable substrates have attracted attention. In this research, biodegradable and flexible neuron culture thin films that enable the selective axonal outgrowth of neurons were fabricated using poly(lactic-co-glycolic acid) (PLGA) thin films with micropatterns of Dulbecco’s phosphate-buffered saline (D-PBS) (-) containing laminin layers. The 100-µm-thick PLGA thin films were fabricated by diluting PLGA in acetone (5% w/w) and the solution was distributed onto a poly(dimethylsiloxane) (PDMS) mold. D-PBS (-) micropatterns containing laminin layers with widths of 10-150 µm were fabricated by micromolding in capillaries (MIMIC) and the microstencil method. Rat neurons were selectively cultured for 3 d on the laminin micropatterns; using the MIMIC method, the cells properly adhered to a pattern wider than 30 µm, while with the microstencil method, the necessary pattern width for proper adhesion was more than 50 µm.

Effect of stacking sequence on mechanical properties neem wood veneer plastic composites

NASA Astrophysics Data System (ADS)

Nagamadhu, M.; Kumar, G. C. Mohan; Jeyaraj, P.

2018-04-01

This study investigates the effect of wood veneer stacking sequence on mechanical properties of neem wood polymer composite (WPC) experimentally. Wood laminated samples were fabricated by conventional hand layup technique in a mold and cured under pressure at room temperature and then post cured at elevated temperature. Initially, the tensile, flexural, and impact test were conducted to understand the effect of weight fraction of fiber on mechanical properties. The mechanical properties have increased with the weight fraction of fiber. Moreover the stacking sequence of neem wood plays an important role. As it has a significant impact on the mechanical properties. The results indicated that 0°/0° WPC shows highest mechanical properties as compared to other sequences (90°/90°, 0°/90°, 45°/90°, 45°/45°). The Fourier Transform Infrared Spectroscopy (FTIR) Analysis were carried out to identify chemical compounds both in raw neem wood and neem wood epoxy composite. The microstructure raw/neat neem wood and the interfacial bonding characteristics of neem wood composite investigated using Scanning electron microscopy images.

Skull reconstruction after resection of bone tumors in a single surgical time by the association of the techniques of rapid prototyping and surgical navigation.

PubMed

Anchieta, M V M; Salles, F A; Cassaro, B D; Quaresma, M M; Santos, B F O

2016-10-01

Presentation of a new cranioplasty technique employing a combination of two technologies: rapid prototyping and surgical navigation. This technique allows the reconstruction of the skull cap after the resection of a bone tumor in a single surgical time. The neurosurgeon plans the craniotomy previously on the EximiusMed software, compatible with the Eximius Surgical Navigator, both from the company Artis Tecnologia (Brazil). The navigator imports the planning and guides the surgeon during the craniotomy. The simulation of the bone fault allows the virtual reconstruction of the skull cap and the production of a personalized modelling mold using the Magics-Materialise (Belgium)-software. The mold and a replica of the bone fault are made by rapid prototyping by the company Artis Tecnologia (Brazil) and shipped under sterile conditions to the surgical center. The PMMA prosthesis is produced during the surgical act with the help of a hand press. The total time necessary for the planning and production of the modelling mold is four days. The precision of the mold is submillimetric and accurately reproduces the virtual reconstruction of the prosthesis. The production of the prosthesis during surgery takes until twenty minutes depending on the type of PMMA used. The modelling mold avoids contraction and dissipates the heat generated by the material's exothermic reaction in the polymerization phase. The craniectomy is performed with precision over the drawing made with the help of the Eximius Surgical Navigator, according to the planned measurements. The replica of the bone fault serves to evaluate the adaptation of the prosthesis as a support for the perforations and the placement of screws and fixation plates, as per the surgeon's discretion. This technique allows the adequate oncologic treatment associated with a satisfactory aesthetic result, with precision, in a single surgical time, reducing time and costs.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Xu, Hongyi; Li, Yang; Zeng, Danielle

Process integration and optimization is the key enabler of the Integrated Computational Materials Engineering (ICME) of carbon fiber composites. In this paper, automated workflows are developed for two types of composites: Sheet Molding Compounds (SMC) short fiber composites, and multi-layer unidirectional (UD) composites. For SMC, the proposed workflow integrates material processing simulation, microstructure representation volume element (RVE) models, material property prediction and structure preformation simulation to enable multiscale, multidisciplinary analysis and design. Processing parameters, microstructure parameters and vehicle subframe geometry parameters are defined as the design variables; the stiffness and weight of the structure are defined as the responses. Formore » multi-layer UD structure, this work focuses on the discussion of different design representation methods and their impacts on the optimization performance. Challenges in ICME process integration and optimization are also summarized and highlighted. Two case studies are conducted to demonstrate the integrated process and its application in optimization.« less

Novel pre-alloyed powder processing of modified alnico 8: Correlation of microstructure and magnetic properties

DOE PAGES

Anderson, I. E.; Kassen, A. G.; White, E. M. H.; ...

2015-04-13

Progress is reviewed on development of an improved near-final bulk magnet fabrication process for alnico 8, as a non-rare earth permanent magnet with promise for sufficient energy density and coercivity for electric drive motors. This study showed that alnico bulk magnets in near-final shape can be made by simple compression molding from spherical high purity gas atomized pre-alloyed powder. Dwell time at peak sintering temperature (1250°C) greatly affected grain size of the resulting magnet alloys. This microstructure transformation was demonstrated to be useful for gaining partially aligned magnetic properties and boosting energy product. Furthermore, while a route to increased coercivitymore » was not identified by these experiments, manufacturability of bulk alnico magnet alloys in near-final shapes was demonstrated, permitting further processing and alloy modification experiments that can target higher coercivity and better control of grain anisotropy during grain growth.« less

Improved silicon nitride for advanced heat engines

NASA Technical Reports Server (NTRS)

Yeh, H. C.; Wimmer, J. M.; Huang, H. H.; Rorabaugh, M. E.; Schienle, J.; Styhr, K. H.

1985-01-01

The AiResearch Casting Company baseline silicon nitride (92 percent GTE SN-502 Si sub 3 N sub 4 plus 6 percent Y sub 2 O sub 3 plus 2 percent Al sub 2 O sub 3) was characterized with methods that included chemical analysis, oxygen content determination, electrophoresis, particle size distribution analysis, surface area determination, and analysis of the degree of agglomeration and maximum particle size of elutriated powder. Test bars were injection molded and processed through sintering at 0.68 MPa (100 psi) of nitrogen. The as-sintered test bars were evaluated by X-ray phase analysis, room and elevated temperature modulus of rupture strength, Weibull modulus, stress rupture, strength after oxidation, fracture origins, microstructure, and density from quantities of samples sufficiently large to generate statistically valid results. A series of small test matrices were conducted to study the effects and interactions of processing parameters which included raw materials, binder systems, binder removal cycles, injection molding temperatures, particle size distribution, sintering additives, and sintering cycle parameters.

Effects of aluminum and copper chill on mechanical properties and microstructures of Cu-Zn-Al alloys with sand casting

NASA Astrophysics Data System (ADS)

Ardhyananta, Hosta; Wibisono, Alvian Toto; Ramadhani, Mavindra; Widyastuti, Farid, Muhammad; Gumilang, Muhammad Shena

2018-04-01

Cu-Zn-Al alloy is one type of brass, which has high strength and high corrosion resistant. It has been applied on ship propellers and marine equipment. In this research, the addition of aluminum (Al) with variation of 1, 2, 3, 4% aluminum to know the effect on mechanical properties and micro structure at casting process using a copper chill and without copper chill. This alloy is melted using furnace in 1100°C without holding. Then, the molten metal is poured into the mold with copper chill and without copper chill. The speciment of Cu-Zn-Al alloy were chracterized by using Optical Emission Spectroscopy (OES), Metallography Test, X-Ray Diffraction (XRD), Hardness Test of Rockwell B and Charpy Impact Test. The result is the addition of aluminum and the use of copper chill on the molds can reduce the grain size, increases the value of hardness and impact.

Three-dimensional microstructural characterization of bulk plutonium and uranium metals using focused ion beam technique

NASA Astrophysics Data System (ADS)

Chung, Brandon W.; Erler, Robert G.; Teslich, Nick E.

2016-05-01

Nuclear forensics requires accurate quantification of discriminating microstructural characteristics of the bulk nuclear material to identify its process history and provenance. Conventional metallographic preparation techniques for bulk plutonium (Pu) and uranium (U) metals are limited to providing information in two-dimension (2D) and do not allow for obtaining depth profile of the material. In this contribution, use of dual-beam focused ion-beam/scanning electron microscopy (FIB-SEM) to investigate the internal microstructure of bulk Pu and U metals is demonstrated. Our results demonstrate that the dual-beam methodology optimally elucidate microstructural features without preparation artifacts, and the three-dimensional (3D) characterization of inner microstructures can reveal salient microstructural features that cannot be observed from conventional metallographic techniques. Examples are shown to demonstrate the benefit of FIB-SEM in improving microstructural characterization of microscopic inclusions, particularly with respect to nuclear forensics.

Three-dimensional microstructural characterization of bulk plutonium and uranium metals using focused ion beam technique

DOE PAGES

Chung, Brandon W.; Erler, Robert G.; Teslich, Nick E.

2016-03-03

Nuclear forensics requires accurate quantification of discriminating microstructural characteristics of the bulk nuclear material to identify its process history and provenance. Conventional metallographic preparation techniques for bulk plutonium (Pu) and uranium (U) metals are limited to providing information in two-dimension (2D) and do not allow for obtaining depth profile of the material. In this contribution, use of dual-beam focused ion-beam/scanning electron microscopy (FIB-SEM) to investigate the internal microstructure of bulk Pu and U metals is demonstrated. Our results demonstrate that the dual-beam methodology optimally elucidate microstructural features without preparation artifacts, and the three-dimensional (3D) characterization of inner microstructures can revealmore » salient microstructural features that cannot be observed from conventional metallographic techniques. As a result, examples are shown to demonstrate the benefit of FIB-SEM in improving microstructural characterization of microscopic inclusions, particularly with respect to nuclear forensics.« less

Laser Cladding of CPM Tool Steels on Hardened H13 Hot-Work Steel for Low-Cost High-Performance Automotive Tooling

NASA Astrophysics Data System (ADS)

Chen, J.; Xue, L.

2012-06-01

This paper summarizes our research on laser cladding of high-vanadium CPM® tool steels (3V, 9V, and 15V) onto the surfaces of low-cost hardened H13 hot-work tool steel to substantially enhance resistance against abrasive wear. The results provide great potential for fabricating high-performance automotive tooling (including molds and dies) at affordable cost. The microstructure and hardness development of the laser-clad tool steels so obtained are presented as well.

Mold growth in on-reserve homes in Canada: the need for research, education, policy, and funding.

PubMed

Optis, Michael; Shaw, Karena; Stephenson, Peter; Wild, Peter

2012-01-01

The impact of mold growth in homes located on First Nations reserves in Canada is part of a national housing crisis that has not been adequately studied. Nearly half of the homes on reserves contain mold at levels of contamination associated with high rates of respiratory and other illnesses to residents. Mold thrives due to increased moisture levels in building envelopes and interior spaces. Increased moisture stems from several deficiencies in housing conditions, including structural damage to the building envelope, overcrowding and insufficient use of ventilation systems, and other moisture-control strategies. These deficiencies have developed due to a series of historical and socioeconomic factors, including disenfranchisement from traditional territory, environmentally inappropriate construction, high unemployment rates, lack of home ownership, and insufficient federal funding for on-reserve housing and socioeconomic improvements. The successful, long-term reduction of mold growth requires increased activity in several research and policy areas. First, the actual impacts on health need to be studied and associated with comprehensive experimental data on mold growth to understand the unique environmental conditions that permit the germination and growth of toxic mold species. Second, field data documenting the extent of mold growth in on-reserve homes do not exist but are essential in understanding the full extent of the crisis. Third, current government initiatives to educate homeowners in mold remediation and prevention techniques must be long lasting and effective. Finally, and most importantly, the federal government must make a renewed and lasting commitment to improve the socioeconomic conditions on reserves that perpetuate mold growth in homes. Without such improvement, the mold crisis will surely persist and likely worsen.

Comparison of Fit of Dentures Fabricated by Traditional Techniques Versus CAD/CAM Technology.

PubMed

McLaughlin, J Bryan; Ramos, Van; Dickinson, Douglas P

2017-11-14

To compare the shrinkage of denture bases fabricated by three methods: CAD/CAM, compression molding, and injection molding. The effect of arch form and palate depth was also tested. Nine titanium casts, representing combinations of tapered, ovoid, and square arch forms and shallow, medium, and deep palate depths, were fabricated using electron beam melting (EBM) technology. For each base fabrication method, three poly(vinyl siloxane) impressions were made from each cast, 27 dentures for each method. Compression-molded dentures were fabricated using Lucitone 199 poly methyl methacrylate (PMMA), and injection molded dentures with Ivobase's Hybrid Pink PMMA. For CAD/CAM, denture bases were designed and milled by Avadent using their Light PMMA. To quantify the space between the denture and the master cast, silicone duplicating material was placed in the intaglio of the dentures, the titanium master cast was seated under pressure, and the silicone was then trimmed and recovered. Three silicone measurements per denture were recorded, for a total of 243 measurements. Each silicone measurement was weighed and adjusted to the surface area of the respective arch, giving an average and standard deviation for each denture. Comparison of manufacturing methods showed a statistically significant difference (p = 0.0001). Using a ratio of the means, compression molding had on average 41% to 47% more space than injection molding and CAD/CAM. Comparison of arch/palate forms showed a statistically significant difference (p = 0.023), with shallow palate forms having more space with compression molding. The ovoid shallow form showed CAD/CAM and compression molding had more space than injection molding. Overall, injection molding and CAD/CAM fabrication methods produced equally well-fitting dentures, with both having a better fit than compression molding. Shallow palates appear to be more affected by shrinkage than medium or deep palates. Shallow ovoid arch forms appear to benefit from the use of injection molding compared to CAD/CAM and compression molding. © 2017 by the American College of Prosthodontists.

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.

Stress and flow analyses of ultraviolet-curable resin during curing

NASA Astrophysics Data System (ADS)

Umezaki, Eisaku; Okano, Akira; Koyama, Hiroto

2014-06-01

The stress and flow generated in ultraviolet (UV)-curable resin during curing in molds were measured to investigate their relationship. The specimens were molds consisting of glass plates and acrylic bars, and UV-curable liquid resin. The specimens were illuminated from above with UV rays. Photoelastic and visual images were separately obtained at a constant time interval using cameras during curing. To help obtain the visual images, acrylic powder was mixed with the liquid resin. The stress was obtained from the photoelastic images by a digital photoelastic technique with phase stepping, and the flow was obtained from the visual images by a particle-tracking velocimetry technique. Results indicate that the stress generated in the UV-curable resin during curing depends on the degree of contact between the mold and the cured area of the resin, and is hardly related to the flow.

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

PubMed Central

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

2017-01-01

The aim of this study was to compare osseointegration and surface characteristics of zirconia implants made by the powder injection molding (PIM) technique and made by the conventional milling procedure in rabbit tibiae. Surface characteristics of 2 types of implant were evaluated. Sixteeen rabbits received 2 types of external hex implants with similar geometry, machined zirconia implants and PIM zirconia implants, in the tibiae. Removal torque tests and histomorphometric analyses were performed. The roughness of 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 rough surfaces on zirconia implants. PMID:26235717

Electrolyzer assembly method and system

DOEpatents

Swala, Dana Ray; Bourgeois, Richard Scott; Paraszczak, Steven; Buckley, Donald Joseph

2017-05-23

The present techniques provide a novel electrolyzer and methods for welding components of such electrolyzers. The techniques may use conductors, such as resistance wires, placed in paths around the internal structural features and edges of the components. The conductors may be incorporated into the components during manufacture by injection molding, or other molding techniques, or may be tacked or otherwise applied to the surface of the components after manufacture. When current, a field or other excitation is applied to the conductors, the plastic surrounding the wire is melted. If this plastic is in direct contact with an adjoining component, a strong, hermetic seal may be formed between the two components, including the internal structural features.

Fabricating microfluidic valve master molds in SU-8 photoresist

NASA Astrophysics Data System (ADS)

Dy, Aaron J.; Cosmanescu, Alin; Sluka, James; Glazier, James A.; Stupack, Dwayne; Amarie, Dragos

2014-05-01

Multilayer soft lithography has become a powerful tool in analytical chemistry, biochemistry, material and life sciences, and medical research. Complex fluidic micro-circuits require reliable components that integrate easily into microchips. We introduce two novel approaches to master mold fabrication for constructing in-line micro-valves using SU-8. Our fabrication techniques enable robust and versatile integration of many lab-on-a-chip functions including filters, mixers, pumps, stream focusing and cell-culture chambers, with in-line valves. SU-8 created more robust valve master molds than the conventional positive photoresists used in multilayer soft lithography, but maintained the advantages of biocompatibility and rapid prototyping. As an example, we used valve master molds made of SU-8 to fabricate PDMS chips capable of precisely controlling beads or cells in solution.

High resolution imaging of objects located within a wall

NASA Astrophysics Data System (ADS)

Greneker, Eugene F.; Showman, Gregory A.; Trostel, John M.; Sylvester, Vincent

2006-05-01

Researchers at Georgia Tech Research Institute have developed a high resolution imaging radar technique that allows large sections of a test wall to be scanned in X and Y dimensions. The resulting images that can be obtained provide information on what is inside the wall, if anything. The scanning homodyne radar operates at a frequency of 24.1 GHz at with an output power level of approximately 10 milliwatts. An imaging technique that has been developed is currently being used to study the detection of toxic mold on the back surface of wallboard using radar as a sensor. The moisture that is associated with the mold can easily be detected. In addition to mold, the technique will image objects as small as a 4 millimeter sphere on the front or rear of the wallboard and will penetrate both sides of a wall made of studs and wallboard. Signal processing is performed on the resulting data to further sharpen the image. Photos of the scanner and images produced by the scanner are presented. A discussion of the signal processing and technical challenges are also discussed.

Processing and Characterization of Functionally Graded Aluminum (A319)—SiCp Metallic Composites by Centrifugal Casting Technique

NASA Astrophysics Data System (ADS)

Jayakumar, E.; Jacob, Jibin C.; Rajan, T. P. D.; Joseph, M. A.; Pai, B. C.

2016-08-01

Functionally graded materials (FGM) are successfully adopted for the design and fabrication of engineering components with location-specific properties. The present study describes the processing and characterization of A319 Aluminum functionally graded metal matrix composites (FGMMC) with 10 and 15 wt pct SiCp reinforcements. The liquid stir casting method is used for composite melt preparation followed by FGMMC formation by vertical centrifugal casting method. The process parameters used are the mold preheating temperature of 523 K (250 °C), melt pouring temperature of 1013 K (740 °C), and mold rotation speed of 1300 rpm. The study analyzes the distribution and concentration of reinforcement particles in the radial direction of the FGMMC disk along with the effects of gradation on density, hardness, mechanical strength, the variation in coefficient of thermal expansion and the wear resistance properties at different zones. Microstructures of FGMMC reveal an outward radial gradient distribution of reinforcements forming different zones. Namely, matrix-rich inner, transition, particles-rich outer, and chill zone of a few millimeters thick at the outer most periphery of the casting are formed. From 10-FGM, a radial shift in the position of SiCp maxima is observed in 15-FGM casting. The mechanical characterization depicts enhanced properties for the particle-rich zone. The hardness shows a graded nature in correlation with particle concentration and a maximum of 94.4 HRB has been obtained at the particle-rich region of 15-FGM. In the particle-rich zone, the lowest CTE value of 20.1 µm/mK is also observed with a compressive strength of 650 MPa and an ultimate tensile strength of 279 MPa. The wear resistance is higher at the particle-rich zone of the FGMMC.

Lightweight sheet molding compound (SMC) composites containing cellulose nanocrystals

Treesearch

Amir Asadi; Mark Miller; Arjun V. Singh; Robert J. Moon; Kyriaki Kalaitzidou

2017-01-01

A scalable technique was introduced to produce high volume lightweight composites using sheet molding compound (SMC) manufacturing method by replacing 10 wt% glass fibers (GF) with a small amount of cellulose nanocrystals (CNC). The incorporation of 1 and 1.5 wt% CNC by dispersing in the epoxy matrix of short GF/epoxy SMC composites with 25 wt% GF content (25GF/CNC-...

Mold Making Series. Educational Resources for the Machine Tool Industry. Course Syllabi, Instructor's Handbook, [and] Student Laboratory Manual.

ERIC Educational Resources Information Center

Texas State Technical Coll. System, Waco.

This package consists of a course syllabi, an instructor's handbook, and a student laboratory manual for a 2-year vocational training program to prepare students for entry-level employment as mold makers. The program was developed through a modification of the DACUM (Developing a Curriculum) technique. The course syllabi volume begins with the…

Characterization and Surface Treatment of Materials Used in MADEAL S.A. Industry Productive Process of Rims by Plasma Assisted Repetitive Pulsed Arcs Technique

NASA Astrophysics Data System (ADS)

Jiménez, H.; Salazar, V. H.; Devia, A.; Jaramillo, S.; Velez, G.

2006-12-01

A study of materials used in the molds production to aluminium rims manufacture in the MADEAL S.A. factory was carried out for apply a plasma assisted surface treatment consists in growing TiAlN hard coatings that it protects this molds in the productive process. This coating resists high oxidation temperatures, of the other of 800 °C, high hardness (2800 Vickers) and low friction coefficient. A plasma assisted repetitive pulsed arcs mono-evaporator system was used in the grow of the TiAlN coatings, the TiAlN target is a sinterized 50% Ti and 50% Al, in the substrate they were used two types of steel that compose the molds injection pieces for the rims production. These materials were subjected to linear and fluctuating thermal changes in the Bruker axs X-Ray diffractometer temperature chamber, what simulated the molds thermal variation in the rims production process and they were compared with TiAlN coatings subjected to same thermal changes. The Materials characterization, before and later of thermal process, was carried out using XRD, SPM and EDS techniques, to analyze the crystallographic, topographic and chemical surface structure behaviours.

Quantitative analysis and feature recognition in 3-D microstructural data sets

NASA Astrophysics Data System (ADS)

Lewis, A. C.; Suh, C.; Stukowski, M.; Geltmacher, A. B.; Spanos, G.; Rajan, K.

2006-12-01

A three-dimensional (3-D) reconstruction of an austenitic stainless-steel microstructure was used as input for an image-based finite-element model to simulate the anisotropic elastic mechanical response of the microstructure. The quantitative data-mining and data-warehousing techniques used to correlate regions of high stress with critical microstructural features are discussed. Initial analysis of elastic stresses near grain boundaries due to mechanical loading revealed low overall correlation with their location in the microstructure. However, the use of data-mining and feature-tracking techniques to identify high-stress outliers revealed that many of these high-stress points are generated near grain boundaries and grain edges (triple junctions). These techniques also allowed for the differentiation between high stresses due to boundary conditions of the finite volume reconstructed, and those due to 3-D microstructural features.

Effect of Custom-Molded Foot Orthoses on Foot Pain and Balance in Children With Symptomatic Flexible Flat Feet

PubMed Central

Lee, Hong-Jae; Lim, Kil-Byung; Yoo, JeeHyun; Yun, Hyun-Ju; Jeong, Tae-Ho

2015-01-01

Objective To evaluate the effect of custom-molded foot orthoses on foot pain and balance in children with symptomatic flexible flat foot 1 month and 3 months after fitting foot orthosis. Method A total of 24 children over 6 years old with flexible flat feet and foot pain for at least 6 months were recruited for this study. Their resting calcaneal stance position and calcaneal pitch angle were measured. Individual custom-molded rigid foot orthoses were prescribed using inverted orthotic technique to control foot overpronation. Pain questionnaire was used to obtain pain sites, degree, and frequency. Balancing ability was determined using computerized posturography. These evaluations were performed prior to custom-molded foot orthoses, 1 month, and 3 months after fitting foot orthoses. Result Of 24 children with symptomatic flexible flat feet recruited for this study, 20 completed the study. Significant (p<0.001) improvements in pain degree and frequency were noted after 1 and 3 months of custom-molded foot orthoses. In addition, significant (p<0.05) improvement in balancing ability was found after 3 months of custom-molded foot orthoses. Conclusion Short-term use of custom-molded foot orthoses significantly improved foot pain and balancing ability in children with symptomatic flexible flat foot. PMID:26798604

Classification of buildings mold threat using electronic nose

NASA Astrophysics Data System (ADS)

Łagód, Grzegorz; Suchorab, Zbigniew; Guz, Łukasz; Sobczuk, Henryk

2017-07-01

Mold is considered to be one of the most important features of Sick Building Syndrome and is an important problem in current building industry. In many cases it is caused by the rising moisture of building envelopes surface and exaggerated humidity of indoor air. Concerning historical buildings it is mostly caused by outdated raising techniques among that is absence of horizontal isolation against moisture and hygroscopic materials applied for construction. Recent buildings also suffer problem of mold risk which is caused in many cases by hermetization leading to improper performance of gravitational ventilation systems that make suitable conditions for mold development. Basing on our research there is proposed a method of buildings mold threat classification using electronic nose, based on a gas sensors array which consists of MOS sensors (metal oxide semiconductor). Used device is frequently applied for air quality assessment in environmental engineering branches. Presented results show the interpretation of e-nose readouts of indoor air sampled in rooms threatened with mold development in comparison with clean reference rooms and synthetic air. Obtained multivariate data were processed, visualized and classified using a PCA (Principal Component Analysis) and ANN (Artificial Neural Network) methods. Described investigation confirmed that electronic nose - gas sensors array supported with data processing enables to classify air samples taken from different rooms affected with mold.

Serial corneal endothelial cell loss with lathe-cut and injection-molded posterior chamber intraocular lenses.

PubMed

Kraff, M C; Sanders, D R; Lieberman, H L

1983-01-01

We compared endothelial cell loss of patients implanted with lathe-cut posterior chamber lenses and those implanted with injection-molded lenses over a three-year postoperative period. Results were based on more than 2,500 measurements of corneal endothelial density. Although the technique of cataract extraction (anterior chamber phacoemulsification, posterior chamber phacoemulsification, or planned extracapsular extraction) significantly affected cell loss (P less than .01), the type of implant (lathe-cut or injection-molded) did not. Significant continuing endothelial cell loss did not occur during the first three postoperative years with injection-molded lenses. There was, however, a statistically significant 7% to 15% additional cell loss after surgery over the first two to three postoperative years with lathe-cut implants. There have been no cases of corneal endothelial decompensation developing after implantation of injection-molded or lathe-cut lenses. Because a standard field clinical specular microscope was used in this study, cell counting errors cannot be ruled out as a cause of these findings.

Net shape fabrication of Alpha Silicon Carbide turbine components

NASA Technical Reports Server (NTRS)

Storm, R. S.

1982-01-01

Development of Alpha Silicon Carbide components by net shape fabrication techniques has continued in conjunction with several turbine engine programs. Progress in injection molding of simple parts has been extended to much larger components. Turbine rotors fabricated by a one piece molding have been successfully spin tested above design speeds. Static components weighing up to 4.5 kg and 33 cc in diameter have also been produced using this technique. Use of sintering fixtures significantly improves dimensional control. A new Si-SiC composite material has also been developed with average strengths up to 1000 MPa (150 ksi) at 1200 C.

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.

Fit of interim crowns fabricated using photopolymer-jetting 3D printing.

PubMed

Mai, Hang-Nga; Lee, Kyu-Bok; Lee, Du-Hyeong

2017-08-01

The fit of interim crowns fabricated using 3-dimensional (3D) printing is unknown. The purpose of this in vitro study was to evaluate the fit of interim crowns fabricated using photopolymer-jetting 3D printing and to compare it with that of milling and compression molding methods. Twelve study models were fabricated by making an impression of a metal master model of the mandibular first molar. On each study model, interim crowns (N=36) were fabricated using compression molding (molding group, n=12), milling (milling group, n=12), and 3D polymer-jetting methods. The crowns were prepared as follows: molding group, overimpression technique; milling group, a 5-axis dental milling machine; and polymer-jetting group using a 3D printer. The fit of interim crowns was evaluated in the proximal, marginal, internal axial, and internal occlusal regions by using the image-superimposition and silicone-replica techniques. The Mann-Whitney U test and Kruskal-Wallis tests were used to compare the results among groups (α=.05). Compared with the molding group, the milling and polymer-jetting groups showed more accurate results in the proximal and marginal regions (P<.001). In the axial regions, even though the mean discrepancy was smallest in the molding group, the data showed large deviations. In the occlusal region, the polymer-jetting group was the most accurate, and compared with the other groups, the milling group showed larger internal discrepancies (P<.001). Polymer-jet 3D printing significantly enhanced the fit of interim crowns, particularly in the occlusal region. Copyright © 2016 Editorial Council for the Journal of Prosthetic Dentistry. Published by Elsevier Inc. All rights reserved.

Simulations of the heat exchange in thermoplastic injection molds manufactured by additive techniques

NASA Astrophysics Data System (ADS)

Daldoul, Wafa; Toulorge, Thomas; Vincent, Michel

2017-10-01

The cost and quality of complex parts manufactured by thermoplastic injection is traditionally limited by design constraints on the cooling system of the mold. A possible solution is to create the mold by additive manufacturing, which makes it possible to freely design the cooling channels. Such molds normally contain hollow parts (alveoli) in order to decrease their cost. However, the complex geometry of the cooling channels and the alveoli makes it difficult to predict the performance of the cooling system. This work aims to compute the heat exchanges between the polymer, the mold and the cooling channels with complex geometries. An Immersed Volume approach is taken, where the different parts of the domain (i.e. the polymer, the cooling channels, the alveoli and the mold) are represented by level-sets and the thermo-mechanical properties of the materials vary smoothly at the interface between the parts. The energy and momentum equations are solved by a stabilized Finite Element method. In order to accurately resolve the large variations of material properties and the steep temperature gradients at interfaces, state-of-the art anisotropic mesh refinement techniques are employed. The filling stage of the process is neglected. In a first step, only the heat equation is solved, so that the packing stage is also disregarded. In a second step, thermo-mechanical effects occurring in the polymer during the packing stage are taken into account, which results in the injection of an additional amount of polymer that significantly influences the temperature evolution. The method is validated on the simple geometry of a center-gated disk and compared with experimental measurements. The agreement is very good. Simulations are performed on an industrial case which illustrates the ability of the method to deal with complex geometries.

Effect of Inoculation Techniques and Relative Humidity on the Growth of Molds on the Surfaces of Yellow Layer Cakes

PubMed Central

Fustier, Patrick; Lafond, Alain; Champagne, Claude P.; Lamarche, François

1998-01-01

Four inoculation techniques were compared for initiation of growth on cake surfaces: spot, air cabinet, spray (atomizer), and talc addition methods. Molds were isolated from commercial cakes and were identified as Aspergillus sydowii, Aspergillus ochraceus, Penicillium funiculosum, and Eurotium herbariorum. Cake surfaces were inoculated with mold spores and incubated under three equilibrium relative humidity (ERH) levels: 97, 85, and 75%. Random contamination by spores in a ventilated air cabinet was the simplest method of inoculation, but standard deviations in the inoculation rates (20% on a relative scale) were almost twice those observed with the other methods. The spot method was the most reproducible. Cake samples inoculated in the air cabinet had colony counts 10 times lower than those obtained for potato dextrose agar plates at 97% ERH, which was not the case with the spray and talc methods. Growth of molds was much slower in the samples incubated in 75% relative humidity, with all methods. Colony counts were generally similar in systems adjusted at 85 to 97% ERH but were lower for samples incubated at 75% ERH. In comparisons of the shelf life estimates obtained by the various inoculation methods, a correlation coefficient (r2) of 0.70 was obtained between the spot method and the other methods of inoculation, while talc, air cabinet, and spray shelf life data were correlated better (r2 ≈ 0.97). The spot method appeared to be the method of choice in consideration of ease of use, precision, and the ability to enable the study of the effects of the environment on mold-free shelf life as well as on the rate of growth of molds on cakes. PMID:16349479

Contact CMOS imaging of gaseous oxygen sensor array

PubMed Central

Daivasagaya, Daisy S.; Yao, Lei; Yi Yung, Ka; Hajj-Hassan, Mohamad; Cheung, Maurice C.; Chodavarapu, Vamsy P.; Bright, Frank V.

2014-01-01

We describe a compact luminescent gaseous oxygen (O2) sensor microsystem based on the direct integration of sensor elements with a polymeric optical filter and placed on a low power complementary metal-oxide semiconductor (CMOS) imager integrated circuit (IC). The sensor operates on the measurement of excited-state emission intensity of O2-sensitive luminophore molecules tris(4,7-diphenyl-1,10-phenanthroline) ruthenium(II) ([Ru(dpp)3]2+) encapsulated within sol–gel derived xerogel thin films. The polymeric optical filter is made with polydimethylsiloxane (PDMS) that is mixed with a dye (Sudan-II). The PDMS membrane surface is molded to incorporate arrays of trapezoidal microstructures that serve to focus the optical sensor signals on to the imager pixels. The molded PDMS membrane is then attached with the PDMS color filter. The xerogel sensor arrays are contact printed on top of the PDMS trapezoidal lens-like microstructures. The CMOS imager uses a 32 × 32 (1024 elements) array of active pixel sensors and each pixel includes a high-gain phototransistor to convert the detected optical signals into electrical currents. Correlated double sampling circuit, pixel address, digital control and signal integration circuits are also implemented on-chip. The CMOS imager data is read out as a serial coded signal. The CMOS imager consumes a static power of 320 µW and an average dynamic power of 625 µW when operating at 100 Hz sampling frequency and 1.8 V DC. This CMOS sensor system provides a useful platform for the development of miniaturized optical chemical gas sensors. PMID:24493909

Contact CMOS imaging of gaseous oxygen sensor array.

PubMed

Daivasagaya, Daisy S; Yao, Lei; Yi Yung, Ka; Hajj-Hassan, Mohamad; Cheung, Maurice C; Chodavarapu, Vamsy P; Bright, Frank V

2011-10-01

We describe a compact luminescent gaseous oxygen (O 2 ) sensor microsystem based on the direct integration of sensor elements with a polymeric optical filter and placed on a low power complementary metal-oxide semiconductor (CMOS) imager integrated circuit (IC). The sensor operates on the measurement of excited-state emission intensity of O 2 -sensitive luminophore molecules tris(4,7-diphenyl-1,10-phenanthroline) ruthenium(II) ([Ru(dpp) 3 ] 2+ ) encapsulated within sol-gel derived xerogel thin films. The polymeric optical filter is made with polydimethylsiloxane (PDMS) that is mixed with a dye (Sudan-II). The PDMS membrane surface is molded to incorporate arrays of trapezoidal microstructures that serve to focus the optical sensor signals on to the imager pixels. The molded PDMS membrane is then attached with the PDMS color filter. The xerogel sensor arrays are contact printed on top of the PDMS trapezoidal lens-like microstructures. The CMOS imager uses a 32 × 32 (1024 elements) array of active pixel sensors and each pixel includes a high-gain phototransistor to convert the detected optical signals into electrical currents. Correlated double sampling circuit, pixel address, digital control and signal integration circuits are also implemented on-chip. The CMOS imager data is read out as a serial coded signal. The CMOS imager consumes a static power of 320 µW and an average dynamic power of 625 µW when operating at 100 Hz sampling frequency and 1.8 V DC. This CMOS sensor system provides a useful platform for the development of miniaturized optical chemical gas sensors.

Microstructures and Mechanical Properties of Co-Cr Dental Alloys Fabricated by Three CAD/CAM-Based Processing Techniques

PubMed Central

Kim, Hae Ri; Jang, Seong-Ho; Kim, Young Kyung; Son, Jun Sik; Min, Bong Ki; Kim, Kyo-Han; Kwon, Tae-Yub

2016-01-01

The microstructures and mechanical properties of cobalt-chromium (Co-Cr) alloys produced by three CAD/CAM-based processing techniques were investigated in comparison with those produced by the traditional casting technique. Four groups of disc- (microstructures) or dumbbell- (mechanical properties) specimens made of Co-Cr alloys were prepared using casting (CS), milling (ML), selective laser melting (SLM), and milling/post-sintering (ML/PS). For each technique, the corresponding commercial alloy material was used. The microstructures of the specimens were evaluated via X-ray diffractometry, optical and scanning electron microscopy with energy-dispersive X-ray spectroscopy, and electron backscattered diffraction pattern analysis. The mechanical properties were evaluated using a tensile test according to ISO 22674 (n = 6). The microstructure of the alloys was strongly influenced by the manufacturing processes. Overall, the SLM group showed superior mechanical properties, the ML/PS group being nearly comparable. The mechanical properties of the ML group were inferior to those of the CS group. The microstructures and mechanical properties of Co-Cr alloys were greatly dependent on the manufacturing technique as well as the chemical composition. The SLM and ML/PS techniques may be considered promising alternatives to the Co-Cr alloy casting process. PMID:28773718

Hot-Tearing Assessment of Multicomponent Nongrain-Refined Al-Cu Alloys for Permanent Mold Castings Based on Load Measurements in a Constrained Mold

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sabau, Adrian S.; Mirmiran, Seyed; Glaspie, Christopher

Here, the hot-tearing resistance of multicomponent Al-Cu alloys during permanent mold casting was investigated using a constrained permanent mold in which the load and temperature were measured. The nominal Cu composition was varied from 5 to 8 wt pct. Casting experiments were conducted without adding any grain-refining inoculants. The following variables, which were obtained from the measured load data during casting, were considered to assess the hot-tearing resistance of the Al-Cu multicomponent alloys: “V”-like signature in the load rate variation, load at solidus point, and load rate average over the freezing range. In addition, a hot-tearing criterion based on themore » variation of the fraction of solid in the late stages of solidification was used. It was found that all criteria considered can accurately predict the alloys with the lowest and highest hot-tear resistance, respectively. It was found that the rate of measured load during casting could be used to indicate substantial hot tearing. However, the load rate variation could not be used to detect when small hot tears were present. Among all the criteria considered, the load at the solidus point shows an excellent agreement with experimentally observed hot-tearing resistance for all but one alloy. The poorly resistant hot-tearing alloys exhibited mainly coarse columnar grains while the most hot-tearing resistant alloys exhibited a much more refined grain microstructure. This is the first study in which good hot-tear resistance is demonstrated for multicomponent Al-Cu alloys with nominal Cu content greater than 7 wt pct.« less

A sacrificial process for fabrication of biodegradable polymer membranes with submicron thickness.

PubMed

Beardslee, Luke A; Stolwijk, Judith; Khaladj, Dimitrius A; Trebak, Mohamed; Halman, Justin; Torrejon, Karen Y; Niamsiri, Nuttawee; Bergkvist, Magnus

2016-08-01

A new sacrificial molding process using a single mask has been developed to fabricate ultrathin 2-dimensional membranes from several biocompatible polymeric materials. The fabrication process is similar to a sacrificial microelectromechanical systems (MEMS) process flow, where a mold is created from a material that can be coated with a biodegradable polymer and subsequently etched away, leaving behind a very thin polymer membrane. In this work, two different sacrificial mold materials, silicon dioxide (SiO2 ) and Liftoff Resist (LOR) were used. Three different biodegradable materials; polycaprolactone (PCL), poly(lactic-co-glycolic acid) (PLGA), and polyglycidyl methacrylate (PGMA), were chosen as model polymers. We demonstrate that this process is capable of fabricating 200-500 nm thin, through-hole polymer membranes with various geometries, pore-sizes and spatial features approaching 2.5 µm using a mold fabricated via a single contact photolithography exposure. In addition, the membranes can be mounted to support rings made from either SU8 or PCL for easy handling after release. Cell culture compatibility of the fabricated membranes was evaluated with human dermal microvascular endothelial cells (HDMECs) seeded onto the ultrathin porous membranes, where the cells grew and formed confluent layers with well-established cell-cell contacts. Furthermore, human trabecular meshwork cells (HTMCs) cultured on these scaffolds showed similar proliferation as on flat PCL substrates, further validating its compatibility. All together, these results demonstrated the feasibility of our sacrificial fabrication process to produce biocompatible, ultra-thin membranes with defined microstructures (i.e., pores) with the potential to be used as substrates for tissue engineering applications. © 2015 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater, 104B: 1192-1201, 2016. © 2015 Wiley Periodicals, Inc.

Hot-Tearing Assessment of Multicomponent Nongrain-Refined Al-Cu Alloys for Permanent Mold Castings Based on Load Measurements in a Constrained Mold

DOE PAGES

Sabau, Adrian S.; Mirmiran, Seyed; Glaspie, Christopher; ...

2018-02-16

Here, the hot-tearing resistance of multicomponent Al-Cu alloys during permanent mold casting was investigated using a constrained permanent mold in which the load and temperature were measured. The nominal Cu composition was varied from 5 to 8 wt pct. Casting experiments were conducted without adding any grain-refining inoculants. The following variables, which were obtained from the measured load data during casting, were considered to assess the hot-tearing resistance of the Al-Cu multicomponent alloys: “V”-like signature in the load rate variation, load at solidus point, and load rate average over the freezing range. In addition, a hot-tearing criterion based on themore » variation of the fraction of solid in the late stages of solidification was used. It was found that all criteria considered can accurately predict the alloys with the lowest and highest hot-tear resistance, respectively. It was found that the rate of measured load during casting could be used to indicate substantial hot tearing. However, the load rate variation could not be used to detect when small hot tears were present. Among all the criteria considered, the load at the solidus point shows an excellent agreement with experimentally observed hot-tearing resistance for all but one alloy. The poorly resistant hot-tearing alloys exhibited mainly coarse columnar grains while the most hot-tearing resistant alloys exhibited a much more refined grain microstructure. This is the first study in which good hot-tear resistance is demonstrated for multicomponent Al-Cu alloys with nominal Cu content greater than 7 wt pct.« less

Fabrication Process for Large Size Mold and Alignment Method for Nanoimprint System

NASA Astrophysics Data System (ADS)

Ishibashi, Kentaro; Kokubo, Mitsunori; Goto, Hiroshi; Mizuno, Jun; Shoji, Shuichi

Nanoimprint technology is considered one of the mass production methods of the display for cellular phone or notebook computer, with Anti-Reflection Structures (ARS) pattern and so on. In this case, the large size mold with nanometer order pattern is very important. Then, we describe the fabrication process for large size mold, and the alignment method for UV nanoimprint system. We developed the original mold fabrication process using nanoimprint method and etching techniques. In 66 × 45 mm2 area, 200nm period seamless patterns were formed using this process. And, we constructed original alignment system that consists of the CCD-camera system, X-Y-θ table, method of moiré fringe, and image processing system, because the accuracy of pattern connection depends on the alignment method. This alignment system accuracy was within 20nm.

Imprint Molding of a Microfluidic Optical Cell on Thermoplastics with Reduced Surface Roughness for the Detection of Copper Ions.

PubMed

Wu, Jing; Lee, Nae Yoon

2016-01-01

Here, we introduce a simple and facile technique for fabricating microfluidic optical cells by utilizing a micropatterned polymer mold, followed by imprinting on thermoplastic substrates. This process has reduced the surface roughness of the microchannel, making it suitable for microscale optical measurements. The micropatterned polymer mold was fabricated by first micromilling on a poly(methylmethacrylate) (PMMA) substrate, and then transferring the micropattern onto an ultraviolet (UV)-curable optical adhesive. After an anti-adhesion treatment of the polymer mold fabricated using the UV-curable optical adhesive, the polymer mold was used repeatedly for imprinting onto various thermoplastics, such as PMMA, polycarbonate (PC), and poly(ethyleneterephthalate) (PET). The roughness values for the PMMA, PC, and PET microchannels were approximately 11.3, 20.3, and 14.2 nm, respectively, as compared to those obtained by micromilling alone, which were 15.9, 76.8, and 207.5 nm, respectively. Using the imprint-molded thermoplastic optical cell, rhodamine B and copper ions were successfully quantified. The reduced roughness of the microchannel surface resulted in improved sensitivity and reduced noise, paving the way for integration of the detection module so as to realize totally integrated microdevices.

Micro Dot Patterning on the Light Guide Panel Using Powder Blasting

PubMed Central

Jang, Ho Su; Cho, Myeong Woo; Park, Dong Sam

2008-01-01

This study is to develop a micromachining technology for a light guide panel(LGP) mold, whereby micro dot patterns are formed on a LGP surface by a single injection process instead of existing screen printing processes. The micro powder blasting technique is applied to form micro dot patterns on the LGP mold surface. The optimal conditions for masking, laminating, exposure, and developing processes to form the micro dot patterns are first experimentally investigated. A LGP mold with masked micro patterns is then machined using the micro powder blasting method and the machinability of the micro dot patterns is verified. A prototype LGP is test- injected using the developed LGP mold and a shape analysis of the patterns and performance testing of the injected LGP are carried out. As an additional approach, matte finishing, a special surface treatment method, is applied to the mold surface to improve the light diffusion characteristics, uniformity and brightness of the LGP. The results of this study show that the applied powder blasting method can be successfully used to manufacture LGPs with micro patterns by just single injection using the developed mold and thereby replace existing screen printing methods. PMID:27879740

Fabrication of high aspect ratio nanopillars and micro/nano combined structures with hydrophobic surface characteristics by injection molding

NASA Astrophysics Data System (ADS)

Zhou, Mingyong; Xiong, Xiang; Jiang, Bingyan; Weng, Can

2018-01-01

Polymer products with micro/nano-structures have excellent mechanical and optical properties, chemical resistance, and other advantages. Injection molding is one of the most potential techniques to fabricate polymer products with micro/nano-structures artificially in large numbers. In this study, a surface approach to fabricate high aspect ratio nanopillars and micro/nano combined structures was presented. Mold insert with micropillar arrays and nanopillars on its surface was prepared by combing anodic aluminum oxide (AAO) template and etched plate. Anti-sticking modification was done on the template to realize a better demolding quality. The influences of mold temperature and polymer material on the final replication quality were investigated. The results showed that the final replication quality of high aspect ratio nanopillars was greatly improved as compared with the unprocessed template. Polymer with low elongation at break was not suitable to fabricate structures with high aspect ratio via injection molding. For polypropylene surface, the experimental results of static contact angles were almost consistent with Cassie-Baxter equation. When the mold temperature reached 178 °C, hair-like polycarbonate nanopillars were observed, resulting in an excellent hydrophobic characteristic.

Indoor mold, toxigenic fungi, and Stachybotrys chartarum: infectious disease perspective.

PubMed

Kuhn, D M; Ghannoum, M A

2003-01-01

Damp buildings often have a moldy smell or obvious mold growth; some molds are human pathogens. This has caused concern regarding health effects of moldy indoor environments and has resulted in many studies of moisture- and mold-damaged buildings. Recently, there have been reports of severe illness as a result of indoor mold exposure, particularly due to Stachybotrys chartarum. While many authors describe a direct relationship between fungal contamination and illness, close examination of the literature reveals a confusing picture. Here, we review the evidence regarding indoor mold exposure and mycotoxicosis, with an emphasis on S. chartarum. We also examine possible end-organ effects, including pulmonary, immunologic, neurologic, and oncologic disorders. We discuss the Cleveland infant idiopathic pulmonary hemorrhage reports in detail, since they provided important impetus for concerns about Stachybotrys. Some valid concerns exist regarding the relationship between indoor mold exposure and human disease. Review of the literature reveals certain fungus-disease associations in humans, including ergotism (Claviceps species), alimentary toxic aleukia (Fusarium), and liver disease (Aspergillys). While many papers suggest a similar relationship between Stachybotrys and human disease, the studies nearly uniformly suffer from significant methodological flaws, making their findings inconclusive. As a result, we have not found well-substantiated supportive evidence of serious illness due to Stachybotrys exposure in the contemporary environment. To address issues of indoor mold-related illness, there is an urgent need for studies using objective markers of illness, relevant animal models, proper epidemiologic techniques, and examination of confounding factors.

Indoor Mold, Toxigenic Fungi, and Stachybotrys chartarum: Infectious Disease Perspective

PubMed Central

Kuhn, D. M.; Ghannoum, M. A.

2003-01-01

Damp buildings often have a moldy smell or obvious mold growth; some molds are human pathogens. This has caused concern regarding health effects of moldy indoor environments and has resulted in many studies of moisture- and mold-damaged buildings. Recently, there have been reports of severe illness as a result of indoor mold exposure, particularly due to Stachybotrys chartarum. While many authors describe a direct relationship between fungal contamination and illness, close examination of the literature reveals a confusing picture. Here, we review the evidence regarding indoor mold exposure and mycotoxicosis, with an emphasis on S. chartarum. We also examine possible end-organ effects, including pulmonary, immunologic, neurologic, and oncologic disorders. We discuss the Cleveland infant idiopathic pulmonary hemorrhage reports in detail, since they provided important impetus for concerns about Stachybotrys. Some valid concerns exist regarding the relationship between indoor mold exposure and human disease. Review of the literature reveals certain fungus-disease associations in humans, including ergotism (Claviceps species), alimentary toxic aleukia (Fusarium), and liver disease (Aspergillys). While many papers suggest a similar relationship between Stachybotrys and human disease, the studies nearly uniformly suffer from significant methodological flaws, making their findings inconclusive. As a result, we have not found well-substantiated supportive evidence of serious illness due to Stachybotrys exposure in the contemporary environment. To address issues of indoor mold-related illness, there is an urgent need for studies using objective markers of illness, relevant animal models, proper epidemiologic techniques, and examination of confounding factors. PMID:12525430

Effects of Electromagnetic Stirring on the Microstructure and High-Temperature Mechanical Properties of a Hyper-eutectic Al-Si-Cu-Ni Alloy

NASA Astrophysics Data System (ADS)

Jang, Youngsoo; Choi, Byounghee; Kang, Byungkeun; Hong, Chun Pyo

2015-02-01

A liquid treatment method by electromagnetic stirring was applied to a hyper-eutectic Al-15wt pctSi-4wt pctCu-3wt pctNi alloy for the piston manufacturing with diecasting process in order to improve high-temperature mechanical properties of the piston heads. The mechanical properties, such as hardness, high-temperature tensile stress, thermal expansion, and high-temperature relative wear resistance, were estimated using the specimens taken from the liquid-treated diecast products, and the results were compared with those of a conventional metal-mold-cast piston.

Development of a PCR protocol to detect aflatoxigenic molds in food products.

PubMed

Luque, M Isabel; Rodríguez, Alicia; Andrade, María J; Martín, Alberto; Córdoba, Juan J

2012-01-01

Aflatoxins are secondary metabolites produced mainly by Aspergillus species growing in foodstuffs. Because aflatoxins have important health effects, the detection of early contamination of foods by aflatoxigenic molds should be useful. In the present work, a reliable conventional PCR method for detecting aflatoxigenic molds of various species was developed. Fifty-six aflatoxigenic and nonaflatoxigenic strains commonly reported in foodstuffs were tested. Aflatoxin production was first confirmed by micellar electrokinetic capillary electrophoresis or/and high-pressure liquid chromatography-mass spectrometry. Based on the conserved regions of the O-methyltransferase gene (omt-1) involved in the aflatoxin biosynthetic pathway, six primer pairs were designed. With only the designed primer pair AFF1-AFR3, the expected PCR product (381 bp) was obtained in all of the tested aflatoxigenic strains of various species and genera. Amplification products were not obtained with this primer pair for any of the nonaflatoxigenic reference molds. However, an amplicon of 453 bp was obtained for all aflatoxigenic and nonaflatoxigenic mold reference strains with a PCR protocol based on the constitutive fungal β-tubulin gene, which was used as a positive fungal control. The PCR protocol based on omt-1 detected as little as 15 pg of DNA from aflatoxigenic molds and 10(2) to 10(3) CFU/g in contaminated food samples. This PCR protocol should be used as a routine technique to detect aflatoxigenic molds in foods.

A cell-laden microfluidic hydrogel.

PubMed

Ling, Yibo; Rubin, Jamie; Deng, Yuting; Huang, Catherine; Demirci, Utkan; Karp, Jeffrey M; Khademhosseini, Ali

2007-06-01

The encapsulation of mammalian cells within the bulk material of microfluidic channels may be beneficial for applications ranging from tissue engineering to cell-based diagnostic assays. In this work, we present a technique for fabricating microfluidic channels from cell-laden agarose hydrogels. Using standard soft lithographic techniques, molten agarose was molded against a SU-8 patterned silicon wafer. To generate sealed and water-tight microfluidic channels, the surface of the molded agarose was heated at 71 degrees C for 3 s and sealed to another surface-heated slab of agarose. Channels of different dimensions were generated and it was shown that agarose, though highly porous, is a suitable material for performing microfluidics. Cells embedded within the microfluidic molds were well distributed and media pumped through the channels allowed the exchange of nutrients and waste products. While most cells were found to be viable upon initial device fabrication, only those cells near the microfluidic channels remained viable after 3 days, demonstrating the importance of a perfused network of microchannels for delivering nutrients and oxygen to maintain cell viability in large hydrogels. Further development of this technique may lead to the generation of biomimetic synthetic vasculature for tissue engineering, diagnostics, and drug screening applications.

Differentiation of four Aspergillus species and one Zygosaccharomyces with two electronic tongues based on different measurement techniques.

PubMed

Söderström, C; Rudnitskaya, A; Legin, A; Krantz-Rülcker, C

2005-09-29

Two electronic tongues based on different measurement techniques were applied to the discrimination of four molds and one yeast. Chosen microorganisms were different species of Aspergillus and yeast specie Zygosaccharomyces bailii, which are known as food contaminants. The electronic tongue developed in Linköping University was based on voltammetry. Four working electrodes made of noble metals were used in a standard three-electrode configuration in this case. The St. Petersburg electronic tongue consisted of 27 potentiometric chemical sensors with enhanced cross-sensitivity. Sensors with chalcogenide glass and plasticized PVC membranes were used. Two sets of samples were measured using both electronic tongues. Firstly, broths were measured in which either one of the molds or the yeast grew until late logarithmic phase or border of the stationary phase. Broths inoculated by either one of molds or the yeast was measured at five different times during microorganism growth. Data were evaluated using principal component analysis (PCA), partial least square regression (PLS) and linear discriminant analysis (LDA). It was found that both measurement techniques could differentiate between fungi species. Merged data from both electronic tongues improved differentiation of the samples in selected cases.

Transfer molding processes for nanoscale patterning of poly-L-lactic acid (PLLA) films

NASA Astrophysics Data System (ADS)

Dhakal, Rabin; Peer, Akshit; Biswas, Rana; Kim, Jaeyoun

2016-03-01

Nanoscale patterned structures composed of biomaterials exhibit great potential for the fabrication of functional biostructures. In this paper, we report cost-effective, rapid, and highly reproducible soft lithographic transfer-molding techniques for creating periodic micro- and nano-scale textures on poly (L-lactic acid) (PLLA) surface. These artificial textures can increase the overall surface area and change the release dynamics of the therapeutic agents coated on it. Specifically, we use the double replication technique in which the master pattern is first transferred to the PDMS mold and the pattern on PDMS is then transferred to the PLLA films through drop-casting as well as nano-imprinting. The ensuing comparison studies reveal that the drop-cast PLLA allows pattern transfer at higher levels of fidelity, enabling the realization of nano-hole and nano-cone arrays with pitch down to ~700 nm. The nano-patterned PLLA film was then coated with rapamycin to make it drug-eluting.

Controlling Radiative Heat Transfer Across the Mold Flux Layer by the Scattering Effect of the Borosilicate Mold Flux System with Metallic Iron

NASA Astrophysics Data System (ADS)

Yoon, Dae-Woo; Cho, Jung-Wook; Kim, Seon-Hyo

2017-08-01

The present study proposes a countermeasure for regulating total heat flux through the mold flux layer by designed mold flux with additive metallic iron particles. The heat flux through the B2O3-CaO-SiO2-Na2O-CaF2-Fe system was investigated using the infrared emitter technique to evaluate total flux density across the mold flux film. Both scanning electron microscope (SEM) and X-ray diffraction analysis were employed in order to identify the morphological and compositional changes of the crystalline phase, according to increasing iron contents in the mold flux. It was confirmed that the crystalline layer of studied mold fluxes does not have a meaningful effect on the total heat flux density due to the similar structure and fraction of the crystalline phase. The extinction coefficient was measured for glassy mold fluxes using an ultraviolet/visible and a Fourier transformation-infrared ray spectrometer in the range of 0.5 to 5 μm. For analyzing the scattering behavior of iron particles on the extinction coefficient, the number density and diameter of particles were observed by an automated SEM (auto-SEM). With these data, Mie scattering theory is adopted to define the scattering behavior of dispersed iron droplets in glassy matrix. It was found that the theoretical scattering coefficient demonstrated about 1623 to 3295 m-1, which is in accordance with the experimental results. In doing so, this study successfully achieves the strong scattering behavior that would contribute greatly to the optimization of overall heat flux through the mold flux film during the casting process.

Ultrasonically-assisted Polymer Molding: An Evaluation

NASA Astrophysics Data System (ADS)

Moles, Matthew; Roy, Anish; Silberschmidt, Vadim

Energy reduction in extrusion and injection molding processes can be achieved by the introduction of ultrasonic energy. Polymer flow can be enhanced on application of ultrasonic vibration, which can reduce the thermal and pressure input requirements to produce the same molding; higher productivity may also be achieved. In this paper, a design of an ultrasound-assisted injection mold machine is explored. An extrusion-die design was augmented with a commercial 1.5 kW ultrasonic transducer and sonotrode designed to resonate close to 20 kHz with up to 100 μm vibration amplitude. The design was evaluated with modal and thermal analysis using finite-element analysis software. The use of numerical techniques, including computational fluid dynamics, fluid-structure interaction and coupled Lagrangian-Eulerian method, to predict the effect of ultrasound on polymer flow was considered. A sonotrode design utilizing ceramic to enhance thermal isolation was also explored.

Micropattern array with gradient size (µPAGS) plastic surfaces fabricated by PDMS (polydimethylsiloxane) mold-based hot embossing technique for investigation of cell-surface interaction.

PubMed

Choi, Min Jin; Park, Ju Young; Cha, Kyoung Je; Rhie, Jong-Won; Cho, Dong-Woo; Kim, Dong Sung

2012-12-01

Recently, it was found that the variations of physical environment significantly affect cell behaviors including cell proliferation, migration and differentiation. Through a plastic surface with controlled mechanical properties such as stiffness, one can change the orientation and migration of cells in a particular direction, thereby determining cell behaviors. In this study, we demonstrate a polydimethylsiloxane (PDMS) mold-based hot embossing technique for rapid, simple and low-cost replication of polystyrene (PS) surfaces having micropatterns. The PDMS mold was fabricated by UV-photolithography followed by PDMS casting; the elastomeric properties of PDMS enabled us to obtain conformal contact of the PDMS mold to a PS surface and to create high transcription quality of micropatterns on the PS surface. Two different types of circular micropillar and microwell arrays were successfully replicated on the PS surfaces based on the suggested technique. The micropatterns were designed to have various diameters (2-150 µm), spacings (2-160 µm) and heights (1.4, 2.4, 8.2 and 14.9 µm), so as to generate the gradient of physical properties on the surface. Experimental parametric studies indicated that (1) the embossing temperature became a critical processing parameter as the aspect ratio of micropattern increased and (2) the PDMS mold-based hot embossing could successfully replicate micropatterns, even having an aspect ratio of 2.7 for micropattern diameter of 6 µm, with an optimal processing condition (embossing pressure and temperature of 0.4 MPa and 130 °C, respectively) in this study. We carried out cell experiments with adipose-derived stem cells on the replicated PS surface with the height of 1.4 µm to investigate cellular behaviors in response to the micropattern array with gradient size. Cellular experiment results showed that the micropillar-arrayed surface improved cell proliferation as compared with the microwell-arrayed surface. We could also estimate the ranges of pattern sizes having the desired effects on the cellular behaviors.

Frequency and amplitude dependences of molding accuracy in ultrasonic nanoimprint technology

NASA Astrophysics Data System (ADS)

Mekaru, Harutaka; Takahashi, Masaharu

2009-12-01

We use neither a heater nor ultraviolet lights, and are researching and developing an ultrasonic nanoimprint as a new nano-patterning technology. In our ultrasonic nanoimprint technology, ultrasonic vibration is not used as a heat generator instead of the heater. A mold is connected with an ultrasonic generator, and mold patterns are pushed down and pulled up at a high speed into a thermoplastic. Frictional heat is generated by ultrasonic vibration between mold patterns and thermoplastic patterns formed by an initial contact force. However, because frictional heat occurs locally, the whole mold is not heated. Therefore, a molding material can be comprehensively processed at room temperature. A magnetostriction actuator was built into our ultrasonic nanoimprint system as an ultrasonic generator, and the frequency and amplitude can be changed between dc-10 kHz and 0-4 µm, respectively. First, the ultrasonic nanoimprint was experimented by using this system on polyethylene terephthalate (PET, Tg = 69 °C), whose the glass transition temperature (Tg) is comparatively low in engineering plastics, and it was ascertained that the most suitable elastic material for this technique was an ethyl urethane rubber. In addition, we used a changeable frequency of the magnetostriction actuator, and nano-patterns in an electroformed-Ni mold were transferred to a 0.5 mm thick sheet of PET, polymethylmethacrylate (PMMA) and polycarbonate (PC), which are typical engineering plastics, under variable molding conditions. The frequency and amplitude dependence of ultrasonic vibration to the molding accuracy were investigated by measuring depth and width of imprinted patterns. As a result, regardless of the molding material, the imprinted depth was changed drastically when the frequency exceeded 5 kHz. On the other hand, when the amplitude of ultrasonic vibration grew, the imprinted depth gradually deepened. Influence of the frequency and amplitude of ultrasonic vibration was not observed on the width of imprinted patterns. Moreover, the imprinted depth deepened as the Tg of the molding material lowered, and a progressive change according to conditions of ultrasonic vibration also became remarkable. Therefore, it seems that impressing ultrasonic vibration with a high frequency and large amplitude promotes thermal deformation and improves the molding accuracy in the ultrasonic nanoimprint technology.

Recent Developments in Microsystems Fabricated by the Liga-Technique

NASA Technical Reports Server (NTRS)

Schulz, J.; Bade, K.; El-Kholi, A.; Hein, H.; Mohr, J.

1995-01-01

As an example of microsystems fabricated by the LIGA-technique (x-ray lithography, electroplating and molding), three systems are described and characterized: a triaxial acceleration sensor system, a micro-optical switch, and a microsystem for the analysis of pollutants. The fabrication technologies are reviewed with respect to the key components of the three systems: an acceleration sensor, and electrostatic actuator, and a spectrometer made by the LIGA-technique. Aa micro-pump and micro-valve made by using micromachined tools for molding and optical fiber imaging are made possible by combining LIGA and anisotropic etching of silicon in a batch process. These examples show that the combination of technologies and components is the key to complex microsystems. The design of such microsystems will be facilitated is standardized interfaces are available.

Prediction model of austenite growth and the role of MnS inclusions in non-quenched and tempered steel

NASA Astrophysics Data System (ADS)

Jiang, Bo; Wu, Meng; Sun, He; Wang, Zhilin; Zhao, Zhigang; Liu, Yazheng

2018-01-01

The austenite growth behavior of non-quenched and tempered steels (casted by continuous casting and molding casting processes) was studied. The austenite grain size of steel B casted by continuous casting process is smaller than that of steel A casted by molding casting process at the same heating parameters. The abnormal austenite growth temperature of the steels A and B are 950 °C and 1000 °C, respectively. Based on the results, the models for the austenite grain growth below and above the abnormal austenite growth temperature of the investigated steels were established. The dispersedly distributed fine particles MnS in steel B is the key factor refining the austenite grain by pinning the migration of austenite grain boundary. The elongated inclusions MnS are ineffective in preventing the austenite grain growth at high heating temperature. For the non-quenched and tempered steel, the continuous casting process should be adopted and the inclusion MnS should be elliptical, smaller in size and distributed uniformly in order to refine the final microstructure and also improve the mechanical properties.

Study on Warm Forging Prosess of 45 Steel Asymmetric Gear

NASA Astrophysics Data System (ADS)

Qi, Yushi; Du, Zhiming; Sun, Hongsheng; Chen, Lihua; Wang, Changshun

2017-09-01

Asymmetric gear has complex structure, so using plastic forming technology to process the gear has problems of large forming load, short die life, bad tooth filling, and so on. To solve these problems, this paper presents a radial warm extrusion process of asymmetric gear to reduce the forming load and improve the filling in the toothed corner portion. Using the new mold and No. 45 steel to conducting forming experiments under the optimal forming parameters: billet temperature is 800°C, mold temperature is 250°C, the forming speed is 30mm/s, and the friction coefficient is 0.15, we can obtain the complete asymmetric gear with better surface and tooth filling. Asymmetric gears’ microstructure analysis and mechanical testing showed that the small grain evenly distributed in the region near the addendum circle with high strength; the area near the central portion of the gear had a coarse grain size, uneven distribution and low strength. Significant metal flow lines at the corner part of the gear indicated that a large number of late-forming metal flowed into the tooth cavity filling the corner portion.

Effect of heat history on the corrosion of ferritic stainless steels used for dental magnetic attachments.

PubMed

Takada, Yukyo; Okuno, Osamu

2005-09-01

This study investigated the effect of heat history on the corrosion of keepers used for dental magnetic attachments. Ferritic stainless steels of SUS 444 and 447J1 were prepared with heat treatments in the temperature range of 550-850 degrees C for 1-5 hours. The stainless steels were electrochemically and metallurgically examined by anodic polarization curves in a 0.9% NaCl solution and by microstructural observation using an electron probe microanalyzer with WDS. Heating both kinds of stainless steel at 650-750 degrees C for two hours or more led to the deterioration of their corrosion resistance. For example, there was evidence of a reduction in the breakdown potentials and an increase in the current densities of the anodic polarization curves. These phenomena were attributed mainly to the precipitation of the sigma (FeCr) or chi (Fe18Cr6Mo5) phase, which sometimes resulted in intergranular corrosion. When dental alloys are cast in investment molds embedding the keepers, the heat time required for thermal expansion of the molds should be kept under one hour.

Correlation between failure and local material property in chopped carbon fiber chip-reinforced sheet molding compound composites under tensile load

DOE PAGES

Tang, Haibin; Chen, Zhangxing; Zhou, Guowei; ...

2018-02-06

To develop further understanding towards the role of a heterogeneous microstructure on tensile crack initiation and failure behavior in chopped carbon fiber chip-reinforced composites, uni-axial tensile tests are performed on coupons cut from compression molded plaque with varying directions. Our experimental results indicate that failure initiation is relevant to the strain localization, and a new criterion with the nominal modulus to predict the failure location is proposed based on the strain analysis. Furthermore, optical microscopic images show that the nominal modulus is determined by the chip orientation distribution. At the area with low nominal modulus, it is found that chipsmore » are mostly aligning along directions transverse to loading direction and/or less concentrated, while at the area with high nominal modulus, more chips are aligning to tensile direction. On the basis of failure mechanism analysis, it is concluded that transversely-oriented chips or resin-rich regions are easier for damage initiation, while longitudinally-oriented chips postpone the fracture. Good agreement is found among failure mechanism, strain localization and chip orientation distribution.« less

Correlation between failure and local material property in chopped carbon fiber chip-reinforced sheet molding compound composites under tensile load

DOE Office of Scientific and Technical Information (OSTI.GOV)

Tang, Haibin; Chen, Zhangxing; Zhou, Guowei

To develop further understanding towards the role of a heterogeneous microstructure on tensile crack initiation and failure behavior in chopped carbon fiber chip-reinforced composites, uni-axial tensile tests are performed on coupons cut from compression molded plaque with varying directions. Our experimental results indicate that failure initiation is relevant to the strain localization, and a new criterion with the nominal modulus to predict the failure location is proposed based on the strain analysis. Furthermore, optical microscopic images show that the nominal modulus is determined by the chip orientation distribution. At the area with low nominal modulus, it is found that chipsmore » are mostly aligning along directions transverse to loading direction and/or less concentrated, while at the area with high nominal modulus, more chips are aligning to tensile direction. On the basis of failure mechanism analysis, it is concluded that transversely-oriented chips or resin-rich regions are easier for damage initiation, while longitudinally-oriented chips postpone the fracture. Good agreement is found among failure mechanism, strain localization and chip orientation distribution.« less

Effects of synthesis techniques on chemical composition, microstructure and dielectric properties of Mg-doped calcium titanate

NASA Astrophysics Data System (ADS)

Jongprateep, Oratai; Sato, Nicha

2018-04-01

Calcium titanate (CaTiO3) has been recognized as a material for fabrication of dielectric components, owing to its moderate dielectric constant and excellent microwave response. Enhancement of dielectric properties of the material can be achieved through doping, compositional and microstructural control. This study, therefore, aimed at investigating effects of powder synthesis techniques on compositions, microstructure, and dielectric properties of Mg-doped CaTiO3. Solution combustion and solid-state reaction were powder synthesis techniques employed in preparation of undoped CaTiO3 and CaTiO3 doped with 5-20 at% Mg. Compositional analysis revealed that powder synthesis techniques did not exhibit a significant effect on formation of secondary phases. When Mg concentration did not exceed 5 at%, the powders prepared by both techniques contained only a single phase. An increase of MgO secondary phase was observed as Mg concentrations increased from 10 to 20 at%. Experimental results, on the contrary, revealed that powder synthesis techniques contributed to significant differences in microstructure. Solution combustion technique produced powders with finer particle sizes, which consequently led to finer grain sizes and density enhancement. High-density specimens with fine microstructure generally exhibit improved dielectric properties. Dielectric measurements revealed that dielectric constants of all samples ranged between 231 and 327 at 1 MHz, and that superior dielectric constants were observed in samples prepared by the solution combustion technique.

Hydroxyapatite implants with designed internal architecture.

PubMed

Chu, T M; Halloran, J W; Hollister, S J; Feinberg, S E

2001-06-01

Porous hydroxyapatite (HA) has been used as a bone graft material in the clinics for decades. Traditionally, the pores in these HAs are either obtained from the coralline exoskeletal patterns or from the embedded organic particles in the starting HA powder. Both processes offer very limited control on the pore structure. A new method for manufacturing porous HA with designed pore channels has been developed. This method is essentially a lost-mold technique with negative molds made with Stereolithography and a highly loaded curable HA suspension as the ceramic carrier. Implants with designed channels and connection patterns were first generated from a Computer-Aided-Design (CAD) software and Computer Tomography (CT) data. The negative images of the designs were used to build the molds on a stereolithography apparatus with epoxy resins. A 40 vol% HA suspension in propoxylated neopentyl glycol diacrylate (PNPGDA) and iso-bornyl acrylate (IBA) was formulated. HA suspension was cast into the epoxy molds and cured into solid at 85 degrees C. The molds and acrylate binders were removed by pyrolysis, followed by HA green body sintering. With this method, implants with six different channel designs were built successfully and the designed channels were reproduced in the sintered HA implants. The channels created in the sintered HA implants were between 366 microm and 968 microm in diameter with standard deviations of 50 microm or less. The porosity created by the channels were between 26% and 52%. The results show that HA implants with designed connection pattern and well controlled channel size can be built with the technique developed in this study. Copyright 2001 Kluwer Academic Publishers

Process Integration and Optimization of ICME Carbon Fiber Composites for Vehicle Lightweighting: A Preliminary Development

DOE PAGES

Xu, Hongyi; Li, Yang; Zeng, Danielle

2017-01-02

Process integration and optimization is the key enabler of the Integrated Computational Materials Engineering (ICME) of carbon fiber composites. In this paper, automated workflows are developed for two types of composites: Sheet Molding Compounds (SMC) short fiber composites, and multi-layer unidirectional (UD) composites. For SMC, the proposed workflow integrates material processing simulation, microstructure representation volume element (RVE) models, material property prediction and structure preformation simulation to enable multiscale, multidisciplinary analysis and design. Processing parameters, microstructure parameters and vehicle subframe geometry parameters are defined as the design variables; the stiffness and weight of the structure are defined as the responses. Formore » multi-layer UD structure, this work focuses on the discussion of different design representation methods and their impacts on the optimization performance. Challenges in ICME process integration and optimization are also summarized and highlighted. Two case studies are conducted to demonstrate the integrated process and its application in optimization.« less

Micro Machining of Injection Mold Inserts for Fluidic Channel of Polymeric Biochips

PubMed Central

Jung, Woo-Chul; Heo, Young-Moo; Yoon, Gil-Sang; Shin, Kwang-Ho; Chang, Sung-Ho; Kim, Gun-Hee; Cho, Myeong-Woo

2007-01-01

Recently, the polymeric micro-fluidic biochip, often called LOC (lab-on-a-chip), has been focused as a cheap, rapid and simplified method to replace the existing biochemical laboratory works. It becomes possible to form miniaturized lab functionalities on a chip with the development of MEMS technologies. The micro-fluidic chips contain many micro-channels for the flow of sample and reagents, mixing, and detection tasks. Typical substrate materials for the chip are glass and polymers. Typical techniques for microfluidic chip fabrication are utilizing various micro pattern forming methods, such as wet-etching, micro-contact printing, and hot-embossing, micro injection molding, LIGA, and micro powder blasting processes, etc. In this study, to establish the basis of the micro pattern fabrication and mass production of polymeric micro-fluidic chips using injection molding process, micro machining method was applied to form micro-channels on the LOC molds. In the research, a series of machining experiments using micro end-mills were performed to determine optimum machining conditions to improve surface roughness and shape accuracy of designed simplified micro-channels. Obtained conditions were used to machine required mold inserts for micro-channels using micro end-mills. Test injection processes using machined molds and COC polymer were performed, and then the results were investigated.

Integrated System of Thermal/Dimensional Analysis for Quality Control of Metallic Melt and Ductile Iron Casting Solidification

NASA Astrophysics Data System (ADS)

Stan, Stelian; Chisamera, Mihai; Riposan, Iulian; Neacsu, Loredana; Cojocaru, Ana Maria; Stan, Iuliana

2018-03-01

The main objective of the present work is to introduce a specific experimental instrument and technique for simultaneously evaluating cooling curves and expansion or contraction of cast metals during solidification. Contraction/expansion analysis illustrates the solidification parameters progression, according to the molten cast iron characteristics, which are dependent on the melting procedure and applied metallurgical treatments, mold media rigidity and thermal behavior [heat transfer parameters]. The first part of the paper summarizes the performance of this two-mold device. Its function is illustrated by representative shrinkage tendency results in ductile cast iron as affected by mold rigidity (green sand and furan resin sand molds) and inoculant type (FeSi-based alloys), published in part previously. The second part of the paper illustrates an application of this equipment adapted for commercial foundry use. It conducts thermal analysis and volume change measurements in a single ceramic cup so that mold media as well as solidification conditions are constants, with cast iron quality as the variable. Experiments compared gray and ductile cast iron solidification patterns. Gray iron castings are characterized by higher undercooling at the beginning and at the end of solidification and lower graphitic expansion. Typically, ductile cast iron exhibits higher graphitic, initial expansion, conducive for shrinkage formation in soft molds.

Lost mold-rapid infiltration forming: Strength control in mesoscale 3Y-TZP ceramics

NASA Astrophysics Data System (ADS)

Antolino, Nicholas E.

The strength of nanoparticulate enabled microdevices and components is directly related to the interfacial control between particles and the flaws introduced as these particles come together to form the device or component. One new application for micro-scale or meso-scale (10's microm to 100's microm) devices is surgical instruments designed to enter the body, perform a host of surgeries within the body cavity, and be extracted with no external incisions to the patient. This new concept in surgery, called natural orifice transluminal endoscopic surgery (NOTES), requires smaller and more functional surgical tools. Conventional processing routes do not exist for making these instruments with the desired size, topology, precision, and strength. A process, called lost mold-rapid infiltration forming (LM-RIF), was developed to satisfy this need. A tetragonally stabilized zirconia polycrystalline material (3Y-TZP) is a candidate material for this process and application because of its high strength, chemical stability, high elastic modulus, and reasonably high toughness for a ceramic. Modern technical ceramics, like Y-TZP, are predicated on dense, fine grained microstructures and functional mesoscale devices must also adhere to this standard. Colloid and interfacial chemistry was used to disperse and concentrate the Y-TZP nanoparticles through a very steep, yet localized, potential energy barrier against the van der Waals attractive force. The interparticle interaction energies were modeled and compared to rheological data on the suspension. At high concentrations, the suspension was pseudoplastic, which is evidence that a structure was formed within the suspension that could be disrupted by a shearing force. The LM-RIF process exploits this rheological behavior to fill mold cavities created by photolithography. The premise of the LM-RIF process is to process the particulate material into a dense ceramic body while the unsintered mesoscale parts are supported en masse by a substrate. Numerous challenges were overcome that relate to the application of photoresist on a refractory substrate capable of withstanding the high temperatures needed to sinter the ceramic parts. Strength of approximately 1 GPa was achieved for the first parts produced, which demonstrated the feasibility of the LM-RIF process. Although respectable, a 1GPa strength is not as strong as would be predicted based on the small size (332 x 26 x 17 microm) of the parts. An effort to identify and eliminate the largest flaws in the specimen produced by the LM-RIF process was undertaken, which ultimately increased the average strength to 2.35 GPa. Geometric defects, previously unreported in ceramic microfabrication techniques, were degrading the strength of the early parts. An in-depth characterization of these defects by optical profilometry and then eliminating the underlying cause was the key to obtaining this high strength. One interesting phenomena discovered in this work was the role that the substrate plays in the sintering of the ceramic part through the enhanced diffusion pathways created by the more intimate contact of the mesoscale parts compared to macroscale analogs. Impurities of alumina and silica were found to adversely affect the sintering kinetics of mesoscale parts causing localized grain growth or exaggerated grain growth depending on the sintering conditions. The role that the microstructure, specifically the grain size, plays in determining the strength versus the role that the surface flaw population plays, as characterized by the surface roughness, was determined through isothermal sintering experiments. It was found that the strength of mesoscale ceramics lies in the transition region between the flaw-dominated stress intensity effect and the Hall-Petch microstructural effect. This proves that processing science and microstructural refinement about equally determine the strength of particulate based mesoscale materials. The hierarchical approach that was used to marry the development of the LM-RIF process to the mechanical design and optimization of surgical instruments is described. This approach used nested iteration loops to refine both the design and fabrication processes to create and test surgical instrument prototypes. These prototypes as well as some of the unique shapes possible with the LM-RIF process are presented.

A catalyst-free, temperature controlled gelation system for in-mold fabrication of microgels.

PubMed

Krüger, Andreas J D; Köhler, Jens; Cichosz, Stefan; Rose, Jonas C; Gehlen, David B; Haraszti, Tamás; Möller, Martin; De Laporte, Laura

2018-06-19

Anisometric microgels are prepared via thermal crosslinking using an in-mold polymerization technique. Star-shaped poly(ethylene oxide-stat-propylene oxide) polymers, end-modified with amine and epoxy groups, form hydrogels, of which the mechanical properties and gelation rate can be adjusted by the temperature, duration of heating, and polymer concentration. Depending on the microgel stiffness, the rod-shaped microgels self-assemble into ordered or disordered structures.

Method for forming pyrrone molding powders and products of said method

NASA Technical Reports Server (NTRS)

Hughes, C. T.; Mchenry, R. J. (Inventor)

1972-01-01

The formation of pyrrone resins of the ladder or semiladder structure is described. The technique involves initial formation of fully cyclized prepolymers having an average degree of polymerization of about 1.5, one with acidic terminal groups, another with amine terminal groups. Thereafter the prepolymers are intimately admixed on a 1:1 stoichiometric basis. The resulting powder mixture is molded at elevated pressures and temperatures to form a fully cyclized resin.

Development of Cu Clad Cu-Zr Based Metallic Glass and Its Solderability

NASA Astrophysics Data System (ADS)

Terajima, Takeshi; Kimura, Hisamichi; Inoue, Akihisa

Soldering is a candidate technique for joining metallic glasses. It can be processed far below the crystallization temperatures of the various metallic glasses so that there is no possibility of crystallization. However, wettability of Cu-Zr based metallic glass by Pb free solder is poor because a strong surface oxide film interferes direct contact between them. To overcome the problem, Cu thin film clad metallic glass was developed. It was preliminary produced by casting a melt of Cu36Zr48Al8Ag8 pre-alloy into Cu mold cavity, inside which Cu thin film with 2 mm in thickness was set on the wall. Cu36Zr48Al8Ag8 metallic glass, whose surface Cu thin film was welded to, was successfully produced. From the microstructure analyses, it was found that reaction layer was formed at the interface between Cu and Cu36Zr48Al8Ag8 metallic glass, however, there was no oxide in the Cu clad layer. Solderability to the metallic glass was drastically increased. The Cu clad layer played an important role to prevent the formation of surface oxide film and consequently improved the solderability.

The fabrication of PLGA microvessel scaffolds with nano-patterned inner walls.

PubMed

Wang, Gou-Jen; Lin, Yan-Cheng; Hsu, Shan-Hui

2010-10-01

Poly (lactic-co-glycolic acid) (PLGA) is one of the most commonly used biodegradable, biocompatible materials. Nanostructured PLGA has immense potential for application in tissue engineering. In this article we discuss a novel approach for the fabrication of PLGA microvessel scaffolds with nanostructured inner walls. In this novel nano-patterning approach, the thermal reflow technique is first adapted to fabricate a semi-cylindrical photoresist master mold. A thin film of titanium and a thin film of aluminum are sputtered in sequence on the semi-cylindrical microvessel network. Aluminum foil anodization is then executed to transform the aluminum thin film into a porous anodic aluminum oxide (AAO) film. During the casting process a PLGA solution is cast on the AAO film to build up semi-cylindrical PLGA microstructures with nanostructured inner walls after which inductive coupled plasma (ICP) is implemented to assist bonding of the two PLGA structures. The result is the building of a network of microchannels with nano-patterned inner walls. Bovine endothelial cells (BECs) are carefully cultured in the scaffold via semi-dynamic seeding for 7 days. Observations show that the BECs grew more separately in a nano-patterned microvessel scaffold than they did in a smooth surface scaffold.

Bladesmithing at South Dakota School of Mines and Technology

NASA Astrophysics Data System (ADS)

Moehring, Jack; Willman, Michael; Pulscher, Isaac; Rowe, Devin

2016-12-01

A Damascus-style layered blade was made by incorporating bloomery iron and crucible steel. A bloomery furnace was constructed and charged with Black Hills, SD bog iron ore, alloys, and hardwood charcoal. At sufficient temperature, the furnace was bottom-tapped to produce a low carbon iron bloom. A high-carbon crucible steel was made in a natural gas-fired furnace using commercial hematite pellets and coke. The steel was cast into sand molds. The two types of iron/steel were forged together using traditional blacksmithing techniques in a coke-fired forge. The forging process continued until the metal could be evenly worked, signifying the homogenization of the two metals. Once homogenized, the metal was shaped into a blade and subsequently ground into near-final shape, heat-treated, and finish-machined. The microstructure and mechanical properties of the blade were characterized using optical microscopy, hardness and tensile testing. The grain structure of the material varied widely and was not entirely homogenous at the welded layers, but the layers themselves were well-homogenized. The finished blade was compared to a common steel (1095) used for bladesmithing and was found to have similar hardness but significantly lower tensile strength.

Implementing and Quantifying the Shape-Memory Effect of Single Polymeric Micro/Nanowires with an Atomic Force Microscope.

PubMed

Fang, Liang; Gould, Oliver E C; Lysyakova, Liudmila; Jiang, Yi; Sauter, Tilman; Frank, Oliver; Becker, Tino; Schossig, Michael; Kratz, Karl; Lendlein, Andreas

2018-04-23

The implementation of shape-memory effects (SME) in polymeric micro- or nano-objects currently relies on the application of indirect macroscopic manipulation techniques, for example, stretchable molds or phantoms, to ensembles of small objects. Here, we introduce a method capable of the controlled manipulation and SME quantification of individual micro- and nano-objects in analogy to macroscopic thermomechanical test procedures. An atomic force microscope was utilized to address individual electro-spun poly(ether urethane) (PEU) micro- or nanowires freely suspended between two micropillars on a micro-structured silicon substrate. In this way, programming strains of 10±1% or 21±1% were realized, which could be successfully fixed. An almost complete restoration of the original free-suspended shape during heating confirmed the excellent shape-memory performance of the PEU wires. Apparent recovery stresses of σ max,app =1.2±0.1 and 33.3±0.1 MPa were obtained for a single microwire and nanowire, respectively. The universal AFM test platform described here enables the implementation and quantification of a thermomechanically induced function for individual polymeric micro- and nanosystems. © 2018 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim.

Influence of different materials and techniques to transfer molding in multiple implants.

PubMed

Faria, Júlio C B; Cruz, Fernando L G; Silva-Concílio, Laís R; Neves, Ana C C

2012-01-01

The aim of this study was to compare different materials and techniques used in transfer molding of multiple implants, by evaluating the space between implants and superstructure. Four external hexagon implants were fixed in a master template and the same on a superstructure. Transfer molding of implants were done using the direct and indirect techniques, with transfers united or not, using the union chemically activated acrylic resin (QA) and other groups polymerized acrylic resin (FT), and sectioned and not split. The casts were made with polyether and models divided into 8 groups (n = 5). The space between the superstructure and the master implants was measured with a microscope and the data was analyzed statistically by Student's t test (p < 0.05). For the material of union there was no significant difference, except when the groups were compared with the resin Duralay QA (G4) and the resin Duolay FT (G8) and groups using resins Duolay QA (G5) and Duolay FT (G7) for the union of the transfers. When comparing the groups who had the union between the transfers and sectioned again united with those in which the union was not severed there was no statistically significant difference. QA resin was superior to the FT with respect to the union of transfers. Techniques with united transfers or not were similar.

Effect of Blood Contamination on Marginal Adaptation and Surface Microstructure of Mineral Trioxide Aggregate: A SEM Study.

PubMed

Salem Milani, Amin; Rahimi, Saeed; Froughreyhani, Mohammad; Vahid Pakdel, Mahdi

2013-01-01

In various clinical situations, mineral trioxide aggregate (MTA) may come into direct contact or even be mixed with blood. The aim of the present study was to evaluate the effect of exposure to blood on marginal adaptation and surface microstructure of MTA. Thirty extracted human single-rooted teeth were used. Standard root canal treatment was carried out. Root-ends were resected, and retrocavities were prepared. The teeth were randomly divided into two groups (n = 15): in group 1, the internal surface of the cavities was coated with fresh blood. Then, the cavities were filled with MTA. The roots were immersed in molds containing fresh blood. In group 2, the aforementioned procedures were performed except that synthetic tissue fluid (STF) was used instead of blood. To assess the marginal adaptation, "gap perimeter" and "maximum gap width" were measured under scanning electron microscope. The surface microstructure was also examined. Independent samples t-test and Mann-Whitney U test were used to analyze the data. Maximum gap width and gap perimeter in the blood-exposed group were significantly larger than those in the STF-exposed group (p < 0.01). In the blood-exposed group, the crystals tended to be more rounded and less angular compared with the STF-exposed group, and there was a general lack of needle-like crystals. Exposure to blood during setting has a negative effect on marginal adaptation of MTA, and blood-exposed MTA has a different surface microstructure compared to STF-exposed MTA.

Building a Competitive Edge with Additive Manufacturing

DTIC Science & Technology

2013-02-14

construct ceramic molds for complex metal parts using a 3D printing technique. They estimate the new 6 technique could eliminate all of the...processes. They include 3D printing and Additive Beam Techniques.15 Most Additive Manufacturing techniques are specific to certain classes of materials...9 Example Additive Manufacturing Techniques16 3D Printing Additive Beam Stereolithography (SLA) Direct Metal Laser Sintering (DMLS

[Application of negative molds technology based on three-dimensional printing in digital maxillofacial prostheses].

PubMed

Gu, X Y; Chen, X B; Jiao, T; Zhang, F Q; Jiang, X Q

2017-06-09

Objective: To explore a digital negative molds technique based on three-dimensional (3D) printing to assist in the manufacture of maxillofacial prostheses, and to improve the deficiency of the current clinical treatment. Methods: Seventeen patients with maxillofacial defects (including nasal defects, orbital defects, cheek defects, auricle defect) were scanned by means of facial optical scanning and computer tomography (CT). The 3D models were then reconstructed and global registration was made to merge the reconstructed models into a new digital model for 3D design. The 3D design of the prostheses was implemented in software. The mechanical connection structure was designed by forward engineering technology for 3 patients with intra-oral defects in maxilla who needed to make removable partial dentures, so that the silicone prostheses and removable partial denture could be combined. The removable partial dentures were made by conventional method and connected with the prostheses. According to the 3D data of the prostheses, the digital negative molds were designed, and the 3D printing technology was used to finish the processing of the resin molds. Silicone for prostheses were filled and cured in the resin molds to fabricate the clinical restorations for the patients. The margin adaptation and retention of the prostheses was detected. Results: Twenty patients with varying degrees of maxillofacial defects were rehabilitated using the courses developed in the study. All patients reported no pain or discomfort during the treatment; and they were satisfied with the final prostheses of the shape, color, retention, stability, etc. Eighteen of the prostheses showed good marginal adaptation, and sixteen of the prostheses showed good retention effect. Conclusions: The digital negative molds technique used in this study could greatly reduce the intensity of manual operation and provided a good therapeutic effect for patients with maxillofacial defects.

Pattern fidelity in nanoimprinted films using CD-SAXS

NASA Astrophysics Data System (ADS)

Jones, Ronald L.; Soles, Christopher L.; Lin, Eric K.; Hu, Walter; Reano, Ronald M.; Pang, Stella W.; Weigand, Steven J.; Keane, Denis T.; Quintana, John P.

2005-05-01

The primary measure of process quality in nanoimprint lithography (NIL) is the fidelity of pattern transfer, comparing the dimensions of the imprinted pattern to those of the mold. As a potential next generation lithography, NIL is capable of true nanofabrication, producing patterns of sub-10 nm dimensions. Routine production of nanoscale patterns will require new metrologies capable of non-destructive dimensional measurements of both the mold and the pattern with sub-nm precision. In this article, a rapid, non-destructive technique termed Critical Dimension Small Angle X-ray Scattering (CD-SAXS) is used to measure the cross sectional shape of both a pattern master, or mold, and the resulting imprinted films. CD-SAXS data are used to extract periodicity as well as pattern height, width, and sidewall angles. Films of varying materials are molded by thermal embossed NIL at temperatures both near and far from the bulk glass transition (TG). The polymer systems include a photoresist, representing a mixture of a polymer and small molecular components, and two pure homopolymers. Molding at low temperatures (T-TG < 40°C) produces small aspect ratio patterns that maintain periodicity to within a single nanometer, but feature large sidewall angles. While the pattern height does not reach that of the mold until very large imprinting temperatures (T-TG ~ 70°C), the pattern width of the mold is accurately transferred for T-TG > 30°C. In addition to obtaining basic dimensions, CD-SAXS data are used to assess the origin of loss in pattern fidelity.

Large-core single-mode rib SU8 waveguide using solvent-assisted microcontact molding.

PubMed

Huang, Cheng-Sheng; Wang, Wei-Chih

2008-09-01

This paper describes a novel fabrication technique for constructing a polymer-based large-core single-mode rib waveguide. A negative tone SU8 photoresist with a high optical transmission over a large wavelength range and stable mechanical properties was used as a waveguide material. A waveguide was constructed by using a polydimethylsiloxane stamp combined with a solvent-assisted microcontact molding technique. The effects on the final pattern's geometry of four different process conditions were investigated. Optical simulations were performed using beam propagation method software. Single-mode beam propagation was observed at the output of the simulated waveguide as well as the actual waveguide through the microscope image.

Trapped rubber processing for advanced composites

NASA Technical Reports Server (NTRS)

Marra, P. J.

1976-01-01

Trapped rubber processing is a molding technique for composites in which precast silicone rubber is placed within a closed cavity where it thermally expands against the composite's surface supported by the vessel walls. The method has been applied by the Douglas Aircraft Company, under contract to NASA-Langley, to the design and fabrication of 10 DC-10 graphite/epoxy upper aft rudder assemblies. A three-bay development tool form mold die has been designed and manufactured, and tooling parameters have been established. Fabrication procedures include graphite layup, assembly of details in the tool, and a cure cycle. The technique has made it possible for the cocured fabrication of complex primary box structures otherwise impracticable via standard composite material processes.

Design and fabrication of an elliptical micro-lens array with grating for laser safety

NASA Astrophysics Data System (ADS)

Li, L. H.; Wu, B. Q.; Chan, C. Y.; Lee, W. B.; Dong, L. H.

2015-10-01

With the enormous expansion of laser usage in medicine, industry and research, all facilities must formulate and adhere to specific safety methods that appropriately address user protection. The protective ellipticalal microstructure with grating is a novel technology which can provide the principal means of ensuring against ocular injury, and must be worn at all times during laser operation. On the basis of Fresnel's law and the diffractive law, Solidworks and Lighttools software are applied to design the elliptical micro-lens array and correspondent grating. The height of the microstructure is 100um and its period is 3mm. The period of grating is 5um. It is shown that the amount of emergent light of a specific wavelength (1064nm) can reflect more than 40° from the incident light through simulation, while the incident light is perpendicular to the microstructure. The fabrication adopts the ultra-precision single point diamond method and injection molding method. However, it is found in the test that the surface roughness has a serious effect on the angle between the emergent and incident light. As a result, the element can reflect the vertical incidence beam into a tilted emergent beam with a certain angular degree , as well as protecting users from laser damage injures.

Computational discovery of extremal microstructure families

PubMed Central

Chen, Desai; Skouras, Mélina; Zhu, Bo; Matusik, Wojciech

2018-01-01

Modern fabrication techniques, such as additive manufacturing, can be used to create materials with complex custom internal structures. These engineered materials exhibit a much broader range of bulk properties than their base materials and are typically referred to as metamaterials or microstructures. Although metamaterials with extraordinary properties have many applications, designing them is very difficult and is generally done by hand. We propose a computational approach to discover families of microstructures with extremal macroscale properties automatically. Using efficient simulation and sampling techniques, we compute the space of mechanical properties covered by physically realizable microstructures. Our system then clusters microstructures with common topologies into families. Parameterized templates are eventually extracted from families to generate new microstructure designs. We demonstrate these capabilities on the computational design of mechanical metamaterials and present five auxetic microstructure families with extremal elastic material properties. Our study opens the way for the completely automated discovery of extremal microstructures across multiple domains of physics, including applications reliant on thermal, electrical, and magnetic properties. PMID:29376124

DOE Office of Scientific and Technical Information (OSTI.GOV)

Moraes, Paulo E.L., E-mail: pauloeduardo.leitedemoraes@gmail.com; Contieri, Rodrigo J., E-mail: contieri@fem.unicamp.br; Lopes, Eder S.N., E-mail: ederlopes@fem.unicamp.br

Ti and Ti alloys are widely used in restorative surgery because of their good biocompatibility, enhanced mechanical behavior and high corrosion resistance in physiological media. The corrosion resistance of Ti-based materials is due to the spontaneous formation of the TiO{sub 2} oxide film on their surface, which exhibits elevated stability in biological fluids. Ti–Nb alloys, depending on the composition and the processing routes to which the alloys are subjected, have high mechanical strength combined with low elastic modulus. The addition of Sn to Ti–Nb alloys allows the phase transformations to be controlled, particularly the precipitation of ω phase. The aimmore » of this study is to discuss the microstructure, mechanical properties and corrosion behavior of cast Ti–Nb alloys to which Sn has been added. Samples were centrifugally cast in a copper mold, and the microstructure was characterized using optical microscopy, scanning electron microscopy and X-ray diffractometry. Mechanical behavior evaluation was performed using Berkovich nanoindentation, Vickers hardness and compression tests. The corrosion behavior was evaluated in Ringer's solution at room temperature using electrochemical techniques. The results obtained suggested that the physical, mechanical and chemical behaviors of the Ti–Nb–Sn alloys are directly dependent on the Sn content. - Graphical abstract: Effects of Sn addition to the Ti–30Nb alloy on the elastic modulus. - Highlights: • Sn addition causes reduction of the ω phase precipitation. • Minimum Vickers hardness and elastic modulus occurred for 6 wt.% Sn content. • Addition of 6 wt.% Sn resulted in maximum ductility and minimum compression strength. • All Ti–30Nb–XSn (X = 0, 2, 4, 6, 8 and 10%) alloys are passive in Ringer's solution. • Highest corrosion resistance was observed for 6 wt.% Sn content.« less

Prefabricated microvascular autograft in tracheal reconstruction.

PubMed

Fayad, J; Kuriloff, D B

1994-10-01

Tracheal reconstruction continues to be a challenge in head and neck surgery. Numerous techniques, including the use of alloplasts, composite grafts, and staged laryngotracheal troughs, have met with limited success because of implant exposure, infection, persistent granulation tissue, and eventual restenosis. With recently introduced techniques for soft-tissue molding, bone induction with bone morphogenetic protein, and microvascular free tissue transfer, a rodent model was developed to create a well-vascularized tracheal autograft. In this model, a rigid tube having the same dimensions and flexibility as the native trachea was created by wrapping a cylindrical silicone tracheal mold with a layer of vascularized adductor thigh muscle pedicled on the femoral vessels in the groin. Tracheal rings were created by filing transverse troughs in the muscle bed with bone morphogenetic protein-primed demineralized bone matrix before wrapping around the silicone mold. Grafts harvested at 2 weeks demonstrated rigid skeletal support provided by heterotopic bone formation in the form of rings and a smooth inner lining produced by fibroplasia. Bone transformation was controlled and restricted to the muscle troughs, allowing intervening regions of soft tissue and thus producing a flexible neotrachia. With this model, a homologous, vascularized tracheal autograft capable of microvascular free tissue transfer was fabricated based on the femoral vessels. Prefabrication of composite grafts, through the use of soft-tissue molding, bone induction, and subsequent free tissue transfer, has an unlimited potential for use in head and neck reconstruction.

Customized cranioplasty implants using three-dimensional printers and polymethyl-methacrylate casting.

PubMed

Kim, Bum-Joon; Hong, Ki-Sun; Park, Kyung-Jae; Park, Dong-Hyuk; Chung, Yong-Gu; Kang, Shin-Hyuk

2012-12-01

The prefabrication of customized cranioplastic implants has been introduced to overcome the difficulties of intra-operative implant molding. The authors present a new technique, which consists of the prefabrication of implant molds using three-dimensional (3D) printers and polymethyl-methacrylate (PMMA) casting. A total of 16 patients with large skull defects (>100 cm(2)) underwent cranioplasty between November 2009 and April 2011. For unilateral cranial defects, 3D images of the skull were obtained from preoperative axial 1-mm spiral computed tomography (CT) scans. The image of the implant was generated by a digital subtraction mirror-imaging process using the normal side of the cranium as a model. For bilateral cranial defects, precraniectomy routine spiral CT scan data were merged with postcraniectomy 3D CT images following a smoothing process. Prefabrication of the mold was performed by the 3D printer. Intraoperatively, the PMMA implant was created with the prefabricated mold, and fit into the cranial defect. The median operation time was 184.36±26.07 minutes. Postoperative CT scans showed excellent restoration of the symmetrical contours and curvature of the cranium in all cases. The median follow-up period was 23 months (range, 14-28 months). Postoperative infection was developed in one case (6.2%) who had an open wound defect previously. Customized cranioplasty PMMA implants using 3D printer may be a useful technique for the reconstruction of various cranial defects.

Development of porous lamellar poly(L-lactic acid) scaffolds by conventional injection molding process.

PubMed

Ghosh, Satyabrata; Viana, Júlio C; Reis, Rui L; Mano, João F

2008-07-01

A novel fabrication technique is proposed for the preparation of unidirectionally oriented, porous scaffolds by selective polymer leaching from lamellar structures created by conventional injection molding. The proof of the concept is implemented using a 50/50 wt.% poly(L-lactic acid)/poly(ethylene oxide) (PLLA/PEO) blend. With this composition, the PLLA and PEO blend is biphasic, containing a homogeneous PLLA/PEO phase and a PEO-rich phase. The two phases were structured using injection molding into well-defined alternating layers of homogeneous PLLA/PEO phase and PEO-rich phase. Leaching of water-soluble PEO from the PEO-rich phase produces macropores, and leaching of phase-separated PEO from the initially homogeneous PLLA/PEO phase produces micropores in the lamellae. Thus, scaffolds with a macroporous lamellar architecture with microporous walls can be produced. The lamellae are continuous along the flow direction, and a continuous lamellar thickness of less than 1 microm could be achieved. Porosities of 57-74% and pore sizes of around 50-100 microm can be obtained using this process. The tensile elastic moduli of the porous constructs were between 580 and 800 MPa. We propose that this organic-solvent-free method of preparing lamellar scaffolds with good mechanical properties, and the reproducibility associated with the injection molding technique, holds promise for a wide range of guided tissue engineering applications.

Crystallization Behavior and Heat Transfer of Fluorine-Free Mold Fluxes with Different Na2O Concentration

NASA Astrophysics Data System (ADS)

Yang, Jian; Zhang, Jianqiang; Sasaki, Yasushi; Ostrovski, Oleg; Zhang, Chen; Cai, Dexiang; Kashiwaya, Yoshiaki

2016-08-01

In this study, the crystallization behavior and heat transfer of CaO-SiO2-Na2O-B2O3-TiO2-Al2O3-MgO-Li2O fluorine-free mold fluxes with different Na2O contents (5 to 11 mass pct) were studied using single/double hot thermocouple technique (SHTT/DHTT) and infrared emitter technique (IET), respectively. Continuous cooling transformation (CCT) and time-temperature transformation (TTT) diagrams constructed using SHTT showed that crystallization temperature increased and incubation time shortened with the increase of Na2O concentration, indicating an enhanced crystallization tendency. The crystallization process of mold fluxes in the temperature field simulating the casting condition was also investigated using DHTT. X-ray diffraction (XRD) analysis of the quenched mold fluxes showed that the dominant phase changed from CaSiO3 to Ca11Si4B2O22 with the increasing concentration of Na2O. The heat transfer examined by IET showed that the increase of Na2O concentration reduced the responding heat flux when Na2O was lower than 9 mass pct but the further increase of Na2O to 11 mass pct enhanced the heat flux. The correlation between crystallinity and heat transfer was discussed in terms of crystallization tendency and crystal morphology.

A microstructural lattice model for strain oriented problems: A combined Monte Carlo finite element technique

NASA Technical Reports Server (NTRS)

Gayda, J.; Srolovitz, D. J.

1987-01-01

A specialized, microstructural lattice model, termed MCFET for combined Monte Carlo Finite Element Technique, was developed which simulates microstructural evolution in material systems where modulated phases occur and the directionality of the modulation is influenced by internal and external stresses. In this approach, the microstructure is discretized onto a fine lattice. Each element in the lattice is labelled in accordance with its microstructural identity. Diffusion of material at elevated temperatures is simulated by allowing exchanges of neighboring elements if the exchange lowers the total energy of the system. A Monte Carlo approach is used to select the exchange site while the change in energy associated with stress fields is computed using a finite element technique. The MCFET analysis was validated by comparing this approach with a closed form, analytical method for stress assisted, shape changes of a single particle in an infinite matrix. Sample MCFET analytical for multiparticle problems were also run and in general the resulting microstructural changes associated with the application of an external stress are similar to that observed in Ni-Al-Cr alloys at elevated temperature.

Microstructural Effects on Initiation Behavior in HMX

NASA Astrophysics Data System (ADS)

Molek, Christopher; Welle, Eric; Hardin, Barrett; Vitarelli, Jim; Wixom, Ryan; Samuels, Philip

Understanding the role microstructure plays on ignition and growth behavior has been the subject of a significant body of research within the detonation physics community. The pursuit of this understanding is important because safety and performance characteristics have been shown to strongly correlate to particle morphology. Historical studies have often correlated bulk powder characteristics to the performance or safety characteristics of pressed materials. We believe that a clearer and more relevant correlation is made between the pressed microstructure and the observed detonation behavior. This type of assessment is possible, as techniques now exist for the quantification of the pressed microstructures. Our talk will report on experimental efforts that correlate directly measured microstructural characteristics to initiation threshold behavior of HMX based materials. The internal microstructures were revealed using an argon ion cross-sectioning technique. This technique enabled the quantification of density and interface area of the pores within the pressed bed using methods of stereology. These bed characteristics are compared to the initiation threshold behavior of three HMX based materials using an electric gun based test method. Finally, a comparison of experimental threshold data to supporting theoretical efforts will be made.

Thermal Molding of Organic Thin-Film Transistor Arrays on Curved Surfaces.

PubMed

Sakai, Masatoshi; Watanabe, Kento; Ishimine, Hiroto; Okada, Yugo; Yamauchi, Hiroshi; Sadamitsu, Yuichi; Kudo, Kazuhiro

2017-12-01

In this work, a thermal molding technique is proposed for the fabrication of plastic electronics on curved surfaces, enabling the preparation of plastic films with freely designed shapes. The induced strain distribution observed in poly(ethylene naphthalate) films when planar sheets were deformed into hemispherical surfaces clearly indicated that natural thermal contraction played an important role in the formation of the curved surface. A fingertip-shaped organic thin-film transistor array molded from a real human finger was fabricated, and slight deformation induced by touching an object was detected from the drain current response. This type of device will lead to the development of robot fingers equipped with a sensitive tactile sense for precision work such as palpation or surgery.

Thermal Molding of Organic Thin-Film Transistor Arrays on Curved Surfaces

NASA Astrophysics Data System (ADS)

Sakai, Masatoshi; Watanabe, Kento; Ishimine, Hiroto; Okada, Yugo; Yamauchi, Hiroshi; Sadamitsu, Yuichi; Kudo, Kazuhiro

2017-05-01

In this work, a thermal molding technique is proposed for the fabrication of plastic electronics on curved surfaces, enabling the preparation of plastic films with freely designed shapes. The induced strain distribution observed in poly(ethylene naphthalate) films when planar sheets were deformed into hemispherical surfaces clearly indicated that natural thermal contraction played an important role in the formation of the curved surface. A fingertip-shaped organic thin-film transistor array molded from a real human finger was fabricated, and slight deformation induced by touching an object was detected from the drain current response. This type of device will lead to the development of robot fingers equipped with a sensitive tactile sense for precision work such as palpation or surgery.

Cranioplasty by means of molded polymethylmethacrylate prosthetic reconstruction after radical excision of neoplasms of the skull in two dogs.

PubMed

Bryant, Karen J; Steinberg, Howard; McAnulty, Jonathan F

2003-07-01

Two dogs with osteoma or multilobulated tumor of bone of the skull were treated with large en bloc resections. The resections resulted in exposure of the brain above the horizon line of the remaining calvarium; in 1 dog, the removal of the dorsal orbital rims also exposed both orbits dorsally. Protection of the brain and exposed tissues and restoration of the cosmetic appearance of the skull were attempted by use of molded polymethylmethacrylate prosthetic reconstruction of the calvarium. The technique described involves cranioplasty by use of a preformed molded polymethylmethacrylate implant. Such prosthetic cranioplasty may benefit dogs undergoing radical excision of extensive tumors, and the usefulness and potential complications of its application are discussed.

Microstructural characterization of multiphase chocolate using X-ray microtomography.

PubMed

Frisullo, Pierangelo; Licciardello, Fabio; Muratore, Giuseppe; Del Nobile, Matteo Alessandro

2010-09-01

In this study, X-ray microtomography (μCT) was used for the image analysis of the microstructure of 12 types of Italian aerated chocolate chosen to exhibit variability in terms of cocoa mass content. Appropriate quantitative 3-dimensional parameters describing the microstructure were calculated, for example, the structure thickness (ST), object structure volume ratio (OSVR), and the percentage object volume (POV). Chemical analysis was also performed to correlate the microstructural data to the chemical composition of the samples. Correlation between the μCT parameters acquired for the pore microstructure evaluation and the chemical analysis revealed that the sugar crystals content does not influence the pore structure and content. On the other hand, it revealed that there is a strong correlation between the POV and the sugar content obtained by chemical analysis. The results from this study show that μCT is a suitable technique for the microstructural analysis of confectionary products such as chocolates and not only does it provide an accurate analysis of the pores and microstructure but the data obtained could also be used to aid in the assessment of its composition and consistency with label specifications. X-ray microtomography (μCT) is a noninvasive and nondestructive 3-D imaging technique that has several advantages over other methods, including the ability to image low-moisture materials. Given the enormous success of μCT in medical applications, material science, chemical engineering, geology, and biology, it is not surprising that in recent years much attention has been focused on extending this imaging technique to food science as a useful technique to aid in the study of food microstructure. X-ray microtomography provides in-depth information on the microstructure of the food product being tested; therefore, a better understanding of the physical structure of the product and from an engineering perspective, knowledge about the microstructure of foods can be used to identify the important processing parameters that affect the quality of a product.

"Estudio tribologico de aceros para moldes. Aplicacion al moldeo por inyeccion de polibutilentereftalato reforzado con fibra de vidrio"

NASA Astrophysics Data System (ADS)

Martinez Mateo, Isidoro Jose

Mould materials for injection moulding of polymers and polymer-matrix composites represent a relevant industrial economic sector due to the large quantity of pieces and components processed. The material selection for mould manufacturing, its composition and heat treatment, the hardening procedures and machining and finishing processes determine the service performance and life of the mould. In the first part of the present study, the relationship between the hardness and microstructure and the wear resistance of mould steels from large blocks has been studied by pin-on-disc tests, studying the main wear mechanisms. In order to determine the surface damage on mould steels under real injection conditions, different commercial steels have been studied by measuring the variation of surface roughness with the number of injected pieces with different reinforcement percentages and different mould geometries, by using optical profilometry and scanning electron microscopy techniques. It was important to determine the variation of surface roughness of the moulded pieces with the number of injection operations. The materials used were polybutyleneterephthalate pure and reinforced with either 20% or 50% glass fibre. For the different mould designs, the evolution of the glass fibre orientation with injection flow has been determined by image analysis and related to roughness changes and surface damage, both of the composite parts and of the mould steel surface. Finally, the abrasion resistance of the composite parts has been studied by scratch tests as a function of the number of injected parts and of the scratch direction with respect to injection flow and glass fibre orientation. Los materiales para moldes de inyeccion de polimeros y materiales compuestos representan un sector economicamente muy relevante debido al gran aumento del numero de componentes fabricados a partir de materiales polimericos obtenidos mediante moldeo por inyeccion. La seleccion del material para la fabricacion del molde, tienen una gran influencia sobre su comportamiento en servicio a lo largo de la vida util del molde. En la primera parte del presente estudio, a partir de ensayos punzon sobre disco, se ha determinado la relacion entre la resistencia al desgaste y la dureza de aceros para moldes obtenidos a partir de bloques de gran espesor, estudiando los principales mecanismos de desgaste que tienen lugar. A continuacion, con el fin de determinar el dano superficial que sufren los aceros para moldes en condiciones reales de inyeccion, se han estudiado distintos tipos de aceros utilizados comercialmente en moldes de inyeccion de polimeros y materiales compuestos, seleccionando las condiciones de operacion para determinar la variacion de la rugosidad superficial del acero en funcion del material inyectado, del numero de operaciones sucesivas de inyeccion y de la orientacion del flujo de inyeccion, mediante tecnicas de perfilometria optica y microscopia electronica de barrido. Ademas del dano superficial sufrido por el acero con el numero de piezas inyectadas, tambien se ha determinado la evolucion de la rugosidad superficial de los materiales inyectados, polibutilentereftalato (PBT) puro y materiales compuestos derivados de PBT por adicion de un 20 o un 50% en peso de fibra de vidrio. En el caso de las piezas inyectadas, se ha caracterizado su microestructura en funcion del flujo de inyeccion y de la densidad de fibra, se han determinado sus propiedades termicas y dinamico-mecanicas, asi como la variacion de la rugosidad superficial de las piezas inyectadas con el numero de operaciones de inyeccion y con la geometria de las distintas secciones de las piezas. Finalmente, se ha evaluado la resistencia a la abrasion de PBT reforzado con un 50% de fibra, en funcion del numero de piezas inyectadas y de la direccion de rayado con respecto a la orientacion del flujo de inyeccion.

Single Stage Silicone Border Molded Closed Mouth Impression Technique-Part II.

PubMed

Solomon, E G R

2011-09-01

Functioning of a complete denture depends to a great extent on the impression technique. Several impression techniques have been described in the literature since the turn of this century when Greene [Clinical courses in dental prothesis, 1916] brothers introduced the first scientific system of recording dental impression. Advocates of each technique have their own claim of superiority over the other. The introduction of elastomeric impression materials [Skinner and Cooper, J Am Dent Assoc 51:523-536, 1955] has made possible new techniques of recording impression for complete denture construction. These rubber like materials are of two types; one has a polysulfide base and is popularily known as polysulfide rubber (Thiokol and Mercaptan). The other variety has a silicone base known as silicone rubber or silicone elastomer. Silicone elastomers are available in four different consistencies; a thin easy flowing light bodied material,a creamy medium bodied material, a highly viscous heavy bodied material and a kneadable putty material. This paper describes an active closed mouth impression technique with one stage border molding using putty silicone material as a substitute for low fusing compound.

A Preliminary Mycological Investigation of Endemic Nephropathy in Yugoslavia,

DTIC Science & Technology

FUNGI , *FOOD, *MOLDS(ORGANISMS), DISEASES, KIDNEYS, CORN, CEREALS, PORK, BIOLOGICAL CONTAMINATION, EPIDEMIOLOGY, DIAGNOSIS(MEDICINE), CORRELATION TECHNIQUES, INFECTIOUS DISEASES, ETIOLOGY, POPULATION, YUGOSLAVIA.

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.

Acrylic Resin Molding Based Head Fixation Technique in Rodents.

PubMed

Roh, Mootaek; Lee, Kyungmin; Jang, Il-Sung; Suk, Kyoungho; Lee, Maan-Gee

2016-01-12

Head fixation is a technique of immobilizing animal's head by attaching a head-post on the skull for rigid clamping. Traditional head fixation requires surgical attachment of metallic frames on the skull. The attached frames are then clamped to a stationary platform resulting in immobilization of the head. However, metallic frames for head fixation have been technically difficult to design and implement in general laboratory environment. In this study, we provide a novel head fixation method. Using a custom-made head fixation bar, head mounter is constructed during implantation surgery. After the application of acrylic resin for affixing implants such as electrodes and cannula on the skull, additional resins applied on top of that to build a mold matching to the port of the fixation bar. The molded head mounter serves as a guide rails, investigators conveniently fixate the animal's head by inserting the head mounter into the port of the fixation bar. This method could be easily applicable if implantation surgery using dental acrylics is necessary and might be useful for laboratories that cannot easily fabricate CNC machined metal head-posts.

Lightweight custom composite prosthetic components using an additive manufacturing-based molding technique.

PubMed

Leddy, Michael T; Belter, Joseph T; Gemmell, Kevin D; Dollar, Aaron M

2015-01-01

Additive manufacturing techniques are becoming more prominent and cost-effective as 3D printing becomes higher quality and more inexpensive. The idea of 3D printed prosthetics components promises affordable, customizable devices, but these systems currently have major shortcomings in durability and function. In this paper, we propose a fabrication method for custom composite prostheses utilizing additive manufacturing, allowing for customizability, as well the durability of professional prosthetics. The manufacturing process is completed using 3D printed molds in a multi-stage molding system, which creates a custom finger or palm with a lightweight epoxy foam core, a durable composite outer shell, and soft urethane gripping surfaces. The composite material was compared to 3D printed and aluminum materials using a three-point bending test to compare stiffness, as well as gravimetric measurements to compare weight. The composite finger demonstrates the largest stiffness with the lowest weight compared to other tested fingers, as well as having customizability and lower cost, proving to potentially be a substantial benefit to the development of upper-limb prostheses.

Advanced nondestructive techniques applied for the detection of discontinuities in aluminum foams

NASA Astrophysics Data System (ADS)

Katchadjian, Pablo; García, Alejandro; Brizuela, Jose; Camacho, Jorge; Chiné, Bruno; Mussi, Valerio; Britto, Ivan

2018-04-01

Metal foams are finding an increasing range of applications by their lightweight structure and physical, chemical and mechanical properties. Foams can be used to fill closed moulds for manufacturing structural foam parts of complex shape [1]; foam filled structures are expected to provide good mechanical properties and energy absorption capabilities. The complexity of the foaming process and the number of parameters to simultaneously control, demand a preliminary and hugely wide experimental activity to manufacture foamed components with a good quality. That is why there are many efforts to improve the structure of foams, in order to obtain a product with good properties. The problem is that even for seemingly identical foaming conditions, the effective foaming can vary significantly from one foaming trial to another. The variation of the foams often is related by structural imperfections, joining region (foam-foam or foam-wall mold) or difficulties in achieving a complete filling of the mould. That is, in a closed mold, the result of the mold filling and its structure or defects are not known a priori and can eventually vary significantly. These defects can cause a drastic deterioration of the mechanical properties [2] and lead to a low performance in its application. This work proposes the use of advanced nondestructive techniques for evaluating the foam distribution after filling the mold to improve the manufacturing process. To achieved this purpose ultrasonic technique (UT) and cone beam computed tomography (CT) were applied on plate and structures of different thicknesses filled with foam of different porosity. UT was carried out on transmission mode with low frequency air-coupled transducers [3], in focused and unfocused configurations.

Wood Technology: Techniques, Processes, and Products

ERIC Educational Resources Information Center

Oatman, Olan

1975-01-01

Seven areas of wood technology illustrates applicable techniques, processes, and products for an industrial arts woodworking curriculum. They are: wood lamination; PEG (polyethylene glycol) diffusion processes; wood flour and/or particle molding; production product of industry; WPC (wood-plastic-composition) process; residential construction; and…

Influence of Processing Conditions on the Mechanical Behavior and Morphology of Injection Molded Poly(lactic-co-glycolic acid) 85:15

PubMed Central

Fancello, Eduardo Alberto

2017-01-01

Two groups of PLGA specimens with different geometries (notched and unnotched) were injection molded under two melting temperatures and flow rates. The mechanical properties, morphology at the fracture surface, and residual stresses were evaluated for both processing conditions. The morphology of the fractured surfaces for both specimens showed brittle and smooth fracture features for the majority of the specimens. Fracture images of the notched specimens suggest that the surface failure mechanisms are different from the core failure. Polarized light techniques indicated birefringence in all specimens, especially those molded with lower temperature, which suggests residual stress due to rapid solidification. DSC analysis confirmed the existence of residual stress in all PLGA specimens. The specimens molded using the lower injection temperature and the low flow rate presented lower loss tangent values according to the DMA and higher residual stress as shown by DSC, and the photoelastic analysis showed extensive birefringence. PMID:28848605

Fabrication of Microfluidic Valves Using a Hydrogel Molding Method

NASA Astrophysics Data System (ADS)

Sugiura, Yusuke; Hirama, Hirotada; Torii, Toru

2015-08-01

In this paper, a method for fabricating a microfluidic valve made of polydimethylsiloxane (PDMS) using a rapid prototyping method for microchannels through hydrogel cast molding is discussed. Currently, the valves in microchannels play an important role in various microfluidic devices. The technology to prototype microfluidic valves rapidly is actively being developed. For the rapid prototyping of PDMS microchannels, a method that uses a hydrogel as the casting mold has been recently developed. This technique can be used to prepare a three-dimensional structure through simple and uncomplicated methods. In this study, we were able to fabricate microfluidic valves easily using this rapid prototyping method that utilizes hydrogel cast molding. In addition, we confirmed that the valve displacement could be predicted within a range of constant pressures. Moreover, because microfluidic valves fabricated using this method can be directly observed from a cross-sectional direction, we anticipate that this technology will significantly contribute to clarifying fluid behavior and other phenomena in microchannels and microfluidic valves with complex structures.

Fabrication of Microfluidic Valves Using a Hydrogel Molding Method.

PubMed

Sugiura, Yusuke; Hirama, Hirotada; Torii, Toru

2015-08-24

In this paper, a method for fabricating a microfluidic valve made of polydimethylsiloxane (PDMS) using a rapid prototyping method for microchannels through hydrogel cast molding is discussed. Currently, the valves in microchannels play an important role in various microfluidic devices. The technology to prototype microfluidic valves rapidly is actively being developed. For the rapid prototyping of PDMS microchannels, a method that uses a hydrogel as the casting mold has been recently developed. This technique can be used to prepare a three-dimensional structure through simple and uncomplicated methods. In this study, we were able to fabricate microfluidic valves easily using this rapid prototyping method that utilizes hydrogel cast molding. In addition, we confirmed that the valve displacement could be predicted within a range of constant pressures. Moreover, because microfluidic valves fabricated using this method can be directly observed from a cross-sectional direction, we anticipate that this technology will significantly contribute to clarifying fluid behavior and other phenomena in microchannels and microfluidic valves with complex structures.

Assessment of matrix effects on methyl benzoate, a potential biomarker for detection of outgassed semi-volatiles from mold in indoor building materials.

PubMed

Parkinson, Don-Roger; Churchill, Tonia J; Rolls, Wyn

2008-11-01

Methyl benzoate - as a biomarker for mold growth - was used as a specific target compound to indicate outgassed MVOC products from mold. Both real and surrogate samples were analyzed from a variety of matrices including: carpet, ceiling tiles, dried paint surfaces, wallboard and wallboard paper. Sampling parameters, including: desorption, extraction time, incubation temperature, pH, salt effects and spinning rate, were optimized. Results suggest that extraction and detection of methyl benzoate amongst other MVOCs can be accomplished cleanly by SPME-GC/MS methods. With detection limits (LOD = 1.5 ppb) and linearity (0.999) over a range of 100 ppm to 2 ppb, this work demonstrates that such a green technique can be contemplated for use in quick assessment or as part of an ongoing assessment strategy to detect mold growth in common indoor buildings and materials for both qualitative and quantitative determinations. Of importance, no matrix effects are observed under optimized extraction conditions.

Fabrication of a high aspect ratio thick silicon wafer mold and electroplating using flipchip bonding for MEMS applications

NASA Astrophysics Data System (ADS)

Kim, Bong-Hwan; Kim, Jong-Bok

2009-06-01

We have developed a microfabrication process for high aspect ratio thick silicon wafer molds and electroplating using flipchip bonding with THB 151N negative photoresist (JSR micro). This fabrication technique includes large area and high thickness silicon wafer mold electroplating. The process consists of silicon deep reactive ion etching (RIE) of the silicon wafer mold, photoresist bonding between the silicon mold and the substrate, nickel electroplating and a silicon removal process. High thickness silicon wafer molds were made by deep RIE and flipchip bonding. In addition, nickel electroplating was developed. Dry film resist (ORDYL MP112, TOK) and thick negative-tone photoresist (THB 151N, JSR micro) were used as bonding materials. In order to measure the bonding strength, the surface energy was calculated using a blade test. The surface energy of the bonding wafers was found to be 0.36-25.49 J m-2 at 60-180 °C for the dry film resist and 0.4-1.9 J m-2 for THB 151N in the same temperature range. Even though ORDYL MP112 has a better value of surface energy than THB 151N, it has a critical disadvantage when it comes to removing residue after electroplating. The proposed process can be applied to high aspect ratio MEMS structures, such as air gap inductors or vertical MEMS probe tips.

3D-glass molds for facile production of complex droplet microfluidic chips.

PubMed

Tovar, Miguel; Weber, Thomas; Hengoju, Sundar; Lovera, Andrea; Munser, Anne-Sophie; Shvydkiv, Oksana; Roth, Martin

2018-03-01

In order to leverage the immense potential of droplet microfluidics, it is necessary to simplify the process of chip design and fabrication. While polydimethylsiloxane (PDMS) replica molding has greatly revolutionized the chip-production process, its dependence on 2D-limited photolithography has restricted the design possibilities, as well as further dissemination of microfluidics to non-specialized labs. To break free from these restrictions while keeping fabrication straighforward, we introduce an approach to produce complex multi-height (3D) droplet microfluidic glass molds and subsequent chip production by PDMS replica molding. The glass molds are fabricated with sub-micrometric resolution using femtosecond laser machining technology, which allows directly realizing designs with multiple levels or even continuously changing heights. The presented technique significantly expands the experimental capabilities of the droplet microfluidic chip. It allows direct fabrication of multilevel structures such as droplet traps for prolonged observation and optical fiber integration for fluorescence detection. Furthermore, the fabrication of novel structures based on sloped channels (ramps) enables improved droplet reinjection and picoinjection or even a multi-parallelized drop generator based on gradients of confinement. The fabrication of these and other 3D-features is currently only available at such resolution by the presented strategy. Together with the simplicity of PDMS replica molding, this provides an accessible solution for both specialized and non-specialized labs to customize microfluidic experimentation and expand their possibilities.

Calculation of grain boundary normals directly from 3D microstructure images

DOE PAGES

Lieberman, E. J.; Rollett, A. D.; Lebensohn, R. A.; ...

2015-03-11

The determination of grain boundary normals is an integral part of the characterization of grain boundaries in polycrystalline materials. These normal vectors are difficult to quantify due to the discretized nature of available microstructure characterization techniques. The most common method to determine grain boundary normals is by generating a surface mesh from an image of the microstructure, but this process can be slow, and is subject to smoothing issues. A new technique is proposed, utilizing first order Cartesian moments of binary indicator functions, to determine grain boundary normals directly from a voxelized microstructure image. In order to validate the accuracymore » of this technique, the surface normals obtained by the proposed method are compared to those generated by a surface meshing algorithm. Specifically, the local divergence between the surface normals obtained by different variants of the proposed technique and those generated from a surface mesh of a synthetic microstructure constructed using a marching cubes algorithm followed by Laplacian smoothing is quantified. Next, surface normals obtained with the proposed method from a measured 3D microstructure image of a Ni polycrystal are used to generate grain boundary character distributions (GBCD) for Σ3 and Σ9 boundaries, and compared to the GBCD generated using a surface mesh obtained from the same image. Finally, the results show that the proposed technique is an efficient and accurate method to determine voxelized fields of grain boundary normals.« less

An Investigation of the Mold-Flux Performance for the Casting of Cr12MoV Steel Using a Mold Simulator Technique

NASA Astrophysics Data System (ADS)

Zhou, Lejun; Wang, Wanlin; Xu, Chao; Zhang, Chen

2017-08-01

Mold flux plays important roles in the process of continuous casting. In this article, the performance of mold flux for the casting of Cr12MoV steel was investigated by using a mold simulator. The results showed that the slag film formed in the gap between the initial shell and mold hot surface is thin and discontinuous during the casting process with the Flux BM, due to the absorption of chromic oxide inclusions into the liquid slag, while the slag film formed in the case of the optimized Flux NEW casting process is uniform. The main precipitated crystals in Flux BM slag film are cuspidine (Ca4Si2O7F2) and Cr3O4, but only Ca4Si2O7F2 precipitated in the Flux NEW case. Besides, both the responding temperature and heat flux in the case of Flux BM are relatively higher and fluctuate in a larger amplitude. The surface of the shell obtained in the case of the Flux BM experiment is quite uneven, and many severe depressions, cracks, and entrapped slags are observed in the surface due to the lack of lubrication. However, the obtained shell surface in the case of the Flux NEW shows good surface quality due to the addition of B2O3 and the adjustment of basicity, which can compensate for the negative effects of the mold-flux properties caused by the absorption of chromic oxide during the casting process.

NUTRITION OF CELLULAR SLIME MOLDS I.

PubMed Central

Hohl, Hans-Rudolf; Raper, Kenneth B.

1963-01-01

Hohl, Hans-Rudolf (University of Wisconsin, Madison) and Kenneth B. Raper. Nutrition of cullular slime molds. I. Growth on living and dead bacteria. J. Bacteriol. 85:191–198. 1963.—Methods for growing selected species of cellular slime molds in liquid culture on living and dead bacteria are described. Species investigated included Polysphondylium pallidum, P. violaceum, Dictyostelium discoideum, and D. purpureum. Maximal growth of myxamoebae occurred in suspensions of 1010 living bacteria (Escherichia coli B/r)/ml in Sörensen's phosphate buffer (pH 6.0), reaching a density of 107 to 2 × 107 cells/ml in 48 hr. The generation time for the different slime molds ranged from 2.4 hr for P. violaceum to 2.9 hr for D. discoideum (strain V-12). Good growth of P. pallidum occurred between pH 3.6 and 7.8. The slime molds grew less well on dead (autoclaved) than on living bacteria and, except for P. pallidum, the amount and rate of growth decreased markedly as the time of autoclaving was increased from 2.5 to 80 min. Bacteria killed with propylene oxide supported growth equal to those autoclaved for a few minutes. The myxamoebae were very sensitive to the osmotic pressure of the culture medium, especially in the presence of living bacteria, and addition of as little as 0.01 m NaCl caused a measurable decrease in slime mold growth. The culture techniques employed afford useful methods for investigating the nutritional requirements of the cellular slime molds, and the experiments described provide the bases for subsequent studies relating to the axenic cultivation of these singular microorganisms. Images PMID:13961228

Accelerated Microstructure Imaging via Convex Optimization (AMICO) from diffusion MRI data.

PubMed

Daducci, Alessandro; Canales-Rodríguez, Erick J; Zhang, Hui; Dyrby, Tim B; Alexander, Daniel C; Thiran, Jean-Philippe

2015-01-15

Microstructure imaging from diffusion magnetic resonance (MR) data represents an invaluable tool to study non-invasively the morphology of tissues and to provide a biological insight into their microstructural organization. In recent years, a variety of biophysical models have been proposed to associate particular patterns observed in the measured signal with specific microstructural properties of the neuronal tissue, such as axon diameter and fiber density. Despite very appealing results showing that the estimated microstructure indices agree very well with histological examinations, existing techniques require computationally very expensive non-linear procedures to fit the models to the data which, in practice, demand the use of powerful computer clusters for large-scale applications. In this work, we present a general framework for Accelerated Microstructure Imaging via Convex Optimization (AMICO) and show how to re-formulate this class of techniques as convenient linear systems which, then, can be efficiently solved using very fast algorithms. We demonstrate this linearization of the fitting problem for two specific models, i.e. ActiveAx and NODDI, providing a very attractive alternative for parameter estimation in those techniques; however, the AMICO framework is general and flexible enough to work also for the wider space of microstructure imaging methods. Results demonstrate that AMICO represents an effective means to accelerate the fit of existing techniques drastically (up to four orders of magnitude faster) while preserving accuracy and precision in the estimated model parameters (correlation above 0.9). We believe that the availability of such ultrafast algorithms will help to accelerate the spread of microstructure imaging to larger cohorts of patients and to study a wider spectrum of neurological disorders. Copyright © 2014 The Authors. Published by Elsevier Inc. All rights reserved.

Crystallization phenomena in slags

NASA Astrophysics Data System (ADS)

Orrling, Carl Folke

2000-09-01

The crystallization of the mold slag affects both the heat transfer and the lubrication between the mold and the strand in continuous casting of steel. In order for mold slag design to become an engineering science rather than an empirical exercise, a fundamental understanding of the melting and solidification behavior of a slag must be developed. Thus it is necessary to be able to quantify the phenomena that occur under the thermal conditions that are found in the mold of a continuous caster. The double hot thermocouple technique (DHTT) and the Confocal Laser Scanning Microscope used in this study are two novel techniques for investigating melting and solidification phenomena of transparent slags. Results from these techniques are useful in defining the phenomena that occur when the slag film infiltrates between the mold and the shell of the casting. TTT diagrams were obtained for various slags and indicated that the onset of crystallization is a function of cooling rate and slag chemistry. Crystal morphology was found to be dependent upon the experimental temperature and four different morphologies were classified based upon the degree of melt undercooling. Continuous cooling experiments were carried out to develop CCT diagrams and it was found that the amount and appearance of the crystalline fraction greatly depends on the cooling conditions. The DHTT can also be used to mimic the cooling profile encountered by the slag in the mold of a continuous caster. In this differential cooling mode (DCT), it was found that the details of the cooling rate determine the actual response of the slag to a thermal gradient and small changes can lead to significantly different results. Crystal growth rates were measured and found to be in the range between 0.11 mum/s to 11.73 mum/s depending on temperature and slag chemistry. Alumina particles were found to be effective innoculants in oxide melts reducing the incubation time for the onset of crystallization and also extending the temperature range of observed crystallization. The effect of changing the gas atmosphere surrounding the sample has been studied. The presence of water vapor increased the nucleation rate and crystal growth rate significantly when compared to experiments carried out in a dry atmosphere. With an atmosphere of Argon and Argon-3% Hydrogen mixture, the incubation time for crystallization was increased with several minutes. The crystal growth rate in these atmospheres was also drastically reduced compared to an atmosphere of normal air. Significant numbers of bubbles were formed during the initial melting of mold slag samples and the melting rate of the slag was found to be related to the rate of bubble generation and to the rate of heat transport.

Development of a new technique for pedicle screw and Magerl screw insertion using a 3-dimensional image guide.

PubMed

Kawaguchi, Yoshiharu; Nakano, Masato; Yasuda, Taketoshi; Seki, Shoji; Hori, Takeshi; Kimura, Tomoatsu

2012-11-01

We developed a new technique for cervical pedicle screw and Magerl screw insertion using a 3-dimensional image guide. In posterior cervical spinal fusion surgery, instrumentation with screws is virtually routine. However, malpositioning of screws is not rare. To avoid complications during cervical pedicle screw and Magerl screw insertion, the authors developed a new technique which is a mold shaped to fit the lamina. Cervical pedicle screw fixation and Magerl screw fixation provide good correction of cervical alignment, rigid fixation, and a high fusion rate. However, malpositioning of screws is not a rare occurrence, and thus the insertion of screws has a potential risk of neurovascular injury. It is necessary to determine a safe insertion procedure for these screws. Preoperative computed tomographic (CT) scans of 1-mm slice thickness were obtained of the whole surgical area. The CT data were imported into a computer navigation system. We developed a 3-dimensional full-scale model of the patient's spine using a rapid prototyping technique from the CT data. Molds of the left and right sides at each vertebra were also constructed. One hole (2.0 mm in diameter and 2.0 cm in length) was made in each mold for the insertion of a screw guide. We performed a simulated surgery using the bone model and the mold before operation in all patients. The mold was firmly attached to the surface of the lamina and the guide wire was inserted using the intraoperative image of lateral vertebra. The proper insertion point, direction, and length of the guide were also confirmed both with the model bone and the image intensifier in the operative field. Then, drilling using a cannulated drill and tapping using a cannulated tapping device were carried out. Eleven consecutive patients who underwent posterior spinal fusion surgery using this technique since 2009 are included. The screw positions in the sagittal and axial planes were evaluated by postoperative CT scan to check for malpositioning. The screw insertion was done in the same manner as the simulated surgery. With the aid of this guide the pedicle screws and Magerl screws could be easily inserted even at the level where the pedicle seemed to be very thin and sclerotic on the CT scan. Postoperative CT scan showed that there were no critical breaches of the screws. This method employing the device using a 3-dimensional image guide seems to be easy and safe to use. The technique may improve the safety of pedicle screw and Magerl screw insertion even in difficult cases with narrow sclerotic pedicles.

A “dry and wet hybrid” lithography technique for multilevel replication templates: Applications to microfluidic neuron culture and two-phase global mixing

PubMed Central

Paul, Debjani; Saias, Laure; Pedinotti, Jean-Cedric; Chabert, Max; Magnifico, Sebastien; Pallandre, Antoine; De Lambert, Bertrand; Houdayer, Claude; Brugg, Bernard; Peyrin, Jean-Michel; Viovy, Jean-Louis

2011-01-01

A broad range of microfluidic applications, ranging from cell culture to protein crystallization, requires multilevel devices with different heights and feature sizes (from micrometers to millimeters). While state-of-the-art direct-writing techniques have been developed for creating complex three-dimensional shapes, replication molding from a multilevel template is still the preferred method for fast prototyping of microfluidic devices in the laboratory. Here, we report on a “dry and wet hybrid” technique to fabricate multilevel replication molds by combining SU-8 lithography with a dry film resist (Ordyl). We show that the two lithography protocols are chemically compatible with each other. Finally, we demonstrate the hybrid technique in two different microfluidic applications: (1) a neuron culture device with compartmentalization of different elements of a neuron and (2) a two-phase (gas-liquid) global micromixer for fast mixing of a small amount of a viscous liquid into a larger volume of a less viscous liquid. PMID:21559239

A versatile technique for fabrication of SiC SPM probes

NASA Astrophysics Data System (ADS)

Therrien, Joel; Schmidt, Daniel; Barrot, Sheetal; Patel, Bhavin

2008-03-01

To date SPM probes have largely been fabricated via methods borrowed from the semiconductor industry for fabricating Micro Electro Mechanical Systems. Although these techniques have enabled SPM to see widespread use, the processes put significant limitations on what structures can be made. We report our progress on fabricating SPM cantilevers composed of Silicon Carbide using polymer molding techniques. A pre-ceramic polymer is molded into the desired probe shape and then converted to SiC via pyrolisys. We will also report on progress in using photo-sterolithography for fabrication of even more complex geometries. In addition to opening up a much larger set of probe structures, the use of SiC leads to improved wear resistance of the resulting probes. Among the potential applications, this method enables the fabrication of low spring constant, high resonant frequency cantilevers via cross sectional geometries not accessible to standard fabrication techniques. Such probes are required for high speed tapping and non-contact imaging.

Fully integrated three-dimensional electrodes for electrochemical detection in microchips: fabrication, characterization, and applications.

PubMed

Pai, Rekha S; Walsh, Kevin M; Crain, Mark M; Roussel, Thomas J; Jackson, Douglas J; Baldwin, Richard P; Keynton, Robert S; Naber, John F

2009-06-15

A scalable and rather inexpensive solution to producing microanalytical systems with "on-chip" three-dimensional (3D) microelectrodes is presented in this study, along with applicability to practical electrochemical (EC) detection scenarios such as preconcentration and interferant removal. This technique to create high-aspect-ratio (as much as 4:1) gold microstructures in constrained areas involved the modification of stud bump geometry with microfabricated silicon molds via an optimized combination of temperature, pressure, and time. The microelectrodes that resulted consisted of an array of square pillars approximately 18 microm tall and 20 microm wide on each side, placed at the end of a microfabricated electrophoresis channel. This technique increased the active surface area of the microelectrodes by as much as a factor of 50, while mass transfer and, consequently, preconcentration collection efficiencies were increased to approximately 100%, compared to approximately 30% efficiency for planar nonmodified microelectrodes (samples that were used included the neurotransmitters dopamine and catechol). The 3D microelectrodes were used both in a stand-alone configuration, for direct EC detection of model catecholamine analytes, and, more interestingly, in dual electrode configurations for EC sample processing prior to detection downstream at a second planar electrode. In particular, the 3D electrodes were shown to be capable of performing coulometry or complete (100%) redox conversion of analyte species over a wide range of concentrations, from 4.3 microM to 4.4 mM, in either plug-flow or continuous-flow formats.

High-Resolution Characterization of UMo Alloy Microstructure

DOE Office of Scientific and Technical Information (OSTI.GOV)

Devaraj, Arun; Kovarik, Libor; Joshi, Vineet V.

2016-11-30

This report highlights the capabilities and procedure for high-resolution characterization of UMo fuels in PNNL. Uranium-molybdenum (UMo) fuel processing steps, from casting to forming final fuel, directly affect the microstructure of the fuel, which in turn dictates the in-reactor performance of the fuel under irradiation. In order to understand the influence of processing on UMo microstructure, microstructure characterization techniques are necessary. Higher-resolution characterization techniques like transmission electron microscopy (TEM) and atom probe tomography (APT) are needed to interrogate the details of the microstructure. The findings from TEM and APT are also directly beneficial for developing predictive multiscale modeling tools thatmore » can predict the microstructure as a function of process parameters. This report provides background on focused-ion-beam–based TEM and APT sample preparation, TEM and APT analysis procedures, and the unique information achievable through such advanced characterization capabilities for UMo fuels, from a fuel fabrication capability viewpoint.« less

Imaging brain microstructure with diffusion MRI: practicality and applications.

PubMed

Alexander, Daniel C; Dyrby, Tim B; Nilsson, Markus; Zhang, Hui

2017-11-29

This article gives an overview of microstructure imaging of the brain with diffusion MRI and reviews the state of the art. The microstructure-imaging paradigm aims to estimate and map microscopic properties of tissue using a model that links these properties to the voxel scale MR signal. Imaging techniques of this type are just starting to make the transition from the technical research domain to wide application in biomedical studies. We focus here on the practicalities of both implementing such techniques and using them in applications. Specifically, the article summarizes the relevant aspects of brain microanatomy and the range of diffusion-weighted MR measurements that provide sensitivity to them. It then reviews the evolution of mathematical and computational models that relate the diffusion MR signal to brain tissue microstructure, as well as the expanding areas of application. Next we focus on practicalities of designing a working microstructure imaging technique: model selection, experiment design, parameter estimation, validation, and the pipeline of development of this class of technique. The article concludes with some future perspectives on opportunities in this topic and expectations on how the field will evolve in the short-to-medium term. Copyright © 2017 John Wiley & Sons, Ltd.

Improving microstructural quantification in FIB/SEM nanotomography.

PubMed

Taillon, Joshua A; Pellegrinelli, Christopher; Huang, Yi-Lin; Wachsman, Eric D; Salamanca-Riba, Lourdes G

2018-01-01

FIB/SEM nanotomography (FIB-nt) is a powerful technique for the determination and quantification of the three-dimensional microstructure in subsurface features. Often times, the microstructure of a sample is the ultimate determiner of the overall performance of a system, and a detailed understanding of its properties is crucial in advancing the materials engineering of a resulting device. While the FIB-nt technique has developed significantly in the 15 years since its introduction, advanced nanotomographic analysis is still far from routine, and a number of challenges remain in data acquisition and post-processing. In this work, we present a number of techniques to improve the quality of the acquired data, together with easy-to-implement methods to obtain "advanced" microstructural quantifications. The techniques are applied to a solid oxide fuel cell cathode of interest to the electrochemistry community, but the methodologies are easily adaptable to a wide range of material systems. Finally, results from an analyzed sample are presented as a practical example of how these techniques can be implemented. Copyright © 2017 Elsevier B.V. All rights reserved.

Exposed-core chalcogenide microstructured optical fibers for chemical sensing

NASA Astrophysics Data System (ADS)

Troles, Johann; Toupin, Perrine; Brilland, Laurent; Boussard-Plédel, Catherine; Bureau, Bruno; Cui, Shuo; Mechin, David; Adam, Jean-Luc

2013-05-01

Chemical bonds of most of the molecules vibrate at a frequency corresponding to the near or mid infrared field. It is thus of a great interest to develop sensitive and portable devices for the detection of specific chemicals and biomolecules for various applications in health, the environment, national security and so on. Optical fibers define practical sensing tools. Chalcogenide glasses are known for their transparency in the infrared optical range and their ability to be drawn as fibers. They are consequently good candidates to be used in biological/chemical sensing. For that matter, in the past decade, chalcogenide glass fibers have been successfully implemented in evanescent wave spectroscopy experiments, for the detection of bio-chemical species in various fields of applications including microbiology and medicine, water pollution and CO2 detection. Different types of fiber can be used: single index fibers or microstructured fibers. Besides, in recent years a new configuration of microstructured fibers has been developed: microstructured exposed-core fibers. This design consists of an optical fiber with a suspended micron-scale core that is partially exposed to the external environment. This configuration has been chosen to elaborate, using the molding method, a chalcogenide fiber for chemical species detection. The sensitivity of this fiber to detect molecules such as propan-2-ol and acetone has been compared with those of single index fibers. Although evanescent wave absorption is inversely proportional to the fiber diameter, the result shows that an exposed-core fiber is much more sensitive than a single index fiber having a twice smaller external diameter.

Microstructure characterization and room temperature deformation of a rapidly solidified NiAl-based eutectic alloy containing trace Dy

NASA Astrophysics Data System (ADS)

Li, Hutian; Guo, Jianting; Huai, Kaiwen; Ye, Hengqiang

2006-04-01

The microstructure and room temperature compressive deformation behavior of a rapidly solidified NiAl-Cr(Mo)-Dy eutectic alloy fabricated by water-cooled copper mold method were studied by a combination of SEM, EDS and compressive tests. The morphology stability after hot isostatic pressing (HIP) treatment was evaluated. Rapid solidification resulted in a shift in the coupled zone for the eutectic growth towards the Cr(Mo) phase, indicating a hypoeutectic composition, hence increasing the volume fraction of primary dendritic NiAl. Meanwhile, significantly refined microstructure and lamellar/rod-like Cr(Mo) transition were observed due to trace rare earth (RE) element Dy addition and rapid solidification effects. Compared with the results in literature [H.E. Cline, J.L. Walter, Metall. Trans. 1(1970)2907-2917; P. Ferrandini, W.W. Batista, R. Caram, J. Alloys Comp. 381(2004)91-98], an interesting phenomenon, viz., NiAl halos around the primary Cr(Mo) dendrites in solidified NiAl-Cr(Mo) hypereutectic alloy, was not observed in this study. This difference was interpreted in terms of their different reciprocal nucleation ability. In addition, it was proposed that the localized destabilization of morphology after HIP treatment is closely related to the presence of primary NiAl dendrites. The improved mechanical properties can be attributed to the synergistic effects of rapid solidification and Dy addition, which included refined microstructure, suppression of the crack development along eutectic grain boundaries, enhancement of density of geometrically necessary dislocations located at NiAl/Cr(Mo) interfaces and the Cr solubility extension in NiAl.

Dynamic shaping of cellular membranes by phospholipids and membrane-deforming proteins.

PubMed

Suetsugu, Shiro; Kurisu, Shusaku; Takenawa, Tadaomi

2014-10-01

All cellular compartments are separated from the external environment by a membrane, which consists of a lipid bilayer. Subcellular structures, including clathrin-coated pits, caveolae, filopodia, lamellipodia, podosomes, and other intracellular membrane systems, are molded into their specific submicron-scale shapes through various mechanisms. Cells construct their micro-structures on plasma membrane and execute vital functions for life, such as cell migration, cell division, endocytosis, exocytosis, and cytoskeletal regulation. The plasma membrane, rich in anionic phospholipids, utilizes the electrostatic nature of the lipids, specifically the phosphoinositides, to form interactions with cytosolic proteins. These cytosolic proteins have three modes of interaction: 1) electrostatic interaction through unstructured polycationic regions, 2) through structured phosphoinositide-specific binding domains, and 3) through structured domains that bind the membrane without specificity for particular phospholipid. Among the structured domains, there are several that have membrane-deforming activity, which is essential for the formation of concave or convex membrane curvature. These domains include the amphipathic helix, which deforms the membrane by hemi-insertion of the helix with both hydrophobic and electrostatic interactions, and/or the BAR domain superfamily, known to use their positively charged, curved structural surface to deform membranes. Below the membrane, actin filaments support the micro-structures through interactions with several BAR proteins as well as other scaffold proteins, resulting in outward and inward membrane micro-structure formation. Here, we describe the characteristics of phospholipids, and the mechanisms utilized by phosphoinositides to regulate cellular events. We then summarize the precise mechanisms underlying the construction of membrane micro-structures and their involvements in physiological and pathological processes. Copyright © 2014 the American Physiological Society.

The importance of new processing techniques in tissue engineering

NASA Technical Reports Server (NTRS)

Lu, L.; Mikos, A. G.; McIntire, L. V. (Principal Investigator)

1996-01-01

The use of polymer scaffolds in tissue engineering is reviewed and processing techniques are examined. The discussion of polymer-scaffold processing explains fiber bonding, solvent casting and particulate leaching, membrane lamination, melt molding, polymer/ceramic fiber composite-foam processing, phase separation, and high-pressure processing.

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.

Physicochemical changes and microbial inactivation after high-intensity ultrasound processing of prebiotic whey beverage applying different ultrasonic power levels.

PubMed

Guimarães, Jonas T; Silva, Eric Keven; Alvarenga, Verônica O; Costa, Ana Letícia R; Cunha, Rosiane L; Sant'Ana, Anderson S; Freitas, Monica Q; Meireles, M Angela A; Cruz, Adriano G

2018-06-01

In this work, we investigated the effects of the ultrasonic power (0, 200, 400 and 600 W) on non-thermal processing of an inulin-enriched whey beverage. We studied the effects of high-intensity ultrasound (HIUS) on microbial inactivation (aerobic mesophilic heterotrophic bacteria (AMHB), total and thermotolerant coliforms and yeasts and molds), zeta potential, microstructure (optical microscopy, particle size distribution), rheology, kinetic stability and color. The non-thermal processing applying 600 W of ultrasonic power was comparable to high-temperature short-time (HTST) treatment (75 °C for 15 s) concerning the inactivation of AMHB and yeasts and molds (2 vs 2 log and 0.2 vs 0.4 log, respectively), although HIUS has reached a lower output temperature (53 ± 3 °C). The HIUS was better than HTST to improve beverage kinetic stability, avoiding phase separation, which was mainly attributed to the decrease of particles size, denaturation of whey proteins and gelation of polysaccharides (inulin and gellan gum). Thus, non-thermal processing by HIUS seems to be an interesting technology for prebiotic dairy beverages production. Copyright © 2018 Elsevier B.V. All rights reserved.

High pressure die casting of Fe-based metallic glass.

PubMed

Ramasamy, Parthiban; Szabo, Attila; Borzel, Stefan; Eckert, Jürgen; Stoica, Mihai; Bárdos, András

2016-10-11

Soft ferromagnetic Fe-based bulk metallic glass key-shaped specimens with a maximum and minimum width of 25.4 and 5 mm, respectively, were successfully produced using a high pressure die casting (HPDC) method, The influence of die material, alloy temperature and flow rate on the microstructure, thermal stability and soft ferromagnetic properties has been studied. The results suggest that a steel die in which the molten metal flows at low rate and high temperature can be used to produce completely glassy samples. This can be attributed to the laminar filling of the mold and to a lower heat transfer coefficient, which avoids the skin effect in the steel mold. In addition, magnetic measurements reveal that the amorphous structure of the material is maintained throughout the key-shaped samples. Although it is difficult to control the flow and cooling rate of the molten metal in the corners of the key due to different cross sections, this can be overcome by proper tool geometry. The present results confirm that HPDC is a suitable method for the casting of Fe-based bulk glassy alloys even with complex geometries for a broad range of applications.

High pressure die casting of Fe-based metallic glass

NASA Astrophysics Data System (ADS)

Ramasamy, Parthiban; Szabo, Attila; Borzel, Stefan; Eckert, Jürgen; Stoica, Mihai; Bárdos, András

2016-10-01

Soft ferromagnetic Fe-based bulk metallic glass key-shaped specimens with a maximum and minimum width of 25.4 and 5 mm, respectively, were successfully produced using a high pressure die casting (HPDC) method, The influence of die material, alloy temperature and flow rate on the microstructure, thermal stability and soft ferromagnetic properties has been studied. The results suggest that a steel die in which the molten metal flows at low rate and high temperature can be used to produce completely glassy samples. This can be attributed to the laminar filling of the mold and to a lower heat transfer coefficient, which avoids the skin effect in the steel mold. In addition, magnetic measurements reveal that the amorphous structure of the material is maintained throughout the key-shaped samples. Although it is difficult to control the flow and cooling rate of the molten metal in the corners of the key due to different cross sections, this can be overcome by proper tool geometry. The present results confirm that HPDC is a suitable method for the casting of Fe-based bulk glassy alloys even with complex geometries for a broad range of applications.

High pressure die casting of Fe-based metallic glass

PubMed Central

Ramasamy, Parthiban; Szabo, Attila; Borzel, Stefan; Eckert, Jürgen; Stoica, Mihai; Bárdos, András

2016-01-01

Soft ferromagnetic Fe-based bulk metallic glass key-shaped specimens with a maximum and minimum width of 25.4 and 5 mm, respectively, were successfully produced using a high pressure die casting (HPDC) method, The influence of die material, alloy temperature and flow rate on the microstructure, thermal stability and soft ferromagnetic properties has been studied. The results suggest that a steel die in which the molten metal flows at low rate and high temperature can be used to produce completely glassy samples. This can be attributed to the laminar filling of the mold and to a lower heat transfer coefficient, which avoids the skin effect in the steel mold. In addition, magnetic measurements reveal that the amorphous structure of the material is maintained throughout the key-shaped samples. Although it is difficult to control the flow and cooling rate of the molten metal in the corners of the key due to different cross sections, this can be overcome by proper tool geometry. The present results confirm that HPDC is a suitable method for the casting of Fe-based bulk glassy alloys even with complex geometries for a broad range of applications. PMID:27725780

Customized Cranioplasty Implants Using Three-Dimensional Printers and Polymethyl-Methacrylate Casting

PubMed Central

Kim, Bum-Joon; Hong, Ki-Sun; Park, Kyung-Jae; Park, Dong-Hyuk; Chung, Yong-Gu

2012-01-01

Objective The prefabrication of customized cranioplastic implants has been introduced to overcome the difficulties of intra-operative implant molding. The authors present a new technique, which consists of the prefabrication of implant molds using three-dimensional (3D) printers and polymethyl-methacrylate (PMMA) casting. Methods A total of 16 patients with large skull defects (>100 cm2) underwent cranioplasty between November 2009 and April 2011. For unilateral cranial defects, 3D images of the skull were obtained from preoperative axial 1-mm spiral computed tomography (CT) scans. The image of the implant was generated by a digital subtraction mirror-imaging process using the normal side of the cranium as a model. For bilateral cranial defects, precraniectomy routine spiral CT scan data were merged with postcraniectomy 3D CT images following a smoothing process. Prefabrication of the mold was performed by the 3D printer. Intraoperatively, the PMMA implant was created with the prefabricated mold, and fit into the cranial defect. Results The median operation time was 184.36±26.07 minutes. Postoperative CT scans showed excellent restoration of the symmetrical contours and curvature of the cranium in all cases. The median follow-up period was 23 months (range, 14-28 months). Postoperative infection was developed in one case (6.2%) who had an open wound defect previously. Conclusion Customized cranioplasty PMMA implants using 3D printer may be a useful technique for the reconstruction of various cranial defects. PMID:23346326

Determination of adhesion between thermoplastic and liquid silicone rubbers in hard-soft-combinations via mechanical peeling test

NASA Astrophysics Data System (ADS)

Kühr, C.; Spörrer, A.; Altstädt, V.

2014-05-01

The production of hard-soft-combinations via multi injection molding gained more and more importance in the last years. This is attributed to different factors. One principle reason is that the use of two-component injection molding technique has many advantages such as cancelling subsequent and complex steps and shortening the process chain. Furthermore this technique allows the combination of the properties of the single components like the high stiffness of the hard component and the elastic properties of the soft component. Because of the incompatibility of some polymers the adhesion on the interface has to be determined. Thereby adhesion is not only influenced by the applied polymers, but also by the injection molding parameters and the characteristics of the mold. Besides already known combinations of thermoplastics with thermoplastic elastomers (TPE), there consists the possibility to apply liquid silicone rubber (LSR) as soft component. A thermoplastic/LSR combination gains in importance due to the specific advantages of LSR to TPE. The faintly adhesion between LSR and thermoplastics is currently one of the key challenges when dealing with those combinations. So it is coercively necessary to improve adhesion between the two components by adding an adhesion promoter. To determine the promoters influence, it is necessary to develop a suitable testing method to investigate e.g. the peel resistance. The current German standard "VDI Richtlinie 2019', which is actually only employed for thermoplastic/TPE combinations, can serve as a model to determine the adhesion of thermoplastic/LSR combinations.

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.

Microhardness, Friction and Wear of SiC and Si3N4 Materials as a Function of Load, Temperature and Environment.

DTIC Science & Technology

1981-10-01

microstructures which may be developed and finally to relate properties to structure and composition (28-31). Sialon materials are alloys of Si3N4 with oxides...techniques. The effects of specimen microstructure on indentation processes were determined by using materials formed by a wide range of fabrication...microhardness techniques. The effects of specimen microstructure on indentation processes were determined by using materials formed by a wide range of

Bulk microstructure and local elastic properties of carbon nanocomposites studied by impulse acoustic microscopy technique

NASA Astrophysics Data System (ADS)

Levin, V.; Petronyuk, Yu.; Morokov, E.; Chernozatonskii, L.; Kuzhir, P.; Fierro, V.; Celzard, A.; Bellucci, S.; Bistarelli, S.; Mastrucci, M.; Tabacchioni, I.

2016-05-01

Bulk microstructure and elastic properties of epoxy-nanocarbon nanocomposites for diverse types and different content of carbon nanofiller has been studied by using impulse acoustic microscopy technique. It has been shown occurrence of various types of mesoscopic structure formed by nanoparticles inside the bulk of nanocomposite materials, including nanoparticle conglomerates and nanoparticle aerogel systems. In spite of the bulk microstructure, nanocarbon composites demonstrate elastic uniformity and negligible influence of nanofiller on elastic properties of carbon nanocomposite materials.

Single and Dual Drug Release Patterns from Shellac Wax-Lutrol Matrix Tablets Fabricated with Fusion and Molding Techniques

PubMed Central

Phaechamud, T.; Choncheewa, C.

2015-01-01

The objective of this investigation was to prepare the shellac wax matrix tablets by fusion and molding technique incorporated with Lutrol in different ratios to modify the hydrophobicity of matrix tablet. The matrix tablets with single drug were loaded either with propranolol hydrochloride or hydrochlorothiazide as hydrophilic and hydrophobic model drugs, and a dual drug formula was also prepared. The single and dual drug release patterns were studied in a dissolution apparatus using distilled water as medium. Propranolol hydrochloride released from matrix was easier than hydrochlorothiazide. Drug release from shellac wax matrix could be enhanced by incorporation of Lutrol. However retardation of drug release from some matrix tablets was evident for the systems that could form dispersion in the dissolution medium. The gel network from high content of Lutrol was hexagonal which was a dense and more compact structure than the other structures found when low amounts of Lutrol were present in the formula. Therefore, the formulae with high content of Lutrol could prolong drug release more efficiently than those containing low content of Lutrol. Hence shellac wax matrix could modulate the drug release with the addition of Lutrol. Sustainable dual drug release was also obtained from these developed matrix tablets. Thus shellac wax-Lutrol component could be used as a potential matrix tablet prepared with fusion and molding technique with excellent controlled drug release. PMID:25767320

Low Cost Manufacturing Approach of High Temperature PMC Components

NASA Technical Reports Server (NTRS)

Kannmacher, Kevin

1997-01-01

The overall objective is to develop a satisfactory sheet molding compound (SMC) of a high temperature polyimide, such as PMR-11-50, VCAP-75, or NB2-76, and to develop compression molding processing parameters for a random, chopped fiber, high temperature, sheet molding compound that will be more affordable than the traditional hand lay-up fabrication methods. Compression molding will reduce manufacturing costs of composites by: (1) minimizing the conventional machining required after fabrication due to the use of full 360 deg matched tooling, (2) reducing fabrication time by minimizing the intensive hand lay-up operations associated with individual ply fabrication techniques, such as ply orientation and ply count and (3) possibly reducing component mold time by advanced B-staging prior to molding. This program is an integral part of Allison's T406/AE engine family's growth plan, which will utilize technologies developed under NASA's Sub-sonic Transport (AST) programs, UHPTET initiatives, and internally through Allison's IR&D projects. Allison is aggressively pursuing this next generation of engines, with both commercial and military applications, by reducing the overall weight of the engine through the incorporation of advanced, lightweight, high temperature materials, such as polymer matrix composites. This infusion of new materials into the engine is also a major factor in reducing engine cost because it permits the use of physically smaller structural components to achieve the same thrust levels as the generation that it replaced. A lighter, more efficient propulsion system translates to a substantial cost and weight savings to an airframe's structure.

Microstructures and performance of CaO-based ceramic cores with different particle size distributions for investment casting

NASA Astrophysics Data System (ADS)

Zhou, P. P.; Wu, G. Q.; Tao, Y.; Cheng, X.; Zhao, J. Q.; Nan, H.

2018-02-01

A series of calcium-based ceramic cores for casting titanium alloy were prepared by mixing different amounts of coarse and fine powders through injection molding. The effects of particle size on the microstructures and properties of the ceramic cores were investigated using quantitative and statistical analysis methods. It is found that the shrinkage and room-temperature strength of the ceramic cores were enhanced as increasing the contents of fine particles. Moreover, the creep resistance of the ceramic cores increased initially and then decreased. The increase in the fine particle content of the cores reduced the number and mean diameter of pores after sintering. The grain boundary density decreased firstly and then increased. The flexural strength of the ceramic cores at room temperature decreased with increasing porosity of ceramic cores, whereas the creep resistance increased with decreasing grain boundary density. A core exhibiting the optimal property was obtained when mixing 65 wt% of coarse powders (75-150 μm) and 35 wt% of fine powders (25-48 μm).

Numerical Estimation of the Elastic Properties of Thin-Walled Structures Manufactured from Short-Fiber-Reinforced Thermoplastics

NASA Astrophysics Data System (ADS)

Altenbach, H.; Naumenko, K.; L'vov, G. I.; Pilipenko, S. N.

2003-05-01

A model which allows us to estimate the elastic properties of thin-walled structures manufactured by injection molding is presented. The starting step is the numerical prediction of the microstructure of a short-fiber-reinforced composite developed during the filling stage of the manufacturing process. For this purpose, the Moldflow Plastic Insight® commercial program is used. As a result of simulating the filling process, a second-rank orientation tensor characterizing the microstructure of the material is obtained. The elastic properties of the prepared material locally depend on the orientational distribution of fibers. The constitutive equation is formulated by means of orientational averaging for a given orientation tensor. The tensor of elastic material properties is computed and translated into the format for a stress-strain analysis based on the ANSYSÒ finite-element code. The numerical procedure and the convergence of results are discussed for a thin strip, a rectangular plate, and a shell of revolution. The influence of manufacturing conditions on the stress-strain state of statically loaded thin-walled elements is illustrated.

Effect of CaO on Hot Workability and Microstructure of Mg-9.5Zn-2Y Alloy

NASA Astrophysics Data System (ADS)

Kwak, Tae-yang; Kim, Daeguen; Yang, Jaehack; Yoon, Young-ok; Kim, Shae K.; Lim, Hyunkyu; Kim, Woo Jin

Mg-Zn-Y system alloys have been a great interest because Mg-Zn-Y alloys with I-phase exhibited high ductility at room and elevated temperatures. According to our preliminary experiments, the addition of CaO improved strength, but the process window became narrow. Therefore, the aim of current work was to find optimum extrusion conditions for CaO added Mg-Zn-Y alloys by processing maps. The 0.3 wt.% of CaO added Mg-9.5Zn-2Y (Mg95.6Zn3.8Y0.6) alloy was prepared by casting into steel mold and homogenizing. Hot compression test were performed in the Gleeble machine at temperature range of 250-400 °C with various strain rates. The alloys were extruded with a reduction ratio of 20:1. To analyze the microstructure and texture, optical micrograph, scanning electron microscope and electron backscattered diffraction were used. Moreover, we investigated the effects of metallic Ca addition in this alloy to compare with the addition of CaO.

Structure and Compressive Properties of Invar-Cenosphere Syntactic Foams.

PubMed

Luong, Dung; Lehmhus, Dirk; Gupta, Nikhil; Weise, Joerg; Bayoumi, Mohamed

2016-02-18

The present study investigates the mechanical performance of syntactic foams produced by means of the metal powder injection molding process having an Invar (FeNi36) matrix and including cenospheres as hollow particles at weight fractions (wt.%) of 5 and 10, respectively, corresponding to approximately 41.6 and 60.0 vol.% in relation to the metal content and at 0.6 g/cm³ hollow particle density. The synthesis process results in survival of cenospheres and provides low density syntactic foams. The microstructure of the materials is investigated as well as the mechanical performance under quasi-static and high strain rate compressive loads. The compressive stress-strain curves of syntactic foams reveal a continuous strain hardening behavior in the plastic region, followed by a densification region. The results reveal a strain rate sensitivity in cenosphere-based Invar matrix syntactic foams. Differences in properties between cenosphere- and glass microsphere-based materials are discussed in relation to the findings of microstructural investigations. Cenospheres present a viable choice as filler material in iron-based syntactic foams due to their higher thermal stability compared to glass microspheres.

On the Solidification and Structure Formation during Casting of Large Inserts in Ferritic Nodular Cast Iron

NASA Astrophysics Data System (ADS)

Tadesse, Abel; Fredriksson, Hasse

2018-06-01

The graphite nodule count and size distributions for boiling water reactor (BWR) and pressurized water reactor (PWR) inserts were investigated by taking samples at heights of 2160 and 1150 mm, respectively. In each cross section, two locations were taken into consideration for both the microstructural and solidification modeling. The numerical solidification modeling was performed in a two-dimensional model by considering the nucleation and growth in eutectic ductile cast iron. The microstructural results reveal that the nodule size and count distribution along the cross sections are different in each location for both inserts. Finer graphite nodules appear in the thinner sections and close to the mold walls. The coarser nodules are distributed mostly in the last solidified location. The simulation result indicates that the finer nodules are related to a higher cooling rate and a lower degree of microsegregation, whereas the coarser nodules are related to a lower cooling rate and a higher degree of microsegregation. The solidification time interval and the last solidifying locations in the BWR and PWR are also different.

[Preparing of Al2O3/ZrO2 composite dental ceramics through isostatic pressing technology].

PubMed

Liang, Xiao-Feng; Yin, Guang-Fu; Yang, Shi-Yuan; Wang, Jun-Xia

2006-08-01

To find out how to prepare high-density dental ceramics through isostatic pressing so that sintering shrinkage will be reduced. To prepare Al2O3/ZrO2 composite powder first, then to mold through dry-pressing, and to shape the green-body through isostatic pressing. The green-bodies were sintered at the temperature of 1 400 degrees C and kept at the temperature for different period of time (2 h, 3 h, 4 h). After that, the density and fracture strength were measured and the microstructure observed by scanning electron microscope (SEM). The sample product's density, line-shrinkage, and fracture strength of ceramics was rising with the sintering time lengthened. The sample product kept under the temperature of 1 400 degrees C for 4 hours, the fracture strength was (497.27 +/- 78.45) MPa and glass phase distributed evenly in the ceramics and the grains were integrated owing to the glass phase. The longer the sintering time, the more even the microstructure was. The sintering quality and the efficiency were improved through isostatic pressing.

Liquid Crystalline Thermosets from Ester, Ester-Imide, and Ester-Amide Oligomers

NASA Technical Reports Server (NTRS)

Dingemans, Theodornus J. (Inventor); Weiser, Erik S. (Inventor); SaintClair, Terry L. (Inventor)

2005-01-01

Main chain thermotropic liquid crystal esters, ester-imides, and ester-amides were prepared from AA, BB, and AB type monomeric materials and were end-capped with phenylacetylene, phenylmaleimide, or nadimide reactive end-groups. The resulting reactive end-capped liquid crystal oligomers exhibit a variety of improved and preferred physical properties. The end-capped liquid crystal oligomers are thermotropic and have, preferably, molecular weights in the range of approximately 1000-15,OOO grams per mole. The end-capped liquid crystal oligomers have broad liquid crystalline melting ranges and exhibit high melt stability and very low melt viscosities at accessible temperatures. The end-capped liquid crystal oligomers are stable for up to an hour in the melt phase. These properties make the end-capped liquid crystal oligomers highly processable by a variety of melt process shape forming and blending techniques including film extrusion, fiber spinning, reactive injection molding (RIM), resin transfer molding (RTM), resin film injection (RFI), powder molding, pultrusion, injection molding, blow molding, plasma spraying and thermo-forming. Once processed and shaped, the end- capped liquid crystal oligomers were heated to further polymerize and form liquid crystalline thermosets (LCT). The fully cured products are rubbers above their glass transition temperatures. The resulting thermosets display many properties that are superior to their non-end-capped high molecular weight analogs.

Liquid crystalline thermosets from ester, ester-imide, and ester-amide oligomers

NASA Technical Reports Server (NTRS)

Dingemans, Theodorous J. (Inventor); Weiser, Erik S. (Inventor); St. Clair, Terry L. (Inventor)

2005-01-01

Main chain thermotropic liquid crystal esters, ester-imides, and ester-amides were prepared from AA, BB, and AB type monomeric materials and were end-capped with phenylacetylene, phenylmaleimide, or nadimide reactive end-groups. The resulting reactive end-capped liquid crystal oligomers exhibit a variety of improved and preferred physical properties. The end-capped liquid crystal oligomers are thermotropic and have, preferably, molecular weights in the range of approximately 1000-15,000 grams per mole. The end-capped liquid crystal oligomers have broad liquid crystalline melting ranges and exhibit high melt stability and very low melt viscosities at accessible temperatures. The end-capped liquid crystal oligomers are stable for up to an hour in the melt phase. These properties make the end-capped liquid crystal oligomers highly processable by a variety of melt process shape forming and blending techniques including film extrusion, fiber spinning, reactive injection molding (RIM), resin transfer molding (RTM), resin film injection (RFI), powder molding, pultrusion, injection molding, blow molding, plasma spraying and thermo-forming. Once processed and shaped, the end-capped liquid crystal oligomers were heated to further polymerize and form liquid crystalline thermosets (LCT). The fully cured products are rubbers above their glass transition temperatures. The resulting thermosets display many properties that are superior to their non-end-capped high molecular weight analogs.

The development of lab-on-a-chip fabricated from two molds

NASA Astrophysics Data System (ADS)

Pramuanjaroenkij, A.; Bunta, J.; Thiangpadung, J.; Sansaradee, S.; Kamsopa, P.; Sodsai, S.; Vichainsan, S.; Wongpanit, K.; Maturos, T.; Lomas, T.; Tuantranont, A.; Cetin, B.; Phankhoksoong, S.; Tongkratoke, A.

2018-01-01

Development of diagnostic technique of microfluidic or lab-on-a-chip (LOCs) is currently of great interest for researchers and inventors for their many advantages. It can be used as a real laboratory was many ways to help to the diagnosis faster. This research aims to develop Polydimethylsiloxane (PDMS) lab-on-a-chip (LOCs) which were produced from different molds; the silicon wafer mold and the stainless mold to investigate the flow of the biological sample as the flow in nanochannels. In addition, this research proposes a means to leakage and the blockage of the channel flow. The experimental results were found that the LOCs casted from the silicon wafer mold sandwiched by both the plasma cleaner machine and H shaped acrylic sheets showed leakages around the electrode areas because the first new electrodes were too thick, the proper thickness of the nickel electrode was at 0.05 millimeters. The LOCs casted from the stainless mold were inserted by the nickel electrodes produced by the from the prototype shaped electroplating process; this LOCs using nickel plated electrodes 2 times to make a groove on the nickel electrode backsides when pouring the PDMS into the LOCs casted from the stainless mold. It was found that PDMS was able to flow under the nickel electrode and the PDMS sheet could stick with the glass slide smoothly. In conclusion, it was possible to develop these LOC designs and new electrode fabrications continually under helps from Micro-Electro-Mechanical system, Thailand National Electronics and Computer Technology Center, since causes of the LOC problems were found, and demonstrated the feasibility of developing the LOCs for chemical detection and disease diagnostics.

Investigation of Heat Transfer at the Mold/Metal Interface in Permanent Mold Casting of Light Alloys

DOE Office of Scientific and Technical Information (OSTI.GOV)

Robert D. Pehlke; John T. Berry

2005-12-16

Accurate modeling of the metal casting process prior to creating a mold design demands reliable knowledge of the interfacial heat transfer coefficient at the mold metal interface as a function of both time and location. The phenomena concerned with the gap forming between the mold and the solidifying metal are complex but need to be understood before any modeling is attempted. The presence of mold coatings further complicates the situation. A commercial casting was chosen and studied in a gravity permanent mold casting process. The metal/mold interfacial heat transfer coefficient (IHTC) was the focus of the research. A simple, directmore » method has been used to evaluate the IHTC. Both the simulation and experiments have shown that a reasonably good estimate of the heat transfer coefficient could be made in the case studied. It has been found that there is a good agreement between experiments and simulations in the temperature profiles during the solidification process, given that the primary mechanism of heat transfer across the gap in permanent mold casting of light alloys is by conduction across the gap. The procedure utilized to determine the interfacial heat transfer coefficient can be applied to other casting processes. A recently completed project involving The University of Michigan and Mississippi State University, together with several industrial partners, which was supported by the USDOE through the Cast Metals Coalition, examined a number of cases of thermal contact. In an investigation which gave special consideration to the techniques of measurement, several mold coatings were employed and results presented as a function of time. Realistic conditions of coating thickness and type together with an appropriate combination of mold preheat and metal pouring temperature were strictly maintained throughout the investigation. Temperature sensors, in particular thermocouples, play an important part in validating the predictions of solidification models. Cooling curve information, as well as temperature gradient history both in the solidifying metal and within the mold are invariably required to be validated. This validation depends upon the response of the sensor concerned, but also on its own effect upon the thermal environment. A joint university/industry team has completed an investigation of the invasive effects of thermocouples upon temperature history in permanent molds determining the degree of uncertainty associated with placement and indicating how the time-temperature history may be recovered. In addition to its relevance to the all important study of thermal contact of the casting with metallic molds, the observations also impact the determination of heat flux and interfacial heat transfer coefficients. In these respects the study represents the first of its kind that has tackled the problem in depth for permanent mold castings. An important ramification of this investigation has been the errors likely to be encountered in mold temperature measurement with thin section aluminum castings, especially with respect to the plans for thermocouple placement. A comparison between the degree of uncertainty experienced in sand molds compared with that found in permanent molds reveals that the associated problems have a lesser impact. These conclusions and the related recommendations have been disseminated to industry and the technical community through project reports and publications.« less

Effect of Zn Concentration on the Microstructure and Mechanical Properties of Al-Mg-Si-Zn Alloys Processed by Gravity Die Casting

NASA Astrophysics Data System (ADS)

Li, Longfei; Ji, Shouxun; Zhu, Qiang; Wang, Yun; Dong, Xixi; Yang, Wenchao; Midson, Stephen; Kang, Yonglin

2018-06-01

The microstructure and mechanical properties of Al-8.1Mg-2.6Si-(0.08 to 4.62)Zn alloys (in wt pct) have been investigated by the permanent mold casting process. X-ray diffraction analysis shows that the τ-Mg32(Al, Zn)49 phase forms when the Zn content is 1.01 wt pct. With higher Zn contents of 2.37 and 3.59 wt pct, the η-MgZn2 and τ-Mg32(Al, Zn)49 phases precipitate in the microstructure, and the η-MgZn2 phase forms when the Zn content is 4.62 wt pct. Metallurgical analysis shows that the η-MgZn2 and τ-Mg32(Al, Zn)49 phases strengthen the Al-8.1Mg-2.6Si-(0.08 to 4.62)Zn alloys. After solutionizing at 510 °C for 180 minutes and aging at 180 °C for 90 minutes, the η'-MgZn2 phase precipitates in the α-Al matrix, which significantly enhances the mechanical properties. Addition of 3.59 wt pct Zn to the Al-8.1Mg-2.6Si alloy with heat treatment increases the yield strength from 96 to 280 MPa, increases the ultimate tensile strength from 267 to 310 MPa, and decreases the elongation from 9.97 to 1.74 pct.

Low-Cost 3D Printing Orbital Implant Templates in Secondary Orbital Reconstructions.

PubMed

Callahan, Alison B; Campbell, Ashley A; Petris, Carisa; Kazim, Michael

Despite its increasing use in craniofacial reconstructions, three-dimensional (3D) printing of customized orbital implants has not been widely adopted. Limitations include the cost of 3D printers able to print in a biocompatible material suitable for implantation in the orbit and the breadth of available implant materials. The authors report the technique of low-cost 3D printing of orbital implant templates used in complex, often secondary, orbital reconstructions. A retrospective case series of 5 orbital reconstructions utilizing a technique of 3D printed orbital implant templates is presented. Each patient's Digital Imaging and Communications in Medicine data were uploaded and processed to create 3D renderings upon which a customized implant was designed and sent electronically to printers open for student use at our affiliated institutions. The mock implants were sterilized and used intraoperatively as a stencil and mold. The final implant material was chosen by the surgeons based on the requirements of the case. Five orbital reconstructions were performed with this technique: 3 tumor reconstructions and 2 orbital fractures. Four of the 5 cases were secondary reconstructions. Molded Medpor Titan (Stryker, Kalamazoo, MI) implants were used in 4 cases and titanium mesh in 1 case. The stenciled and molded implants were adjusted no more than 2 times before anchored in place (mean 1). No case underwent further revision. The technique and cases presented demonstrate 1) the feasibility and accessibility of low-cost, independent use of 3D printing technology to fashion patient-specific implants in orbital reconstructions, 2) the ability to apply this technology to the surgeon's preference of any routinely implantable material, and 3) the utility of this technique in complex, secondary reconstructions.

Microgroove fabrication with excimer laser ablation techniques for optical fiber array alignment purposes

NASA Astrophysics Data System (ADS)

Naessens, Kris; Van Hove, An; Coosemans, Thierry; Verstuyft, Steven; Vanwassenhove, Luc; Van Daele, Peter; Baets, Roel G.

2000-11-01

Currently, an ever increasing need for bandwidth, compactness and efficiency characterizes the world of interconnect and data communication. This tendency has already led to serial links being gradually replaced by parallel optical interconnect solutions. However, as the maximum capacity for the latter will be reached in the near future, new approaches are required to meet demand. One possible option is to switch to 2D parallel implementations of fiber arrays. In this paper we present the fabrication of a 2D connector for coupling a 4x8 array of plastic optical fibers to RCLED or VCSEL arrays. The connector consists primarily of dedicated PMMA plates in which arrays of 8 precisely dimensioned grooves at a pitch of 250 micrometers are introduced. The trenches are each 127 micrometers deep and their width is optimized to allow fixation of plastic optical fibers. We used excimer laser ablation for prototype fabrication of these alignment microstructures. In a later stage, the plates can be replicated using standard molding techniques. The laser ablation technique is extremely well suited for rapid prototyping and proves to be a versatile process yielding high accuracy dimensioning and repeatability of features in a wide diversity of materials. The dependency of the performance in terms of quality of the trenches (bottom roughness) and wall angle on various parameters (wavelength, energy density, pulse frequency and substrate material) is discussed. The fabricated polymer sheets with grooves are used to hold optical fibers by means of a UV-curable adhesive. In a final phase, the plates are stacked and glued in order to realize the 2D-connector of plastic optical fibers for short distance optical interconnects.

Microstructures and properties of rapidly solidified alloys

NASA Technical Reports Server (NTRS)

Shechtman, D.; Horowitz, E.

1984-01-01

The microstructure and properties of rapidly solidified aluminum alloys were researched. The effects of powder and flake chemistry and morphology and alternative consolidation processing parameters are being conducted. Samples of the powders being utilized were obtained for comprehensive metallurgical characterization. Seven aluminum alloys in the form of thin foils were studied by a variety of techniques including optical metallography, scanning electron microscope, and transmission electron microscope. Details of the microstructural characteristics are presented along with a discussion of the solidification process. A better understanding of the microstructure of the rapidly solidified aluminum alloys prepared by a variety of techniques such as roller quenching, the vacuum atomized procedure, ultrasonically atomized in inert atmospheres, and atomized in flue gas was provided.

Measurement of carbon nanotube microstructure relative density by optical attenuation and observation of size-dependent variations.

PubMed

Park, Sei Jin; Schmidt, Aaron J; Bedewy, Mostafa; Hart, A John

2013-07-21

Engineering the density of carbon nanotube (CNT) forest microstructures is vital to applications such as electrical interconnects, micro-contact probes, and thermal interface materials. For CNT forests on centimeter-scale substrates, weight and volume can be used to calculate density. However, this is not suitable for smaller samples, including individual microstructures, and moreover does not enable mapping of spatial density variations within the forest. We demonstrate that the relative mass density of individual CNT microstructures can be measured by optical attenuation, with spatial resolution equaling the size of the focused spot. For this, a custom optical setup was built to measure the transmission of a focused laser beam through CNT microstructures. The transmittance was correlated with the thickness of the CNT microstructures by Beer-Lambert-Bouguer law to calculate the attenuation coefficient. We reveal that the density of CNT microstructures grown by CVD can depend on their size, and that the overall density of arrays of microstructures is affected significantly by run-to-run process variations. Further, we use the technique to quantify the change in CNT microstructure density due to capillary densification. This is a useful and accessible metrology technique for CNTs in future microfabrication processes, and will enable direct correlation of density to important properties such as stiffness and electrical conductivity.

LIGA-based microsystem manufacturing:the electrochemistry of through-mold depostion and material properties.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kelly, James J.; Goods, Steven Howard

2005-06-01

The report presented below is to appear in ''Electrochemistry at the Nanoscale'', Patrik Schmuki, Ed. Springer-Verlag, (ca. 2005). The history of the LIGA process, used for fabricating dimensional precise structures for microsystem applications, is briefly reviewed, as are the basic elements of the technology. The principal focus however, is on the unique aspects of the electrochemistry of LIGA through-mask metal deposition and the generation of the fine and uniform microstructures necessary to ensure proper functionality of LIGA components. We draw from both previously published work by external researchers in the field as well as from published and unpublished studies frommore » within Sandia.« less

Production of al-si alloy feedstocks using the solvent hot mixing method

NASA Astrophysics Data System (ADS)

Ni, J. Q.; Han, K. Q.; Yu, M. H.

2018-05-01

Powder injection molding is a promising low-cost technique for net shape processing of metal and ceramic components. This study aimed to investigate a new method for preparing aluminium (Al) – silicon (Si) alloy feedstock using the solvent hot mixing process. For this purpose, micron-sized Al-Si (20 wt. %) alloy powder was mixed with a binder consisting of 55 wt. % carnauba wax, 45 wt. % high-density polyethylene, and 3 wt. % stearic acid in a hot xylene bath. The scanning electron microscopy technique, thermogravimetric analysis, density measurement and torque measurements were used to verify the homogeneity of the feedstock. Moreover, the feedstock was chosen to perform the molding, debinding cycle and sintering. An Al-Si (20 wt. %) alloy part was successfully produced using this new method.

Design and fabricate multi channel microfluidic mold on top of glass slide using SU-8

NASA Astrophysics Data System (ADS)

Azman, N. A. N.; Rajapaksha, R. D. A. A.; Uda, M. N. A.; Hashim, U.

2017-09-01

Microfluidic is the study of fluid in microscale. Microfluidics provides miniaturized fluidic networks for processing and analyzing liquids in the nanoliter to milliliter range. Microfluidic device comprises of some essential segments or structure that are micromixer, microchannel and microchamber. The SU-8 mold is known as the most used technique in microfluidic fabrication due to the characteristic of very gooey polymer that can be spread over a thickness. In this study, in order to reduce the fabrication cost, the development and fabrication of SU-8 mold is replace by using a glass plate instead of silicon wafer which is used in the previous research. We designed a microfluidic chip for use with an IDE sensors to conduct multiplex detection of multiple channels. The microfluidic chip was designed to include multiplex detection for pathogen that consists of multiple channels of simultaneous results. The multi-channel microfluidic chip was designed, including the fluid outlet and inlet. A multi-channel microfluidic chip was used for pathogen detection. This paper sum up the fabrication of lab SU-8 mold using glass slide.

Comparison of culture media, simplate, and petrifilm for enumeration of yeasts and molds in food.

PubMed

Taniwaki, M H; Silva, N; Banhe, A A; Iamanaka, B T

2001-10-01

The efficacy of three culture media, dichloran rose bengal chloramphenicol (DRBC), dichloran 18% glycerol agar (DG18), and potato dextrose agar (PDA) supplemented with two antibiotics, were compared with the Simplate and Petrifilm techniques for mold and yeast enumeration. The following foods were analyzed: corn meal, wheat flour, cassava flour, bread crumbs, whole meal, sliced bread, ground peanuts, mozzarella cheese, grated parmesan cheese, cheese rolls, orange juice, pineapple pulp, pineapple cake, and mushroom in conserve. Correlation coefficients of DRBC versus PDA and DG18 for recovering total mold and yeast counts from the composite of 14 foods indicated that the three media were generally equivalent. Correlation coefficients for Petrifilm versus culture media were acceptable, although not as good as between culture media. Correlation coefficients of Simplate versus DRBC, DG18, PDA, and Petrifilm for recovering total yeasts and molds from a composite of 11 foods demonstrated that there was no equivalence between the counts obtained by Simplate and other culture media and Petrifilm, with significant differences observed for the most foods analyzed.

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

Liquid Composite Molding (LCM) encompasses a growing list of composite material manufacturing techniques. These processes have provided the promise for complex fiber reinforced plastics parts, manufactured from a single molding step. In recent years a significant research effort has been invested in development of process simulations, providing tools that have advanced current LCM technology and broadened the range of applications. The requirement for manufacture of larger, more complex parts has motivated investigation of active control of LCM processes. Due to the unlimited variety of part geometries that can be produced, finite element based process simulations will be used to some extent in design of actively controlled processes. Ongoing efforts are being made to improve material parameter specification for process simulations, increasing their value as design tools. Several phenomena occurring during mold filling have been addressed through flow visualization experimentation and analysis of manufactured composite parts. The influence of well defined air channels within a mold cavity is investigated, incorporating their effects within existing filling simulations. Three different flow configurations have been addressed, testing the application of 'equivalent permeabilities', effectively approximating air channels as representative porous media. LCM parts having doubly curved regions require preform fabrics to undergo significant, and varying deformation throughout a mold cavity. Existing methods for predicting preform deformation, and the resulting permeability distribution have been applied to a conical mold geometry. Comparisons between experiment and simulation are promising, while the geometry studied has required large deformation over much of the part, shearing the preform fabric beyond the scope of the models applied. An investigational study was performed to determine the magnitude of effect, if any, on mold filling caused by corners within LCM mold 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.

Water-cooled probe technique for the study of freeze lining formation

NASA Astrophysics Data System (ADS)

Verscheure, Karel; Campforts, Mieke; Verhaeghe, Frederik; Boydens, Eddy; Blanpain, Bart; Wollants, Patrick; van Camp, Maurits

2006-12-01

Furnace protection by water-cooled freeze linings becomes increasingly important as the metal producing industry attempts to achieve higher process intensities. Systematic investigations of the growth and the resulting microstructure and compositional profile of freeze linings are necessary to understand the behavior of freeze linings, their relation with the industrial process, and their interaction with the wall cooling system. We have developed a technique based on the submergence of a water-cooled probe into a liquid slag bath. Freeze linings of two industrial nonferrous slags have been produced using this technique and their growth, microstructural, and compositional profiles as a function of submergence time were determined. Thermodynamic equilibrium for the investigated slag systems was calculated and compared with the observed microstructures. The freeze linings form in approximately 15 minutes. Close to the water cooling, the freeze linings are predominantly amorphous in structure. With increasing distance from the water cooling, the proportion of crystalline phases increases and bath material is entrapped in the microstructure. Cellular crystals are observed close to the bath. The freeze linings exhibit an approximate homogeneous composition. The results demonstrate that the technique is a successful tool in obtaining information on the growth, microstructure, and composition of freeze linings in industrial water-cooled furnaces.

Development of Superhydrophobic Material SS 17-4 PH for Bracket Orthodontic Application by Metal Injection Molding

NASA Astrophysics Data System (ADS)

Supriadi, S.; Suharno, B.; Widjaya, T.; Ayuningtyas, S. T.; Baek, E. R.

2018-01-01

Dental’s plaque is a common problem that encountered during orthodontic treatment using bracket. It is caused by demineralization of enamel due to the activity of bacteria. The bacteria increase with remaining excess food which trapped in teeth and bracket. A hydrophobic surface could reduce food attachment on the bracket because of extremely low wettability properties that make it easy to clean with water. There are several methods to obtain hydrophobic surfaces, which are sol-gel, template replica and also etching. The propose of this work is to compare etching treatment and surface modification on sintered SS 17-4 PH as bracket material using CuCl2 and HCl as an etchant while stearic acid was used for surface modification. Hydrophobic surfaces were produced under various etching time i.e 15, 30, 45 and 60 seconds for CuCl2 and 40, 50, 60 and 70 minutes for HCl and also HCl concentration i.e 1,2 and 3 mol/L at room temperature. The hydrophobicity is observed using contact angle measurement while the microstructures observed by Scanning Electron Microscope. The result shows the contact angle could be achieved up to 60% higher than the as-sintered material. Hydrophobic structure has successfully fabricated using etching technique that might be applied to the orthodontic bracket.

An automated method of quantifying ferrite microstructures using electron backscatter diffraction (EBSD) data.

PubMed

Shrestha, Sachin L; Breen, Andrew J; Trimby, Patrick; Proust, Gwénaëlle; Ringer, Simon P; Cairney, Julie M

2014-02-01

The identification and quantification of the different ferrite microconstituents in steels has long been a major challenge for metallurgists. Manual point counting from images obtained by optical and scanning electron microscopy (SEM) is commonly used for this purpose. While classification systems exist, the complexity of steel microstructures means that identifying and quantifying these phases is still a great challenge. Moreover, point counting is extremely tedious, time consuming, and subject to operator bias. This paper presents a new automated identification and quantification technique for the characterisation of complex ferrite microstructures by electron backscatter diffraction (EBSD). This technique takes advantage of the fact that different classes of ferrite exhibit preferential grain boundary misorientations, aspect ratios and mean misorientation, all of which can be detected using current EBSD software. These characteristics are set as criteria for identification and linked to grain size to determine the area fractions. The results of this method were evaluated by comparing the new automated technique with point counting results. The technique could easily be applied to a range of other steel microstructures. © 2013 Published by Elsevier B.V.

A complete denture impression technique survey of postdoctoral prosthodontic programs in the United States.

PubMed

Mehra, Mamta; Vahidi, Farhad; Berg, Robert W

2014-06-01

The purpose of the study was to survey program directors of postdoctoral prosthodontic programs in the United States regarding their programs' complete denture impression techniques. The key objectives of the survey were to identify the current trends in complete denture impression making and to determine which techniques and materials are taught in US postdoctoral prosthodontic programs. An online survey was sent to all program directors of US postdoctoral prosthodontic programs. The survey comprised two sections: preliminary impressions and final impressions. The survey contained 22 questions that would take approximately 5 minutes to complete. All responses remained anonymous throughout the survey. The response rate for the survey was 87%. A majority of the programs did not separately border mold the tray prior to making the preliminary impressions (82%). The impression material of choice for the preliminary impression was irreversible hydrocolloid (88%). Selective pressure was the predominantly used impression philosophy (80%). All programs border molded the custom tray, and 95% recorded the borders in sections. The material of choice for border molding the custom tray was modeling plastic impression compound (71%). The most commonly used impression material for the final impressions was polyvinylsiloxane (PVS) (42%), and the second most commonly used impression material was polysulphide (32%). The most common technique for locating the posterior palatal seal was marking intraorally and transferring onto the final impression (65%). Most programs routinely advised their patients not to wear their existing dentures for at least 24 hours before the final impressions were made (83%). Based on the results of this study, the following conclusions can be drawn: (1) The most commonly used material for the preliminary impression was irreversible hydrocolloid and for the final impression was PVS. (2) Modeling plastic impression compound was used by most programs to border mold the custom trays. (3) Selective pressure was the predominantly used impression philosophy. (4) A majority of the programs made a special consideration for excessive movable (flabby) tissue. (5) Most programs routinely advised their patients to not wear their existing dentures for at least 24 hours before the final impressions were made. © 2013 by the American College of Prosthodontists.

Characterization of polymeric binders for Metal Injection Molding (MIM) process

NASA Astrophysics Data System (ADS)

Adames, Juan M.

The Metal Injection Molding (MIM) process is an economically attractive method of producing large amounts of small and complex metallic parts. This is achieved by combining the productivity of injection molding with the versatility of sintering of metal particulates. In MIM, the powdered metal is blended with a plastic binder to obtain the feedstock. The binder imparts flowability to the blend at injection molding conditions and strength at ambient conditions. After molding, the binder is removed in a sequence of steps that usually involves solvent-extraction and polymer burn-out. Once the binder is removed, the metal particles are sintered. In this research several topics of the MIM process were studied to understand how the polymeric binder, similar to the one used in the sponsoring company, works. This was done by examining the compounding and water debinding processes, the rheological and thermal properties, and the microstructure of the binder/metal composite at different processing stages. The factors studied included the metal contents, the composition of the binder and the processing conditions. The three binders prepared during the course of this research were blends of a polyolefin, polyoxymethylene copolymer (POM) and a water-soluble polymer (WSP). The polyolefin resins included polypropylene (PP), high-density polyethylene (HDPE) and linear low-density polyethylene (LLDPE). The powdered metal in the feedstocks was 316 L stainless steel. The compounding studies were completed in an internal mixer under different conditions of temperature, rotational speed and feedstock composition. It was found that the metal concentration was the most important factor in determining the torque evolution curves. The observation of microstructure with Scanning Electron Microscope (SEM) at different stages during compounding revealed that the metal particles neither agglomerate nor touch each other. The liquid extraction of the water-soluble polymer (WSP) from the molded parts (or water debinding) was investigated using two configurations of flow of water relative to the samples. Both permitted the reduction of the mass transfer resistance outside the parts, revealing information on the diffusion of the WSP inside the part exclusively. The debinding studies showed that a single effective diffusivity could be used to model the extraction process of the binder from molded parts. This approach is more accurate when the debinding time is above 2 hours. Steady shear and dynamic experiments were conducted on the binder and feedstocks samples containing LLDPE. The results of both experiments revealed that the feedstocks did not show yield stress even though the highest metal content was 64% by volume. Therefore, it was concluded that there were only hydrodynamic interactions between the metal particles. The thermal characterization of binders, polymers and feedstocks included differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). The DSC tests were performed after preheating and quenching of the samples. The heating rate was 20°C/min. The TGA scans were conducted from room temperature to 700°C at 20°C/min. The DSC tests revealed that the melting point of the polymers depressed when blended in the binders and feedstocks. The depression was more intense for POM and the water-soluble polymer than for the polyolefins. Therefore, it was concluded that the melting point depression of POM and the water-soluble polymer was caused by their entrapment in the polyolefin matrix and in between the metal particles. The TGA scans showed that the feedstocks with higher metal concentration had higher final decomposition temperature, but similar onset temperature. The reason was that the higher the metal concentration the more difficult the diffusion of the products of the decomposition of the binder out of the samples. The morphological studies revealed that the binders were heterogeneous showing domains of the polar resins, embedded in a continuous phase composed of polyolefin. This distribution of phases was the result of the immiscibility between the polymeric components, and of the higher concentration (>70 vol%) of the polyolefin with respect to the polar components (polyoxymethylene and water-soluble polymer). The deformation during steady shear testing and compounding of the binder with the metal modified the size of the dispersed domains. The steady shearing increased the size of the dispersed domains by coalescence of the particles. On the other hand, the presence of powdered metal during compounding forced a redistribution of the dispersed phases. Apparently, a thin heterogeneous layer of binder surrounded the metal particles while most of the polyolefin occupied the space between the coated metal particles. The SEM study on samples obtained after water debinding revealed that the water-soluble polymer did not distribute uniformly on the surface of the molded disk of feedstock used for water debinding tests.

Overview on Techniques to Construct Tissue Arrays with Special Emphasis on Tissue Microarrays

PubMed Central

Vogel, Ulrich

2014-01-01

With the advent of new histopathological staining techniques (histochemistry, immunohistochemistry, in situ hybridization) and the discovery of thousands of new genes, mRNA, and proteins by molecular biology, the need grew for a technique to compare many different cells or tissues on one slide in a cost effective manner and with the possibility to easily track the identity of each specimen: the tissue array (TA). Basically, a TA consists of at least two different specimens per slide. TAs differ in the kind of specimens, the number of specimens installed, the dimension of the specimens, the arrangement of the specimens, the embedding medium, the technique to prepare the specimens to be installed, and the technique to construct the TA itself. A TA can be constructed by arranging the tissue specimens in a mold and subsequently pouring the mold with the embedding medium of choice. In contrast, preformed so-called recipient blocks consisting of the embedding medium of choice have punched, drilled, or poured holes of different diameters and distances in which the cells or tissue biopsies will be deployed manually, semi-automatically, or automatically. The costs of constructing a TA differ from a few to thousands of Euros depending on the technique/equipment used. Remarkably high quality TAs can be also achieved by low cost techniques. PMID:27600339

SU-E-T-419: Fabricating Cerrobend Grids with 3D Printing for Spatially Modulated Radiation Therapy: A Feasibility Study

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhu, X; Driewer, J; Lei, Y

2015-06-15

Purpose: Grid therapy has promising applications in the radiation treatment of bulky and large tumors. However, research and applications of grid therapy is limited by the accessibility of the specialized blocks that produce the grid of pencil-like radiation beams. In this study, a Cerrobend grid block was fabricated using a 3D printing technique. Methods: A grid block mold was designed with divergent tubes following beam central rays. The mold was printed using a resin with the working temperature below 230 °C. The melted Cerrobend liquid at 120°oC was cast into the resin mold to yield a block with a thicknessmore » of 7.4 cm. The grid had a hexagonal pattern, with each pencil beam diameter of 1.4 cm at the iso-center plane; the distance between the beam centers was 2 cm. The dosimetric properties of the grid block were studied using radiographic film and small field dosimeters. Results: the grid block was fabricated to be mounted at the third accessory mount of a Siemens Oncor linear accelerator. Fabricating a grid block using 3D printing is similar to making cutouts for traditional radiotherapy photon blocks, with the difference being that the mold was created by a 3D printer rather than foam. In this study, the valley-to-peak ratio for a 6MV photon grid beam was 20% at dmax, and 30% at 10 cm depth, respectively. Conclusion: We have demonstrated a novel process for implementing grid radiotherapy using 3D printing techniques. Compared to existing approaches, our technique combines reduced cost, accessibility, and flexibility in customization with efficient delivery. This lays the groundwork for future studies to improve our understanding of the efficacy of grid therapy and apply it to improve cancer treatment.« less

Effect of microstructure and surface features on wetting angle of a Fe-3.2 wt%C.E. cast iron with water

NASA Astrophysics Data System (ADS)

Riahi, Samira; Niroumand, Behzad; Dorri Moghadam, Afsaneh; Rohatgi, Pradeep K.

2018-05-01

In the present study, variation in surface wetting behavior of a hypoeutectic cast iron with its microstructural features and surface roughness was investigated. Samples with an identical composition, i.e. Fe-3.2 wt%C.E., and different microstructures (a gray cast iron with A-type flake graphite and a white cast iron) were fabricated by gravity casting of molten cast iron in a chill mold at different cooling rates. A variation of surface roughness was also developed by polishing, a four-stage electroetching and a four-stage mechanical abrading on the samples. Roughness and water contact angles of all surfaces were then measured. The surface roughness factor and the solid fraction in contact with water by the Wenzel and Cassie-Baxter contact models were also calculated and compared with the corresponding measured contact angles to find out which regime was active. Results indicated that the surface microstructure and the type of constituents present at the surface influenced the cast iron surface wettability and that it was possible to change the surface contact angle by modification of the surface microstructure. The mechanically abraded gray cast iron followed the Wenzel-type regime while the electroetched surfaces of gray cast iron exhibited a transition from Wenzel to Cassie-Baxter type regime. In white cast iron, the results indicated Wenzel type behavior in the electroetched samples while for the mechanically abraded samples, none of these two models could predict the wetting behavior. Furthermore, the wetting angles of both gray and white cast irons were measured after 1, 2, 3 and 4 weeks of air exposure. The results showed that the wetting angles of both samples increased to above 90° after one week of air exposure which was likely due to adsorption of low surface energy hydrocarbons on the surfaces.

The experimental study of heat transfer around molds inside a model autoclave

NASA Astrophysics Data System (ADS)

Ghamlouch, Taleb; Roux, Stéphane; Lefèvre, Nicolas; Bailleul, Jean-Luc; Sobotka, Vincent

2018-05-01

The temperature distribution within composite parts manufactured inside autoclaves plays a key role in determining the parts quality at the end of the curing cycle. Indeed, heat transfer between the parts and the surroundings inside an autoclave is strongly coupled with the flow field around the molds and can be modeled through the convective heat transfer coefficient (HTC). The aerodynamically unsuitable geometry of the molds generates complex turbulent non-uniform flows around them accompanied with the presence of dead zones. This heterogeneity can imply non-uniform convective heat transfers leading to temperature gradients inside parts that can be prejudicial. Given this fact, the purpose of this study is to perform experimental measurements in order to describe the flow field and the convective heat transfer behavior around representative industrial molds installed inside a home-made model. A key point of our model autoclave is the ease of use of non-intrusive measuring instruments: the Particle Image Velocimetry (PIV) technique and infrared imaging camera for the study of the flow field and the heat transfer coefficient distribution around the molds respectively. The experimental measurements are then compared to computational fluid dynamics (CFD) calculations performed on the computer code ANSYS Fluent 16.0®. This investigation has revealed, as expected, a non-uniform distribution of the convective heat transfer coefficient around the molds and therefore the presence of thermal gradients which can reduce the composite parts quality during an autoclave process. A good agreement has been achieved between the experimental and the numerical results leading then to the validation of the performed numerical simulations.

Procedure for flaw detection in cast stainless steel

DOEpatents

Kupperman, David S.

1988-01-01

A method of ultrasonic flaw detection in cast stainless steel components incorporating the steps of determining the nature of the microstructure of the cast stainless steel at the site of the flaw detection measurements by ultrasonic elements independent of the component thickness at the site; choosing from a plurality of flaw detection techniques, one such technique appropriate to the nature of the microstructure as determined and detecting flaws by use of the chosen technique.

Modified Activation Technique for Nasal Stent of Nasoalveolar Molding Appliance for Columellar Lengthening in Bilateral Cleft Lip/Palate.

PubMed

Patil, Pravinkumar G; Nimbalkar-Patil, Smita P

2018-01-01

Bilateral cleft lip/cleft palate is associated with nasal deformities typified by a short columella. The presurgical nasoalveolar molding (NAM) therapy approach includes reduction of the size of the intraoral alveolar cleft as well as positioning of the surrounding deformed soft tissues and cartilages. In a bilateral cleft patient, NAM, along with columellar elongation, eliminates the need for columellar lengthening surgery. Thus the frequent surgical intervention to achieve the desired esthetic results can be avoided. This article proposes a modified activation technique of the nasal stent for a NAM appliance for columellar lengthening in bilateral cleft lip/palate patients. The design highlights relining of the columellar portion of the nasal stent and the wire-bending of the nasal stent to achieve desirable results within the limited span of plasticity of the nasal cartilages. With this technique the vertical taping of the premaxilla to the oral plate can be avoided. © 2016 by the American College of Prosthodontists.

Microstructurally tailored ceramics for advanced energy applications by thermoreversible gelcasting

NASA Astrophysics Data System (ADS)

Shanti, Noah Omar

Thermoreversible gelcasting (TRG) is an advantageous technique for rapidly producing bulk, net-shape ceramics and laminates. In this method, ceramic powder is suspended in warm acrylate triblock copolymer/alcohol solutions that reversibly gel upon cooling by the formation of endblock aggregates, to produce slurries which are cast into molds. Gel properties can be tailored by controlling the endblock and midblock lengths of the copolymer network-former and selecting an appropriate alcohol solvent. This research focuses on expanding and improving TRG techniques, focusing specifically on advanced energy applications including the solid oxide fuel cell (SOFC). Rapid drying of filled gels can lead to warping and cracking caused by high differential capillary stresses. A new drying technique using concentrated, alcohol-based solutions as liquid desiccants (LDs) to greatly reduce warping is introduced. The optimal LD is a poly(tert-butyl acrylate)/isopropyl alcohol solution with 5 mol% tert-butyl acrylate units. Alcohol emissions during drying are completely eliminated by combining initial drying in an LD with final stage drying in a vacuum oven having an in-line solvent trap. Porous ceramics are important structures for many applications, including SOFCs. Pore network geometries are tailored by the addition of fugitive fillers to TRG slurries. Uniform spherical, bimodal spherical and uniform fibrous fillers are used. Three-dimensional pore structures are visualized by X-ray computed tomography, allowing for direct measurements of physical parameters such as concentration and morphology as well as transport properties such as tortuosity. Tortuosity values as low as 1.52 are achieved when 60 vol% of solids are uniform spherical filler. Functionally graded laminates with layers ranging from 10 mum to > 1 mm thick are produced with a new technique that combines TRG with tape casting. Gels used for bulk casting are not suitable for use with tape casting, and appropriate base gels are selected for this technique. Each layer is cast in a single pass, and the layers are directly laminated. The anode support, anode functional layer, and electrolyte of anode-supported SOFCs are produced using this technique. The performance of SOFCs produced this way is not yet equal to that of traditionally processed cells, but shows the promise of this technique.

Development of a continuous roll-to-roll processing system for mass production of plastic optical film

NASA Astrophysics Data System (ADS)

Chang, Chih-Yuan; Tsai, Meng-Hsun

2015-12-01

This paper reports a highly effective method for the mass production of large-area plastic optical films with a microlens array pattern based on a continuous roll-to-roll film extrusion and roller embossing process. In this study, a thin steel mold with a micro-circular hole array pattern is fabricated by photolithography and a wet chemical etching process. The thin steel mold was then wrapped onto a metal cylinder to form an embossing roller mold. During the roll-to-roll process operation, a thermoplastic raw material (polycarbonate grains) was put into the barrel of the plastic extruder with a flat T-die. Then, the molten polymer film was extruded and immediately pressed against the surface of the embossing roller mold. Under the proper processing conditions, the molten polymer will just partially fill the micro-circular holes of the mold and due to surface tension form a convex lens surface. A continuous plastic optical film with a microlens array pattern was obtained. Experiments are carried out to investigate the effect of plastic microlens formation on the roll-to-roll process. Finally, the geometrical and optical properties of the fabricated plastic optical film were measured and proved satisfactory. This technique shows great potential for the mass production of large-area plastic optical films with a microlens array pattern.

The Fabrication of Nanoimprinted P3HT Nanograting by Patterned ETFE Mold at Room Temperature and Its Application for Solar Cell

NASA Astrophysics Data System (ADS)

Ding, Guangzhu; Wang, Kaixuan; Li, Xiaohui; Chen, Qing; Hu, Zhijun; Liu, Jieping

2016-05-01

Nanoimprinting lithography (NIL) is investigated as a promising method to define nanostructure; however, finding a practical method to achieve large area patterning of conjugated polymer remains a challenge. We demonstrate here that a simple and cost-effective technique is proposed to fabricate the nanoimprinted P3HT nanograting by solvent-assisted room temperature NIL (SART-NIL) method with patterned ETFE film as mold. The patterned ETFE template is produced by embossing ETFE film into a patterned silicon master and is used as template to transfer nanogratings during the SART-NIL process. It indicates that highly reproducible and well-controlled P3HT nanograting film is obtained successfully with feature size of nanogratings ranging from 130 to 700 nm, due to the flexibility, stiffness, and low surface energy of ETFE mold. Moreover, the SART-NIL method using ETFE mold is able to fabricate nanogratings but not to induce the change of molecular orientation within conjugated polymer. The conducting ability of P3HT nanograting in the vertical direction is also not damaged after patterning. Finally, we further apply P3HT nanograting for the fabrication of active layer of OBHJ solar cell device, to investigate the morphology role presented by ETFE mold in device performance. The device performance of OBHJ solar cell is preferential to that of PBHJ device obviously.

The Fabrication of Nanoimprinted P3HT Nanograting by Patterned ETFE Mold at Room Temperature and Its Application for Solar Cell.

PubMed

Ding, Guangzhu; Wang, Kaixuan; Li, Xiaohui; Chen, Qing; Hu, Zhijun; Liu, Jieping

2016-12-01

Nanoimprinting lithography (NIL) is investigated as a promising method to define nanostructure; however, finding a practical method to achieve large area patterning of conjugated polymer remains a challenge. We demonstrate here that a simple and cost-effective technique is proposed to fabricate the nanoimprinted P3HT nanograting by solvent-assisted room temperature NIL (SART-NIL) method with patterned ETFE film as mold. The patterned ETFE template is produced by embossing ETFE film into a patterned silicon master and is used as template to transfer nanogratings during the SART-NIL process. It indicates that highly reproducible and well-controlled P3HT nanograting film is obtained successfully with feature size of nanogratings ranging from 130 to 700 nm, due to the flexibility, stiffness, and low surface energy of ETFE mold. Moreover, the SART-NIL method using ETFE mold is able to fabricate nanogratings but not to induce the change of molecular orientation within conjugated polymer. The conducting ability of P3HT nanograting in the vertical direction is also not damaged after patterning. Finally, we further apply P3HT nanograting for the fabrication of active layer of OBHJ solar cell device, to investigate the morphology role presented by ETFE mold in device performance. The device performance of OBHJ solar cell is preferential to that of PBHJ device obviously.

A new proposal to evaluate the healing of open skin wounds: volumetry.

PubMed

Paulo, Danilo Nagib Salomão; Fiorot, Antonio Wilson

2011-12-01

To present a new proposal to evaluate the healing of an open subcutaneous and skin wound, which we termed "volumetry". A total of 32 circular wounds were performed in the subcutaneous tissues and skin of four feet of pigs (8 each). Each wound had about 1 cm in diameter and was 0.2 cm deep. Volume was calculated from the wound filled with saline and mass Xantopren. With the aid of a magnifying glass and local lighting, the liquid was dripped with a micropipette inside the wound until complete fullness. Volume repletion was calculated in microliters, corresponding to the volume of the wound. The mass of Xantopren was placed inside the wound to obtain a mold of the lesion. Mold volume was calculated using the formula of the volume of a cylinder closest resembling a geometric figure with mold. The calculation of wound volume was possible with both Xantopren and mold techniques. Volume as calculated by micropipette was 119.37 ± 30.87 microliters while the volume calculated by mold was 122.41 ± 33.90 mm3 (p=0.79). Volumetry in pig feet is simple and reproducible. Volumetry perfomed with saline did not differ from the volumetry with mass Xantopren. This method may be a useful tool to help evaluate the healing of open skin wounds in experimental and clinical research.

Economical processing of fiber-reinforced components with thermal expansion molding

NASA Technical Reports Server (NTRS)

Schneider, K.

1979-01-01

The concept of economical fabrication of fiber-reinforced structural components is illustrated with an example of a typical control surface (aileron). The concept provides for fabricating struts, ribs, and a cover plate as an integral structure in a hardening device and then joining the closure cover plate mechanically. Fabrication of the integral structure is achieved by the 'thermal expansion molding' technique. The hardening pressure is produced by silicone rubber cores which expand under the influence of temperature. Test results are presented for several rubber materials as well as for various structural pieces. The technique is demonstrated extensively for an aileron, consisting of five ribs, struts, and a cover plate. Economically, for a large scale technical production of an aileron, cost savings of twenty-five percent can be realized compared to those for a sheet metal structure.

Targets and processes for fabricating same

DOEpatents

Cowan, Thomas [Dresden, DE; Malekos, Steven [Reno, NV; Korgan, Grant [Reno, NV; Adams, Jesse [Reno, NV; Sentoku, Yasuhiko [Reno, NV; Le Galloudec, Nathalie [Reno, NV; Fuchs, Julien [Paris, FR

2012-07-24

In particular embodiments, the present disclosure provides targets including a metal layer and defining a hollow inner surface. The hollow inner surface has an internal apex. The distance between at least two opposing points of the internal apex is less than about 15 .mu.m. In particular examples, the distance is less than about 1 .mu.m. Particular implementations of the targets are free standing. The targets have a number of disclosed shaped, including cones, pyramids, hemispheres, and capped structures. The present disclosure also provides arrays of such targets. Also provided are methods of forming targets, such as the disclosed targets, using lithographic techniques, such as photolithographic techniques. In particular examples, a target mold is formed from a silicon wafer and then one or more sides of the mold are coated with a target material, such as one or more metals.

Targets and processes for fabricating same

DOEpatents

Adams, Jesse D; Malekos, Steven; Le Galloudec, Nathalie; Korgan, Grant; Cowan, Thomas; Sentoku, Yasuhiko

2016-05-17

In particular embodiments, the present disclosure provides targets including a metal layer and defining a hollow inner surface. The hollow inner surface has an internal apex. The distance between at least two opposing points of the internal apex is less than about 15 .mu.m. In particular examples, the distance is less than about 1 .mu.m. Particular implementations of the targets are free standing. The targets have a number of disclosed shaped, including cones, pyramids, hemispheres, and capped structures. The present disclosure also provides arrays of such targets. Also provided are methods of forming targets, such as the disclosed targets, using lithographic techniques, such as photolithographic techniques. In particular examples, a target mold is formed from a silicon wafer and then one or more sides of the mold are coated with a target material, such as one or more metals.

Targets and processes for fabricating same

DOEpatents

Cowna, Thomas; Malekos, Steven; Korgan, Grant; Adams, Jesse; Sentoku, Yasuhiko; LeGalloudec, Nathalie

2014-06-10

In particular embodiments, the present disclosure provides targets including a metal layer and defining a hollow inner surface. The hollow inner surface has an internal apex. The distance between at least two opposing points of the internal apex is less than about 15 .mu.m. In particular examples, the distance is less than about 1 .mu.m. Particular implementations of the targets are free standing. The targets have a number of disclosed shaped, including cones, pyramids, hemispheres, and capped structures. The present disclosure also provides arrays of such targets. Also provided are methods of forming targets, such as the disclosed targets, using lithographic techniques, such as photolithographic techniques. In particular examples, a target mold is formed from a silicon wafer and then one or more sides of the mold are coated with a target material, such as one or more metals.

Compact self-aligning assemblies with refractive microlens arrays made by contactless embossing

NASA Astrophysics Data System (ADS)

Schulze, Jens; Ehrfeld, Wolfgang; Mueller, Holger; Picard, Antoni

1998-04-01

The hybrid integration of microlenses and arrays of microlenses in micro-optical systems is simplified using contactless embossing of microlenses (CEM) in combination with LIGA microfabrication. CEM is anew fabrication technique for the production of precise refractive microlens arrays. A high precision matrix of holes made by LIGA technique is used as a compression molding tool to form the microlenses. The tool is pressed onto a thermoplastic sample which is heated close to the glass transformation temperature of the material. The material bulges into the openings of the molding tool due to the applied pressure and forms lens-like spherical structures. The name refers to the fact that the surface of the microlens does not get in contact with the compression molding tool during the shaping process and optical quality of the surface is maintained. Microlenses and arrays of microlenses with lens diameters from 30 micrometers up to 700 micrometers and numerical aperture values of up to 0.25 have been fabricated in different materials. Cost-effectiveness in the production process, excellent optical performance and the feature of easy replication are the main advantages of this technique. The most promising feature of this method is the possibility to obtain self- aligned assemblies then can be further integrated into a micro-optical bench setup. The CEM fabrication method in combination with LIGA microfabrication considerably enhances the hybrid integration in micro-optical devices which results in a more cost-effective production of compact micro-opto-electro-mechanical systems.

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. © 2013 Elsevier Ltd. All rights reserved.

THE COMPARISON OF SEVERAL STANDARD MATERIALS AND TECHNIQUES FOR THE WARREN-AVERBACH DETERMINATION OF MICRO-STRUCTURE CHARACTERISTICS OF CALCIUM HYDROXIDE SORBENT MATERIALS

EPA Science Inventory

The paper gives results of a comparison of several standard materials and techniques for the Warren-Averbach determination of microstructure characteristics of calcium hydroxide--Ca(OH)2--sorbent materials. The comparison is part of an investigation of the injection of dry Ca(OH)...

Nondestructive examination of decarburised layer of steels using eddy current and magnetic Barkhausen noise testing techniques

NASA Astrophysics Data System (ADS)

Falahat, S.; Ghanei, S.; Kashefi, M.

2018-04-01

Eddy current and Barkhausen noise nondestructive testing techniques were considered to evaluate the magnetic properties of the decarburised steels as a function of microstructure. To make changes in decarburising depth, carbon steel samples were austenitised at 890 °C for 120-270 min. Considering different decarburised depths, height, position and width of the noise profiles were extracted in order to analyse the magnetic Barkhausen noise measurements. Next, the eddy current test was performed to detect the changes in the microstructure through decarburising of the steel taking into account the impedance variations. According to the results, both techniques allow us to detect changes in the magnetic properties of the decarburised steels and link them with their microstructural changes, nondestructively.

Reducing the orientation influence of Mueller matrix measurements for anisotropic scattering media

NASA Astrophysics Data System (ADS)

Sun, Minghao; He, Honghui; Zeng, Nan; Du, E.; He, Yonghong; Ma, Hui

2014-09-01

Mueller matrix polarimetry techniques contain rich micro-structural information of samples, such as the sizes and refractive indices of scatterers. Recently, Mueller matrix imaging methods have shown great potentials as powerful tools for biomedical diagnosis. However, the orientations of anisotropic fibrous structures in tissues have prominent influence on Mueller matrix measurements, resulting in difficulties for extracting micro-structural information effectively. In this paper, we apply the backscattering Mueller matrix imaging technique to biological samples with different microstructures, such as chicken heart muscle, bovine skeletal muscle, porcine liver and fat tissues. Experimental results show that the directions of the muscle fibers have prominent influence on the Mueller matrix elements. In order to reduce the orientation influence, we adopt the rotation-independent MMT and RLPI parameters, which were proposed in our previous studies, to the tissue samples. Preliminary results in this paper show that the orientation-independent parameters and their statistic features are helpful for analyzing the tissues to obtain their micro-structural properties. Since the micro-structure variations are often related to the pathological changes, the method can be applied to microscope imaging techniques and used to detect abnormal tissues such as cancer and other lesions for diagnosis purposes.

Imaging of Scleral Collagen Deformation Using Combined Confocal Raman Microspectroscopy and Polarized Light Microscopy Techniques.

PubMed

Chakraborty, Nilay; Wang, Mian; Solocinski, Jason; Kim, Wonsuk; Argento, Alan

2016-01-01

This work presents an optospectroscopic characterization technique for soft tissue microstructure using site-matched confocal Raman microspectroscopy and polarized light microscopy. Using the technique, the microstructure of soft tissue samples is directly observed by polarized light microscopy during loading while spatially correlated spectroscopic information is extracted from the same plane, verifying the orientation and arrangement of the collagen fibers. Results show the response and orientation of the collagen fiber arrangement in its native state as well as during tensile and compressive loadings in a porcine sclera model. An example is also given showing how the data can be used with a finite element program to estimate the strain in individual collagen fibers. The measurements demonstrate features that indicate microstructural reorganization and damage of the sclera's collagen fiber arrangement under loading. The site-matched confocal Raman microspectroscopic characterization of the tissue provides a qualitative measure to relate the change in fibrillar arrangement with possible chemical damage to the collagen microstructure. Tests and analyses presented here can potentially be used to determine the stress-strain behavior, and fiber reorganization of the collagen microstructure in soft tissue during viscoelastic response.

Evaluation of agave fiber delignification by means of microscopy techniques and image analysis.

PubMed

Hernández-Hernández, Hilda M; Chanona-Pérez, Jorge J; Calderón-Domínguez, Georgina; Perea-Flores, María J; Mendoza-Pérez, Jorge A; Vega, Alberto; Ligero, Pablo; Palacios-González, Eduardo; Farrera-Rebollo, Reynold R

2014-10-01

Recently, the use of different types of natural fibers to produce paper and textiles from agave plants has been proposed. Agave atrovirens can be a good source of cellulose and lignin; nevertheless, the microstructural changes that happen during delignification have scarcely been studied. The aim of this work was to study the microstructural changes that occur during the delignification of agave fibers by means of microscopy techniques and image analysis. The fibers of A. atrovirens were obtained from leaves using convective drying, milling, and sieving. Fibers were processed using the Acetosolv pulping method at different concentrations of acetic acid; increasing acid concentration promoted higher levels of delignification, structural damage, and the breakdown of fiber clumps. Delignification followed by spectrometric analysis and microstructural studies were carried out by light, confocal laser scanning and scanning electron microscopy and showed that the delignification process follows three stages: initial, bulk, and residual. Microscopy techniques and image analysis were efficient tools for microstructural characterization during delignification of agave fibers, allowing quantitative evaluation of the process and the development of linear prediction models. The data obtained integrated numerical and microstructural information that could be valuable for the study of pulping of lignocellulosic materials.

The fabrication of subwavelength anti-reflective nanostructures using a bio-template

NASA Astrophysics Data System (ADS)

Xie, Guoyong; Zhang, Guoming; Lin, Feng; Zhang, Jin; Liu, Zhongfan; Mu, Shichen

2008-03-01

This paper describes a paradigm, a simple, low-cost and conventional approach to the fabrication of large-area subwavelength anti-reflective nanostructures on films directly with a bio-template. Specifically, the nano-nipple arrays on the surface of cicada wings have been precisely replicated to a PMMA (polymethyl methacrylate) film with high reproducibility by a technique of replica molding, which mainly involves two processes: one is that a negative Au mold is prepared directly from the bio-template of the cicada wing by thermal deposition; the other is that the Au mold is used to obtain the replica of the nanostructures on the original cicada wing by casting polymer. The reflectance spectra measurement shows that the replicated PMMA film can considerably reduce reflectivity at its surface over a large wavelength range from 250 to 800 nm, indicating that the anti-reflective property has also been inherited by the PMMA film.

A mass reduction effort of the electric and hybrid vehicle. [composite door panels

NASA Technical Reports Server (NTRS)

Freeman, R. B.; Jahnle, H. A.

1980-01-01

Weight reduction, cost competitiveness, and elimination of the intrusion beam resulted from the redesign and fabrication using composite materials of the door outer panel and intrusion beam from a Chevrolet Impala. The basis of the redesign involved replacing these two steel parts with a single compression molding using the unique approach of simultaneously curing a sheet molding compound outside panel with a continuous glass fiber intrusion strap. A weight reduction of nearly 11 pounds per door was achieved. Additional weight savings are possible by taking advantage of the elimination of the intrusion beam to design thinner door structures. The parts consolidation approach allows the composite structure to be cost competitive with the original steel design for both the lower production car models and for the near to midterm production vehicles using current state of the art composite production techniques. The design, prototype fabrication, costing, material, properties and compression molding production requirements are discussed.

Molded underfill (MUF) encapsulation for flip-chip package: A numerical investigation

NASA Astrophysics Data System (ADS)

Azmi, M. A.; Abdullah, M. K.; Abdullah, M. Z.; Ariff, Z. M.; Saad, Abdullah Aziz; Hamid, M. F.; Ismail, M. A.

2017-07-01

This paper presents the numerical simulation of epoxy molding compound (EMC) filling in multi flip-chip packages during encapsulation process. The empty and a group flip chip packages were considered in the mold cavity in order to study the flow profile of the EMC. SOLIDWORKS software was used for three-dimensional modeling and it was incorporated into fluid analysis software namely as ANSYS FLUENT. The volume of fluid (VOF) technique was used for capturing the flow front profiles and Power Law model was applied for its rheology model. The numerical result are compared and discussed with previous experimental and it was shown a good conformity for model validation. The prediction of flow front was observed and analyzed at different filling time. The possibility and visual of void formation in the package is captured and the number of flip-chip is one factor that contributed to the void formation.

Principles of Biomimetic Vascular Network Design Applied to a Tissue-Engineered Liver Scaffold

PubMed Central

Hoganson, David M.; Pryor, Howard I.; Spool, Ira D.; Burns, Owen H.; Gilmore, J. Randall

2010-01-01

Branched vascular networks are a central component of scaffold architecture for solid organ tissue engineering. In this work, seven biomimetic principles were established as the major guiding technical design considerations of a branched vascular network for a tissue-engineered scaffold. These biomimetic design principles were applied to a branched radial architecture to develop a liver-specific vascular network. Iterative design changes and computational fluid dynamic analysis were used to optimize the network before mold manufacturing. The vascular network mold was created using a new mold technique that achieves a 1:1 aspect ratio for all channels. In vitro blood flow testing confirmed the physiologic hemodynamics of the network as predicted by computational fluid dynamic analysis. These results indicate that this biomimetic liver vascular network design will provide a foundation for developing complex vascular networks for solid organ tissue engineering that achieve physiologic blood flow. PMID:20001254

Principles of biomimetic vascular network design applied to a tissue-engineered liver scaffold.

PubMed

Hoganson, David M; Pryor, Howard I; Spool, Ira D; Burns, Owen H; Gilmore, J Randall; Vacanti, Joseph P

2010-05-01

Branched vascular networks are a central component of scaffold architecture for solid organ tissue engineering. In this work, seven biomimetic principles were established as the major guiding technical design considerations of a branched vascular network for a tissue-engineered scaffold. These biomimetic design principles were applied to a branched radial architecture to develop a liver-specific vascular network. Iterative design changes and computational fluid dynamic analysis were used to optimize the network before mold manufacturing. The vascular network mold was created using a new mold technique that achieves a 1:1 aspect ratio for all channels. In vitro blood flow testing confirmed the physiologic hemodynamics of the network as predicted by computational fluid dynamic analysis. These results indicate that this biomimetic liver vascular network design will provide a foundation for developing complex vascular networks for solid organ tissue engineering that achieve physiologic blood flow.

Investigations on Microstructure and Corrosion behavior of Superalloy 686 weldments by Electrochemical Corrosion Technique

NASA Astrophysics Data System (ADS)

Arulmurugan, B.; Manikandan, M.

2018-02-01

In the present study, microstructure and the corrosion behavior of Nickel based superalloy 686 and its weld joints has been investigated by synthetic sea water environment. The weldments were fabricated by Gas Tungsten Arc Welding (GTAW) and Pulsed Current Gas Tungsten Arc Welding (PCGTAW) techniques with autogenous mode and three different filler wires (ERNiCrMo-4, ERNiCrMo-10 and ERNiCrMo-14). Microstructure and Scanning electron microscope examination was carried out to evaluate the structural changes in the fusion zones of different weldments. Energy Dispersive X-ray Spectroscopy (EDS) analysis was carried out to evaluate the microsegregation of alloying elements in the different weld joints. Potentiodynamic polarization study was experimented on the base metal and weld joints in the synthetic sea water environment to evaluate the corrosion rate. Tafel’s interpolation technique was used to obtain the corrosion rate. The microstructure examination revealed that the fine equiaxed dendrites were observed in the pulsed current mode. EDS analysis shows the absence of microsegregation in the current pulsing technique. The corrosion rates of weldments are compared with the base metal. The results show that the fine microstructure with the absence of microsegregation in the PCGTA weldments shows improved corrosion resistance compared to the GTAW. Autogenous PCGTAW shows higher corrosion resistance irrespective of all weldments employed in the present study.

Comparison of three‐dimensional analysis and stereological techniques for quantifying lithium‐ion battery electrode microstructures

PubMed Central

TAIWO, OLUWADAMILOLA O.; FINEGAN, DONAL P.; EASTWOOD, DAVID S.; FIFE, JULIE L.; BROWN, LEON D.; DARR, JAWWAD A.; LEE, PETER D.; BRETT, DANIEL J.L.

2016-01-01

Summary Lithium‐ion battery performance is intrinsically linked to electrode microstructure. Quantitative measurement of key structural parameters of lithium‐ion battery electrode microstructures will enable optimization as well as motivate systematic numerical studies for the improvement of battery performance. With the rapid development of 3‐D imaging techniques, quantitative assessment of 3‐D microstructures from 2‐D image sections by stereological methods appears outmoded; however, in spite of the proliferation of tomographic imaging techniques, it remains significantly easier to obtain two‐dimensional (2‐D) data sets. In this study, stereological prediction and three‐dimensional (3‐D) analysis techniques for quantitative assessment of key geometric parameters for characterizing battery electrode microstructures are examined and compared. Lithium‐ion battery electrodes were imaged using synchrotron‐based X‐ray tomographic microscopy. For each electrode sample investigated, stereological analysis was performed on reconstructed 2‐D image sections generated from tomographic imaging, whereas direct 3‐D analysis was performed on reconstructed image volumes. The analysis showed that geometric parameter estimation using 2‐D image sections is bound to be associated with ambiguity and that volume‐based 3‐D characterization of nonconvex, irregular and interconnected particles can be used to more accurately quantify spatially‐dependent parameters, such as tortuosity and pore‐phase connectivity. PMID:26999804

Comparison of three-dimensional analysis and stereological techniques for quantifying lithium-ion battery electrode microstructures.

PubMed

Taiwo, Oluwadamilola O; Finegan, Donal P; Eastwood, David S; Fife, Julie L; Brown, Leon D; Darr, Jawwad A; Lee, Peter D; Brett, Daniel J L; Shearing, Paul R

2016-09-01

Lithium-ion battery performance is intrinsically linked to electrode microstructure. Quantitative measurement of key structural parameters of lithium-ion battery electrode microstructures will enable optimization as well as motivate systematic numerical studies for the improvement of battery performance. With the rapid development of 3-D imaging techniques, quantitative assessment of 3-D microstructures from 2-D image sections by stereological methods appears outmoded; however, in spite of the proliferation of tomographic imaging techniques, it remains significantly easier to obtain two-dimensional (2-D) data sets. In this study, stereological prediction and three-dimensional (3-D) analysis techniques for quantitative assessment of key geometric parameters for characterizing battery electrode microstructures are examined and compared. Lithium-ion battery electrodes were imaged using synchrotron-based X-ray tomographic microscopy. For each electrode sample investigated, stereological analysis was performed on reconstructed 2-D image sections generated from tomographic imaging, whereas direct 3-D analysis was performed on reconstructed image volumes. The analysis showed that geometric parameter estimation using 2-D image sections is bound to be associated with ambiguity and that volume-based 3-D characterization of nonconvex, irregular and interconnected particles can be used to more accurately quantify spatially-dependent parameters, such as tortuosity and pore-phase connectivity. © 2016 The Authors. Journal of Microscopy published by John Wiley & Sons Ltd on behalf of Royal Microscopical Society.

Long-Term Morphological and Microarchitectural Stability of Tissue-Engineered, Patient-Specific Auricles In Vivo

PubMed Central

Cohen, Benjamin Peter; Hooper, Rachel C.; Puetzer, Jennifer L.; Nordberg, Rachel; Asanbe, Ope; Hernandez, Karina A.; Spector, Jason A.

2016-01-01

Current techniques for autologous auricular reconstruction produce substandard ear morphologies with high levels of donor-site morbidity, whereas alloplastic implants demonstrate poor biocompatibility. Tissue engineering, in combination with noninvasive digital photogrammetry and computer-assisted design/computer-aided manufacturing technology, offers an alternative method of auricular reconstruction. Using this method, patient-specific ears composed of collagen scaffolds and auricular chondrocytes have generated auricular cartilage with great fidelity following 3 months of subcutaneous implantation, however, this short time frame may not portend long-term tissue stability. We hypothesized that constructs developed using this technique would undergo continued auricular cartilage maturation without degradation during long-term (6 month) implantation. Full-sized, juvenile human ear constructs were injection molded from high-density collagen hydrogels encapsulating juvenile bovine auricular chondrocytes and implanted subcutaneously on the backs of nude rats for 6 months. Upon explantation, constructs retained overall patient morphology and displayed no evidence of tissue necrosis. Limited contraction occurred in vivo, however, no significant change in size was observed beyond 1 month. Constructs at 6 months showed distinct auricular cartilage microstructure, featuring a self-assembled perichondrial layer, a proteoglycan-rich bulk, and rounded cellular lacunae. Verhoeff's staining also revealed a developing elastin network comparable to native tissue. Biochemical measurements for DNA, glycosaminoglycan, and hydroxyproline content and mechanical properties of aggregate modulus and hydraulic permeability showed engineered tissue to be similar to native cartilage at 6 months. Patient-specific auricular constructs demonstrated long-term stability and increased cartilage tissue development during extended implantation, and offer a potential tissue-engineered solution for the future of auricular reconstructions. PMID:26847742

Photopatterned free-standing polyacrylamide gels for microfluidic protein electrophoresis.

PubMed

Duncombe, Todd A; Herr, Amy E

2013-06-07

Designed for compatibility with slab-gel polyacrylamide gel electrophoresis (PAGE) reagents and instruments, we detail development of free-standing polyacrylamide gel (fsPAG) microstructures supporting electrophoretic performance rivalling that of microfluidic platforms. For the protein electrophoresis study described here, fsPAGE lanes are comprised of a sample reservoir and contiguous separation gel. No enclosed microfluidic channels are employed. The fsPAG devices (120 μm tall) are directly photopatterned atop of and covalently attached to planar polymer or glass surfaces. Leveraging the fast <1 h design-prototype-test cycle - significantly faster than mold based fabrication techniques - we optimize the fsPAG architecture to minimize injection dispersion for rapid (<1 min) and short (1 mm) protein separations. The facile fabrication and prototyping of the fsPAGE provides researchers a powerful tool for developing custom analytical assays. We highlight the utility of assay customization by fabricating a polyacrylamide gel with a spatial pore-size distribution and demonstrate the resulting enhancement in separation performance over a uniform gel. Further, we up-scale from a unit separation to an array of 96 concurrent fsPAGE assays in 10 min run time driven by one electrode pair. The fsPAG array layout matches that of a 96-well plate to facilitate integration of the planar free standing gel array with multi-channel pipettes while remaining compatible with conventional slab-gel PAGE reagents, such as staining for label-free protein detection. Notably, the entire fsPAGE workflow from fabrication, to operation, and readout uses readily available materials and instruments - making this technique highly accessible.

Self-assembled biomimetic antireflection coatings

NASA Astrophysics Data System (ADS)

Linn, Nicholas C.; Sun, Chih-Hung; Jiang, Peng; Jiang, Bin

2007-09-01

The authors report a simple self-assembly technique for fabricating antireflection coatings that mimic antireflective moth eyes. Wafer-scale, nonclose-packed colloidal crystals with remarkable large hexagonal domains are created by a spin-coating technology. The resulting polymer-embedded colloidal crystals exhibit highly ordered surface modulation and can be used directly as templates to cast poly(dimethylsiloxane) (PDMS) molds. Moth-eye antireflection coatings with adjustable reflectivity can then be molded against the PDMS master. The specular reflection of replicated nipple arrays matches the theoretical prediction using a thin-film multilayer model. These biomimetic films may find important technological application in optical coatings and solar cells.

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.

The Effects of micro Aluminum fillers In Epoxy resin on the thermal conductivity

NASA Astrophysics Data System (ADS)

Jasim, Kareem A.; Fadhil, Rihab N.

2018-05-01

A hand lay-up molding method was used to prepare Epoxy / Aluminum composites. As a matrix used Epoxy resin (EP) with reinforced by Aluminum particles. The preparation technique includes preparing carousel mold with different weight percentage of fillers (0, 0.05, 0.15, 0.25, 0.35, and 0.45). Standard specimens (in 30 mm diameter) were prepared to the thermal conductivity tests. The result of experimental thermal conductivity (k), for EP/Aluminum composites show that, k increase with increasing Aluminums percentage and it have maximum values of (1.4595 W/m.K).

Mass Culture of a Slime Mold, Physarum polycephalum1

PubMed Central

Brewer, E. N.; Kuraishi, S.; Garver, J. C.; Strong, F. M.

1964-01-01

The slime mold, Physarum polycephalum, was cultivated in a soluble natural medium in shake flasks and in 30-liter and 50-gal conventional baffled fermentors. Yields of 6 to 10 g (dry weight) per liter were obtained in the large-scale fermentations. Because of the slow growth of the myxomycete, particular attention had to be paid to aseptic technique. The inability of this organism to withstand the normal degree of agitation employed with most aerobic fermentations made it difficult to obtain adequate aeration. Conditions for growth of the organism on a pilot-plant scale are presented. PMID:14131366

Imaging subtle microstructural variations in ceramics with precision ultrasonic velocity and attenuation measurements

NASA Technical Reports Server (NTRS)

Generazio, Edward R.; Roth, Don J.; Baaklini, George Y.

1987-01-01

Acoustic images of a silicon carbide ceramic disk were obtained using a precision scanning contact pulse echo technique. Phase and cross-correlation velocity, and attenuation maps were used to form color images of microstructural variations. These acoustic images reveal microstructural variations not observable with X-ray radiography.

Microstructural and microtextural characterization of oxide scale on steel using electron backscatter diffraction.

PubMed

Birosca, S; Dingley, D; Higginson, R L

2004-03-01

High-temperature oxidation of steel has been extensively studied. The microstructure of iron oxides is, however, not well understood because of the difficulty in imaging it using conventional methods, such as optical or electron microscopy. A knowledge of the oxide microstructure and texture is critical in understanding how the oxide film behaves during high-temperature deformation of steels and more importantly how it can be removed following processing. Recently, electron back-scatter diffraction (EBSD) has proved to be a powerful technique for distinguishing the different phases in scales. This technique gives valuable information both on the microstructure and on the orientation relationships between the steel and the scale layers. In the current study EBSD has been used to investigate the microstructure and microtexture of iron oxide layers grown on interstitial free steel at different times and temperatures. Heat treatments have been carried out under normal oxidation conditions in order to relate the results to real steel manufacturing in industry. The composition, morphologies, microstructure and microtexture of selected conditions have been studied using EBSD.

A front-end wafer-level microsystem packaging technique with micro-cap array

NASA Astrophysics Data System (ADS)

Chiang, Yuh-Min

2002-09-01

The back-end packaging process is the remaining challenge for the micromachining industry to commercialize microsystem technology (MST) devices at low cost. This dissertation presents a novel wafer level protection technique as a final step of the front-end fabrication process for MSTs. It facilitates improved manufacturing throughput and automation in package assembly, wafer level testing of devices, and enhanced device performance. The method involves the use of a wafer-sized micro-cap array, which consists of an assortment of small caps micro-molded onto a material with adjustable shapes and sizes to serve as protective structures against the hostile environments during packaging. The micro-cap array is first constructed by a micromachining process with micro-molding technique, then sealed to the device wafer at wafer level. Epoxy-based wafer-level micro cap array has been successfully fabricated and showed good compatibility with conventional back-end packaging processes. An adhesive transfer technique was demonstrated to seal the micro cap array with a MEMS device wafer. No damage or gross leak was observed while wafer dicing or later during a gross leak test. Applications of the micro cap array are demonstrated on MEMS, microactuators fabricated using CRONOS MUMPS process. Depending on the application needs, the micro-molded cap can be designed and modified to facilitate additional component functions, such as optical, electrical, mechanical, and chemical functions, which are not easily achieved in the device by traditional means. Successful fabrication of a micro cap array comprised with microlenses can provide active functions as well as passive protection. An optical tweezer array could be one possibility for applications of a micro cap with microlenses. The micro cap itself could serve as micro well for DNA or bacteria amplification as well.

Simultaneous fabrication of very high aspect ratio positive nano- to milliscale structures.

PubMed

Chen, Long Qing; Chan-Park, Mary B; Zhang, Qing; Chen, Peng; Li, Chang Ming; Li, Sai

2009-05-01

A simple and inexpensive technique for the simultaneous fabrication of positive (i.e., protruding), very high aspect (>10) ratio nanostructures together with micro- or millistructures is developed. The method involves using residual patterns of thin-film over-etching (RPTO) to produce sub-micro-/nanoscale features. The residual thin-film nanopattern is used as an etching mask for Si deep reactive ion etching. The etched Si structures are further reduced in size by Si thermal oxidation to produce amorphous SiO(2), which is subsequently etched away by HF. Two arrays of positive Si nanowalls are demonstrated with this combined RPTO-SiO(2)-HF technique. One array has a feature size of 150 nm and an aspect ratio of 26.7 and another has a feature size of 50 nm and an aspect ratio of 15. No other parallel reduction technique can achieve such a very high aspect ratio for 50-nm-wide nanowalls. As a demonstration of the technique to simultaneously achieve nano- and milliscale features, a simple Si nanofluidic master mold with positive features with dimensions varying continuously from 1 mm to 200 nm and a highest aspect ratio of 6.75 is fabricated; the narrow 200-nm section is 4.5 mm long. This Si master mold is then used as a mold for UV embossing. The embossed open channels are then closed by a cover with glue bonding. A high aspect ratio is necessary to produce unblocked closed channels after the cover bonding process of the nanofluidic chip. The combined method of RPTO, Si thermal oxidation, and HF etching can be used to make complex nanofluidic systems and nano-/micro-/millistructures for diverse applications.

Measuring Weld Profiles By Computer Tomography

NASA Technical Reports Server (NTRS)

Pascua, Antonio G.; Roy, Jagatjit

1990-01-01

Noncontacting, nondestructive computer tomography system determines internal and external contours of welded objects. System makes it unnecessary to take metallurgical sections (destructive technique) or to take silicone impressions of hidden surfaces (technique that contaminates) to inspect them. Measurements of contours via tomography performed 10 times as fast as measurements via impression molds, and tomography does not contaminate inspected parts.

Nasal changes with nasoalveolar molding in Colombian patients with unilateral cleft lip and palate.

PubMed

López-Palacio, Ana María; Cerón-Zapata, Ana María; Gómez, David F; Dávila-Calle, Angela P; Ojalvo-Arias, María Adelaida

2012-01-01

Presurgical nasoalveolar molding (PNAM) is controversial in maxillofacial orthopedics. It supposedly improves the nasal esthetics and function in unilateral cleft lip/palate (UCLP) patients. However, there is no research available in South America to support this claim. The purpose of this study was to evaluate the efficacy of presurgical nasoalveolar molding therapy on morphological changes of the noses of unilateral cleft lip/palate patients in a Colombian sample. Seventeen neonate UCLP patients using PNAM received facial impressions at the beginning of treatment; before primary rhinocheiloplasty; and before palatoplasty. A submentovertex photograph of each cast was taken and analyzed by digital photogrammetry. Wilcoxon and Friedman tests were used for within- and between-group comparisons. A statistically significant reduction of cleft nostril width, without significant changes in noncleft nostril width or total nasal width, was found after PNAM. A significant increase in cleft and noncleft nostril height, plus a nonsignificant increase in nostril area in both sides and a nonsignificant uprighting of the columella were found. These changes were maintained or further improved after rhinocheiloplasty. The presurgical nasoalveolar molding technique improved nasal tip projection and alar cartilage depression and decreased partially columella deviation before rhinocheiloplasty in South American unilateral cleft lip/palate patients.

A 3D visualization system for molecular structures

NASA Technical Reports Server (NTRS)

Green, Terry J.

1989-01-01

The properties of molecules derive in part from their structures. Because of the importance of understanding molecular structures various methodologies, ranging from first principles to empirical technique, were developed for computing the structure of molecules. For large molecules such as polymer model compounds, the structural information is difficult to comprehend by examining tabulated data. Therefore, a molecular graphics display system, called MOLDS, was developed to help interpret the data. MOLDS is a menu-driven program developed to run on the LADC SNS computer systems. This program can read a data file generated by the modeling programs or data can be entered using the keyboard. MOLDS has the following capabilities: draws the 3-D representation of a molecule using stick, ball and ball, or space filled model from Cartesian coordinates, draws different perspective views of the molecule; rotates the molecule on the X, Y, Z axis or about some arbitrary line in space, zooms in on a small area of the molecule in order to obtain a better view of a specific region; and makes hard copy representation of molecules on a graphic printer. In addition, MOLDS can be easily updated and readily adapted to run on most computer systems.

An improved compression molding technology for continuous fiber reinforced composite laminate. Part 1: AS-4/LaRC-TPI 1500 (HFG) Prepreg system

NASA Technical Reports Server (NTRS)

Hou, Tan-Hung; Kidder, Paul W.; Reddy, Rakasi M.

1991-01-01

Poor processability of fiber reinforced high performance polyimide thermoplastic resin composites is a well recognized issue which, in many cases, prohibits the fabrication of composite parts with satisfactorily consolidated quality. Without modifying the resin matrix chemistry, improved compression modeling procedures were proposed and investigated with the AS-4/LaRC-TPI 1500 High Flow Grade (HFG) prepreg system. Composite panels with excellent C-scans can be consistently molded by this method under 700 F and a consolidation pressure as low as 100 psi. A mechanism for the consolidation of the composite under this improved molding technique is discussed. This mechanism reveals that a certain degree of matrix shear and tow filament slippage and nesting between plies occur during consolidation, which leads to a reduction of the consolidating pressure necessary to offset the otherwise intimate inter fiber-fiber contact and consequently achieves a better consolidation quality. Outstanding short beam shear strength and flexural strength were obtained from the molded panels. A prolonged consolidation step under low pressure, i.e., 100 psi at 700 F for 75 minutes, was found to significantly enhance the composite mechanical properties.

Fabrication process analysis and experimental verification for aluminum bipolar plates in fuel cells by vacuum die-casting

NASA Astrophysics Data System (ADS)

Jin, Chul Kyu; Kang, Chung Gil

2011-10-01

There are various methods for the fabrication of bipolar plates, but these are still limited to machining and stamping processes. High-pressure die casting (HPDC) is an ideal process for the manufacture of bipolar plates This study aims to investigate the formability of bipolar plates for polymer electrolyte membrane fuel cells (PEMFCs) fabricated by vacuum HPDC of an Al-Mg alloy (ALDC6). The cavity of the mold consisted of a thin-walled plate (200 mm × 200 mm × 0.8 mm) with a layer of serpentine channel (50 mm × 50 mm). The location and direction of the channel in the final mold design was determined by computational simulation (MAGMA soft). In addition, simulation results for different conditions of plunger stroke control were compared to those from actual die-casting experiments. Under a vacuum pressure of 35 kPa and for injection speeds of 0.3 and 2.5 m s-1 in the low and high speed regions, respectively, the samples had few casting defects. In addition, the hardness was higher and porosity in microstructure was less than those of the samples made under other injection speed conditions. In case of thin-walled plates, vacuum die casting is beneficial in terms of formability compared to conventional die casting.

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%. Copyright © 2016 Elsevier Ltd. All rights reserved.

Experimental investigation on in-situ microwave casting of copper

NASA Astrophysics Data System (ADS)

Raman Mishra, Radha; Sharma, Apurbba Kumar

2018-04-01

The in-situ microwave casting of metallic materials is a recently developed casting process. The process works on the principles of hybrid microwave heating and is accomplished inside the applicator cavity. The process involves – melting of the charge, in-situ pouring and solidification of the melt. The electromagnetic and thermal properties of the charge affects microwave-material interaction and hence melting of the charge. On the other hand, cooling conditions inside the applicator controls solidification process. The present work reports on in-situ casting of copper developed inside a multimode cavity at 2.45 GHz using 1400 W. The molten metal was allowed to get poured in-situ inside a graphite mold and solidification was carried out in the same mold inside the applicator cavity. The interaction of microwave with the charge during exposure was studied and the role of oxide layer during meltingthe copper blocks has been presented. The developed in-situ cast was characterized to access the cast quality. Microstructural study revealed the homogeneous and dense structure of the cast. The X-ray diffraction pattern indicated presence of copper in different orientations with (1 1 1) as the dominant orientation. The average micro indentation hardness of the casts was found 93±20 HV.

Coupled Oscillators System in the True Slime Mold

NASA Astrophysics Data System (ADS)

Takamatsu, A.; Fujii, T.; Endo, I.

The Plasmodium of true slime mold, Physarum polycephalum, which shows various oscillatory phenomena, can be regarded as a coupled nonlinear oscillators system. The partial bodies of the Plasmodium are interconnected by microscale tubes, whose dimension can be related to the coupling strength between the plasmodial oscillators. Investigation on the collective behavior of the oscillators under the condition that the configuration of the tube structure can be manipulated gives significant information on the characteristics of the Plasmodium from the viewpoint of nonlinear dynamics. In this study, we propose a living coupled oscillators system. Using a microfabricated structure, we patterned the geometry and the dimensions of the microscale tube structure of the Plasmodium. As the first step, the Plasmodium was grown in the microstructure for coupled two oscillators system that has two wells (oscillator part) and a microchannel (coupling part). We investigated the oscillation bahavior by monitoring the thickness oscillation of Plasmodium in the strucutre with various width (W) and length (L) of microchannel. We found that there are various types of oscillation bahavior, such as anti-phase and in-phase oscillations depending on the channel dimension W and L. The present method is suitable for further studies of the network of the Plasmodium as a collective nonlinear oscillators system.

Engineering specification and system design for CAD/CAM of custom shoes: UMC project effort

NASA Technical Reports Server (NTRS)

Bao, Han P.

1990-01-01

Further experimentations were made to improve the design and fabrication techniques of the integrated sole. The sole design is shown to be related to the foot position requirements and the actual shape of the foot including presence of neurotropic ulcers or other infections. Factors for consideration were: heel pitch, balance line, and rigidity conditions of the foot. Machining considerations were also part of the design problem. Among these considerations, widths of each contour, tool motion, tool feed rate, depths of cut, and slopes of cut at the boundary were the key elements. The essential fabrication techniques evolved around the idea of machining a mold then, using quick-firm latex material, casting the sole through the mold. Two main mold materials were experimented with: plaster and wood. Plaster was very easy to machine and shape but could barely support the pressure in the hydraulic press required by the casting process. Wood was found to be quite effective in terms of relative cost, strength, and surface smoothness except for the problem of cutting against the fibers which could generate ragged surfaces. The programming efforts to convert the original dBase programs into C programs so that they could be executed on the SUN Computer at North Carolina State University are discussed.

Assembly of metallic nanoparticle arrays on glass via nanoimprinting and thin-film dewetting

PubMed Central

Lee, Sun-Kyu; Hwang, Sori; Kim, Yoon-Kee

2017-01-01

We propose a nanofabrication process to generate large-area arrays of noble metal nanoparticles on glass substrates via nanoimprinting and dewetting of metallic thin films. Glass templates were made via pattern transfer from a topographic Si mold to an inorganically cross-linked sol–gel (IGSG) resist on glass using a two-layer polydimethylsiloxane (PDMS) stamp followed by annealing, which turned the imprinted resist into pure silica. The transparent, topographic glass successfully templated the assembly of Au and Ag nanoparticle arrays via thin-film deposition and dewetting at elevated temperatures. The microstructural and mechanical characteristics that developed during the processes were discussed. The results are promising for low-cost mass fabrication of devices for several photonic applications. PMID:28546899

Assembly of metallic nanoparticle arrays on glass via nanoimprinting and thin-film dewetting.

PubMed

Lee, Sun-Kyu; Hwang, Sori; Kim, Yoon-Kee; Oh, Yong-Jun

2017-01-01

We propose a nanofabrication process to generate large-area arrays of noble metal nanoparticles on glass substrates via nanoimprinting and dewetting of metallic thin films. Glass templates were made via pattern transfer from a topographic Si mold to an inorganically cross-linked sol-gel (IGSG) resist on glass using a two-layer polydimethylsiloxane (PDMS) stamp followed by annealing, which turned the imprinted resist into pure silica. The transparent, topographic glass successfully templated the assembly of Au and Ag nanoparticle arrays via thin-film deposition and dewetting at elevated temperatures. The microstructural and mechanical characteristics that developed during the processes were discussed. The results are promising for low-cost mass fabrication of devices for several photonic applications.

Multi-Scale Porous Ultra High Temperature Ceramics

DTIC Science & Technology

2015-01-08

different techniques: replica, particle stabilized foams, ice templating (freeze casting) and partial sintering. The pore morphology (closed-bubble...the porosity, pore size, shape and morphology . X-Ray Tomography was used to study their 3D microstructure. The 3D microstructures captured with...four different techniques: replica, particle stabilized foams, ice templating (freeze casting) and partial sintering. The pore morphology (closed-bubble

Presurgical Nasoalveolar Molding for Correction of Cleft Lip Nasal Deformity: Experience From Northern India

PubMed Central

Mishra, Brijesh; Singh, Arun K.; Zaidi, Javed; Singh, G. K.; Agrawal, Rajiv; Kumar, Vijay

2010-01-01

Context: The cleft lip type nasal deformity presents one of the most complex surgical challenges. The long-term postoperative results are still not satisfactory despite an emphasis on primary nasal correction. This is attributed to tissue memory and healing. Nasoalveolar molding is used effectively to reshape the nasal cartilage and to mold the maxillary arch before cleft lip repair. Aims: This study was undertaken to evaluate the role of presurgical nasoalveolar molding in correction of cleft lip nasal deformity for patients with unilateral and bilateral clefts of the lip. Settings and Design: Twenty-three cases of clefts of lip and palate with nasal deformity were subjected to present study from May 2004 to May 2006. These cases were initially treated on outpatient basis, and they were admitted at the time of operation. All of these patients were children of less than 1 year of age, belonging to north Indian population. Material and Methods: Study consisted of patients of cleft lip and palate who were given presurgical nasoalveolar splints at early age. Lip repair was done after at least 2 months of molding. These patients along with control group (without presurgical nasoalveolar molding) were followed up for 1 year. Measurements were taken at different intervals in study over dental cast and on patients. Data obtained from comparison of 2 groups were analyzed using “MSTAT” analysis software (developed by Dr Russel Freed, Professor & Director, Crop & Soil Sciences Department, Michigan State University, East Lansing, Michigan). Results: In our study, we found that nostril height was more in patients of experimental group (P = .18), while nostril width and alar perimeter were not changed significantly. Children with nasoalveolar molding had significant lengthening of columella (P = .02). Patients of unilateral cleft lip had more reduction in alveolar gap (P = .08) than bilateral group (P = .15). Conclusions: Nasoalveolar molding can be a useful adjunct for treatment of cleft lip nasal deformity. It is a cost-effective technique that can reduce the number of future surgeries such as alveolar bone grafting and secondary rhinoplasties. PMID:20694165

Soft lithography using perfluorinated polyether molds and PRINT technology for fabrication of 3-D arrays on glass substrates

NASA Astrophysics Data System (ADS)

Wiles, Kenton B.; Wiles, Natasha S.; Herlihy, Kevin P.; Maynor, Benjamin W.; Rolland, Jason P.; DeSimone, Joseph M.

2006-03-01

The fabrication of nanometer size structures and complex devices for microelectronics is of increasing importance so as to meet the challenges of large-scale commercial applications. Soft lithography typically employs elastomeric polydimethylsiloxane (PDMS) molds to replicate micro- and nanoscale features. However, the difficulties of PDMS for nanoscale fabrication include inherent incompatibility with organic liquids and the production of a residual scum or flash layer that link features where the nano-structures meet the substrate. An emerging technologically advanced technique known as Pattern Replication in Non-wetting Templates (PRINT) avoids both of these dilemmas by utilizing photocurable perfluorinated polyether (PFPE) rather than PDMS as the elastomeric molding material. PFPE is a liquid at room temperature that exhibits low modulus and high gas permeability when cured. The highly fluorinated PFPE material allows for resistance to swelling by organic liquids and very low surface energies, thereby preventing flash layer formation and ease of separation of PFPE molds from the substrates. These enhanced characteristics enable easy removal of the stamp from the molded material, thereby minimizing damage to the nanoscale features. Herein we describe that PRINT can be operated in two different modes depending on whether the objects to be molded are to be removed and harvested (i.e. to make shape specific organic particles) or whether scum free objects are desired which are adhered onto the substrate (i.e. for scum free pattern generation using imprint lithography). The former can be achieved using a non-reactive, low surface energy substrate (PRINT: Particle Replication in Non-wetting Templates) and the latter can be achieved using a reactive, low surface energy substrate (PRINT: Pattern Replication in Non-wetting Templates). We show that the PRINT technology can been used to fabricate nano-particle arrays covalently bound to a glass substrate with no scum layer. The nanometer size arrays were fabricated using a PFPE mold and a self-assembled monolayer (SAM) fluorinated glass substrate that was also functionalized with free-radically reactive SAM methacrylate moieties. The molded polymeric materials were covalently bound to the glass substrate through thermal curing with the methacrylate groups to permit three dimensional array fabrication. The low surface energies of the PFPE mold and fluorinated glass substrate allowed for no flash layer formation, permitting well resolved structures.

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

DOE Office of Scientific and Technical Information (OSTI.GOV)

Nguyen, Ba Nghiep; Sanborn, Scott E.; Mathur, Raj N.

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/PA66more » (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 support part molding. 12) Toyota and Magna discussed with PNNL on tool modification for molding the complex part. Toyota sent the CAD files of the complex part to PNNL to build ASMI models of the part for mold filling analysis to provide guidance to tooling and part molding.« less

A simulated RTM process for fabricating polyimide (AMB-21) carbon fiber composites

NASA Technical Reports Server (NTRS)

Avva, V. Sarma; Sadler, Robert L.; Thomas, Shanon

1995-01-01

An experimental polyimide matrix, AMB-21 - supplied by NASA/LeRC, was especially formulated to be non-carcinogenic. It was also expected to be amenable to a Resin Transfer Molding Process (RTM). AMB-21 is a solid at room temperature and must be heated to a very high temperature to obtain a fluid state. However, even after heating it to a realistic high temperature, it was found to be too viscous for use in a RTM process. As a result, a promising approach was experimented leading to the introduction of the resin into a solvent solution in order to obtain a viscosity suitable for RTM. A mixture of methanol and tetrahydroferone was found to be a suitable solvent mixture. The matrix solution was introduced into carbon-fiber preform using two techniques: (1) injection of matrix into a Resin Transfer Mold after positioning the preform into the 'mold cavity', and (2) infiltration of matrix into the preform using the 'autoclave through-the-thickness transfer process'. After completing the resin transfer (infiltration) process, the 'filled' preform was heated to 300 F for one hour to reduce the solvent content. The temperature was then increased to 400 F under a vacuum to complete the solvent evaporation and to remove volatile products of the polyimide imidization. The impregnated preform was removed from the mold and press-cured at 200 psi and 600 FF for two hours. The resulting panel was found to be of reasonably good quality. This observation was based on the results obtained from short beam shear strength (700-8000 psi) tests and microscopic examination of the cross-section indicating a very low level of porosity. Further, the flash around the molded panels from the compression molding was free of porosity indicating the removal of volatiles, solvents, and other imidization products. Based on these studies, a new RTM mold containing a diaphragm capable of applying 200 psi at 600 F has been designed and constructed with the expectation that it will allow the incorporation of all of the above processing steps, including the consolidation with the preform in the mold cavity. Moreover, the new diaphragm design will enable to process larger preform panels. Processing studies with the diaphragm mold are being initiated.

Neural autoantibodies and neurophysiologic abnormalities in patients exposed to molds in water-damaged buildings.

PubMed

Campbell, Andrew W; Thrasher, Jack D; Madison, Roberta A; Vojdani, Aristo; Gray, Michael R; Johnson, Al

2003-08-01

Adverse health effects of fungal bioaerosols on occupants of water-damaged homes and other buildings have been reported. Recently, it has been suggested that mold exposure causes neurological injury. The authors investigated neurological antibodies and neurophysiological abnormalities in patients exposed to molds at home who developed symptoms of peripheral neuropathy (i.e., numbness, tingling, tremors, and muscle weakness in the extremities). Serum samples were collected and analyzed with the enzyme-linked immunosorbent assay (ELISA) technique for antibodies to myelin basic protein, myelin-associated glycoprotein, ganglioside GM1, sulfatide, myelin oligodendrocyte glycoprotein, alpha-B-crystallin, chondroitin sulfate, tubulin, and neurofilament. Antibodies to molds and mycotoxins were also determined with ELISA, as reported previously. Neurophysiologic evaluations for latency, amplitude, and velocity were performed on 4 motor nerves (median, ulnar, peroneal, and tibial), and for latency and amplitude on 3 sensory nerves (median, ulnar, and sural). Patients with documented, measured exposure to molds had elevated titers of antibodies (immunoglobulin [Ig]A, IgM, and IgG) to neural-specific antigens. Nerve conduction studies revealed 4 patient groupings: (1) mixed sensory-motor polyneuropathy (n = 55, abnormal), (2) motor neuropathy (n = 17, abnormal), (3) sensory neuropathy (n = 27, abnormal), and (4) those with symptoms but no neurophysiological abnormalities (n = 20, normal controls). All groups showed significantly increased autoantibody titers for all isotypes (IgA, IgM, and IgG) of antibodies to neural antigens when compared with 500 healthy controls. Groups 1 through 3 also exhibited abnormal neurophysiologic findings. The authors concluded that exposure to molds in water-damaged buildings increased the risk for development of neural autoantibodies, peripheral neuropathy, and neurophysiologic abnormalities in exposed individuals.

Airborne Mold and Endotoxin Concentrations in New Orleans, Louisiana, after Flooding, October through November 2005

PubMed Central

Solomon, Gina M.; Hjelmroos-Koski, Mervi; Rotkin-Ellman, Miriam; Hammond, S. Katharine

2006-01-01

Background The hurricanes and flooding in New Orleans, Louisiana, in October and November 2005 resulted in damp conditions favorable to the dispersion of bioaerosols such as mold spores and endotoxin. Objective Our objective in this study was to assess potential human exposure to bioaerosols in New Orleans after the flooding of the city. Methods A team of investigators performed continuous airborne sampling for mold spores and endotoxin outdoors in flooded and nonflooded areas, and inside homes that had undergone various levels of remediation, for periods of 5–24 hr during the 2 months after the flooding. Results The estimated 24-hr mold concentrations ranged from 21,000 to 102,000 spores/m3 in outdoor air and from 11,000 to 645,000 spores/m3 in indoor air. The mean outdoor spore concentration in flooded areas was roughly double the concentration in nonflooded areas (66,167 vs. 33,179 spores/m3; p < 0.05). The highest concentrations were inside homes. The most common mold species were from the genera of Cladosporium and Aspergillus/Penicillium; Stachybotrys was detected in some indoor samples. The airborne endotoxin concentrations ranged from 0.6 to 8.3 EU (endo-toxin units)/m3 but did not vary with flooded status or between indoor and outdoor environments. Conclusions The high concentration of mold measured indoors and outdoors in the New Orleans area is likely to be a significant respiratory hazard that should be monitored over time. Workers and returning residents should use appropriate personal protective equipment and exposure mitigation techniques to prevent respiratory morbidity and long-term health effects. PMID:16966092

Cell origami: self-folding of three-dimensional cell-laden microstructures driven by cell traction force.

PubMed

Kuribayashi-Shigetomi, Kaori; Onoe, Hiroaki; Takeuchi, Shoji

2012-01-01

This paper describes a method of generating three-dimensional (3D) cell-laden microstructures by applying the principle of origami folding technique and cell traction force (CTF). We harness the CTF as a biological driving force to fold the microstructures. Cells stretch and adhere across multiple microplates. Upon detaching the microplates from a substrate, CTF causes the plates to lift and fold according to a prescribed pattern. This self-folding technique using cells is highly biocompatible and does not involve special material requirements for the microplates and hinges to induce folding. We successfully produced various 3D cell-laden microstructures by just changing the geometry of the patterned 2D plates. We also achieved mass-production of the 3D cell-laden microstructures without causing damage to the cells. We believe that our methods will be useful for biotechnology applications that require analysis of cells in 3D configurations and for self-assembly of cell-based micro-medical devices.

The Development of Layered Photonic Band Gap Structures Using a Micro-Transfer Molding Technique

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sutherland, Kevin Jerome

Photonic band gap (PBG) crystals are periodic dielectric structures that manipulate electromagnetic radiation in a manner similar to semiconductor devices manipulating electrons. Whereas a semiconductor material exhibits an electronic band gap in which electrons cannot exist, similarly, a photonic crystal containing a photonic band gap does not allow the propagation of specific frequencies of electromagnetic radiation. This phenomenon results from the destructive Bragg diffraction interference that a wave propagating at a specific frequency will experience because of the periodic change in dielectric permitivity. This gives rise to a variety of optical applications for improving the efficiency and effectiveness of opto-electronicmore » devices. These applications are reviewed later. Several methods are currently used to fabricate photonic crystals, which are also discussed in detail. This research involves a layer-by-layer micro-transfer molding ({mu}TM) and stacking method to create three-dimensional FCC structures of epoxy or titania. The structures, once reduced significantly in size can be infiltrated with an organic gain media and stacked on a semiconductor to improve the efficiency of an electronically pumped light-emitting diode. Photonic band gap structures have been proven to effectively create a band gap for certain frequencies of electro-magnetic radiation in the microwave and near-infrared ranges. The objective of this research project was originally two-fold: to fabricate a three dimensional (3-D) structure of a size scaled to prohibit electromagnetic propagation within the visible wavelength range, and then to characterize that structure using laser dye emission spectra. As a master mold has not yet been developed for the micro transfer molding technique in the visible range, the research was limited to scaling down the length scale as much as possible with the current available technology and characterizing these structures with other methods.« less

Predicting Stress vs. Strain Behaviors of Thin-Walled High Pressure Die Cast Magnesium Alloy with Actual Pore Distribution

DOE Office of Scientific and Technical Information (OSTI.GOV)

Choi, Kyoo Sil; Barker, Erin; Cheng, Guang

2016-01-06

In this paper, a three-dimensional (3D) microstructure-based finite element modeling method (i.e., extrinsic modeling method) is developed, which can be used in examining the effects of porosity on the ductility/fracture of Mg castings. For this purpose, AM60 Mg tensile samples were generated under high-pressure die-casting in a specially-designed mold. Before the tensile test, the samples were CT-scanned to obtain the pore distributions within the samples. 3D microstructure-based finite element models were then developed based on the obtained actual pore distributions of the gauge area. The input properties for the matrix material were determined by fitting the simulation result to themore » experimental result of a selected sample, and then used for all the other samples’ simulation. The results show that the ductility and fracture locations predicted from simulations agree well with the experimental results. This indicates that the developed 3D extrinsic modeling method may be used to examine the influence of various aspects of pore sizes/distributions as well as intrinsic properties (i.e., matrix properties) on the ductility/fracture of Mg castings.« less

Development of ultrafine Ti-Fe-Sn in-situ composite with enhanced plasticity

NASA Astrophysics Data System (ADS)

Mondal, B.; Samal, S.; Biswas, K.; Govind

2012-01-01

The present investigation is aimed at developing ultrafine eutectic/dendrite Ti-Fe-Sn in-situ composite with balanced combination of strength and plasticity. It also studies the microstructure evolution in the series of hypereutectic Ti-Fe-Sn ternary alloys. Sn concentration of these alloys has been varied from 0 - 10 atom% in the binary alloy (Ti71Fe29) keeping the Ti concentration fixed. These alloys have been prepared by arc melting under an Ar atmosphere on a water-cooled Cu hearth, which are subsequently suction cast in a split Cu-mold under an Ar atmosphere. Detailed X-ray diffraction (XRD) study shows the presence of TiFe, β-Ti, and Ti3Sn phases. The SEM micrographs reveal that the microstructures consist of fine scale eutectic matrix (β-Ti and TiFe) with primary dendrite phases (TiFe and/or Ti3Sn) depending on concentration of Sn. α -Ti forms as a eutectoid reaction product of β-Ti. The room temperature uniaxial compressive test reveals simultaneous improvement in the strength (1942 MPa) and plasticity (13.1 %) for Ti71Fe26Sn3 ternary alloy. The fracture surface indicates a ductile mode of fracture for the alloy.

High coercivity microcrystalline Nd-rich Nd-Fe-Co-Al-B bulk magnets prepared by direct copper mold casting

NASA Astrophysics Data System (ADS)

Zhao, L. Z.; Hong, Y.; Fang, X. G.; Qiu, Z. G.; Zhong, X. C.; Gao, X. S.; Liu, Z. W.

2016-06-01

High coercivity Nd25Fe40Co20Al15-xBx (x=7-15) hard magnets were prepared by a simple process of injection casting. Different from many previous investigations on nanocomposite compositions, the magnets in this work contain hard magnetic Nd2(FeCoAl)14B, Nd-rich, and Nd1+ε(FeCo)4B4 phases. The magnetic properties, phase evolution, and microstructure of the as-cast and annealed magnets were investigated. As the boron content increased from 7 to 11 at%, the intrinsic coercivity Hcj of the as-cast magnet increased from 816 to 1140 kA/m. The magnets annealed at 750 °C have shown more regular and smaller grains than the as-cast alloys, especially for the x=11 alloy. The high intrinsic coercivities for the annealed alloys with x=8~11 result from the presence of small-sized grains in the microstructure. The highest Hcj of 1427 kA/m was obtained for the heat treated alloy with x=10. This work provides an alternative approach for preparing fully dense Nd-rich bulk hard magnets with relatively good properties.

Melt-processed polymeric cellular dosage forms for immediate drug release.

PubMed

Blaesi, Aron H; Saka, Nannaji

2015-12-28

The present immediate-release solid dosage forms, such as the oral tablets and capsules, comprise granular matrices. While effective in releasing the drug rapidly, they are fraught with difficulties inherent in processing particulate matter. By contrast, liquid-based processes would be far more predictable; but the standard cast microstructures are unsuited for immediate-release because they resist fluid percolation and penetration. In this article, we introduce cellular dosage forms that can be readily prepared from polymeric melts by incorporating the nucleation, growth, and coalescence of microscopic gas bubbles in a molding process. We show that the cell topology and formulation of such cellular structures can be engineered to reduce the length-scale of the mass-transfer step, which determines the time of drug release, from as large as the dosage form itself to as small as the thickness of the cell wall. This allows the cellular dosage forms to achieve drug release rates over an order of magnitude faster compared with those of cast matrices, spanning the entire spectrum of immediate-release and beyond. The melt-processed polymeric cellular dosage forms enable predictive design of immediate-release solid dosage forms by tailoring microstructures, and could be manufactured efficiently in a single step.

Superplasticity of Annealed H13 Steel

PubMed Central

Duan, Zhenxin; Pei, Wen; Gong, Xuebo; Chen, Hua

2017-01-01

H13 steel is a widely used hot work die material. A new type of hot working method is imperative to develop complex and precise dies. In this paper, the heat treatment of H13 steel (AISI) was carried out by annealing, the final structure is a point or spherical pearlite, and the grain size is about 30–40 μm. The tensile properties of the annealed microstructure were investigated at 650, 750, and 850 °C with the strain rates of 1 × 10−3 s−1, 5 × 10−4 s−1, and 1 × 10−4 s−1. The tensile fracture and microstructure were analyzed by SEM and HREM. The results show that the tensile samples reach superplasticity at the strain rate of 1 × 10−4 s−1 in the temperature range of 750–850 °C. When the temperature is 850 °C, the maximum elongation rate reaches 112.5%. This demonstrates the possibility of making superplastic forming molds. During the tensile process, the refined M23C6 and other high hardness carbides which are dispersed uniformly in the matrix, effectively inhibits grain growth and hinders dislocation movement, leading to the improvement of plasticity. PMID:28773231

Molded transparent photopolymers and phase shift optics for fabricating three dimensional nanostructures

DOE PAGES

Jeon, Seokwoo; Shir, Daniel J.; Nam, Yun Suk; ...

2007-05-08

This paper introduces approaches that combine micro/nanomolding, or nanoimprinting, techniques with proximity optical phase mask lithographic methods to form three dimensional (3D) nanostructures in thick, transparent layers of photopolymers. The results demonstrate three strategies of this type, where molded relief structures in these photopolymers represent (i) fine (<1 μm) features that serve as the phase masks for their own exposure, (ii) coarse features (>1 μm) that are used with phase masks to provide access to large structure dimensions, and (iii) fine structures that are used together phase masks to achieve large, multilevel phase modulations. Several examples are provided, together withmore » optical modeling of the fabrication process and the transmission properties of certain of the fabricated structures. Lastly, these approaches provide capabilities in 3D fabrication that complement those of other techniques, with potential applications in photonics, microfluidics, drug delivery and other areas.« less

Micromolding of polymer waveguides

NASA Astrophysics Data System (ADS)

Hanemann, Thomas; Ulrich, Hermann; Ruprecht, Robert; Hausselt, Juergen H.

1999-10-01

In microsystem technology the fabrication of either passive or active micro optical components made from polymers becomes more and more evident with respect to the intense expanding application possibilities e.g. in telecommunication. Actually, the LIGA process developed at the FZK, Germany allows the direct fabrication of microcomponents with lateral dimensions in the micrometer range, structural details in the submicrometer range, high aspect ratios of up to several hundreds and a final average surface roughness of less than 50 nm in small up to large scales. The molding of polymer components for microoptical applications, especially in the singlemode range, is determined by the achievable maximum accuracy of the molding technique itself and of the acceptable tolerances for low damping and coupling losses. Following the LIGA and related technique e.g. mechanical microengineering we want to present in this work the fabrication of polymer singlemode waveguides using a combination of micromolding and light- curing steps.

Shrink-induced superhydrophobic and antibacterial surfaces in consumer plastics.

PubMed

Freschauf, Lauren R; McLane, Jolie; Sharma, Himanshu; Khine, Michelle

2012-01-01

Structurally modified superhydrophobic surfaces have become particularly desirable as stable antibacterial surfaces. Because their self-cleaning and water resistant properties prohibit bacteria growth, structurally modified superhydrophobic surfaces obviate bacterial resistance common with chemical agents, and therefore a robust and stable means to prevent bacteria growth is possible. In this study, we present a rapid fabrication method for creating such superhydrophobic surfaces in consumer hard plastic materials with resulting antibacterial effects. To replace complex fabrication materials and techniques, the initial mold is made with commodity shrink-wrap film and is compatible with large plastic roll-to-roll manufacturing and scale-up techniques. This method involves a purely structural modification free of chemical additives leading to its inherent consistency over time and successive recasting from the same molds. Finally, antibacterial properties are demonstrated in polystyrene (PS), polycarbonate (PC), and polyethylene (PE) by demonstrating the prevention of gram-negative Escherichia coli (E. coli) bacteria growth on our structured plastic surfaces.

Imaging brain tumour microstructure.

PubMed

Nilsson, Markus; Englund, Elisabet; Szczepankiewicz, Filip; van Westen, Danielle; Sundgren, Pia C

2018-05-08

Imaging is an indispensable tool for brain tumour diagnosis, surgical planning, and follow-up. Definite diagnosis, however, often demands histopathological analysis of microscopic features of tissue samples, which have to be obtained by invasive means. A non-invasive alternative may be to probe corresponding microscopic tissue characteristics by MRI, or so called 'microstructure imaging'. The promise of microstructure imaging is one of 'virtual biopsy' with the goal to offset the need for invasive procedures in favour of imaging that can guide pre-surgical planning and can be repeated longitudinally to monitor and predict treatment response. The exploration of such methods is motivated by the striking link between parameters from MRI and tumour histology, for example the correlation between the apparent diffusion coefficient and cellularity. Recent microstructure imaging techniques probe even more subtle and specific features, providing parameters associated to cell shape, size, permeability, and volume distributions. However, the range of scenarios in which these techniques provide reliable imaging biomarkers that can be used to test medical hypotheses or support clinical decisions is yet unknown. Accurate microstructure imaging may moreover require acquisitions that go beyond conventional data acquisition strategies. This review covers a wide range of candidate microstructure imaging methods based on diffusion MRI and relaxometry, and explores advantages, challenges, and potential pitfalls in brain tumour microstructure imaging. Copyright © 2018. Published by Elsevier Inc.

Structural integrity of additive materials: Microstructure, fatigue behavior, and surface processing

NASA Astrophysics Data System (ADS)

Book, Todd A.

Although Additive Manufacturing (AM) offers numerous performance advantages over existing methods, AM structures are not being utilized for critical aerospace and mechanical applications due to uncertainties in their structural integrity as a result of the microstructural variations and defects arising from the AM process itself. Two of these uncertainties are the observed scatter in tensile strength and fatigue lives of direct metal laser sintering (DMLS) parts. With strain localization a precursor for material failure, this research seeks to explore the impact of microstructural variations in DMLS produced materials on strain localization. The first part of this research explores the role of the microstructure in strain localization of DMLS produced IN718 and Ti6Al4V specimens (as-built and post-processed) through the characterization of the linkage between microstructural variations, and the accumulation of plastic strain during monotonic and low cycle fatigue loading. The second part of this research explores the feasibility for the application of select surface processing techniques in-situ during the DMLS build process to alter the microstructure in AlSi10Mg to reduce strain localization and improve material cohesion. This study is based on utilizing experimental observations through the employment of advanced material characterization techniques such as digital image correlation to illustrate the impacts of DMLS microstructural variation.

Material cutting, shaping, and forming: A compilation

NASA Technical Reports Server (NTRS)

1974-01-01

Information is presented concerning cutting, shaping, and forming of materials, and the equipment and techniques required for utilizing these materials. The use of molds, electrical fields, and mechanical devices are related to forming materials. Material cutting methods by devices including borers and slicers are presented along with chemical techniques. Shaping and fabrication techniques are described for tubing, honeycomb panels, and ceramic structures. The characteristics of the materials are described. Patent information is included.

Cryomilled and spark plasma sintered titanium: the evolution of microstructure

NASA Astrophysics Data System (ADS)

Kozlík, Jiří; Becker, Hanka; Harcuba, Petr; Stráský, Josef; Janeček, Milos

2017-05-01

Bulk ultra-fine grained (UFG) commercially pure Ti was prepared by cryogenic milling in liquid argon and subsequent spark plasma sintering (SPS). During cryogenic milling, individual powder particles are repetitively severely deformed by attrition forces. Powder particles were not significantly refined, but due to severe repetitive plastic deformation, ultra-fine grained microstructure emerges within each powder particle. Cryogenic milling can be therefore considered as a specific severe plastic deformation (SPD) method. Compactization of cryomilled powder by SPS technique (also referred to as field assisted sintering technique - FAST) requires significantly lower sintering temperatures and shorter sintering times for successful compaction when compared to any other sintering technique. This is crucial for maintaining the UFG microstructure due to its limited thermal stability. Several specimens were prepared by varying processing parameters, in particular the sintering temperature. The microstructure of powders and compacted samples was observed by scanning electron microscopy (SEM). Increased sintering temperature results in recrystallization and grain growth. A trade-off relationship between the density of compacted material and grain size was identified. Microhardness of the material was found to depend on residual porosity rather than grain size. This contribution presents cryogenic milling and spark plasma sintering as a viable alternative for achieving UFG microstructure in commercially pure Ti.

Microstructural Characterization of a Polycrystalline Nickel-Based Superalloy Processed via Tungsten-Intert-Gas-Shaped Metal Deposition

NASA Astrophysics Data System (ADS)

Clark, Daniel; Bache, Martin R.; Whittaker, Mark T.

2010-12-01

Recent trials have produced tungsten-inert-gas (TIG)-welded structures of a suitable scale to allow an evaluation of the technique as an economic and commercial process for the manufacture of complex aeroengine components. The employment of TIG welding is shown to have specific advantages over alternative techniques based on metal inert gas (MIG) systems. Investigations using the nickel-based superalloy 718 have shown that TIG induces a smaller weld pool with less compositional segregation. In addition, because the TIG process involves a pulsed power source, a faster cooling rate is achieved, although this rate, in turn, compromises the deposition rate. The microstructures produced by the two techniques differ significantly, with TIG showing an absence of the detrimental delta and Laves phases typically produced by extended periods at a high temperature using MIG. Instead, an anisotropic dendritic microstructure was evident with a preferred orientation relative to the axis of epitaxy. Niobium was segregated to the interdendritic regions. A fine-scale porosity was evident within the microstructure with a maximum diameter of approximately 5 μm. This porosity often was found in clusters and usually was associated with the interdendritic regions. Subsequent postdeposition heat treatment was shown to have no effect on preexisting porosity and to have a minimal effect on the microstructure.

Application of Image Analysis for Characterization of Spatial Arrangements of Features in Microstructure

NASA Technical Reports Server (NTRS)

Louis, Pascal; Gokhale, Arun M.

1995-01-01

A number of microstructural processes are sensitive to the spatial arrangements of features in microstructure. However, very little attention has been given in the past to the experimental measurements of the descriptors of microstructural distance distributions due to the lack of practically feasible methods. We present a digital image analysis procedure to estimate the micro-structural distance distributions. The application of the technique is demonstrated via estimation of K function, radial distribution function, and nearest-neighbor distribution function of hollow spherical carbon particulates in a polymer matrix composite, observed in a metallographic section.

Solvent/Non-Solvent Sintering To Make Microsphere Scaffolds

NASA Technical Reports Server (NTRS)

Laurencin, Cato T.; Brown, Justin L.; Nair, Lakshmi

2011-01-01

A solvent/non-solvent sintering technique has been devised for joining polymeric microspheres to make porous matrices for use as drug-delivery devices or scaffolds that could be seeded with cells for growing tissues. Unlike traditional sintering at elevated temperature and pressure, this technique is practiced at room temperature and pressure and, therefore, does not cause thermal degradation of any drug, protein, or other biochemical with which the microspheres might be loaded to impart properties desired in a specific application. Also, properties of scaffolds made by this technique are more reproducible than are properties of comparable scaffolds made by traditional sintering. The technique involves the use of two miscible organic liquids: one that is and one that is not a solvent for the affected polymer. The polymeric microspheres are placed in a mold having the size and shape of the desired scaffold, then the solvent/non-solvent mixture is poured into the mold to fill the void volume between the microspheres, then the liquid mixture is allowed to evaporate. Some of the properties of the resulting scaffold can be tailored through choice of the proportions of the liquids and the diameter of the microspheres.

ZEP520A cold-development technique and tool for ultimate resolution to fabricate 1Xnm bit pattern EB master mold for nano-imprinting lithography for HDD/BPM development

NASA Astrophysics Data System (ADS)

Kobayashi, Hideo; Iyama, Hiromasa

2012-06-01

Poor solvent developers are effective for resolution enhancement on a polymer-type EB resist such as ZEP520A. Another way is to utilize "cold-development" technique which was accomplished by a dip-development technique usually. We then designed and successfully built a single-wafer spin-development tool for the cold-development down to -10degC in order to dissolve difficulties of the dip-development. The cold-development certainly helped improve ZEP520A resolution and hole CD size uniformity, and achieved 35nm pitch BPM patterns with the standard developer ZED-N50, but not 25nm pitch yet. By employing a poor solvent mixture of iso-Propyl Alcohol (IPA) and Fluoro-Carbon (FC), 25nm pitch BPM patterns were accomplished. However, the cold-development showed almost no improvement on the IPA/FC mixture developer solvent. This paper describes cold-development technique and a tool, as well as its results, for ZEP520A resolution enhancement to fabricate 1Xnm bits (holes) for EB master-mold for Nano-Imprinting Lithography for 1Tbit/inch2 and 25nm pitch Bit Patterned Media development.

Analysis of in-service failures and advances in microstructural characterization. Microstructural science Volume 26

DOE Office of Scientific and Technical Information (OSTI.GOV)

Abramovici, E.; Northwood, D.O.; Shehata, M.T.

1999-01-01

The contents include Analysis of In-Service Failures (tutorials, transportation industry, corrosion and materials degradation, electronic and advanced materials); 1998 Sorby Award Lecture by Kay Geels, Struers A/S (Metallographic Preparation from Sorby to the Present); Advances in Microstructural Characterization (characterization techniques using high resolution and focused ion beam, characterization of microstructural clustering and correlation with performance); Advanced Applications (advanced alloys and intermetallic compounds, plasma spray coatings and other surface coatings, corrosion, and materials degradation).

Design, Manufacturing, and In Vitro Testing of a Patient-Specific Shape-Memory Expander for Nose Reconstruction With Forehead Flap Technique.

PubMed

Borghi, Alessandro; Rodgers, Will; Schievano, Silvia; Ponniah, Allan; O'Hara, Justine; Jeelani, Owase; Dunaway, David

2016-01-01

Forehead skin is widely acknowledged as a good donor site for total nasal reconstruction, thanks to its matching color, texture, and abundant vascularity. The forehead flap technique uses an axial pattern flap forehead skin to replace missing nasal tissue. To increase the amount of available tissue and reduce the size of the tissue defect after flap mobilization, tissue expanders may be used. Although this is a relatively established technique, limitations include reduced moldability of the forehead skin (which is thicker than the nasal skin), and the need for multiple sessions of expansion to achieve a sufficient yield to close the forehead.Shape-memory metals, such as nitinol, can be programmed to "remember" complex shapes. In this work, the methodology for producing a prototype of nitinol tissue expander able to mold the skin in a predetermined patient-specific skin shape is described. A realistic nose mold was manufactured using metal rapid prototyping; nitinol sheet and mesh were molded into nose-shape constructs, having hyperelastic as well as shape-memory capability. Computed tomography scanning was performed to assess the ability of the structure to regain its shape after phase transformation upon cooling within 2% of initial dimensions. The prototypes were implanted in a pig forehead to test its ability to impose a nose shape to the forehead skin.The shape-memory properties of nitinol offer the possibility of producing bespoke tissue expanders able to deliver complex, precisely designed skin envelopes. The hyperelastic properties of nitinol allow constant preprogrammed expansion forces to be generated throughout the expansion process.

Microstructural Characterization of Irradiated U0.7ZrH1.6 Using Ultrasonic Techniques

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ramuhalli, Pradeep; Jacob, Richard E.; MacFarlan, Paul J.

In recent years, there has been an increased level of effort to understand the changes in microstructure that occur due to irradiation of nuclear fuel. The primary driver for this increased effort is the potential for designing new fuels that are safer and more reliable, in turn enabling new and improved reactor technologies. Much of the data on microstructural change in irradiated fuels is generated through a host of post irradiation examination techniques such as optical microscopy (OM), scanning electron microscopy (SEM), and transmission electron microscopy (TEM) to determine grain structure, porosity, crack geometry, etc. in irradiated fuels. Such “traditional”more » examination techniques were recently used to characterize a novel new fuel consisting of U0.17ZrH1.6 pellets bonded to zircaloy-2 cladded with lead-bismuth eutectic before and after irradiation. However, alternative methods such as ultrasonic inspection can provide an opportunity for nondestructively assessing microstructure in both in-pile and post-irradiation examinations. In this paper, we briefly describe initial results of ultrasonic examination of the U0.17ZrH1.6 pellets (unirradiated and irradiated), in a post-irradiation examination study. Data indicate some correlation with microstructural changes due to irradiation; however, it is not clear what the specific microstructural changes are that are influencing the ultrasonic measurements. Interestingly, specimens with nominally identical burnup show differences in ultrasonic signatures, indicating apparent microstructural differences between these specimens. A summary of the experimental study, preliminary data and findings are presented in this short paper. Additional details of the analysis will be included in the presentation.« less

3D Microfabrication Using Emulsion Mask Grayscale Photolithography Technique

NASA Astrophysics Data System (ADS)

Lee, Tze Pin; Mohamed, Khairudin

2016-02-01

Recently, the rapid development of technology such as biochips, microfluidic, micro-optical devices and micro-electromechanical-systems (MEMS) demands the capability to create complex design of three-dimensional (3D) microstructures. In order to create 3D microstructures, the traditional photolithography process often requires multiple photomasks to form 3D pattern from several stacked photoresist layers. This fabrication method is extremely time consuming, low throughput, costly and complicated to conduct for high volume manufacturing scale. On the other hand, next generation lithography such as electron beam lithography (EBL), focused ion beam lithography (FIB) and extreme ultraviolet lithography (EUV) are however too costly and the machines require expertise to setup. Therefore, the purpose of this study is to develop a simplified method in producing 3D microstructures using single grayscale emulsion mask technique. By using this grayscale fabrication method, microstructures of thickness as high as 500μm and as low as 20μm are obtained in a single photolithography exposure. Finally, the fabrication of 3D microfluidic channel has been demonstrated by using this grayscale photolithographic technique.

Fabrication of tissue engineered osteochondral grafts for restoring the articular surface of diarthrodial joints

PubMed Central

Roach, Brendan L.; Hung, Clark T.; Cook, James L.; Ateshian, Gerard A.; Tan, Andrea R.

2015-01-01

Osteochondral allograft implantation is an effective cartilage restoration technique for large defects (>10 cm2), though the demand far exceeds the supply of available quality donor tissue. Large bilayered engineered cartilage tissue constructs with accurate anatomical features (i.e. contours, thickness, architecture) could be beneficial in replacing damaged tissue. When creating these osteochondral constructs, however, it is pertinent to maintain biofidelity to restore functionality. Here, we describe a step-by-step framework for the fabrication of a large osteochondral construct with correct anatomical architecture and topology through a combination of high-resolution imaging, rapid prototyping, impression molding, and injection molding. PMID:25794950

Flexible polymeric rib waveguide with self-align couplers system

PubMed Central

Huang, Cheng-Sheng; Wang, Wei-Chih

2011-01-01

The authors report a polymeric based rib waveguide with U shape self-align fiber couplers system using a simple micromolding process with SU8 as a molding material and polydimethysiloxane as a waveguide material. The material is used for its good optical transparency, low surface tension, biocompatibility, and durability. Furthermore, the material is highly formable. This unique fabrication molding technique provides a means of keeping the material and manufacturing costs to a minimum. The self-align fiber couplers system also proves a fast and simple means of light coupling. The flexible nature of the waveguide material makes this process ideal for a potential wearable optical sensor. PMID:22171151

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.

Differential Curing In Fiber/Resin Laminates

NASA Technical Reports Server (NTRS)

Webster, Charles N.

1989-01-01

Modified layup schedule counteracts tendency toward delamination. Improved manufacturing process resembles conventional process, except prepregs partially cured laid on mold in sequence in degree of partial cure decreases from mold side to bag side. Degree of partial cure of each layer at time of layup selected by controlling storage and partial-curing temperatures of prepreg according to Arrhenius equation for rate of gel of resin as function of temperature and time from moment of mixing. Differential advancement of cure in layers made large enough to offset effect of advance bag-side heating in oven or autoclave. Technique helps prevent entrapment of volatile materials during manufacturing of fiber/resin laminates.

On the microstructure analysis of FSW joints of aluminium components made via direct metal laser sintering

NASA Astrophysics Data System (ADS)

Scherillo, Fabio; Astarita, Antonello; di Martino, Daniela; Contaldi, Vincenzo; di Matteo, Luca; di Petta, Paolo; Casarin, Renzo; Squillace, Antonino; Langella, Antonio

2017-10-01

Additive Manufacturing (AM), applied to metal industry, is a family of processes that allow complex shape components to be realized from raw materials in the form of powders. The compaction of the powders can be achieved by local melting of the powder bed or by solid state sintering. Direct Metal Laser Sintering (DMLS) is an additive manufacturing process in which a focalized laser beam is the heat source that allows the powders to be compacted. By DMLS it is possible to realize complex shape components. One of the limits of DMLS, as for every additive layer manufacturing techniques, is the unfeasibility to realize large dimension parts. Due to this limit the study of joining process of parts made via ALM is of great interest. One of the most promising options is the Friction Stir Welding (FSW), a solid state welding technique that has been proven to be very effective in the welding of metals difficult to weld, above all aluminium alloys. Since FSW is a solid-state technique, the microstructure of the various zone of the weld bead depends not only by the process itself but also by the parent microstruct ure of the parts to be welded. Furthermore, parts made of aluminium alloy via DMLS have a particular microstructure that is the result of repeated severe thermal cycles. In the present work the authors, starting from the description of the parent microstructure of parts made of AlSi10Mg aluminium alloy, study the microstructure evolution occurred within the joint made by Friction Stir Welding, analysing in details the microstructure of the main well recognized zone of the weld bead. The structure of the parent material is characterized by the presence of melting pools with a very fine microstructure. In the joint the recrystallization, the grain refinement and, above all, the redistribution of intermetallic phases occurs, resulting in an homogenization of the microstructure and in an increase of micro hardness.

Hierarchically-driven Approach for Quantifying Materials Uncertainty in Creep Deformation and Failure of Aerospace Materials

DTIC Science & Technology

2016-07-01

characteristics and to examine the sensitivity of using such techniques for evaluating microstructure. In addition to the GUI tool, a manual describing its use has... Evaluating Local Primary Dendrite Arm Spacing Characterization Techniques Using Synthetic Directionally Solidified Dendritic Microstructures, Metallurgical and...driven approach for quanti - fying materials uncertainty in creep deformation and failure of aerspace materials, Multi-scale Structural Mechanics and

A quantitative and non-contact technique to characterise microstructural variations of skin tissues during photo-damaging process based on Mueller matrix polarimetry.

PubMed

Dong, Yang; He, Honghui; Sheng, Wei; Wu, Jian; Ma, Hui

2017-10-31

Skin tissue consists of collagen and elastic fibres, which are highly susceptible to damage when exposed to ultraviolet radiation (UVR), leading to skin aging and cancer. However, a lack of non-invasive detection methods makes determining the degree of UVR damage to skin in real time difficult. As one of the fundamental features of light, polarization can be used to develop imaging techniques capable of providing structural information about tissues. In particular, Mueller matrix polarimetry is suitable for detecting changes in collagen and elastic fibres. Here, we demonstrate a novel, quantitative, non-contact and in situ technique based on Mueller matrix polarimetry for monitoring the microstructural changes of skin tissues during UVR-induced photo-damaging. We measured the Mueller matrices of nude mouse skin samples, then analysed the transformed parameters to characterise microstructural changes during the skin photo-damaging and self-repairing processes. Comparisons between samples with and without the application of a sunscreen showed that the Mueller matrix-derived parameters are potential indicators for fibrous microstructure in skin tissues. Histological examination and Monte Carlo simulations confirmed the relationship between the Mueller matrix parameters and changes to fibrous structures. This technique paves the way for non-contact evaluation of skin structure in cosmetics and dermatological health.

Critical fiber length technique for composite manufacturing processes

DOE Office of Scientific and Technical Information (OSTI.GOV)

Sivley, G.N.; Vandiver, T.L.; Dougherty, N.S.

1996-12-31

An improved injection technique for composite structures has been cooperatively developed by the U.S. Army Missile Command (MICOM) and Rockwell International (RI). This process simultaneously injects chopped fiberglass fibers and an epoxy resin matrix into a mold. Four injection techniques: (1){open_quotes}Little Willie{close_quotes} RTM system, (2) Pressure Vat system, (3) Pressure Vat system with vacuum assistance, and (4) Injection gun system, were investigated for use with a 304.8 mm x 304.8 mm x 5.08 mm (12 in x 12 in x 0.2 in) flat plaque mold. The driving factors in the process optimization included: fiber length, fiber weight, matrix viscosity, injectionmore » pressure, flow rate, and tool design. At fiber weights higher than 30 percent, the injection gun appears to have advantages over the other systems investigated. Results of an experimental investigation are reviewed in this paper. The investigation of injection techniques is the initial part of the research involved in a developing process, {open_quotes}Critical Fiber Length Technique{close_quotes}. This process will use the data collected in injection experiment along with mechanical properties derived from coupon test data to be incorporated into a composite material design code. The {open_quotes}Critical Fiber Length Technique{close_quotes} is part of a Cooperative Research and Development Agreement (CRADA) established in 1994 between MICOM and RI.« less

A study of reduced chromium content in a nickel-base superalloy via element substitution and rapid solidification processing. Ph.D. ThesisFinal Report

NASA Technical Reports Server (NTRS)

Powers, William O.

1987-01-01

A study of reduced chromium content in a nickel base superalloy via element substitution and rapid solidification processing was performed. The two elements used as partial substitutes for chromium were Si and Zr. The microstructure of conventionally solidified materials was characterized using microscopy techniques. These alloys were rapidly solidified using the chill block melt spinning technique and the rapidly solidified microstructures were characterized using electron microscopy. The spinning technique and the rapidly solidified microstructures was assessed following heat treatments at 1033 and 1272 K. Rapidly solidified material of three alloys was reduced to particulate form and consolidated using hot isostatic pressing (HIP). The consolidated materials were also characterized using microscopy techniques. In order to evaluate the relative strengths of the consolidated alloys, compression tests were performed at room temperature and 1033 K on samples of as-HIPed and HIPed plus solution treated material. Yield strength, porosity, and oxidation resistance characteristics are given and compared.

Method for collecting spores from a mold

DOEpatents

Au, Frederick H. F.; Beckert, Werner F.

1977-01-01

A technique and apparatus used therewith for determining the uptake of plutonium and other contaminants by soil microorganisms which, in turn, gives a measure of the plutonium and/or other contaminants available to the biosphere at that particular time. A measured quantity of uncontaminated spores of a selected mold is added to a moistened sample of the soil to be tested. The mixture is allowed to sit a predetermined number of days under specified temperature conditions. An agar layer is then applied to the top of the sample. After three or more days, when spores of the mold growing in the sample have formed, the spores are collected by a miniature vacuum collection apparatus operated under preselected vacuum conditions, which collect only the spores with essentially no contamination by mycelial fragments or culture medium. After collection, the fungal spores are dried and analyzed for the plutonium and/or other contaminants. The apparatus is also suitable for collection of pollen, small insects, dust and other small particles, material from thin-layer chromatography plates, etc.

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.

Creating physically-based three-dimensional microstructures: Bridging phase-field and crystal plasticity models.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lim, Hojun; Owen, Steven J.; Abdeljawad, Fadi F.

In order to better incorporate microstructures in continuum scale models, we use a novel finite element (FE) meshing technique to generate three-dimensional polycrystalline aggregates from a phase field grain growth model of grain microstructures. The proposed meshing technique creates hexahedral FE meshes that capture smooth interfaces between adjacent grains. Three dimensional realizations of grain microstructures from the phase field model are used in crystal plasticity-finite element (CP-FE) simulations of polycrystalline a -iron. We show that the interface conformal meshes significantly reduce artificial stress localizations in voxelated meshes that exhibit the so-called "wedding cake" interfaces. This framework provides a direct linkmore » between two mesoscale models - phase field and crystal plasticity - and for the first time allows mechanics simulations of polycrystalline materials using three-dimensional hexahedral finite element meshes with realistic topological features.« less

The influence of sintering temperature on microstructure and mechanical properties of Ni-Al intermetallics fabricated by SPS

DOE Office of Scientific and Technical Information (OSTI.GOV)

Thömmes, A., E-mail: thoemmes.alexander@gmail.com; Shevtsova, L. I., E-mail: edeliya2010@mail.ru; Laptev, I. S., E-mail: ilya-laptev-nstu@mail.ru

2015-10-27

In the present study PN85Yu15 was used as elemental powder to produce a sintered compound with Ni3Al as main phase. The Spark Plasma Sintering (SPS) technique is used to compact the powders. The powder was sintered in a temperature range between 1000°C and 1150°C to observe the influence of the sintering temperature on the microstructure and the mechanical properties. The microstructure was observed with optical microscope (OM), the phase composition was characterized by X-ray diffraction (XRD) technique. Density and microhardness were observed and compared the values with the results of other researchers. The compressive-, density- and microhardness tests show asmore » clear result that with increasing the sintering temperature nearly all properties become better and also the microstructure studies show that porous places become less.« less

Influence of Size on the Microstructure and Mechanical Properties of an AISI 304L Stainless Steel—A Comparison between Bulk and Fibers

PubMed Central

Baldenebro-Lopez, Francisco J.; Gomez-Esparza, Cynthia D.; Corral-Higuera, Ramon; Arredondo-Rea, Susana P.; Pellegrini-Cervantes, Manuel J.; Ledezma-Sillas, Jose E.; Martinez-Sanchez, Roberto; Herrera-Ramirez, Jose M.

2015-01-01

In this work, the mechanical properties and microstructural features of an AISI 304L stainless steel in two presentations, bulk and fibers, were systematically studied in order to establish the relationship among microstructure, mechanical properties, manufacturing process and effect on sample size. The microstructure was analyzed by XRD, SEM and TEM techniques. The strength, Young’s modulus and elongation of the samples were determined by tensile tests, while the hardness was measured by Vickers microhardness and nanoindentation tests. The materials have been observed to possess different mechanical and microstructural properties, which are compared and discussed. PMID:28787949

Rattles of Clay.

ERIC Educational Resources Information Center

Banning, Donna

1983-01-01

Using the rattles of Native American cultures as inspiration, students used pinching, coiling, and slab and molding techniques to form the bodies of rattles and clay pellets for sound. Surface decoration included glazed and unglazed areas as well as added handles, feathers, and leather. (IS)

Review on Microstructure Analysis of Metals and Alloys Using Image Analysis Techniques

NASA Astrophysics Data System (ADS)

Rekha, Suganthini; Bupesh Raja, V. K.

2017-05-01

The metals and alloys find vast application in engineering and domestic sectors. The mechanical properties of the metals and alloys are influenced by their microstructure. Hence the microstructural investigation is very critical. Traditionally the microstructure is studied using optical microscope with suitable metallurgical preparation. The past few decades the computers are applied in the capture and analysis of the optical micrographs. The advent of computer softwares like digital image processing and computer vision technologies are a boon to the analysis of the microstructure. In this paper the literature study of the various developments in the microstructural analysis, is done. The conventional optical microscope is complemented by the use of Scanning Electron Microscope (SEM) and other high end equipments.

Mycotoxins

USGS Publications Warehouse

Creekmore, Lynn H.

1999-01-01

Mycotoxins are toxins produced by molds (fungi) that, when they are ingested, can cause diseases called mycotoxicosis. These diseases are are not infectious. The effects on the animal are caused by fungal toxins in foods ingested, usually grains, and are not caused by infection with the fungus. Many different molds produce mycotoxins and many corresponding disease syndromes have been described for domestic animals. However, only two types of mycotoxin poisoning, aflatoxicosis and fusariotoxicosis, have been documented in free-ranging migratory birds. Until recently, sickness or death caused by mycotoxins were rarely reported in migratory birds. Identification of mycotoxins as the cause of a mortality event can be difficult for a number of reasons. The effects may be subtle and difficult to detect or identify, or the effects may be delayed and the bird may have moved away from the contaminated food source before becoming sick or dying. Also, grain containing toxin-producing molds can be difficult or impossible to recognize because it may not appear overtly moldy.Techniques to detect and quantify a variety of mycotoxins important to domestic animal and human health are available through many diagnostic laboratories that serve health needs for those species. These same techniques are applicable for wildlife. Further study and improved diagnostic technology is likely to result in identification of additional types of mycotoxins as causes of disease and death in waterfowl and other wildlife.