Modeling injection molding of net-shape active ceramic components.

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

Baer, Tomas; Cote, Raymond O.; Grillet, Anne Mary

2006-11-01

To reduce costs and hazardous wastes associated with the production of lead-based active ceramic components, an injection molding process is being investigated to replace the current machining process. Here, lead zirconate titanate (PZT) ceramic particles are suspended in a thermoplastic resin and are injected into a mold and allowed to cool. The part is then bisque fired and sintered to complete the densification process. To help design this new process we use a finite element model to describe the injection molding of the ceramic paste. Flow solutions are obtained using a coupled, finite-element based, Newton-Raphson numerical method based on themore » GOMA/ARIA suite of Sandia flow solvers. The evolution of the free surface is solved with an advanced level set algorithm. This approach incorporates novel methods for representing surface tension and wetting forces that affect the evolution of the free surface. Thermal, rheological, and wetting properties of the PZT paste are measured for use as input to the model. The viscosity of the PZT is highly dependent both on temperature and shear rate. One challenge in modeling the injection process is coming up with appropriate constitutive equations that capture relevant phenomenology without being too computationally complex. For this reason we model the material as a Carreau fluid and a WLF temperature dependence. Two-dimensional (2D) modeling is performed to explore the effects of the shear in isothermal conditions. Results indicate that very low viscosity regions exist near walls and that these results look similar in terms of meniscus shape and fill times to a simple Newtonian constitutive equation at the shear-thinned viscosity for the paste. These results allow us to pick a representative viscosity to use in fully three-dimensional (3D) simulation, which because of numerical complexities are restricted to using a Newtonian constitutive equation. Further 2D modeling at nonisothermal conditions shows that the choice of representative Newtonian viscosity is dependent on the amount of heating of the initially room temperature mold. An early 3D transient model shows that the initial design of the distributor is sub-optimal. However, these simulations take several months to run on 4 processors of an HP workstation using a preconditioner/solver combination of ILUT/GMRES with fill factors of 3 and PSPG stabilization. Therefore, several modifications to the distributor geometry and orientations of the vents and molds have been investigated using much faster 3D steady-state simulations. The pressure distribution for these steady-state calculations is examined for three different distributor designs to see if this can indicate which geometry has the superior design. The second modification, with a longer distributor, is shown to have flatter, more monotonic isobars perpendicular to the flow direction indicating a better filling process. The effects of the distributor modifications, as well as effects of the mold orientation, have also been examined with laboratory experiments in which the flow of a viscous Newtonian oil entering transparent molds is recorded visually. Here, the flow front is flatter and voids are reduced for the second geometry compared to the original geometry. A horizontal orientation, as opposed to the planned vertical orientation, results in fewer voids. Recently, the Navier-Stokes equations have been stabilized with the Dohrman-Bochev PSPP stabilization method, allowing us to calculate transient 3D simulations with computational times on the order of days instead of months. Validation simulations are performed and compared to the experiments. Many of the trends of the experiments are captured by the level set modeling, though quantitative agreement is lacking mainly due to the high value of the gas phase viscosity necessary for numerical stability, though physically unrealistic. More correct trends are predicted for the vertical model than the horizontal model, which is serendipitous as the actual mold is held in a vertical geometry. The full, transient mold filling calculations indicate that the flow front is flatter and voids may be reduced for the second geometry compared to the original geometry. The validated model is used to predict mold filling for the actual process with the material properties for the PZT paste, the original distributor geometry, and the mold in a vertical orientation. This calculation shows that voids may be trapped at the four corners of the mold opposite the distributor.« less

Apparatus for characterizing the temporo-spatial properties of a dynamic fluid front and method thereof

DOEpatents

Battiste, Richard L

2013-12-31

Methods and apparatus are described for characterizing the temporal-spatial properties of a dynamic fluid front within a mold space while the mold space is being filled with fluid. A method includes providing a mold defining a mold space and having one or more openings into the mold space; heating a plurality of temperature sensors that extend into the mold space; injecting a fluid into th emold space through the openings, the fluid experiencing a dynamic fluid front while filling the mold space with a fluid; and characterizing temporal-spatial properties of the dynamic fluid front by monitoring a termperature of each of the plurality of heated temperature sensors while the mold space is being filled with the fluid. An apparatus includes a mold defining a mold space; one or more openings for introducing a fluid into th emold space and filling the mold space with the fluid, the fluid experiencing a dynamic fluid front while filling the mold space; a plurality of heated temperature sensors extending into the mold space; and a computer coupled to the plurality of heated temperature sensors for characterizing the temporal-spatial properties of the dynamic fluid front.

Modeling of process-induced residual stresses and resin flow behavior in resin transfer molded composites with woven fiber mats

NASA Astrophysics Data System (ADS)

Golestanian, Hossein

This research focuses on modeling Resin Transfer Molding process for manufacture of composite parts with woven fiber mats. Models are developed to determine cure dependent stiffness matrices for composites manufactured with two types of woven fiber mats. Five-harness carbon and eight-harness fiberglass mats with EPON 826 resin composites are considered. The models presented here take into account important material/process parameters with emphasis on; (1) The effects of cure-dependent resin mechanical properties, (2) Fiber undulation due to the weave of the fiber fill and warp bundles, and (3) Resin interaction with the fiber bundles at a microscopic scale. Cure-dependent mechanical properties were then used in numerical models to determine residual stresses and deformation in the composite parts. The complete cure cycle was modeled in these analyses. Also the cool down stage after the composite cure was analyzed. The effect of 5% resin shrinkage on residual stresses and deformations was also investigated. In the second part of the study, Finite Element models were developed to simulate mold filling in RTM processes. Resin flow in the fiber mats was modeled as flow through porous media. Physical models were also developed to investigate resin flow behavior into molds of rectangular and irregular shapes. Silicone fluids of 50 and 100 centistoke viscosities as well as EPON 826 epoxy resin were used in the mold filling experiments. The reinforcements consisted of several layers of woven fiberglass and carbon fiber mats. The effects of injection pressure, fluid viscosity, type of reinforcement, and mold geometry on mold filling times were investigated. Fiber mat permeabilities were determined experimentally for both types of reinforcements. Comparison of experimental and numerical resin front positions indicated the importance of edge effects in resin flow behavior in small cavities. The resin front positions agreed well for the rectangular mold geometry.

Numerical simulation of the casting process of titanium tooth crowns and bridges.

PubMed

Wu, M; Augthun, M; Wagner, I; Sahm, P R; Spiekermann, H

2001-06-01

The objectives of this paper were to simulate the casting process of titanium tooth crowns and bridges; to predict and control porosity defect. A casting simulation software, MAGMASOFT, was used. The geometry of the crowns with fine details of the occlusal surface were digitized by means of laser measuring technique, then converted and read in the simulation software. Both mold filling and solidification were simulated, the shrinkage porosity was predicted by a "feeding criterion", and the gas pore sensitivity was studied based on the mold filling and solidification simulations. Two types of dental prostheses (a single-crown casting and a three-unit-bridge) with various sprue designs were numerically "poured", and only one optimal design for each prosthesis was recommended for real casting trial. With the numerically optimized design, real titanium dental prostheses (five replicas for each) were made on a centrifugal casting machine. All the castings endured radiographic examination, and no porosity was detected in the cast prostheses. It indicates that the numerical simulation is an efficient tool for dental casting design and porosity control. Copyright 2001 Kluwer Academic Publishers

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.

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

NASA Astrophysics Data System (ADS)

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

2015-03-01

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

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.

American Society of Composites, 32nd Technical Conference

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

Aitharaju, Venkat; Yu, Hang; Zhao, Selina

Resin transfer molding (RTM) has become increasingly popular for the manufacturing of composite parts. To enable high volume manufacturing and obtain good quality parts at an acceptable cost to automotive industry, accurate process simulation tools are necessary to optimize the process conditions. Towards that goal, General Motors and the ESI-group are involved in developing a state of the art process simulation tool for composite manufacturing in a project supported by the Department of Energy. This paper describes the modeling of various stages in resin transfer molding such as resin injection, resin curing, and part distortion. An instrumented RTM system locatedmore » at the General Motors Research and Development center was used to perform flat plaque molding experiments. The experimental measurements of fill time, in-mold pressure versus time, cure variation with time, and part deformation were compared with the model predictions and very good correlations were observed.« less

Dynamic analysis of bulk-fill composites: Effect of food-simulating liquids.

PubMed

Eweis, Ahmed Hesham; Yap, Adrian U-Jin; Yahya, Noor Azlin

2017-10-01

This study investigated the effect of food simulating liquids on visco-elastic properties of bulk-fill restoratives using dynamic mechanical analysis. One conventional composite (Filtek Z350 [FZ]), two bulk-fill composites (Filtek Bulk-fill [FB] and Tetric N Ceram [TN]) and a bulk-fill giomer (Beautifil-Bulk Restorative [BB]) were evaluated. Specimens (12 × 2 × 2mm) were fabricated using customized stainless steel molds. The specimens were light-cured, removed from their molds, finished, measured and randomly divided into six groups. The groups (n = 10) were conditioned in the following mediums for 7 days at 37°C: air (control), artificial saliva (SAGF), distilled water, 0.02N citric acid, heptane, 50% ethanol-water solution. Specimens were assessed using dynamic mechanical testing in flexural three-point bending mode and their respective mediums at 37°C and a frequency range of 0.1-10Hz. The distance between the supports were fixed at 10mm and an axial load of 5N was employed. Data for elastic modulus, viscous modulus and loss tangent were subjected to ANOVA/Tukey's tests at significance level p < 0.05. Significant differences in visco-elastic properties were observed between materials and mediums. Apart from bulk-fill giomer, elastic modulus was the highest after conditioning in heptane. No apparent trends were noted for viscous modulus. Generally, loss tangent was the highest after conditioning in ethanol. The effect of food-simulating liquids on the visco-elastic properties of bulk-fill composites was material and medium dependent. Copyright © 2017 Elsevier Ltd. All rights reserved.

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

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

Nguyen, Ba Nghiep; Jin, Xiaoshi; Wang, Jin

2012-02-23

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

Pyrotechnic filled molding powder

DOEpatents

Hartzel, Lawrence W.; Kettling, George E.

1978-01-01

The disclosure relates to thermosetting molding compounds and more particularly to a pyrotechnic filled thermosetting compound comprising a blend of unfilled diallyl phthalate molding powder and a pyrotechnic mixture.

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.

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.

Improved Sand-Compaction Method for Lost-Foam Metal Casting

NASA Technical Reports Server (NTRS)

Bakhtiyarov, Sayavur I.; Overfelt, Ruel A.

2008-01-01

An improved method of filling a molding flask with sand and compacting the sand around a refractory-coated foam mold pattern has been developed for incorporation into the lost-foam metal-casting process. In comparison with the conventional method of sand filling and compaction, this method affords more nearly complete filling of the space around the refractory-coated foam mold pattern and more thorough compaction of the sand. In so doing, this method enables the sand to better support the refractory coat under metallostatic pressure during filling of the mold with molten metal.

Analytical modeling and sensor monitoring for optimal processing of advanced textile structural composites by resin transfer molding

NASA Technical Reports Server (NTRS)

Loos, Alfred C.; Macrae, John D.; Hammond, Vincent H.; Kranbuehl, David E.; Hart, Sean M.; Hasko, Gregory H.; Markus, Alan M.

1993-01-01

A two-dimensional model of the resin transfer molding (RTM) process was developed which can be used to simulate the infiltration of resin into an anisotropic fibrous preform. Frequency dependent electromagnetic sensing (FDEMS) has been developed for in situ monitoring of the RTM process. Flow visualization tests were performed to obtain data which can be used to verify the sensor measurements and the model predictions. Results of the tests showed that FDEMS can accurately detect the position of the resin flow-front during mold filling, and that the model predicted flow-front patterns agreed well with the measured flow-front patterns.

Effects of mold design of aspheric projector lens for head up display

NASA Astrophysics Data System (ADS)

Chen, Chao-Chang A.; Tang, Jyun-Cing; Teng, Lin-Ming

2010-08-01

This paper investigates the mold design and related effects on an aspheric projector lens for Head Up Display (HUD) with injection molding process. Injection flow analysis with a commercial software, Moldex3D has been used to simulate this projector lens for filling, packing, shrinkage, and flow-induced residual stress. This projector lens contains of variant thickness due to different aspheric design on both surfaces. Defects may be induced as the melt front from the gate into the cavity with jet-flow phenomenon, short shot, weld line, and even shrinkage. Thus, this paper performs a gate design to find the significant parameters including injection velocity, melt temperature, and mold temperature. After simulation by the Moldex3D, gate design for the final assembly of Head Up Display (HUD) has been obtained and then experimental tests have been proceeded for verification of short-shot, weight variation, and flow-induced stress. Moreover, warpage analysis of the Head Up Display (HUD) can be integrated with the optical design specification in future work.

Development of Metal Plate with Internal Structure Utilizing the Metal Injection Molding (MIM) Process.

PubMed

Shin, Kwangho; Heo, Youngmoo; Park, Hyungpil; Chang, Sungho; Rhee, Byungohk

2013-12-12

In this study, we focus on making a double-sided metal plate with an internal structure, such as honeycomb. The stainless steel powder was used in the metal injection molding (MIM) process. The preliminary studies were carried out for the measurement of the viscosity of the stainless steel feedstock and for the prediction of the filling behavior through Computer Aided Engineering (CAE) simulation. PE (high density polyethylene (HDPE) and low density polyethylene (LDPE)) and polypropylene (PP) resins were used to make the sacrificed insert with a honeycomb structure using a plastic injection molding process. Additionally, these sacrificed insert parts were inserted in the metal injection mold, and the metal injection molding process was carried out to build a green part with rectangular shape. Subsequently, debinding and sintering processes were adopted to remove the sacrificed polymer insert. The insert had a suitable rigidity that was able to endure the filling pressure. The core shift analysis was conducted to predict the deformation of the insert part. The 17-4PH feedstock with a low melting temperature was applied. The glass transition temperature of the sacrificed polymer insert would be of a high grade, and this insert should be maintained during the MIM process. Through these processes, a square metal plate with a honeycomb structure was made.

Development of Metal Plate with Internal Structure Utilizing the Metal Injection Molding (MIM) Process

PubMed Central

Shin, Kwangho; Heo, Youngmoo; Park, Hyungpil; Chang, Sungho; Rhee, Byungohk

2013-01-01

In this study, we focus on making a double-sided metal plate with an internal structure, such as honeycomb. The stainless steel powder was used in the metal injection molding (MIM) process. The preliminary studies were carried out for the measurement of the viscosity of the stainless steel feedstock and for the prediction of the filling behavior through Computer Aided Engineering (CAE) simulation. PE (high density polyethylene (HDPE) and low density polyethylene (LDPE)) and polypropylene (PP) resins were used to make the sacrificed insert with a honeycomb structure using a plastic injection molding process. Additionally, these sacrificed insert parts were inserted in the metal injection mold, and the metal injection molding process was carried out to build a green part with rectangular shape. Subsequently, debinding and sintering processes were adopted to remove the sacrificed polymer insert. The insert had a suitable rigidity that was able to endure the filling pressure. The core shift analysis was conducted to predict the deformation of the insert part. The 17-4PH feedstock with a low melting temperature was applied. The glass transition temperature of the sacrificed polymer insert would be of a high grade, and this insert should be maintained during the MIM process. Through these processes, a square metal plate with a honeycomb structure was made. PMID:28788427

Formation Mechanism of Surface Crack in Low Pressure Casting of A360 Alloy

NASA Astrophysics Data System (ADS)

Liu, Shan-Guang; Cao, Fu-Yang; Ying, Tao; Zhao, Xin-Yi; Liu, Jing-Shun; Shen, Hong-Xian; Guo, Shu; Sun, Jian-Fei

2017-12-01

A surface crack defect is normally found in low pressure castings of Al alloy with a sudden contraction structure. To further understand the formation mechanism of the defect, the mold filling process is simulated by a two-phase flow model. The experimental results indicate that the main reason for the defect deformation is the mismatching between the height of liquid surface in the mold and pressure in the crucible. In the case of filling, a sudden contraction structure with an area ratio smaller than 0.5 is obtained, and the velocity of the liquid front increases dramatically with the influence of inertia. Meanwhile, the pressurizing speed in the crucible remains unchanged, resulting in the pressure not being able to support the height of the liquid level. Then the liquid metal flows back to the crucible and forms a relatively thin layer solidification shell on the mold wall. With the increasing pressure in the crucible, the liquid level rises again, engulfing the shell and leading to a surface crack. As the filling velocity is characterized by the damping oscillations, surface cracks will form at different heights. The results shed light on designing a suitable pressurizing speed for the low pressure casting process.

INTEGRATION OF COST MODELS AND PROCESS SIMULATION TOOLS FOR OPTIMUM COMPOSITE MANUFACTURING PROCESS

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

Pack, Seongchan; Wilson, Daniel; Aitharaju, Venkat

Manufacturing cost of resin transfer molded composite parts is significantly influenced by the cycle time, which is strongly related to the time for both filling and curing of the resin in the mold. The time for filling can be optimized by various injection strategies, and by suitably reducing the length of the resin flow distance during the injection. The curing time can be reduced by the usage of faster curing resins, but it requires a high pressure injection equipment, which is capital intensive. Predictive manufacturing simulation tools that are being developed recently for composite materials are able to provide variousmore » scenarios of processing conditions virtually well in advance of manufacturing the parts. In the present study, we integrate the cost models with process simulation tools to study the influence of various parameters such as injection strategies, injection pressure, compression control to minimize high pressure injection, resin curing rate, and demold time on the manufacturing cost as affected by the annual part volume. A representative automotive component was selected for the study and the results are presented in this paper« less

Ring-Mold Craters on Lineated Valley Fill, Lobate Debris Aprons, and Concentric Crater Fill on Mars: Implications for Near-Surface Structure, Composition, and Age.

NASA Astrophysics Data System (ADS)

Kress, A.; Head, J. W.

2009-03-01

Analysis of ring-mold crater populations on lineated valley fill, lobate debris aprons, and concentric crater fill on Mars and of ice-impact experiments suggest crater-count-derived ages may be erroneously old.

Application of the lattice Boltzmann method for simulation of the mold filling process in the casting industry

NASA Astrophysics Data System (ADS)

Szucki, Michal; Suchy, J. S.; Lelito, J.; Malinowski, P.; Sobczyk, J.

2017-12-01

The aim of this work is the development of the lattice Boltzmann model for simulation of the mold filling process. The authors present a simplified approach to the modeling of liquid metal-gas flows with particular emphasis on the interactions between these phases. The boundary condition for momentum transfer of the moving free surface to the gaseous phase is shown. Simultaneously, the method for modeling influence of gas back pressure on a position and shape of the interfacial boundary is explained in details. The problem of the lattice Boltzmann method (LBM) stability is also analyzed. Since large differences in viscosity of both fluids are a source of the model instability, the so-called fractional step (FS) method allowing to improve the computation stability is applied. The presented solution is verified on the bases of the available reference data and the results of experiments. It is shown that the model describes properly such effects as: gas bubbles formation and air back pressure, accompanying liquid-gas flows in the casting mold. At the same time the proposed approach is easy to be implemented and characterized by a lower demand of operating memory as compared to typical LBM models of two-phase flows.

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

PubMed

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

2015-10-01

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

Remelt Ingot Production Technology

NASA Astrophysics Data System (ADS)

Grandfield, J. F.

The technology related to the production of remelt ingots (small ingots, sows and T-Bar) is reviewed. Open mold conveyors, sow casting, wheel and belt casting and VDC and HDC casting are described and compared. Process economics, capacity, product quality and process problems are listed. Trends in casting machine technology such as longer open mold conveyor lines are highlighted. Safety issues related to the operation of these processes are discussed. The advantages and disadvantages of the various machine configurations and options e.g. such as dry filling with the mold out of water and wet filling with the mold in water for open mould conveyors are discussed. The effect of mold design on machine productivity, mold cracking and mold life is also examined.

Triple Plate Mold Final Report: Optimization of the Mold Design and Casting Parameters for a Thin U-10mo Fuel Casting

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

Aikin, Jr., Robert M.

This work describes the experiments and modeling that have been performed to improve and try to optimize the simultaneous casting of three plates of U-10wt%Mo in a single coil vacuum induction melting (VIM) furnace. The plates of interest are 280 mm wide by 203 mm tall by 5 mm thick (11" x 8" x 0.2"). The initial mold design and processing parameters were supplied by Y-12. The mold and casting cavity were instrumented with a number of thermocouples, and the casting performed to determine the thermal history of the mold and casting. The resulting cast plates were radiographed and numerousmore » defects identified. Metallography was performed to help identify the nature of the radiographically observed defects. This information was then used to validate a mold filling and solidification model of that casting. Based on the initial casting, good casting design practice, and process simulation of several design alternatives, a revised design was developed with the goal of minimizing casting defects such as porosity. The redesigned mold had a larger hot-top and had its long axis along the horizontal direction. These changes were to try to develop a strong thermal gradient conducive to good feeding and minimization of micro- and macroporosity in the cast plates. An instrumented casting was then performed with the revised mold design and a linear distributor. This design yielded cast plates with significantly less radiographically identified defects. Unfortunately, there was significant variation in plate weight and metal content in their hot-tops. Fluid flow simulations were then performed on this mold/distributor design. This helped identify the issue with this linear distributor design. Additional simulations were then performed on candidate distributor redesigns and a preferred distributor annular design was identified. This improved annular design was used to produce a third instrumented casting with favorable results. These refined designs and their radiographic characterization are compared to the initial design.« less

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

PubMed

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

2014-11-01

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

Chip-scale pattern modification method for equalizing residual layer thickness in nanoimprint lithography

NASA Astrophysics Data System (ADS)

Youn, Sung-Won; Suzuki, Kenta; Hiroshima, Hiroshi

2018-06-01

A software program for modifying a mold design to obtain a uniform residual layer thickness (RLT) distribution has been developed and its validity was verified by UV-nanoimprint lithography (UV-NIL) simulation. First, the effects of granularity (G) on both residual layer uniformity and filling characteristics were characterized. For a constant complementary pattern depth and a granularity that was sufficiently larger than the minimum pattern width, filling time decreased with the decrease in granularity. For a pattern design with a wide density range and an irregular distribution, the choice of a small granularity was not always a good strategy since the etching depth required for a complementary pattern occasionally exceptionally increased with the decrease in granularity. On basis of the results obtained, the automated method was applied to a chip-scale pattern modification. Simulation results showed a marked improvement in residual layer thickness uniformity for a capacity-equalized (CE) mold. For the given conditions, the standard deviation of RLT decreased in the range from 1/3 to 1/5 in accordance with pattern designs.

18. INTERIOR VIEW WITH IRON POURERS FILLING COMPLETED MOLDS ON ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

18. INTERIOR VIEW WITH IRON POURERS FILLING COMPLETED MOLDS ON GREY IRON UNIT NO. 1 MOLD CONVEYOR WITH MOLTEN IRON FROM MOBILE LADLES AS THEY STAND ON WHAT USED TO BE A PLATFORM MOVING AT THE SAME RATE OF SPEED AS THE CONVEYOR. - Stockham Pipe & Fittings Company, Grey Iron Foundry, 4000 Tenth Avenue North, Birmingham, Jefferson County, AL

Predicting Pattern Tooling and Casting Dimensions for Investment Casting, Phase III

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

Sabau, Adrian S

2008-04-01

Efforts during Phase III focused mainly on the shell-alloy systems. A high melting point alloy, 17-4PH stainless steel, was considered. The experimental part of the program was conducted at ORNL and commercial foundries, where wax patterns were injected, molds were invested, and alloys were poured. Shell molds made of fused-silica and alumino-silicates were considered. A literature review was conducted on thermophysical and thermomechanical properties alumino-silicates. Material property data, which were not available from material suppliers, was obtained. For all the properties of 17-4PH stainless steel, the experimental data available in the literature did not cover the entire temperature range necessarymore » for process simulation. Thus, some material properties were evaluated using ProCAST, based on CompuTherm database. A comparison between the predicted material property data and measured property data was made. It was found that most material properties were accurately predicted only over several temperature ranges. No experimental data for plastic modulus were found. Thus, several assumptions were made and ProCAST recommendations were followed in order to obtain a complete set of mechanical property data at high temperatures. Thermal expansion measurements for the 17-4PH alloy were conducted during heating and cooling. As a function of temperature, the thermal expansion for both the alloy and shell mold materials showed different evolution on heating and cooling. Numerical simulations were performed using ProCAST for the investment casting of 17-4PH stainless steel parts in fused silica molds using the thermal expansion obtained on heating and another one with thermal expansion obtained on cooling. Since the fused silica shells had the lowest thermal expansion properties in the industry, the dewaxing phase, including the coupling between wax-shell systems, was neglected. The shell mold was considered to be a pure elastic material. The alloy dimensions were obtained from numerical simulations. For 17-4PH stainless steel parts, the alloy shrinkage factors were over-predicted, as compared with experimental data. Additional R&D focus was placed on obtaining material property data for filled waxes, waxes that are common in the industry. For the first time in the investment casting industry, the thermo-mechanical properties of unfilled and filled waxes were measured. Test specimens of three waxes were injected at commercial foundries. Rheometry measurement of filled waxes was conducted at ORNL. The analysis of the rheometry data to obtain viscoelastic properties was not completed due to the reduction in the budget of the project (approximately 50% funds were received).« less

Numerical simulation of the casting process of titanium removable partial denture frameworks.

PubMed

Wu, Menghuai; Wagner, Ingo; Sahm, Peter R; Augthun, Michael

2002-03-01

The objective of this work was to study the filling incompleteness and porosity defects in titanium removal partial denture frameworks by means of numerical simulation. Two frameworks, one for lower jaw and one for upper jaw, were chosen according to dentists' recommendation to be simulated. Geometry of the frameworks were laser-digitized and converted into a simulation software (MAGMASOFT). Both mold filling and solidification of the castings with different sprue designs (e.g. tree, ball, and runner-bar) were numerically calculated. The shrinkage porosity was quantitatively predicted by a feeding criterion, the potential filling defect and gas pore sensitivity were estimated based on the filling and solidification results. A satisfactory sprue design with process parameters was finally recommended for real casting trials (four replica for each frameworks). All the frameworks were successfully cast. Through X-ray radiographic inspections it was found that all the castings were acceptably sound except for only one case in which gas bubbles were detected in the grasp region of the frame. It is concluded that numerical simulation aids to achieve understanding of the casting process and defect formation in titanium frameworks, hence to minimize the risk of producing defect casting by improving the sprue design and process parameters.

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.

2009 Navy ManTech Project Book

DTIC Science & Technology

2009-01-01

pieces which are welded together, filled with syntactic foam , and welded to the sail and hull structure. The ManTech project was successful in...cladding has demonstrated the required performance characteristics . The testing demonstrated manufacturability of optical fibers with enhanced hard...using Liquid Injection Molding Simulation (LIMS) and Polyworx software tools for infusion set-up optimization. Test articles fabricated are

40 CFR Table 9 to Subpart Wwww of... - Initial Compliance With Work Practice Standards

Code of Federal Regulations, 2014 CFR

2014-07-01

... compression/injection molding uncover, unwrap or expose only one charge per mold cycle per compression/injection molding machine. For machines with multiple molds, one charge means sufficient material to fill... cycle per compression/injection molding machine, or prior to the loader, hoppers are closed except when...

CAE for Injection Molding — Past, Present and the Future

NASA Astrophysics Data System (ADS)

Wang, Kuo K.

2004-06-01

It is well known that injection molding is the most effective process for mass-producing discrete plastic parts of complex shape to the highest precision at the lowest cost. However, due to the complex property of polymeric materials undergoing a transient non-isothermal process, it is equally well recognized that the quality of final products is often difficult to be assured. This is particularly true when a new mold or material is encountered. As a result, injection molding has often been viewed as an art than a science. During the past few decades, numerical simulation of injection molding process based on analytic models has become feasible for practical use as computers became faster and cheaper continually. A research effort was initiated at the Cornell Injection Molding Program (CIMP) in 1974 under a grant from the National Science Foundation. Over a quarter of the century, CIMP has established some scientific bases ranging from materials characterization, flow analysis, to prediction of part quality. Use of such CAE tools has become common place today in industry. Present effort has been primarily aimed at refinements of many aspects of the process. Computational efficiency and user-interface have been main thrusts by commercial software developers. Extension to 3-dimensional flow analysis for certain parts has drawn some attention. Research activities are continuing on molding of fiber-filled materials and reactive polymers. Expanded molding processes such as gas-assisted, co-injection, micro-molding and many others are continually being investigated. In the future, improvements in simulation accuracy and efficiency will continue. This will include in-depth studies on materials characterization. Intelligent on-line process control may draw more attention in order to achieve higher degree of automation. As Internet technology continues to evolve, Web-based CAE tools for design, production, remote process monitoring and control can come to path. The CAE tools will eventually be integrated into an Enterprise Resources Planning (ERP) system as the trend of enterprise globalization continues.

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

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

Hausnerova, Berenika; Sanetrnik, Daniel; Paravanova, Gordana

2014-05-15

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

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

NASA Astrophysics Data System (ADS)

Hausnerova, Berenika; Sanetrnik, Daniel; Paravanova, Gordana

2014-05-01

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

Numerical simulation on semi-solid die-casting of magnesium matrix composite based on orthogonal experiment

NASA Astrophysics Data System (ADS)

Liu, Huihui; He, Xiongwei; Guo, Peng

2017-04-01

Three factors (pouring temperature, injection speed and mold temperature) were selected to do three levels L9 (33)orthogonal experiment, then simulate processing of semi-solid die-casting of magnesium matrix composite by Flow-3D software. The stress distribution, temperature field and defect distribution of filling process were analyzed to find the optimized processing parameter with the help of orthogonal experiment. The results showed that semi-solid has some advantages of well-proportioned stress and temperature field, less defect concentrated in the surface. The results of simulation were the same as the experimental results.

Development of In-Mold Assembly Methods for Producing Mesoscale Revolute Joints

DTIC Science & Technology

2009-01-01

tolerances available for manufacturing the molds are relatively low. Any inaccuracy in mold First stage part (ABS) Second stage part ( LDPE ) Pins...case, the viscosity of LDPE is also a function of temperature. For each of these cases, they have considered the filling of a thin mold cavity. From...predicting the weld-line strengths of crystalline polymers such as LDPE . 63 3 Issues in In-Mold Assembly at the Mesoscale 3.1 Motivation In-mold

Fabrication of metallic microstructures by micromolding nanoparticles

DOEpatents

Morales, Alfredo M.; Winter, Michael R.; Domeier, Linda A.; Allan, Shawn M.; Skala, Dawn M.

2002-01-01

A method is provided for fabricating metallic microstructures, i.e., microcomponents of micron or submicron dimensions. A molding composition is prepared containing an optional binder and nanometer size (1 to 1000 nm in diameter) metallic particles. A mold, such as a lithographically patterned mold, preferably a LIGA or a negative photoresist mold, is filled with the molding composition and compressed. The resulting microstructures are then removed from the mold and the resulting metallic microstructures so provided are then sintered.

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

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

Nguyen, Ba Nghiep; Fifield, Leonard S.; Mathur, Raj N.

2014-09-30

During the last quarter of FY 2014, the following technical progress has been made toward project milestones: 1) Autodesk, Inc. (Autodesk) has implemented a new fiber length distribution (FLD) model based on an unbreakable length assumption with Reduced Order Modeling (ROM) by the Proper Orthogonal Decomposition (POD) approach in the mid-plane, dual-domain and 3D solvers. 2) Autodesk improved the ASMI 3D solver for fiber orientation prediction using the anisotropic rotary diffusion (ARD) – reduced strain closure (RSC) model. 3) Autodesk received consultant services from Prof. C.L. Tucker at the University of Illinois on numerical simulation of fiber orientation and fibermore » length. 4) PlastiComp, Inc. (PlastiComp) suggested to Purdue University a procedure for fiber separation using an inert-gas atmosphere in the burn-off furnace. 5) Purdue University (Purdue) hosted a face-to-face project review meeting at Purdue University on August 6-7, 2014. 6) Purdue conducted fiber orientation measurements for 3 PlastiComp plaques: fast-fill 30wt% LCF/PP edged-gated, slow-fill 50wt% LCF/PP edge-gated, and slow-fill 50wt% LCF/PP center-gated plaques, and delivered the orientation data for these plaques at the selected locations (named A, B, and C) to PNNL. 7) PNNL conducted ASMI mid-plane analyses for the above PlastiComp plaques and compared the predicted fiber orientations with the measured data provided by Purdue at Locations A, B, and C on these plaques. 8) PNNL planned the project review meeting (August 6-7, 2014) with Purdue. 9) PNNL performed ASMI analyses for the Toyota complex parts with and without ribs, having different wall thicknesses, and using the PlastiComp 50wt% LCF/PP, 50wt% LCF/PA66, 30wt% LCF/PP, and 30wt% LCF/PA66 materials to provide guidance for tool design and modifications needed for molding these parts. 10) Magna Exteriors and Interiors Corp. (Magna) molded plaques from the 50% LCF/PP and 50% LCF/PA66 materials received from Plasticomp in order to extract machine purgings (purge materials) from Magna’s 200-Ton Injection Molding machine targeted to mold the complex part. 11) Toyota and Magna discussed with PNNL tool modification for molding the complex part.« less

Method and mold for casting thin metal objects

DOEpatents

Pehrson, Brandon P; Moore, Alan F

2014-04-29

Provided herein are various embodiments of systems for casting thin metal plates and sheets. Typical embodiments include layers of mold cavities that are oriented vertically for casting the metal plates. In some embodiments, the mold cavities include a beveled edge such that the plates that are cast have a beveled edge. In some embodiments, the mold cavities are filled with a molten metal through an open horizontal edge of the cavity. In some embodiments, the mold cavities are filled through one or more vertical feed orifices. Further disclosed are methods for forming a thin cast metal plate or sheet where the thickness of the cast part is in a range from 0.005 inches to 0.2 inches, and the surface area of the cast part is in a range from 16 square inches to 144 square inches.

Brittle Materials Design, High Temperature Gas Turbine

DTIC Science & Technology

1975-04-01

was directed toward fabricating flaw- free one-piece first stage stators using a silicon metal powder injection molding composition yielding reaction...process was used because this composition utilizes thermoset polymers which cannot be handled on available injection molding equipment. Silicon...molded of several compositions incorporating slight variations. Some of the components molded had completely filled the die cavity and appeared

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 fast mold surface temperature evolution on iPP part morphology gradients

NASA Astrophysics Data System (ADS)

Liparoti, Sara; Sorrentino, Andrea; Guzman, Gustavo; Cakmak, Mukerrem; Titomanlio, Giuseppe

2016-03-01

The control of mold surface temperature is an important factor that affects the sample surface morphology as well as the structural gradients (orientation crystal size, and type) as well as cooling stresses. The frozen layer thickness formed during the filling stage also has a very significant effect on the flow resistance and thus on the resulting pressure drop and flow length in thin wall parts. The possibility to have a hot mold during filling and a quick cooling soon afterward is a significant process enhancement particularly for specialized applications such as micro injection molding and for the reproduction of micro structured surfaces. Up to now, several methods (electromagnetic, infrared, hot vapor fleshing etc,) were tried to achieve fast temperature evolution of the mold. Unfortunately, all these methods require a complex balance between thermal and mechanical problems, equipment cost, energy consumption, safety, molding cycle time and part quality achievable. In this work, a thin electrical resistance was designed and used to generate a fast and confined temperature variation on mold surface (by joule effect). Since the whole temperature evolution can take place in a few seconds, one can couple the advantages of a high surface temperature during filling with the advantages of a low mold temperature, fast cooling and low heating dissipation. Some experiments were performed with a commercial iPP resin. The effects of the surface temperature and of the heating time (under constant electric power) on surface finishing and on the final morphology (thickness and structure of the different layers) are explored and discussed.

Effect of fast mold surface temperature evolution on iPP part morphology gradients

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

Liparoti, Sara; Sorrentino, Andrea; Guzman, Gustavo

The control of mold surface temperature is an important factor that affects the sample surface morphology as well as the structural gradients (orientation crystal size, and type) as well as cooling stresses. The frozen layer thickness formed during the filling stage also has a very significant effect on the flow resistance and thus on the resulting pressure drop and flow length in thin wall parts. The possibility to have a hot mold during filling and a quick cooling soon afterward is a significant process enhancement particularly for specialized applications such as micro injection molding and for the reproduction of micromore » structured surfaces. Up to now, several methods (electromagnetic, infrared, hot vapor fleshing etc,) were tried to achieve fast temperature evolution of the mold. Unfortunately, all these methods require a complex balance between thermal and mechanical problems, equipment cost, energy consumption, safety, molding cycle time and part quality achievable. In this work, a thin electrical resistance was designed and used to generate a fast and confined temperature variation on mold surface (by joule effect). Since the whole temperature evolution can take place in a few seconds, one can couple the advantages of a high surface temperature during filling with the advantages of a low mold temperature, fast cooling and low heating dissipation. Some experiments were performed with a commercial iPP resin. The effects of the surface temperature and of the heating time (under constant electric power) on surface finishing and on the final morphology (thickness and structure of the different layers) are explored and discussed.« less

Ultrasound - Aided ejection in micro injection molding

NASA Astrophysics Data System (ADS)

Masato, D.; Sorgato, M.; Lucchetta, G.

2018-05-01

In this work, an ultrasound-aided ejection system was designed and tested for different polymers (PS, COC and POM) and mold topographies. The proposed solution aims at reducing the ejection friction by decreasing the adhesion component of the frictional force, which is controlled by the contact area developed during the filling stage of the injection molding process. The experimental results indicate a positive effect of ultrasound vibration on the friction force values, with a maximum reduction of 16. Moreover, it is demonstrated that the ultrasound effect is strictly related to both polymer selection and mold roughness. The combined effect on the ejection force of mold surface roughness, melt viscosity during filling and polymer elastic modulus at ejection was modeled to the experimental data, in order to demonstrate that the effect of ultrasound vibration on the ejection friction reduction is due to the heating of the contact interface and the consequent reduction of the polymer elastic modulus.

Gating geometry studies of thin-walled 17-4PH investment castings

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

Maguire, M.C.; Zanner, F.J.

1992-11-01

The ability to design gating systems that reliably feed and support investment castings is often the result of ``cut-and-try`` methodology. Factors such as hot tearing, porosity, cold shuts, misruns, and shrink are defects often corrected by several empirical gating design iterations. Sandia National Laboratories is developing rules that aid in removing the uncertainty involved in the design of gating systems for investment castings. In this work, gating geometries used for filling of thin walled investment cast 17-4PH stainless steel flat plates were investigated. A full factorial experiment evaluating the influence of metal pour temperature, mold preheat temperature, and mold channelmore » thickness were conducted for orientations that filled a horizontal flat plate from the edge. A single wedge gate geometry was used for the edge-gated configuration. Thermocouples placed along the top of the mold recorded metal front temperatures, and a real-time x-ray imaging system tracked the fluid flow behavior during filling of the casting. Data from these experiments were used to determine the terminal fill volumes and terminal fill times for each gate design.« less

Gating geometry studies of thin-walled 17-4PH investment castings

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

Maguire, M.C.; Zanner, F.J.

1992-01-01

The ability to design gating systems that reliably feed and support investment castings is often the result of cut-and-try'' methodology. Factors such as hot tearing, porosity, cold shuts, misruns, and shrink are defects often corrected by several empirical gating design iterations. Sandia National Laboratories is developing rules that aid in removing the uncertainty involved in the design of gating systems for investment castings. In this work, gating geometries used for filling of thin walled investment cast 17-4PH stainless steel flat plates were investigated. A full factorial experiment evaluating the influence of metal pour temperature, mold preheat temperature, and mold channelmore » thickness were conducted for orientations that filled a horizontal flat plate from the edge. A single wedge gate geometry was used for the edge-gated configuration. Thermocouples placed along the top of the mold recorded metal front temperatures, and a real-time x-ray imaging system tracked the fluid flow behavior during filling of the casting. Data from these experiments were used to determine the terminal fill volumes and terminal fill times for each gate design.« less

Prediction of the As-Cast Structure of Al-4.0 Wt Pct Cu Ingots

NASA Astrophysics Data System (ADS)

Ahmadein, Mahmoud; Wu, M.; Li, J. H.; Schumacher, P.; Ludwig, A.

2013-06-01

A two-stage simulation strategy is proposed to predict the as-cast structure. During the first stage, a 3-phase model is used to simulate the mold-filling process by considering the nucleation, the initial growth of globular equiaxed crystals and the transport of the crystals. The three considered phases are the melt, air and globular equiaxed crystals. In the second stage, a 5-phase mixed columnar-equiaxed solidification model is used to simulate the formation of the as-cast structure including the distinct columnar and equiaxed zones, columnar-to-equiaxed transition, grain size distribution, macrosegregation, etc. The five considered phases are the extradendritic melt, the solid dendrite, the interdendritic melt inside the equiaxed grains, the solid dendrite, and the interdendritic melt inside the columnar grains. The extra- and interdendritic melts are treated as separate phases. In order to validate the above strategy, laboratory ingots (Al-4.0 wt pct Cu) are poured and analyzed, and a good agreement with the numerical predictions is achieved. The origin of the equiaxed crystals by the "big-bang" theory is verified to play a key role in the formation of the as-cast structure, especially for the castings poured at a low pouring temperature. A single-stage approach that only uses the 5-phase mixed columnar-equiaxed solidification model and ignores the mold filling can predict satisfactory results for a casting poured at high temperature, but it delivers false results for the casting poured at low temperature.

Photopolymerizable liquid encapsulants for microelectronic devices

NASA Astrophysics Data System (ADS)

Baikerikar, Kiran K.

2000-10-01

Plastic encapsulated microelectronic devices consist of a silicon chip that is physically attached to a leadframe, electrically interconnected to input-output leads, and molded in a plastic that is in direct contact with the chip, leadframe, and interconnects. The plastic is often referred to as the molding compound, and is used to protect the chip from adverse mechanical, thermal, chemical, and electrical environments. Encapsulation of microelectronic devices is typically accomplished using a transfer molding process in which the molding compound is cured by heat. Most transfer molding processes suffer from significant problems arising from the high operating temperatures and pressures required to fill the mold. These aspects of the current process can lead to thermal stresses, incomplete mold filling, and wire sweep. In this research, a new strategy for encapsulating microelectronic devices using photopolymerizable liquid encapsulants (PLEs) has been investigated. The PLEs consist of an epoxy novolac-based vinyl ester resin (˜25 wt.%), fused silica filler (70--74 wt.%), and a photoinitiator, thermal initiator, and silane coupling agent. For these encapsulants, the use of light, rather than heat, to initiate the polymerization allows precise control over when the reaction starts, and therefore completely decouples the mold filling and the cure. The low viscosity of the PLEs allows for low operating pressures and minimizes problems associated with wire sweep. In addition, the in-mold cure time for the PLEs is equivalent to the in-mold cure times of current transfer molding compounds. In this thesis, the thermal and mechanical properties, as well as the viscosity and adhesion of photopolymerizable liquid encapsulants, are reported in order to demonstrate that a UV-curable formulation can have the material properties necessary for microelectronic encapsulation. In addition, the effects of the illumination time, postcure time, fused silica loading, and the inclusion of a thermal initiator on the thermal and mechanical properties of the final cured encapsulants have been investigated. The results show that the material properties of the PLEs are the same, if not better, than those exhibited by conventional transfer molding compounds and demonstrate the potential of using PLEs for encapsulating microelectronic devices.

Additive Manufacturing of Ultem Polymers and Composites

NASA Technical Reports Server (NTRS)

Chuang, Kathy C.; Grady, Joseph E.; Draper, Robert D.; Shin, Euy-Sik E.; Patterson, Clark; Santelle, Thomas D.

2015-01-01

The objective of this project was to conduct additive manufacturing to produce aircraft engine components by Fused Deposition Modeling (FDM), using commercially available polyetherimdes Ultem 9085 and experimental Ultem 1000 filled with 10 chopped carbon fiber. A property comparison between FDM-printed and injection molded coupons for Ultem 9085, Ultem 1000 resin and the fiber-filled composite Ultem 1000 was carried out. Furthermore, an acoustic liner was printed from Ultem 9085 simulating conventional honeycomb structured liners and tested in a wind tunnel. Composite compressor inlet guide vanes were also printed using fiber-filled Ultem 1000 filaments and tested in a cascade rig. The fiber-filled Ultem 1000 filaments and composite vanes were characterized by scanning electron microscope (SEM) and acid digestion to determine the porosity of FDM-printed articles which ranged from 25-31. Coupons of Ultem 9085, experimental Ultem 1000 composites and XH6050 resin were tested at room temperature and 400F to evaluate their corresponding mechanical properties.

Applications of nanocomposites and woodfiber plastics for microcellular injection molding

Treesearch

Lih-Sheng Turng; Mingjun Yuan; Hrishikesh Kharbas; Herman Winata; Daniel F. Caulfield

2003-01-01

The paper reviews the processing advantages and challenges of microcellular injection molding and presents recent research results on applications of nanocomposites and woodfiber-plastic composites as well as new process develop for the microcellular injection molding process. In particular, two types of polyamide (PA-6) neat resins and their filled counterparts, such...

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

NASA Astrophysics Data System (ADS)

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

2007-04-01

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

Method for casting thin metal objects

DOEpatents

Pehrson, Brandon P; Moore, Alan F

2015-04-14

Provided herein are various embodiments of systems for casting thin metal plates and sheets. Typical embodiments include layers of mold cavities that are oriented vertically for casting the metal plates. In some embodiments, the mold cavities include a beveled edge such that the plates that are cast have a beveled edge. In some embodiments, the mold cavities are filled with a molten metal through an open horizontal edge of the cavity. In some embodiments, the mold cavities are filled through one or more vertical feed orifices. Further disclosed are methods for forming a thin cast metal plate or sheet where the thickness of the cast part is in a range from 0.005 inches to 0.2 inches, and the surface area of the cast part is in a range from 16 square inches to 144 square inches.

Experimental analysis for fabrication of high-aspect-ratio piezoelectric ceramic structure by micro-powder injection molding process

NASA Astrophysics Data System (ADS)

Han, Jun Sae; Gal, Chang Woo; Park, Jae Man; Kim, Jong Hyun; Park, Seong Jin

2018-04-01

Aspect ratio effects in the micro-powder injection molding process were experimentally analyzed for fabrication of high-aspect-ratio piezoelectric ceramic structure. The mechanisms of critical defects have been studied according to individual manufacturing steps. In the molding process, incomplete filling phenomenon determines the critical aspect ratios of a micro pattern. According to mold temperature, an incomplete filling phenomenon has been analyzed with respect to different pattern sizes and aspect ratio. In demolding and drying process, the capillary behavior of sacrificial polymeric mold insert determines the critical aspect ratio of a micro pattern. With respect to pattern dimensions, slumping behavior has been analyzed. Based on our current systems, micro PZT feature has stability when it has lower aspect ratio than 5. Under optimized processing conditions, 20 μm and 40 μm ceramic rod array feature which has 5 of aspect ratio were successfully fabricated by the developed process. Further modification points to fabricate the smaller and higher feature were specifically addressed.

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.)

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.

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

NASA Astrophysics Data System (ADS)

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

2016-03-01

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

16. THE INSTALLATION OF CONVEYORS AND OVERHEAD RAILS ELIMINATED THE ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

16. THE INSTALLATION OF CONVEYORS AND OVERHEAD RAILS ELIMINATED THE NEED TO LAY MOLDS OUT ON FLOORS AND HAND-POUR THEM. INSTEAD, WORKERS PULLED LARGE LADLES ALONG OVERHEAD RAILS AND FILLED CONVEYOR-DRIVEN MOLDS WHILE THEY STOOD ON A MOVING PLATFORM THAT TRAVELED AT THE SAME SPEED AS THE MOLD CONVEYOR, CA. 1950. - Stockham Pipe & Fittings Company, 4000 Tenth Avenue North, Birmingham, Jefferson County, AL

Method for foam encapsulating laser targets

DOEpatents

Hendricks, Charles D.

1977-01-01

Foam encapsulated laser fusion targets are made by positioning a fusion fuel-filled sphere within a mold cavity of suitable configuration and dimensions, and then filling the cavity with a material capable of producing a low density, microcellular foam, such as cellulose acetate dissolved in an acetone-based solvent. The mold assembly is dipped into an ice water bath to gel the material and thereafter soaked in the water bath to leach out undesired components, after which the gel is frozen, then freeze-dried wherein water and solvents sublime and the gel structure solidifies into a low-density microcellular foam, thereafter the resulting foam encapsulated target is removed from the mold cavity. The fuel-filled sphere is surrounded by foam having a thickness of about 10 to 100 .mu.m, a cell size of less than 2 .mu.m, and density of 0.065 to 0.6 .times. 10.sup.3 kg/m.sup.3. Various configured foam-encapsulated targets capable of being made by this encapsulation method are illustrated.

Studies on unsaturated flow in dual-scale fiber fabrics

NASA Astrophysics Data System (ADS)

Yan, Fei; Yan, Shilin; Li, Yongjing

2018-03-01

Fiber fabrics in liquid composite molding (LCM) can be recognized as a dual-scale structure. As sink theory developed, this unsaturated flow behavior has already been simulated successfully; however, most of simulated results based on a unit cell under ideal status, thus making results were not agreement with experiment. In this study, an experimental method to establish sink function was proposed. After compared the simulation results by this sink function, it shows high accuracy with the experimental data. Subsequently, the key influencing factors for unsaturated flow have been further investigated; results show that the filling time for unsaturated flow was much longer than saturated flow. In addition, the injection pressure and permeability were the key factors lead to unsaturated flow.

Study of a Single-Power Two-Circuit ESR Process with Current-Carrying Mold: Mathematical Simulation of the Process and Experimental Verification

NASA Astrophysics Data System (ADS)

Dong, Yanwu; Hou, Zhiwen; Jiang, Zhouhua; Cao, Haibo; Feng, Qianlong; Cao, Yulong

2018-02-01

A novel single-power two-circuit ESR process (ESR-STCCM) with current-carrying mold has been investigated via numerical simulation and experimental research in this paper. A 2D quasi-steady-state mathematical model is developed to describe ESR-STCCM. The electromagnetic field, flow field, slag pool temperature distribution, and the shape of a molten steel pool in ESR-STCCM have been investigated by FLUENT software as well as user-defined functions (UDF). The results indicate that ESR-STCCM is different from the conventional ESR process. The maximum electromagnetic force, current density, Joule heat, and slag pool flow velocity are located in the lower part of the conductor in the ESR-STCCM process. The direction of the maximum electromagnetic force inclines upward. There are two distinct vortices in the slag pool. The larger swirl rotates counterclockwise near the conductor, with a value of 0.0263 m s-1 due to the interaction of the electromagnetic force and gravity. The maximum temperature of the slag pool is 2070 K (1797 °C) and is located in the center of the swirl with a filling ratio of 0.6 and a 20 mm electrode immersion depth. The depth of a molten steel pool is shallower, which is conducive to improving solidification quality. In addition, the filling ratio of 0.6 is conducive to controlling steel solidification quality. Some experiments have been done, and the numerical model is confirmed by experimental results.

Viscoelastic properties of chalcogenide glasses and the simulation of their molding processes

NASA Astrophysics Data System (ADS)

Liu, Weiguo; Shen, Ping; Jin, Na

In order to simulate the precision molding process, the viscoelastic properties of chalcogenide glasses under high temperatures were investigated. Thermomechanical analysis were performed to measure and analysis the thermomechanical properties of chalcogenide glasses. The creep responses of the glasses at different temperatures were obtained. Finite element analysis was applied for the simulation of the molding processes. The simulation results were in consistence with previously reported experiment results. Stress concentration and evolution during the molding processes was also described with the simulation results.

Method of forming a spacer for field emission flat panel displays

DOEpatents

Bernhardt, A.F.; Contolini, R.J.

1997-08-19

Spacers are disclosed for applications such as field emission flat panel displays and vacuum microelectronics, and which involves the application of aerogel/xerogel technology to the formation of the spacer. In a preferred approach the method uses a mold and mold release agent wherein the gel precursor is a liquid which can be applied to the mold filling holes which expose the substrate (either the baseplate or the faceplate). A release agent is applied to the mold prior to precursor application to ease removal of the mold after formation of the dielectric spacer. The shrinkage of the gel during solvent extraction also improves mold removal. The final spacer material is a good dielectric, such as silica, secured to the substrate. 3 figs.

Method of forming a spacer for field emission flat panel displays

DOEpatents

Bernhardt, Anthony F.; Contolini, Robert J.

1997-01-01

Spacers for applications such as field emission flat panel displays and vacuum microelectronics, and which involves the application of aerogel/xerogel technology to the formation of the spacer. In a preferred approach the method uses a mold and mold release agent wherein the gel precursor is a liquid which can be applied to the mold filling holes which expose the substrate (either the baseplate or the faceplate). A release agent is applied to the mold prior to precursor application to ease removal of the mold after formation of the dielectric spacer. The shrinkage of the gel during solvent extraction also improves mold removal. The final spacer material is a good dielectric, such as silica, secured to the substrate.

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

Nick Cannell; Adrian S. Sabau

The investment casting process allows the production of complex-shape parts and close dimensional tolerances. One of the most important phases in the investment casting process is the design of the pattern die. Pattern dies are used to create wax patterns by injecting wax into dies. The first part of the project involved preparation of reports on the state of the art at that time for all the areas under consideration (die-wax, wax-shell, and shell-alloy). The primary R&D focus during Phase I was on the wax material since the least was known about it. The main R&D accomplishments during this phasemore » were determination of procedures for obtaining the thermal conductivity and viscoelastic properties of an unfilled wax and validating those procedures. Phase II focused on die-wax and shell-alloy systems. A wax material model was developed based on results obtained during the previous R&D phase, and a die-wax model was successfully incorporated into and used in commercial computer programs. Current computer simulation programs have complementary features. A viscoelastic module was available in ABAQUS but unavailable in ProCAST, while the mold-filling module was available in ProCAST but unavailable in ABAQUS. Thus, the numerical simulation results were only in good qualitative agreement with experimental results, the predicted shrinkage factors being approximately 2.5 times larger than those measured. Significant progress was made, and results showed that the testing and modeling of wax material had great potential for industrial applications. Additional R&D focus was placed on one shell-alloy system. The fused-silica shell mold and A356 aluminum alloy were considered. The experimental part of the program was conducted at ORNL and commercial foundries, where wax patterns were injected, molds were invested, and alloys were poured. It was very important to obtain accurate temperature data from actual castings, and significant effort was made to obtain temperature profiles in the shell mold. A model for thermal radiation within the shell mold was developed, and the thermal model was successfully validated using ProCAST. Since the fused silica shells had the lowest thermal expansion properties in the industry, the dewaxing phase, including the coupling between wax-shell systems, was neglected. The prefiring of the empty shell mold was considered in the model, and the shell mold was limited to a pure elastic material. The alloy dimensions were obtained from numerical simulations only with coupled shell-alloy systems. The alloy dimensions were in excellent quantitative agreement with experimental data, validating the deformation module. For actual parts, however, the creep properties of the shell molds must also be obtained, modeled, and validated.« less

Micro-channel filling flow considering surface tension effect

NASA Astrophysics Data System (ADS)

Kim, Dong Sung; Lee, Kwang-Cheol; Kwon, Tai Hun; Lee, Seung S.

2002-05-01

Understanding filling flow into micro-channels is important in designing micro-injection molding, micro-fluidic devices and an MIMIC (micromolding in capillaries) process. In this paper, we investigated, both experimentally and numerically, 'transient filling' flow into micro-channels, which differs from steady-state completely 'filled' flow in micro-channels. An experimental flow visualization system was devised to facilitate observation of flow characteristics in filling into micro-channels. Three sets of micro-channels of various widths of different thicknesses (20, 30, and 40 μm) were fabricated using SU-8 on the silicon substrate to find a geometric effect with regard to pressure gradient, viscous force and, in particular, surface tension. A numerical analysis system has also been developed taking into account the surface tension effect with a contact angle concept. Experimental observations indicate that surface tension significantly affects the filling flow to such an extent that even a flow blockage phenomenon was observed at channels of small width and thickness. A numerical analysis system also confirms that the flow blockage phenomenon could take place due to the flow hindrance effect of surface tension, which is consistent with experimental observation. For proper numerical simulations, two correction factors have also been proposed to correct the conventional hydraulic radius for the filling flow in rectangular cross-sectioned channels.

Mechanical Properties Studies of Components Formulation for Mixing Process Contain of Polypropylene, Polyethylene, and Aluminium Powder

NASA Astrophysics Data System (ADS)

Hamsi, A.; Dinzi, R.

2017-03-01

Certain powder and others components can induce toxic reactions if not properly handled in the mixing stage. During handling, the small particles can become airborne and be trapped in the lungs, another concern is inhomogeneities in the mixing process. Uniform quantities of the particles of the components are needed in all portions of the mixture. This paper reports the results of mechanical properties studies of mixing three components formulation for mixing process. Contain of Polyethylene (PE), Polyprophylene (PP) and Aluminium Powder. Powder mixer, Autodesk mold flow and computer based on excell method was carried out to study the influence of each formulation component on the flow %, PE 20% and Aluminium powder 2%. Macroscopic optic and macro photo was carried out to identify the homogenity of mixing, tensile test for identify the strength of component after mixing. Finally the optimal tensile test with composition PP 785,PE 20% and Aluminium powder 2% at speed 52 rpm, temperature 1500C, the tensile strength 20,92 N/mm2. At temperature 1600C, speed 100 rpm the optimum tensile strength 17,91 N/mm2. The result of simulation autodesk mold flow adviser the filling time 6 seconds. Otherwise on manual hot hidraulic press the time of filling 10 seconds.

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

Research on burnout fault of moulded case circuit breaker based on finite element simulation

NASA Astrophysics Data System (ADS)

Xue, Yang; Chang, Shuai; Zhang, Penghe; Xu, Yinghui; Peng, Chuning; Shi, Erwei

2017-09-01

In the failure event of molded case circuit breaker, overheating of the molded case near the wiring terminal has a very important proportion. The burnout fault has become an important factor restricting the development of molded case circuit breaker. This paper uses the finite element simulation software to establish the model of molded case circuit breaker by coupling multi-physics field. This model can simulate the operation and study the law of the temperature distribution. The simulation results show that the temperature near the wiring terminal, especially the incoming side of the live wire, of the molded case circuit breaker is much higher than that of the other areas. The steady-state and transient simulation results show that the temperature at the wiring terminals is abnormally increased by increasing the contact resistance of the wiring terminals. This is consistent with the frequent occurrence of burnout of the molded case in this area. Therefore, this paper holds that the burnout failure of the molded case circuit breaker is mainly caused by the abnormal increase of the contact resistance of the wiring terminal.

Additive Manufacturing and Characterization of Ultem Polymers and Composites

NASA Technical Reports Server (NTRS)

Chuang, Kathy C.; Grady, Joseph E.; Draper, Robert D.; Shin, Euy-Sik E.; Patterson, Clark; Santelle, Thomas D.

2015-01-01

The objective of this project was to conduct additive manufacturing to produce aircraft engine components by Fused Deposition Modeling (FDM), using commercially available polyetherimides - Ultem 9085 and experimental Ultem 1000 mixed with 10 percent chopped carbon fiber. A property comparison between FDM-printed and injection-molded coupons for Ultem 9085, Ultem 1000 resin and the fiber-filled composite Ultem 1000 was carried out. Furthermore, an acoustic liner was printed from Ultem 9085 simulating conventional honeycomb structured liners and tested in a wind tunnel. Composite compressor inlet guide vanes were also printed using fiber-filled Ultem 1000 filaments and tested in a cascade rig. The fiber-filled Ultem 1000 filaments and composite vanes were characterized by scanning electron microscope (SEM) and acid digestion to determine the porosity of FDM-printed articles which ranged from 25-31 percent. Coupons of Ultem 9085 and experimental Ultem 1000 composites were tested at room temperature and 400 degrees Fahrenheit to evaluate their corresponding mechanical properties.

Reference Manual on Interference Seals and Connectors for Undersea Electrical Applications

DTIC Science & Technology

1976-07-01

processes. It has a standard line of metal shell connectors, the ER and EB series, which are available with braided and laced harnass work and breakouts, and...Assemblies (RM) 4-10 4.3.2 Molded Plastic Assemblies (PM) 4-11 4.3.3 Metal Shell Assemblies (MS) 4-12 4.3.4 Pressure-balanced Oil-filled Assemblies...connectors according to material composition. The classes of connectors include: Rubber Molded (RM), Plastic Molded (PM), Metal Shell (MS), Pressure-Balanced

40 CFR Appendix D to Part 403 - Selected Industrial Subcategories Considered Dilute for Purposes of the Combined Wastestream Formula

Code of Federal Regulations, 2011 CFR

2011-07-01

... (40 CFR parts 413/433). Capacitors (Fluid Fill) Carbon and Graphite Products Dry Transformers Ferrite... Resistors Swithchgear Transformer (Fluid Fill) Metal Molding and Casting (40 CFR part 464) Nickel Casting...

40 CFR Appendix D to Part 403 - Selected Industrial Subcategories Considered Dilute for Purposes of the Combined Wastestream Formula

Code of Federal Regulations, 2014 CFR

2014-07-01

... (40 CFR parts 413/433). Capacitors (Fluid Fill) Carbon and Graphite Products Dry Transformers Ferrite... Resistors Swithchgear Transformer (Fluid Fill) Metal Molding and Casting (40 CFR part 464) Nickel Casting...

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

PubMed

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

2013-05-14

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

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

PubMed Central

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

2013-01-01

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

Silicon micro-mold and method for fabrication

DOEpatents

Morales, Alfredo M.

2005-01-11

The present invention describes a method for rapidly fabricating a robust 3-dimensional silicon micro-mold for use in preparing complex metal micro-components. The process begins by depositing a conductive metal layer onto one surface of a silicon wafer. A thin photoresist and a standard lithographic mask are then used to transfer a trace image pattern onto the opposite surface of the wafer by exposing and developing the resist. The exposed portion of the silicon substrate is anisotropically etched through the wafer thickness down to conductive metal layer to provide an etched pattern consisting of a series of rectilinear channels and recesses in the silicon which serve as the silicon micro-mold. Microcomponents are prepared with this mold by first filling the mold channels and recesses with a metal deposit, typically by electroplating, and then removing the silicon micro-mold by chemical etching.

Silicon micro-mold

DOEpatents

Morales, Alfredo M [Livermore, CA

2006-10-24

The present invention describes a method for rapidly fabricating a robust 3-dimensional silicon-mold for use in preparing complex metal micro-components. The process begins by depositing a conductive metal layer onto one surface of a silicon wafer. A thin photoresist and a standard lithographic mask are then used to transfer a trace image pattern onto the opposite surface of the wafer by exposing and developing the resist. The exposed portion of the silicon substrate is anisotropically etched through the wafer thickness down to conductive metal layer to provide an etched pattern consisting of a series of rectilinear channels and recesses in the silicon which serve as the silicon micro-mold. Microcomponents are prepared with this mold by first filling the mold channels and recesses with a metal deposit, typically by electroplating, and then removing the silicon micro-mold by chemical etching.

3D simulation of polyurethane foam injection and reacting mold flow in a complex geometry

NASA Astrophysics Data System (ADS)

Özdemir, İ. Bedii; Akar, Fırat

2018-05-01

The aim of the present work is to develop a flow model which can be used to determine the paths of the polyurethane foam in the mold filling process of a refrigerator cabinet so that improvements in the distribution and the size of the venting holes can be achieved without the expensive prototyping and experiments. For this purpose, the multi-component, two-phase chemically reacting flow is described by Navier Stokes and 12 scalar transport equations. The air and the multi-component foam zones are separated by an interface, which moves only with advection since the mass diffusion of species are set zero in the air zone. The inverse density, viscosity and other diffusion coefficients are calculated by a mass fraction weighted average of the corresponding temperature-dependent values of all species. Simulations are performed in a real refrigerator geometry, are able to reveal the problematical zones where air bubbles and voids trapped in the solidified foam are expected to occur. Furthermore, the approach proves itself as a reliable design tool to use in deciding the locations of air vents and sizing the channel dimensions.

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

The mitochondrial genome of the ethanol-metabolizing, wine cellar mold Zasmidium cellare is the smallest for a filamentous ascomycete

USDA-ARS?s Scientific Manuscript database

The wine cellar mold, Zasmidium cellare, produces thick curtains of mycelia in cellars with high humidity, and its ability to metabolize volatile organic compounds is thought to improve air quality. Whether these abilities have affected its mitochondrial genome is not known. To fill this gap, its mi...

Structure development in melt processing isotactic polypropylene, polypropylene blends/compounds and dynamically vulcanized polyolefin TPEs

NASA Astrophysics Data System (ADS)

Yu, Yishan

The influence of various fillers, nucleating agents and ethylene propylene diene terpolymer (EPDM) additive on crystalline modification (alpha-, beta- and smectic forms) and crystalline orientation of polypropylene in die extrudates, melt spun filaments, thick rods, blow molded bottles and injection molded parts of isotactic polypropylene (PP), its blends/compounds and dynamically vulcanized polypropylene thermoplastic elastomers (TPEs) were experimentally studied under a range of cooling and processing conditions. The phenomena of crystallization, polymorphism and orientation in processing of both thin and thick samples (filaments, rods, bottles and injection molded parts) were simulated through transport laws incorporating polymer crystallization kinetics. Continuous cooling transformation (CCT) curves for the various material systems investigated were developed under quiescent and uniaxial stress conditions. We applied experimental data on polymorphism of thin sections to predict crystalline structure variation in thick parts. The predictions were consistent with experiments. For filaments, the polypropylene crystalline orientation-spinline stress relationship is generally similar for the neat PP, blends/compounds and TPEs. However, the blends and TPEs have much lower birefringence apparently due to a lack of orientation in the rubber phase. It was shown that the polypropylene contribution to the birefringence for the neat PP and its blends is the same at the same spinline stress. For bottles, the inflation pressures used have little effect on orientation of either polypropylene crystals or disc-shaped talc filler. The talc discs are highly oriented parallel to the bottle surface. For the bottles without talc, the orientation of polypropylene crystallographic axes are low. The polypropylene crystallographic b-axes in the talc filled bottles are more highly oriented. For injection molded parts, it was found that a low orientation layer exists between the part surface and an intermediate highly oriented layer in the parts of neat PP and its blends/compounds. The thickness of this layer increases as the injection pressure decreases. This layer was not formed in the TPE parts. This would seem to be associated with the TPEs exhibiting a yield stress in shear flow and not exhibiting fountain flow in mold filling. For all parts studied, the orientation characteristics of polypropylene crystallographic axes in the highly oriented layer are similar from sample to sample. The strong orientation of the c-axis parallel to the machine direction and the b-axis perpendicular to the machine direction are observed in the highly oriented layer. The talc discs in both the highly oriented layer and the intermediate position are highly oriented parallel to the part face due to melt flow. At intermediate position in the talc-filled parts, the polypropylene crystallographic (040) planes prefer to align themselves parallel to the part surface but are not so well oriented when the talc is absent.

Investigation of Materials Processing Technology

DTIC Science & Technology

1993-07-01

Figure 6: Time-temperature curves of A357 casting in Cu mold ................. 12 Figure 7: Time-temperature curves of 17 -4 casting in ceramic mold...simulation of 17 -4 ................ 17 Figure 12: IHTC from IHEAT simulation of 17 -4 casting ..................... 18 Figure 13: Temperature profiles...mold used for Ti castings .......................... 23 Figure 16: Cooling curves for a Ti casting in ceramic mold .................. 24 Figure 17

THE DURABILITY OF LARGE-SCALE ADDITIVE MANUFACTURING COMPOSITE MOLDS

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

Post, Brian K; Love, Lonnie J; Duty, Chad

2016-01-01

Oak Ridge National Laboratory s Big Area Additive Manufacturing (BAAM) technology permits the rapid production of thermoplastic composite molds using a carbon fiber filled Acrylonitrile-Butadiene-Styrene (ABS) thermoplastic. Demonstration tools (i.e. 0.965 m X 0.559 m X 0.152 m) for composite part fabrication have been printed, coated, and finished with a traditional tooling gel. We present validation results demonstrating the stability of thermoplastic printed molds for room temperature Vacuum Assisted Resin Transfer Molding (VARTM) processes. Arkema s Elium thermoplastic resin was investigated with a variety of reinforcement materials. Experimental results include dimensional characterization of the tool surface using laser scanning techniquemore » following demolding of 10 parts. Thermoplastic composite molds offer rapid production compared to traditionally built thermoset molds in that near-net deposition allows direct digital production of the net geometry at production rate of 45 kg/hr.« less

17. CUPOLA TENDERS FILLED THE LARGE LADLES WORKERS USED TO ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

17. CUPOLA TENDERS FILLED THE LARGE LADLES WORKERS USED TO POUR MOLDS ON THE CONVEYORS FROM BULL LADLES THAT WERE USED TO STORE BATCH QUANTITIES OF IRON TAPPED FROM THE CUPOLA, CA. 1950. - Stockham Pipe & Fittings Company, 4000 Tenth Avenue North, Birmingham, Jefferson County, AL

Estimation of state and material properties during heat-curing molding of composite materials using data assimilation: A numerical study.

PubMed

Matsuzaki, Ryosuke; Tachikawa, Takeshi; Ishizuka, Junya

2018-03-01

Accurate simulations of carbon fiber-reinforced plastic (CFRP) molding are vital for the development of high-quality products. However, such simulations are challenging and previous attempts to improve the accuracy of simulations by incorporating the data acquired from mold monitoring have not been completely successful. Therefore, in the present study, we developed a method to accurately predict various CFRP thermoset molding characteristics based on data assimilation, a process that combines theoretical and experimental values. The degree of cure as well as temperature and thermal conductivity distributions during the molding process were estimated using both temperature data and numerical simulations. An initial numerical experiment demonstrated that the internal mold state could be determined solely from the surface temperature values. A subsequent numerical experiment to validate this method showed that estimations based on surface temperatures were highly accurate in the case of degree of cure and internal temperature, although predictions of thermal conductivity were more difficult.

Mechanism for Angular Deformation of L-shaped Specimens —Influence of Filling Material and Shrinkage Factor—

NASA Astrophysics Data System (ADS)

Furuhashi, Hiroshi; Aoki, Takerou; Okabe, Sayaka; Arai, Tsuyoshi; Seto, Masahiro; Yamabe, Masashi

L-shape is the important and fundamental shape for injection molded parts. Therefore to reveal the corner angular deformation mechanism of this shape is also valuable for understanding the warpage mechanism of injection molded parts. In this study, we investigated the influence of the filling materials (fiber, talc and not filled) and two kinds of anisotropic shrinkage factors, solidification shrinkage and shrinkage caused by thermal expansion coefficient during cooling, to the angular deformation of L-shaped specimens and the following conclusions were obtained 1) The anisotropic solidification shrinkage of MD/TD and the anisotropic thermal expansion coefficient of MD/TD are considered to cause the angular deformation of L-shaped specimens. But the contribution ratios of these two anisotropies depend on the filling material for plastics. 2) The angular deformation of PP and PBT filled with glass fiber is mainly caused by the anisotropic thermal expansion coefficient and on the other hand, that of PP and PBT without filling material is caused by anisotropic solidification shrinkage. However both anisotropies cause the angular deformation of PP filled with talc. 3) The plate thickness dependence of the angular deformation of PP filled with talc is the singular peculiar phenomenon. The plate thickness dependence of anisotropic solidification shrinkage of this material (it is also singular) is considered to have an important influence on this phenomenon.

Quantitative Experimental Study of Defects Induced by Process Parameters in the High-Pressure Die Cast Process

NASA Astrophysics Data System (ADS)

Sharifi, P.; Jamali, J.; Sadayappan, K.; Wood, J. T.

2018-05-01

A quantitative experimental study of the effects of process parameters on the formation of defects during solidification of high-pressure die cast magnesium alloy components is presented. The parameters studied are slow-stage velocity, fast-stage velocity, intensification pressure, and die temperature. The amount of various defects are quantitatively characterized. Multiple runs of the commercial casting simulation package, ProCAST™, are used to model the mold-filling and solidification events. Several locations in the component including knit lines, last-to-fill region, and last-to-solidify region are identified as the critical regions that have a high concentration of defects. The area fractions of total porosity, shrinkage porosity, gas porosity, and externally solidified grains are separately measured. This study shows that the process parameters, fluid flow and local solidification conditions, play major roles in the formation of defects during HPDC process.

Comparison of 3D Echocardiogram-Derived 3D Printed Valve Models to Molded Models for Simulated Repair of Pediatric Atrioventricular Valves.

PubMed

Scanlan, Adam B; Nguyen, Alex V; Ilina, Anna; Lasso, Andras; Cripe, Linnea; Jegatheeswaran, Anusha; Silvestro, Elizabeth; McGowan, Francis X; Mascio, Christopher E; Fuller, Stephanie; Spray, Thomas L; Cohen, Meryl S; Fichtinger, Gabor; Jolley, Matthew A

2018-03-01

Mastering the technical skills required to perform pediatric cardiac valve surgery is challenging in part due to limited opportunity for practice. Transformation of 3D echocardiographic (echo) images of congenitally abnormal heart valves to realistic physical models could allow patient-specific simulation of surgical valve repair. We compared materials, processes, and costs for 3D printing and molding of patient-specific models for visualization and surgical simulation of congenitally abnormal heart valves. Pediatric atrioventricular valves (mitral, tricuspid, and common atrioventricular valve) were modeled from transthoracic 3D echo images using semi-automated methods implemented as custom modules in 3D Slicer. Valve models were then both 3D printed in soft materials and molded in silicone using 3D printed "negative" molds. Using pre-defined assessment criteria, valve models were evaluated by congenital cardiac surgeons to determine suitability for simulation. Surgeon assessment indicated that the molded valves had superior material properties for the purposes of simulation compared to directly printed valves (p < 0.01). Patient-specific, 3D echo-derived molded valves are a step toward realistic simulation of complex valve repairs but require more time and labor to create than directly printed models. Patient-specific simulation of valve repair in children using such models may be useful for surgical training and simulation of complex congenital cases.

Three-dimensional numerical simulation for plastic injection-compression molding

NASA Astrophysics Data System (ADS)

Zhang, Yun; Yu, Wenjie; Liang, Junjie; Lang, Jianlin; Li, Dequn

2018-03-01

Compared with conventional injection molding, injection-compression molding can mold optical parts with higher precision and lower flow residual stress. However, the melt flow process in a closed cavity becomes more complex because of the moving cavity boundary during compression and the nonlinear problems caused by non-Newtonian polymer melt. In this study, a 3D simulation method was developed for injection-compression molding. In this method, arbitrary Lagrangian- Eulerian was introduced to model the moving-boundary flow problem in the compression stage. The non-Newtonian characteristics and compressibility of the polymer melt were considered. The melt flow and pressure distribution in the cavity were investigated by using the proposed simulation method and compared with those of injection molding. Results reveal that the fountain flow effect becomes significant when the cavity thickness increases during compression. The back flow also plays an important role in the flow pattern and redistribution of cavity pressure. The discrepancy in pressures at different points along the flow path is complicated rather than monotonically decreased in injection molding.

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

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

Nguyen, Ba Nghiep; Fifield, Leonard S.; Mori, Steven

During the third quarter of FY 2015, the following technical progress has been made toward project milestones: 1) Magna oversaw the tool build and prepared the molding plan for the complex part of Phase II. 2) PlastiComp hosted a visit by Magna and Toyota on April 23rd to finalize the molding scope and schedule. The plan for molding trials including selection of molding parameters for both LFT and D-LFT for the U-shape complex part was established. 3) Toyota shipped the U-shape complex part tool to Magna on May 28th, 2015. 4) Plasticomp provided 30wt% LCF/PP and 30wt% LCF/PA66 compounded pelletsmore » to Magna for molding the complex part. 5) Magna performed preliminary molding trials on June 2nd, 2015 to validate wall thickness, fill profile, tool temperature and shot size requirements for the complex part. 6) Magna performed the first complex part run on June 16th and 17th, 2015 at Magna’s Composite Centre of Excellence in Concord, ON, Canada. Dale Roland of Plasticomp, and Umesh Gandhi of Toyota also attended the molding. 7) Magna discussed and finalized the plan with PNNL and the team for cutting samples from molded parts at selected locations for fiber orientation and length measurements. 8) Magna provided the computer-aided design (CAD) files of the complex parts with and without ribs to PNNL and Autodesk to build the corresponding ASMI models for injection molding simulations. Magna also provided the actual parameters used. 9) Plasticomp’s provided knowledge and experience of molding LCF materials essential to the successful molding of the parts including optimization of fill speed, tool temperatures, and plasticizing conditions for the 30wt% LCF/PP and 30wt% LCF/PA66 materials in both rib and non-rib versions. 10) Magna molded additional parts for evaluation of mechanical property testing including torsional stiffness on June 29th and 30th, 2015 at Magna’s Composite Center of Excellence. 11) Toyota began preparation for the torsion test of the specimens. Preparation of a computer-aided engineering (CAE) model to predict the performance is in progress. 12) Autodesk fixed an error in the implementation of the proper orthogonal decomposition (POD) calculation of fiber length that had caused the ASMI solution to crash and provided an updated build of ASMI containing the fix. 13)Autodesk reviewed and provided feedback for the complex part molding and measurement locations. 14) Autodesk provided support to set up the workflow for ASMI-ABAQUS® analysis, and provided a fix and workaround for a bug in the ASMI-ABAQUS® output command. 15) Autodesk helped build ASMI analysis models for the complex parts with and without ribs. 16) Autodesk worked on improving the orientation prediction accuracy in the shearing layer for 3D meshes based on comparison to measured data of the plaque moldings. 17) PNNL installed a new ASMI version received from Autodesk and performed comparative analyses to assess mid-plane versus 3D fiber length predictions using the full fiber length model and the reduced-order model (ROM) using POD. 18) PNNL presented the project scope, accomplishments, significant results and future plans to DOE and the USCAR Materials Tech Team on June 3rd, 2015. 19) PNNL discussed the cutting of samples from molded parts and finalized a plan with Magna and the team suggesting the sample size, locations and number of samples per location. 20) PNNL and Autodesk built ASMI models for the complex parts with and without ribs, and preliminary analyses of the part with ribs were conducted using the actual molding parameters received from Magna. 21) PNNL worked on a procedure to extract fiber orientation and length results from a 3D ASMI analysis to a 3D ABAQUS model. This procedure is essential to import ASMI fiber orientation and length to a 3D ABAQUS model of the part allowing future part structural analysis for weight reduction study.« less

Forming of complex-shaped composite tubes using optimized bladder-assisted resin transfer molding

NASA Astrophysics Data System (ADS)

Schillfahrt, Christian; Fauster, Ewald; Schledjewski, Ralf

2018-05-01

This work addresses the manufacturing of tubular composite structures by means of bladder-assisted resin transfer molding using elastomeric bladders. In order to achieve successful processing of such parts, knowledge of the compaction and impregnation behavior of the textile preform is vital. Hence, efficient analytical models that describe the influencing parameters of the preform compaction and filling stage were developed and verified through practical experiments. A process window describing optimal and critical operating conditions during the injection stage was created by evaluating the impact of the relevant process pressures on filling time. Finally, a cascaded injection procedure was investigated that particularly facilitates the manufacturing of long composite tubes.

Uniformly dense polymeric foam body

DOEpatents

Whinnery, Jr., Leroy

2003-07-15

A method for providing a uniformly dense polymer foam body having a density between about 0.013 g/cm.sup.3 to about 0.5 g/cm.sup.3 is disclosed. The method utilizes a thermally expandable polymer microsphere material wherein some of the microspheres are unexpanded and some are only partially expanded. It is shown that by mixing the two types of materials in appropriate ratios to achieve the desired bulk final density, filling a mold with this mixture so as to displace all or essentially all of the internal volume of the mold, heating the mold for a predetermined interval at a temperature above about 130.degree. C., and then cooling the mold to a temperature below 80.degree. C. the molded part achieves a bulk density which varies by less then about .+-.6% everywhere throughout the part volume.

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.

Textile composite processing science

NASA Technical Reports Server (NTRS)

Loos, Alfred C.; Hammond, Vincent H.; Kranbuehl, David E.; Hasko, Gregory H.

1993-01-01

A multi-dimensional model of the Resin Transfer Molding (RTM) process was developed for the prediction of the infiltration behavior of a resin into an anisotropic fiber preform. Frequency dependent electromagnetic sensing (FDEMS) was developed for in-situ monitoring of the RTM process. Flow visualization and mold filling experiments were conducted to verify sensor measurements and model predictions. Test results indicated good agreement between model predictions, sensor readings, and experimental data.

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

DIRECT INGOT PROCESS FOR PRODUCING URANIUM

DOEpatents

Leaders, W.M.; Knecht, W.S.

1960-11-15

A process is given in which uranium tetrafluoride is reduced to the metal with magnesium and in the same step the uranium metal formed is cast into an ingot. For this purpose a mold is arranged under and connected with the reaction bomb, and both are filled with the reaction mixture. The entire mixture is first heated to just below reaction temperature, and thereafter heating is restricted to the mixture in the mold. The reaction starts in the mold whereby heat is released which brings the rest of the mixture to reaction temperature. Pure uranium metal settles in the mold while the magnesium fluoride slag floats on top of it. After cooling, the uranium is separated from the slag by mechanical means.

Applying simulation to optimize plastic molded optical parts

NASA Astrophysics Data System (ADS)

Jaworski, Matthew; Bakharev, Alexander; Costa, Franco; Friedl, Chris

2012-10-01

Optical injection molded parts are used in many different industries including electronics, consumer, medical and automotive due to their cost and performance advantages compared to alternative materials such as glass. The injection molding process, however, induces elastic (residual stress) and viscoelastic (flow orientation stress) deformation into the molded article which alters the material's refractive index to be anisotropic in different directions. Being able to predict and correct optical performance issues associated with birefringence early in the design phase is a huge competitive advantage. This paper reviews how to apply simulation analysis of the entire molding process to optimize manufacturability and part performance.

Study of a Compression-Molding Process for Ultraviolet Light-Emitting Diode Exposure Systems via Finite-Element Analysis

PubMed Central

Wu, Kuo-Tsai; Hwang, Sheng-Jye; Lee, Huei-Huang

2017-01-01

Although wafer-level camera lenses are a very promising technology, problems such as warpage with time and non-uniform thickness of products still exist. In this study, finite element simulation was performed to simulate the compression molding process for acquiring the pressure distribution on the product on completion of the process and predicting the deformation with respect to the pressure distribution. Results show that the single-gate compression molding process significantly increases the pressure at the center of the product, whereas the multi-gate compressing molding process can effectively distribute the pressure. This study evaluated the non-uniform thickness of product and changes in the process parameters through computer simulations, which could help to improve the compression molding process. PMID:28617315

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

PubMed

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

2009-04-01

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

Blowing Polymer Bubbles in an Acoustic Levitator

NASA Technical Reports Server (NTRS)

Lee, M. C.

1985-01-01

In new manufacturing process, small gas-filled polymer shells made by injecting gas directly into acoustically levitated prepolymer drops. New process allows sufficient time for precise control of shell geometry. Applications foreseen in fabrication of deuterium/tritium-filled fusion targets and in pharmaceutical coatings. New process also useful in glass blowing and blow molding.

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.

Surface quality of unsaturated polyester resin processed via continuous multi-shot rotational molding

NASA Astrophysics Data System (ADS)

Ogila, K. O.; Yang, W.; Shao, M.; Tan, J.

2017-05-01

Unsaturated Polyester Resin is a versatile and cost efficient thermosetting plastic whose application in rotational molding is currently limited by its relatively high initial viscosity and heat of reaction. These material characteristics result in uneven material distribution, poor surface finish and imperfections in the moldings especially when large wall thicknesses are required. The current work attempts to remedy these shortcomings through the development of a continuous multi-shot system which adds predetermined loads of unsaturated polyester resin into a rotating mold at various intervals. As part of this system, a laboratory-scale uniaxial rotational molding machine was used to produce Unsaturated Polyester Resin moldings in single and double shots. Optimal processing conditions were determined through visual studies, three dimensional microscopic studies, thickness distribution analysis and Fourier Transform Infrared spectroscopy. Volume filling fractions of 0.049-0.065, second shot volumes of 0.5-0.75 from the first shot, rotational speeds of 15-20 rpm and temperatures of 30-50 °C resulted in moldings of suitable quality on both the inner and outer surfaces.

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

Low cost tooling material and process for graphite and Kevlar composites

NASA Technical Reports Server (NTRS)

Childs, William I.

1987-01-01

An Extruded Sheet Tooling Compound (ESTC) was developed for use in quickly building low cost molds for fabricating composites. The ESTC is a very highly mineral-filled resin system formed into a 6 mm thick sheet. The sheet is laid on the pattern, vacuum (bag) is applied to remove air from the pattern surface, and the assembly is heat cured. The formed ESTC is then backed and/or framed and ready for use. The cured ESTC exhibits low coefficient of thermal expansion and maintains strength at temperatures of 180 to 200 C. Tools were made and used successfully for: Compression molding of high strength epoxy sheet molding compound, stamping of aluminum, resin transfer molding of polyester, and liquid resin molding of polyester. Several variations of ESTC can be made for specific requirements. Higher thermal conductivity can be achieved by using an aluminum particle filler. Room temperature gel is possible to allow use of foam patterns.

Method for forming a uniformly dense polymer foam body

DOEpatents

Whinnery, Jr., Leroy

2002-01-01

A method for providing a uniformly dense polymer foam body having a density between about 0.013 .sup.g /.sub.cm.sup..sub.3 to about 0.5 .sup.g /.sub.cm.sup..sub.3 is disclosed. The method utilizes a thermally expandable polymer microballoon material wherein some of the microballoons are unexpanded and some are only partially expanded. It is shown that by mixing the two types of materials in appropriate ratios to achieve the desired bulk final density, filling a mold with this mixture so as to displace all or essentially all of the internal volume of the mold, heating the mold for a predetermined interval at a temperature above about 130.degree. C., and then cooling the mold to a temperature below 80.degree. C. the molded part achieves a bulk density which varies by less then about .+-.6% everywhere throughout the part volume.

Study on the PTC/NTC effect of carbon black-filled polymer composites

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

Tang, Hao; Chen, Xinfang; Luo, Yunxia

1995-12-01

In this work, the effect of processing condition and radiation-crosslinking on the electrical and dynamic behaviors of carbon black filled low density polyethylene (LDPE) composites were investigated. Compared with the solution counterpart, the mechanical composites have a strong PTC effect and a great dynamic elastic mold, which results from the strong interaction between carbon black and LDPE. The experiment result shows that the NTC effect is caused by the decrease of elastic mold of LDPE at high temperature, and it can be declined significantly by radiation-crosslinking. We conclude that the strong interaction between polymer and carbon black is essentially importantmore » for composites to have a great PTC intensity good electrical reproducibility and high dynamic elastic sold.« less

Finite Element Simulation of Compression Molding of Woven Fabric Carbon Fiber/Epoxy Composites: Part I Material Model Development

DOE PAGES

Li, Yang; Zhao, Qiangsheng; Mirdamadi, Mansour; ...

2016-01-06

Woven fabric carbon fiber/epoxy composites made through compression molding are one of the promising choices of material for the vehicle light-weighting strategy. Previous studies have shown that the processing conditions can have substantial influence on the performance of this type of the material. Therefore the optimization of the compression molding process is of great importance to the manufacturing practice. An efficient way to achieve the optimized design of this process would be through conducting finite element (FE) simulations of compression molding for woven fabric carbon fiber/epoxy composites. However, performing such simulation remains a challenging task for FE as multiple typesmore » of physics are involved during the compression molding process, including the epoxy resin curing and the complex mechanical behavior of woven fabric structure. In the present study, the FE simulation of the compression molding process of resin based woven fabric composites at continuum level is conducted, which is enabled by the implementation of an integrated material modeling methodology in LS-Dyna. Specifically, the chemo-thermo-mechanical problem of compression molding is solved through the coupling of three material models, i.e., one thermal model for temperature history in the resin, one mechanical model to update the curing-dependent properties of the resin and another mechanical model to simulate the behavior of the woven fabric composites. Preliminary simulations of the carbon fiber/epoxy woven fabric composites in LS-Dyna are presented as a demonstration, while validations and models with real part geometry are planned in the future work.« less

Multicomponent micropatterned sol-gel materials by capillary molding

NASA Astrophysics Data System (ADS)

Lochhead, Michael J.; Yager, Paul

1997-10-01

A physically and chemically benign method for patterning multiple sol-gel materials onto a single substrate is described. Structures are demonstrated for potential micro- optical chemical sensor, biosensor, and waveguiding applications. Fabrication is based on the micro molding in capillaries (MIMIC) approach. A novel mold design allows several sols to be cast simultaneously. Closely spaced, organically modified silica ridges containing fluorescent dyes are demonstrated. Ridges have cross sectional dimensions from one to 50 micrometers and are centimeters in length. Processing issues, particularly those related to mold filling, are discussed in detail. Because sol-gel MIMIC avoids the harsh physical and chemical environments normally associated with patterning, the approach allows full exploitation of sol- gel processing advantages, such as the ability to entrap sensitive organic dopant molecules in the sol-gel matrix.

FRONT VIEW OF POURING FROM #61 HOLDING FURNACE AT #02 ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

FRONT VIEW OF POURING FROM #61 HOLDING FURNACE AT #02 STATION INTO THREE VERTICAL MOLDS SUBMERGED IN A WATER-FILLED TANK BELOW THE CASTING FLOOR. THE CASTING CREW'S JOBS DURING THIS PHASE OF THE OPERATION INCLUDE REGULATING THE POURING RATE AND MONITORING THE VALVE RODS THAT CONTROL THE WATER SPRAYS ON THE MOLDS. DIFFERENT ALLOYS REQUIRE SPECIFIC POURING SPEEDS AND WATER PRESSURES. - American Brass Foundry, 70 Sayre Street, Buffalo, Erie County, NY

Macrosegregation Resulting from Directional Solidification Through an Abrupt Change in Cross-Sections

NASA Technical Reports Server (NTRS)

Lauer, M.; Poirier, D. R.; Ghods, M.; Tewari, S. N.; Grugel, R. N.

2017-01-01

Simulations of the directional solidification of two hypoeutectic alloys (Al-7Si alloy and Al-19Cu) and resulting macrosegregation patterns are presented. The casting geometries include abrupt changes in cross-section from a larger width of 9.5 mm to a narrower 3.2 mm width then through an expansion back to a width of 9.5 mm. The alloys were chosen as model alloys because they have similar solidification shrinkages, but the effect of Cu on changing the density of the liquid alloy is about an order of magnitude greater than that of Si. The simulations compare well with experimental castings that were directionally solidified in a graphite mold in a Bridgman furnace. In addition to the simulations of the directional solidification in graphite molds, some simulations were effected for solidification in an alumina mold. This study showed that the mold must be included in numerical simulations of directional solidification because of its effect on the temperature field and solidification. For the model alloys used for the study, the simulations clearly show the interaction of the convection field with the solidifying alloys to produce a macrosegregation pattern known as "steepling" in sections with a uniform width. Details of the complex convection- and segregation-patterns at both the contraction and expansion of the cross-sectional area are revealed by the computer simulations. The convection and solidification through the expansions suggest a possible mechanism for the formation of stray grains. The computer simulations and the experimental castings have been part of on-going ground-based research with the goal of providing necessary background for eventual experiments aboard the ISS. For casting practitioners, the results of the simulations demonstrate that computer simulations should be applied to reveal interactions between alloy solidification properties, solidification conditions, and mold geometries on macrosegregation. The simulations also presents the possibility of engineering the mold-material to avoid, or mitigate, the effects of thermosolutal convection and macrosegregation by selecting a mold material with suitable thermal properties, especially its thermal conductivity.

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.

Combination Of Investment And Centrifugal Casting

NASA Technical Reports Server (NTRS)

Creeger, Gordon A.

1994-01-01

Modifications, including incorporation of centrifugal casting, made in investment-casting process reducing scrap rate. Used to make first- and second-stage high-pressure-fuel-turbopump nozzles, containing vanes with thin trailing edges and other thin sections. Investment mold spun for short time while being filled, and stopped before solidification occurs. Centrifugal force drives molten metal into thin trailing edges, ensuring they are filled. With improved filling, preheat and pour temperatures reduced and solidification hastened so less hot tearing.

Composite materials molding simulation for purpose of automotive industry

NASA Astrophysics Data System (ADS)

Grabowski, Ł.; Baier, A.; Majzner, M.; Sobek, M.

2016-08-01

Composite materials loom large increasingly important role in the overall industry. Composite material have a special role in the ever-evolving automotive industry. Every year the composite materials are used in a growing number of elements included in the cars construction. Development requires the search for ever new applications of composite materials in areas where previously were used only metal materials. Requirements for modern solutions, such as reducing the weight of vehicles, the required strength and vibration damping characteristics go hand in hand with the properties of modern composite materials. The designers faced the challenge of the use of modern composite materials in the construction of bodies of power steering systems in vehicles. The initial choice of method for producing composite bodies was the method of molding injection of composite material. Molding injection of polymeric materials is a widely known and used for many years, but the molding injection of composite materials is a relatively new issue, innovative, it is not very common and is characterized by different conditions, parameters and properties in relation to the classical method. Therefore, for the purpose of selecting the appropriate composite material for injection for the body of power steering system computer analysis using Siemens NX 10.0 environment, including Moldex 3d and EasyFill Advanced tool to simulate the injection of materials from the group of possible solutions were carried out. Analyses were carried out on a model of a modernized wheel case of power steering system. During analysis, input parameters, such as temperature, pressure injectors, temperature charts have been analysed. An important part of the analysis was to analyse the propagation of material inside the mold during injection, so that allowed to determine the shape formability and the existence of possible imperfections of shapes and locations air traps. A very important parameter received from computer analysis was to determine the occurrence of the shrinkage of the material, which significantly affects the behaviour of the assumed geometry of the tested component. It also allowed the prediction of existence of shrincage of material during the process of modelling the shape of body. The next step was to analyse the numerical analysis results received from Siemens NX 10 and Moldex 3D EasyFlow Advanced environment. The process of injection were subjected to shape of prototype body of power steering. The material used in process of injection was similar to one of excepted material to be used in process of molding. Nextly, the results were analysed in purpose of geometry, where samples has aberrations in comparison to a given shape of mold. The samples were also analysed in terms of shrinkage. Research and results were described in detail in this paper.

Investigation of the shear thinning behavior of epoxy resins for utilization in vibration assisted liquid composite molding processes

NASA Astrophysics Data System (ADS)

Meier, R.; Kirdar, C.; Rudolph, N.; Zaremba, S.; Drechsler, K.

2014-05-01

Efficient production and consumption of energy are of greatest importance for contemporary industries and their products. This has led to an increasing application of lightweight materials in general and of Carbon Fiber Reinforced Plastics (CFRP) in particular. However, broader application of CFRP is often limited by high costs and manual labor production processes. These constraints are addressed by Liquid Composite Molding (LCM) processes. In LCM a dry fibrous preform is placed into a cavity and infiltrated mostly by thermoset resins; epoxy resins are wide spread in CFRP applications. One crucial parameter for a fast mold filling is the viscosity of the resin, which is affected by the applied shear rates as well as temperature and curing time. The work presented focuses on the characterization of the shear thinning behavior of epoxy resins. Furthermore, the correlation with the conditions in vibration assisted LCM processes, where additional shear rates are created during manufacture, is discussed. Higher shear rates result from high frequencies and/or high amplitudes of the vibration motions which are created by a vibration engine mounted on the mold. In rheological investigations the shear thinning behavior of a representative epoxy resin is studied by means of rotational and oscillatory experiments. Moreover, possible effects of shear rates on the chemical curing reaction are studied. Here, the time for gelation is measured for different levels of shear rates in a pre-shearing phase. Based on the rheological studies, the beneficial effect of vibration assistance in LCM processes with respect to mold filling can further be predicted and utilized.

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.

An in-mold packaging process for plastic fluidic devices.

PubMed

Yoo, Y E; Lee, K H; Je, T J; Choi, D S; Kim, S K

2011-01-01

Micro or nanofluidic devices have many channel shapes to deliver chemical solutions, body fluids or any fluids. The channels in these devices should be covered to prevent the fluids from overflowing or leaking. A typical method to fabricate an enclosed channel is to bond or weld a cover plate to a channel plate. This solid-to-solid bonding process, however, takes a considerable amount of time for mass production. In this study, a new process for molding a cover layer that can enclose open micro or nanochannels without solid-to-solid bonding is proposed and its feasibility is estimated. First, based on the design of a model microchannel, a brass microchannel master core was machined and a plastic microchannel platform was injection-molded. Using this molded platform, a series of experiments was performed for four process or mold design parameters. Some feasible conditions were successfully found to enclosed channels without filling the microchannels for the injection molding of a cover layer over the plastic microchannel platform. In addition, the bond strength and seal performance were estimated in a comparison with those done by conventional bonding or welding processes.

A finite element/level set model of polyurethane foam expansion and polymerization

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

Rao, Rekha R.; Long, Kevin Nicholas; Roberts, Christine Cardinal

Polyurethane foams are used widely for encapsulation and structural purposes because they are inexpensive, straightforward to process, amenable to a wide range of density variations (1 lb/ft3 - 50 lb/ft3), and able to fill complex molds quickly and effectively. Computational model of the filling and curing process are needed to reduce defects such as voids, out-of-specification density, density gradients, foam decomposition from high temperatures due to exotherms, and incomplete filling. This paper details the development of a computational fluid dynamics model of a moderate density PMDI structural foam, PMDI-10. PMDI is an isocyanate-based polyurethane foam, which is chemically blown withmore » water. The polyol reacts with isocyanate to produces the polymer. PMDI- 10 is catalyzed giving it a short pot life: it foams and polymerizes to a solid within 5 minutes during normal processing. To achieve a higher density, the foam is over-packed to twice or more of its free rise density of 10 lb/ft3. The goal for modeling is to represent the expansion, filling of molds, and the polymerization of the foam. This will be used to reduce defects, optimize the mold design, troubleshoot the processed, and predict the final foam properties. A homogenized continuum model foaming and curing was developed based on reaction kinetics, documented in a recent paper; it uses a simplified mathematical formalism that decouples these two reactions. The chemo-rheology of PMDI is measured experimentally and fit to a generalized- Newtonian viscosity model that is dependent on the extent of cure, gas fraction, and temperature. The conservation equations, including the equations of motion, an energy balance, and three rate equations are solved via a stabilized finite element method. The equations are combined with a level set method to determine the location of the foam-gas interface as it evolves to fill the mold. Understanding the thermal history and loads on the foam due to exothermicity and oven curing is very important to the results, since the kinetics, viscosity, and other material properties are all sensitive to temperature. Results from the model are compared to experimental flow visualization data and post-test X-ray computed tomography (CT) data for the density. Several geometries are investigated including two configurations of a mock structural part and a bar geometry to specifically test the density model. We have found that the model predicts both average density and filling profiles well. However, it under predicts density gradients, especially in the gravity direction. Further model improvements are also discussed for future work.« less

Effect of mold designs on molten metal behaviour in high-pressure die casting

NASA Astrophysics Data System (ADS)

Ibrahim, M. D.; Rahman, M. R. A.; Khan, A. A.; Mohamad, M. R.; Suffian, M. S. Z. M.; Yunos, Y. S.; Wong, L. K.; Mohtar, M. Z.

2017-04-01

This paper presents a research study conducted in a local automotive component manufacturer that produces aluminium alloy steering housing local and global markets. This study is to investigate the effect of design modification of mold in die casting as to improve the production rate. Design modification is carried out on the casting shot of the mold. Computer flow simulation was carried out to study the flow of molten metal in the mold with respect to the mold design modification. The design parameters of injection speed, die temperature and clamping force has been included in the study. The result of the simulation showed that modifications of casting shot give significant impact towards the molten flow behaviour in casting process. The capabilities and limitations of die casting process simulation to conduct defect analysis had been optimized. This research will enhance the efficiency of the mass production of the industry of die casting with the understanding of defect analysis, which lies on the modification of the mold design, a way early in its stages of production.

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

Beyond input-output computings: error-driven emergence with parallel non-distributed slime mold computer.

PubMed

Aono, Masashi; Gunji, Yukio-Pegio

2003-10-01

The emergence derived from errors is the key importance for both novel computing and novel usage of the computer. In this paper, we propose an implementable experimental plan for the biological computing so as to elicit the emergent property of complex systems. An individual plasmodium of the true slime mold Physarum polycephalum acts in the slime mold computer. Modifying the Elementary Cellular Automaton as it entails the global synchronization problem upon the parallel computing provides the NP-complete problem solved by the slime mold computer. The possibility to solve the problem by giving neither all possible results nor explicit prescription of solution-seeking is discussed. In slime mold computing, the distributivity in the local computing logic can change dynamically, and its parallel non-distributed computing cannot be reduced into the spatial addition of multiple serial computings. The computing system based on exhaustive absence of the super-system may produce, something more than filling the vacancy.

Mechanical characterization and structural analysis of recycled fiber-reinforced-polymer resin-transfer-molded beams

NASA Astrophysics Data System (ADS)

Tan, Eugene Wie Loon

1999-09-01

The present investigation was focussed on the mechanical characterization and structural analysis of resin-transfer-molded beams containing recycled fiber-reinforced polymers. The beams were structurally reinforced with continuous unidirectional glass fibers. The reinforcing filler materials consisted entirely of recycled fiber-reinforced polymer wastes (trim and overspray). The principal resin was a 100-percent dicyclo-pentadiene unsaturated polyester specially formulated with very low viscosity for resin transfer molding. Variations of the resin transfer molding technique were employed to produce specimens for material characterization. The basic materials that constituted the structural beams, continuous-glass-fiber-reinforced, recycled-trim-filled and recycled-overspray-filled unsaturated polyesters, were fully characterized in axial and transverse compression and tension, and inplane and interlaminar shear, to ascertain their strengths, ultimate strains, elastic moduli and Poisson's ratios. Experimentally determined mechanical properties of the recycled-trim-filled and recycled-overspray-filled materials from the present investigation were superior to those of unsaturated polyester polymer concretes and Portland cement concretes. Mechanical testing and finite element analyses of flexure (1 x 1 x 20 in) and beam (2 x 4 x 40 in) specimens were conducted. These structurally-reinforced specimens were tested and analyzed in four-point, third-point flexure to determine their ultimate loads, maximum fiber stresses and mid-span deflections. The experimentally determined load capacities of these specimens were compared to those of equivalent steel-reinforced Portland cement concrete beams computed using reinforced concrete theory. Mechanics of materials beam theory was utilized to predict the ultimate loads and mid-span deflections of the flexure and beam specimens. However, these predictions proved to be severely inadequate. Finite element (fracture propagation) analyses of the flexure and beam specimens were also performed. These progressive failure analyses more closely approximated flexural behavior under actual testing conditions by reducing the elastic moduli of elements that were considered to have partially or totally failed. Individual element failures were predicted using the maximum stress, Tsai-Hill and Tsai-Wu failure criteria. Excellent predictions of flexural behavior were attributed to the progressive failure analyses combined with an appropriate failure criterion, and the reliable input material properties that were generated.

Casting Simulation of an Austrian Bronze Age Sword Hilt

NASA Astrophysics Data System (ADS)

Pola, Annalisa; Mödlinger, Marianne; Piccardo, Paolo; Montesano, Lorenzo

2015-07-01

Bronze Age swords with a metal hilt can be considered the peak of Bronze Age casting technologies. To reconstruct the casting techniques used more than 3000 years ago, a metal hilted sword of the Schalenknauf type from Lower Austria was studied with the aid of macroscopic analyses and simulation of mold filling and casting solidification. A three-dimensional model of the hilt was created based on optical scanner measurements performed on a hilt recently discovered during archaeological excavations. Three different configurations of the gating system were considered, two on the pommel disk and one on the knob, and the effect of its location on the formation of casting defects was investigated. Three-dimensional computed tomography was used to detect internal defects, such as gas and shrinkage porosity, which were then compared with those calculated by simulation. The best match between actual and predicted hilt quality demonstrated the location of the gating system, which turned out to be on the pommel disk.

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

Li, Yang; Zhao, Qiangsheng; Mirdamadi, Mansour

Woven fabric carbon fiber/epoxy composites made through compression molding are one of the promising choices of material for the vehicle light-weighting strategy. Previous studies have shown that the processing conditions can have substantial influence on the performance of this type of the material. Therefore the optimization of the compression molding process is of great importance to the manufacturing practice. An efficient way to achieve the optimized design of this process would be through conducting finite element (FE) simulations of compression molding for woven fabric carbon fiber/epoxy composites. However, performing such simulation remains a challenging task for FE as multiple typesmore » of physics are involved during the compression molding process, including the epoxy resin curing and the complex mechanical behavior of woven fabric structure. In the present study, the FE simulation of the compression molding process of resin based woven fabric composites at continuum level is conducted, which is enabled by the implementation of an integrated material modeling methodology in LS-Dyna. Specifically, the chemo-thermo-mechanical problem of compression molding is solved through the coupling of three material models, i.e., one thermal model for temperature history in the resin, one mechanical model to update the curing-dependent properties of the resin and another mechanical model to simulate the behavior of the woven fabric composites. Preliminary simulations of the carbon fiber/epoxy woven fabric composites in LS-Dyna are presented as a demonstration, while validations and models with real part geometry are planned in the future work.« less

Powder Injection Molding of Ceramic Engine Components for Transportation

NASA Astrophysics Data System (ADS)

Lenz, Juergen; Enneti, Ravi K.; Onbattuvelli, Valmikanathan; Kate, Kunal; Martin, Renee; Atre, Sundar

2012-03-01

Silicon nitride has been the favored material for manufacturing high-efficiency engine components for transportation due to its high temperature stability, good wear resistance, excellent corrosion resistance, thermal shock resistance, and low density. The use of silicon nitride in engine components greatly depends on the ability to fabricate near net-shape components economically. The absence of a material database for design and simulation has further restricted the engineering community in developing parts from silicon nitride. In this paper, the design and manufacturability of silicon nitride engine rotors for unmanned aerial vehicles by the injection molding process are discussed. The feedstock material property data obtained from experiments were used to simulate the flow of the material during injection molding. The areas susceptible to the formation of defects during the injection molding process of the engine component were identified from the simulations. A test sample was successfully injection molded using the feedstock and sintered to 99% density without formation of significant observable defects.

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

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

Nguyen, Ba Nghiep; Fifield, Leonard S.; Wollan, Eric J.

2015-11-13

During the last quarter of FY 2015, the following technical progress has been made toward project milestones: 1) PlastiComp used the PlastiComp direct in-line (D-LFT) Pushtrusion system to injection mold 40 30wt% LCF/PP parts with ribs, 40 30wt% LCF/PP parts without ribs, 10 30wt% LCF/PA66 parts with ribs, and 35 30wt% LCF/PA66 parts without ribs. In addition, purge materials from the injection molding nozzle were obtained for fiber length analysis, and molding parameters were sent to PNNL for process modeling. 2) Magna cut samples at four selected locations (named A, B, C and D) from the non-ribbed Magna-molded parts basedmore » on a plan discussed with PNNL and the team and shipped these samples to Virginia Tech for fiber orientation and length measurements. 3) Virginia Tech started fiber orientation and length measurements for the samples taken from the complex parts using Virginia Tech’s established procedure. 4) PNNL and Autodesk built ASMI models for the complex parts with and without ribs, reviewed process datasheets and performed preliminary analyses of these complex parts using the actual molding parameters received from Magna and PlastiComp to compare predicted to experimental mold filling patterns. 5) Autodesk assisted PNNL in developing the workflow to use Moldflow fiber orientation and length results in ABAQUS® simulations. 6) Autodesk advised the team on the practicality and difficulty of material viscosity characterization from the D-LFT process. 7) PNNL developed a procedure to import fiber orientation and length results from a 3D ASMI analysis to a 3D ABAQUS® model for structural analyses of the complex part for later weight reduction study. 8) In discussion with PNNL and Magna, Toyota developed mechanical test setups and built fixtures for three-point bending and torsion tests of the complex parts. 9) Toyota built a finite element model for the complex parts subjected to torsion loading. 10) PNNL built the 3D ABAQUS® model of the complex ribbed part subjected to 3-point bending. 11) University of Illinois (Prof. C.L. Tucker) advised the team on fiber orientation and fiber length measurement options, modeling issues as well as interpretation of data.« less

Occurrence of molds on laminated paperboard for aseptic packaging, selection of the most hydrogen peroxide- and heat-resistant isolates and determination of their thermal death kinetics in sterile distilled water.

PubMed

Delgado, Denise Aparecida; de Souza Sant'ana, Anderson; de Massaguer, Pilar Rodriguez

2012-07-01

This study aimed at enumerating molds (heat-labile and heat-resistant) on the surface of paperboard material to be filled with tomato pulps through an aseptic system and at determining the most heat- and hydrogen peroxide-resistant strains. A total of 118 samples of laminated paperboard before filling were collected, being 68 before and 50 after the hydrogen peroxide bath. Seven molds, including heat-resistant strains (Penicillium variotii and Talaromyces flavus) with counts ranging between 0.71 and 1.02 CFU/cm(2) were isolated. P. variotii was more resistant to hydrogen peroxide than T. flavus and was inactivated after heating at 85 °C/15 min. When exposed to 35 % hydrogen peroxide at 25 °C, T. flavus (F5E2) and N. fischeri (control) were less resistant than P. variotti (F1A1). P. citrinum (F7E2) was shown to be as resistant as P. variotti. The D values (the time to cause one logarithmic cycle reduction in a microbial population at a determined temperature) for spores of P. variotii (F1A1) and N. fischeri (control) with 4 months of age at 85 and 90 °C were 3.9 and 4.5 min, respectively. Although the contamination of packages was low, the presence of heat- and chemical-resistant molds may be of concern for package sterility and product stability during shelf-life. To our knowledge, this is the first report that focuses on the isolation of molds, including heat-resistant ones, contaminating paperboard packaging material and on estimating their resistance to the chemical and physical processes used for packaging sterilization.

Nonisothermal glass molding for the cost-efficient production of precision freeform optics

NASA Astrophysics Data System (ADS)

Vu, Anh-Tuan; Kreilkamp, Holger; Dambon, Olaf; Klocke, Fritz

2016-07-01

Glass molding has become a key replication-based technology to satisfy intensively growing demands of complex precision optics in the today's photonic market. However, the state-of-the-art replicative technologies are still limited, mainly due to their insufficiency to meet the requirements of mass production. This paper introduces a newly developed nonisothermal glass molding in which a complex-shaped optic is produced in a very short process cycle. The innovative molding technology promises a cost-efficient production because of increased mold lifetime, less energy consumption, and high throughput from a fast process chain. At the early stage of the process development, the research focuses on an integration of finite element simulation into the process chain to reduce time and labor-intensive cost. By virtue of numerical modeling, defects including chill ripples and glass sticking in the nonisothermal molding process can be predicted and the consequent effects are avoided. In addition, the influences of process parameters and glass preforms on the surface quality, form accuracy, and residual stress are discussed. A series of experiments was carried out to validate the simulation results. The successful modeling, therefore, provides a systematic strategy for glass preform design, mold compensation, and optimization of the process parameters. In conclusion, the integration of simulation into the entire nonisothermal glass molding process chain will significantly increase the manufacturing efficiency as well as reduce the time-to-market for the mass production of complex precision yet low-cost glass optics.

Cerebral NIRS performance testing with molded and 3D-printed phantoms (Conference Presentation)

NASA Astrophysics Data System (ADS)

Wang, Jianting; Huang, Stanley; Chen, Yu; Welle, Cristin G.; Pfefer, T. Joshua

2017-03-01

Near-infrared spectroscopy (NIRS) has emerged as a low-cost, portable approach for rapid, point-of-care detection of hematomas caused by traumatic brain injury. As a new technology, there is a need to develop standardized test methods for objective, quantitative performance evaluation of these devices. Towards this goal, we have developed and studied two types of phantom-based testing approaches. The first involves 3D-printed phantoms incorporating hemoglobin-filled inclusions. Phantom layers representing specific cerebral tissues were printed using photopolymers doped with varying levels of titanium oxide and black resin. The accuracy, precision and spectral dependence of printed phantom optical properties were validated using spectrophotometry. The phantom also includes a hematoma inclusion insert which was filled with a hemoglobin solution. Oxygen saturation levels were modified by adding sodium dithionite at calibrated concentrations. The second phantom approach involves molded silicone layers with a superficial region - simulating the scalp and skull - comprised of removable layers to vary hematoma size and depth, and a bottom layer representing brain matter. These phantoms were tested with both a commercial hematoma detector and a custom NIRS system to optimize their designs and validate their utility in performing inter-device comparisons. The effects of hematoma depth, diameter, and height, as well as tissue optical properties and biological variables including hemoglobin saturation level and scalp/skull thickness were studied. Results demonstrate the ability to quantitatively compare NIRS device performance and indicate the promise of using 3D printing to achieve phantoms with realistic variations in tissue optical properties for evaluating biophotonic device performance.

Depth of cure of resin composites: is the ISO 4049 method suitable for bulk fill materials?

PubMed

Flury, Simon; Hayoz, Stefanie; Peutzfeldt, Anne; Hüsler, Jürg; Lussi, Adrian

2012-05-01

To evaluate if depth of cure D(ISO) determined by the ISO 4049 method is accurately reflected with bulk fill materials when compared to depth of cure D(new) determined by Vickers microhardness profiles. D(ISO) was determined according to "ISO 4049; Depth of cure" and resin composite specimens (n=6 per group) were prepared of two control materials (Filtek Supreme Plus, Filtek Silorane) and four bulk fill materials (Surefil SDR, Venus Bulk Fill, Quixfil, Tetric EvoCeram Bulk Fill) and light-cured for either 10s or 20s. For D(new), a mold was filled with one of the six resin composites and light-cured for either 10 s or 20 s (n=22 per group). The mold was placed under a microhardness indentation device and hardness measurements (Vickers hardness, VHN) were made at defined distances, beginning at the resin composite that had been closest to the light-curing unit (i.e. at the "top") and proceeding toward the uncured resin composite (i.e. toward the "bottom"). On the basis of the VHN measurements, Vickers hardness profiles were generated for each group. D(ISO) varied between 1.76 and 6.49 mm with the bulk fill materials showing the highest D(ISO). D(new) varied between 0.2 and 4.0 mm. D(new) was smaller than D(ISO) for all resin composites except Filtek Silorane. For bulk fill materials the ISO 4049 method overestimated depth of cure compared to depth of cure determined by Vickers hardness profiles. Copyright © 2012 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

Electromagnetic microforging apparatus for low-cost fabrication of molds for microlens arrays

NASA Astrophysics Data System (ADS)

Pribošek, Jaka; Diaci, Janez

2015-06-01

This study addresses the problem of low-cost microlens fabrication and outlines the development of a novel microforging apparatus for microlens mold fabrication. The apparatus consists of an electromagnetic impact tool which strikes a piston with a hardened steel ball into a workpiece. The impact creates a spherical indentation which serves as a lens cavity. The microforging apparatus is controlled by a microprocessor control unit communicating with a personal computer and enables on-the-fly variation of electromagnetic excitation to control the microforging process. We studied the effects of process parameters on the diameter of the fabricated lens cavities inspected by a custom automatic image processing algorithm. Different microforging regimes are analyzed and discussed. The surface quality of fabricated cavities has been inspected by confocal microscopy and the influence of fill factor on sphericity error has been studied. The proposed microforging method enables the fabrication of molds with 100% fill factor, surface roughness as low as Ra 0.15 µm and sphericity error lower than 0.5 µm. The fabricated microlens arrays exhibit nearly diffraction-limited performance, offering a wide range of possible applications. We believe this study provides access to microoptical technology for smaller optical and computer vision laboratories.

Rapid fabrication method of a microneedle mold with controllable needle height and width.

PubMed

Lin, Yen-Heng; Lee, I-Chi; Hsu, Wei-Chieh; Hsu, Ching-Hong; Chang, Kai-Ping; Gao, Shao-Syuan

2016-10-01

The main issue of transdermal drug delivery is that macromolecular drugs cannot diffuse through the stratum corneum of skin. Many studies have pursued micro-sized needles encapsulated with drugs to overcome this problem, as these needles can pierce the stratum corneum and allow drugs to enter the circulatory system of the human body. However, most microneedle fabrication processes are time-consuming and require expensive equipment. In this study, we demonstrate a rapid method for fabricating a microneedle mold using drawing lithography and a UV-cured resin. The mold was filled with a water-soluble material, polyvinylpyrrolidone (PVP), which was then demolded to produce a water-soluble microneedle array. The results of an in vitro skin insertion test using PVP microneedles and pig ear skin demonstrated the feasibility of the microneedle mold. In addition, by controlling the viscosity of the UV-cured resin through various heat treatments, microneedles with different heights and aspect ratios were produced. Compared with other methods, this technology significantly simplifies and accelerates the mold fabrication process. In addition, the required equipment is relatively simple and inexpensive. Through this technology, we can rapidly fabricate microneedle molds with controllable dimensions for various applications.

49 CFR 178.356-1 - General requirements.

Code of Federal Regulations, 2010 CFR

2010-10-01

... filled with a molded-in-place, fire-resistant, phenolic-foam insulation interspersed with wooden members... over 5 gallons capacity must be closed by means of 12-gauge bolted ring with drop forged lugs, one of...

49 CFR 178.356-1 - General requirements.

Code of Federal Regulations, 2013 CFR

2013-10-01

... filled with a molded-in-place, fire-resistant, phenolic-foam insulation interspersed with wooden members... over 5 gallons capacity must be closed by means of 12-gauge bolted ring with drop forged lugs, one of...

49 CFR 178.356-1 - General requirements.

Code of Federal Regulations, 2011 CFR

2011-10-01

... filled with a molded-in-place, fire-resistant, phenolic-foam insulation interspersed with wooden members... over 5 gallons capacity must be closed by means of 12-gauge bolted ring with drop forged lugs, one of...

49 CFR 178.356-1 - General requirements.

Code of Federal Regulations, 2012 CFR

2012-10-01

... filled with a molded-in-place, fire-resistant, phenolic-foam insulation interspersed with wooden members... over 5 gallons capacity must be closed by means of 12-gauge bolted ring with drop forged lugs, one of...

Mathematical modeling of the in-mold coating process for injection-molded thermoplastic parts

NASA Astrophysics Data System (ADS)

Chen, Xu

In-Mold Coating (IMC) has been successfully used for many years for exterior body panels made from compression molded Sheet Molding Compound (SMC). The coating material is a single component reactive fluid, designed to improve the surface quality of SMC moldings in terms of functional and cosmetic properties. When injected onto a cured SMC part, IMC cures and bonds to provide a pain-like surface. Because of its distinct advantages, IMC is being considered for application to injection molded thermoplastic parts. For a successful in mold coating operation, there are two key issues related to the flow of the coating. First, the injection nozzle should be located such that the thermoplastic substrate is totally covered and the potential for air trapping is minimized. The selected location should be cosmetically acceptable since it most likely will leave a mark on the coated surface. The nozzle location also needs to be accessible for easy of maintenance. Secondly, the hydraulic force generated by the coating injection pressure should not exceed the available clamping tonnage. If the clamping force is exceeded, coating leakage will occur. In this study, mathematical models for IMC flow on the compressible thermoplastic substrate have been developed. Finite Difference Method (FDM) is first used to solve the 1 dimensional (1D) IMC flow problem. In order to investigate the application of Control Volume based Finite Element Method (CV/FEM) to more complicated two dimensional IMC flow, that method is first evaluated by solving the 1D IMC flow problem. An analytical solution, which can be obtained when a linear relationship between the coating thickness and coating injection pressure is assumed, is used to verify the numerical results. The mathematical models for the 2 dimensional (2D) IMC flow are based on the generalized Hele-Shaw approximation. It has been found experimentally that the power law viscosity model adequately predicts the rheological behavior of the coating. The compressibility of the substrate is modeled by the 2-domain Tait PVT equation. CV/FEM is used to solve the discretized governing equations. A computer code has been developed to predict the fill pattern of the coating and the injection pressure. A number of experiments have been conducted to verify the numerical predictions of the computer code. It has been found both numerically and experimentally that the substrate thickness plays a significant role on the IMC fill pattern.

Enabling Learning through the Assessment Process

DTIC Science & Technology

2010-04-08

Software, 47. 32 a specific pattern over time.”98 Johnson provides an example of this when discussing the computer simulation of slime mold growth. He...asserts that since the designers understood the underlying interactions between the individual slime molds , they could increase or decrease the...density of individual mold cells and the aggregating chemical that is required for the molds to group together. Furthermore, Johnson suggests that this

Study of the Effect of Mold Corner Shape on the Initial Solidification Behavior of Molten Steel Using Mold Simulator

NASA Astrophysics Data System (ADS)

Lyu, Peisheng; Wang, Wanlin; Long, Xukai; Zhang, Kaixuan; Gao, Erzhuo; Qin, Rongshan

2018-02-01

The chamfered mold with a typical corner shape (angle between the chamfered face and hot face is 45 deg) was applied to the mold simulator study in this paper, and the results were compared with the previous results from a well-developed right-angle mold simulator system. The results suggested that the designed chamfered structure would increase the thermal resistance and weaken the two-dimensional heat transfer around the mold corner, causing the homogeneity of the mold surface temperatures and heat fluxes. In addition, the chamfered structure can decrease the fluctuation of the steel level and the liquid slag flow around the meniscus at mold corner. The cooling intensities at different longitudinal sections of shell are close to each other due to the similar time-average solidification factors, which are 2.392 mm/s1/2 (section A-A: chamfered center), 2.372 mm/s1/2 (section B-B: 135 deg corner), and 2.380 mm/s1/2 (section D-D: face), respectively. For the same oscillation mark (OM), the heights of OM roots at different positions (profile L1 (face), profile L2 (135 deg corner), and profile L3 (chamfered center)) are very close to each other. The average value of height difference (HD) between two OMs roots for L1 and L2 is 0.22 mm, and for L2 and L3 is 0.38 mm. Finally, with the help of metallographic examination, the shapes of different hooks were also discussed.

INJECTION-MOLDING APPARATUS

DOEpatents

Lobell, G.M.

1958-02-11

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

Fluxing agent for metal cast joining

DOEpatents

Gunkel, Ronald W.; Podey, Larry L.; Meyer, Thomas N.

2002-11-05

A method of joining an aluminum cast member to an aluminum component. The method includes the steps of coating a surface of an aluminum component with flux comprising cesium fluoride, placing the flux coated component in a mold, filling the mold with molten aluminum alloy, and allowing the molten aluminum alloy to solidify thereby joining a cast member to the aluminum component. The flux preferably includes aluminum fluoride and alumina. A particularly preferred flux includes about 60 wt. % CsF, about 30 wt. % AlF.sub.3, and about 10 wt. % Al.sub.2 O.sub.3.

Experimental and Numerical Analysis of Injection Molding of Ti-6Al-4V Powders for High-Performance Titanium Parts

NASA Astrophysics Data System (ADS)

Lin, Dongguo; Kang, Tae Gon; Han, Jun Sae; Park, Seong Jin; Chung, Seong Taek; Kwon, Young-Sam

2018-02-01

Both experimental and numerical analysis of powder injection molding (PIM) of Ti-6Al-4V alloy were performed to prepare a defect-free high-performance Ti-6Al-4V part with low carbon/oxygen contents. The prepared feedstock was characterized with specific experiments to identify its viscosity, pressure-volume-temperature and thermal properties to simulate its injection molding process. A finite-element-based numerical scheme was employed to simulate the thermomechanical process during the injection molding. In addition, the injection molding, debinding, sintering and hot isostatic pressing processes were performed in sequence to prepare the PIMed parts. With optimized processing conditions, the PIMed Ti-6Al-4V part exhibits excellent physical and mechanical properties, showing a final density of 99.8%, tensile strength of 973 MPa and elongation of 16%.

FIBER ORIENTATION IN INJECTION MOLDED LONG CARBON FIBER THERMOPLASTIC COMPOSITES

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

Wang, Jin; Nguyen, Ba Nghiep; Mathur, Raj N.

2015-03-23

A set of edge-gated and center-gated plaques were injection molded with long carbon fiber-reinforced thermoplastic composites, and the fiber orientation was measured at different locations of the plaques. Autodesk Simulation Moldflow Insight (ASMI) software was used to simulate the injection molding of these plaques and to predict the fiber orientation, using the anisotropic rotary diffusion and the reduced strain closure models. The phenomenological parameters of the orientation models were carefully identified by fitting to the measured orientation data. The fiber orientation predictions show very good agreement with the experimental data.

Investigation on the Effect of Mold Constraints and Cooling Rate on Residual Stress During the Sand-Casting Process of 1086 Steel by Employing a Thermomechanical Model

NASA Astrophysics Data System (ADS)

Baghani, Amir; Davami, Parviz; Varahram, Naser; Shabani, Mohsen Ostad

2014-06-01

In this study, the effects of mold constraints and cooling rate on residual stress were analyzed during the shaped casting process. For this purpose, an H-shaped sample was designed in which the contraction of its middle portion is highly restricted by the mold during the cooling process. The effects of an increasing cooling rate combined with mold constraints were analyzed by reducing the thickness of the middle portion in the second sample. A three-dimensional coupled temperature-displacement analysis was performed in finite-element code ABAQUS to simulate residual stress distribution, and then numerical results were verified by the hole-drilling strain-gauge method. It was concluded that the mold constraints have a greater effect on the values of residual stress than the cooling rate (thin section) in steel sand casting. Increasing the cooling rate would increase the amount of residual stress, only in the presence of mold constraints. It is also suggested that employing the elastic-plastic stress model for the sand mold will satisfy the experimental results and avoid exaggerated values of residual stress in simulation.

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

NASA Astrophysics Data System (ADS)

Fetecau, Catalin; Stan, Felicia; Dobrea, Daniel

2011-01-01

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

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.

Design and Checking Analysis of Injection Mold for a Plastic Cup

NASA Astrophysics Data System (ADS)

Li, Xuebing

2018-03-01

A special injection mold was designed for the structural characteristics of a plastic cup part. The mold was simulated by Moldflow software and verified by calculating the stripping force, the pulling force and the clamping force of the mold so that to determine the appropriate injection parameters. It has been proved that the injection mold is effective and practical in the actual producing and can meet the quality requirements during the course of using it, which solved some problems for injection molding of this kind of parts and can provide some reference for the production of other products in the same industry.

Rheology of Organodispersions of Alumina Nanopowders Used in Producing Articles from Engineering Ceramics

NASA Astrophysics Data System (ADS)

Palcevskis, E.; Faitelson, L.; Jakobsons, E.

2005-05-01

The rheological properties of molding suspensions of alumina nanopowder in paraffin have been studied. Powders with specific surface areas of 32 and 55 m2/g and the surface-active substances oleic acid and Hypermer LP1 were used. The Hamaker constant for alumina particles in paraffin wax was estimated. A rough calculation showed that a gel should arise in the suspensions studied. The linearly viscoelastic characteristics determined by the method of small-amplitude periodic shear (on the frequency range from 0.063 to 157 s-1) confirmed this conclusion. The flow curves of the molding feedstock, determined over a broad range of shear rates (from 0.018 to 1070 s-1), point to a pseudoplastic character of the flow. From the rheological studies it follows that, in manufacturing engineering ceramics by injection molding from the suspensions investigated and in designing or selecting the forming equipment, the realization of maximum high shear strains must be ensured, which will promote a qualitative filling of intricately shaped and small-size molds.

Rapid Prototyping of Nanofluidic Slits in a Silicone Bilayer

PubMed Central

Kole, Thomas P.; Liao, Kuo-Tang; Schiffels, Daniel; Ilic, B. Robert; Strychalski, Elizabeth A.; Kralj, Jason G.; Liddle, J. Alexander; Dritschilo, Anatoly; Stavis, Samuel M.

2015-01-01

This article reports a process for rapidly prototyping nanofluidic devices, particularly those comprising slits with microscale widths and nanoscale depths, in silicone. This process consists of designing a nanofluidic device, fabricating a photomask, fabricating a device mold in epoxy photoresist, molding a device in silicone, cutting and punching a molded silicone device, bonding a silicone device to a glass substrate, and filling the device with aqueous solution. By using a bilayer of hard and soft silicone, we have formed and filled nanofluidic slits with depths of less than 400 nm and aspect ratios of width to depth exceeding 250 without collapse of the slits. An important attribute of this article is that the description of this rapid prototyping process is very comprehensive, presenting context and details which are highly relevant to the rational implementation and reliable repetition of the process. Moreover, this process makes use of equipment commonly found in nanofabrication facilities and research laboratories, facilitating the broad adaptation and application of the process. Therefore, while this article specifically informs users of the Center for Nanoscale Science and Technology (CNST) at the National Institute of Standards and Technology (NIST), we anticipate that this information will be generally useful for the nanofabrication and nanofluidics research communities at large, and particularly useful for neophyte nanofabricators and nanofluidicists. PMID:26958449

Optimization of Casting Design Parameters on Fabrication of Reliable Semi-Solid Aluminum Suspension Control Arm

NASA Astrophysics Data System (ADS)

Ragab, Kh. A.; Bouaicha, A.; Bouazara, M.

2017-09-01

The semi-solid casting process has the advantage of providing reliable mechanical aluminum parts that work continuously in dynamic as control arm of the suspension system in automotive vehicles. The quality performance of dynamic control arm is related to casting mold and gating system designs that affect the fluidity of semi-solid metal during filling the mold. Therefore, this study focuses on improvement in mechanical performance, depending on material characterization, and casting design optimization, of suspension control arms made of A357 aluminum semi-solid alloys. Mechanical and design analyses, applied on the suspension arm, showed the occurrence of mechanical failures at unexpected weak points. Metallurgical analysis showed that the main reason lies in the difficult flow of semi-solid paste through the thin thicknesses of a complex geometry. A design modification procedure is applied to the geometry of the suspension arm to avoid this problem and to improve its quality performance. The design modification of parts was carried out by using SolidWorks design software, evaluation of constraints with ABAQUS, and simulation of flow with ProCast software. The proposed designs showed that the modified suspension arm, without ribs and with a central canvas designed as Z, is considered as a perfect casting design showing an increase in the structural strength of the component. In this case, maximum von Mises stress is 199 MPa that is below the yield strength of the material. The modified casting mold design shows a high uniformity and minim turbulence of molten metal flow during semi-solid casting process.

Casting inorganic structures with DNA molds

PubMed Central

Sun, Wei; Boulais, Etienne; Hakobyan, Yera; Wang, Wei Li; Guan, Amy; Bathe, Mark; Yin, Peng

2014-01-01

We report a general strategy for designing and synthesizing inorganic nanostructures with arbitrarily prescribed three-dimensional shapes. Computationally designed DNA strands self-assemble into a stiff “nano-mold” that contains a user-specified three-dimensional cavity and encloses a nucleating gold “seed”. Under mild conditions, this seed grows into a larger cast structure that fills and thus replicates the cavity. We synthesized a variety of nanoparticles with three nanometer resolution: three distinct silver cuboids with three independently tunable dimensions, silver and gold nanoparticles with diverse cross sections, and composite structures with homo-/heterogeneous components. The designer equilateral silver triangular and spherical nanoparticles exhibited plasmonic properties consistent with electromagnetism-based simulations. Our framework is generalizable to more complex geometries and diverse inorganic materials, offering a range of applications in biosensing, photonics, and nanoelectronics. PMID:25301973

Simulation of mechanical behavior and optimization of simulated injection molding process for PLA based antibacterial composite and nanocomposite bone screws using central composite design.

PubMed

Heidari, Behzad Shiroud; Oliaei, Erfan; Shayesteh, Hadi; Davachi, Seyed Mohammad; Hejazi, Iman; Seyfi, Javad; Bahrami, Mozhgan; Rashedi, Hamid

2017-01-01

In this study, injection molding of three poly lactic acid (PLA) based bone screws was simulated and optimized through minimizing the shrinkage and warpage of the bone screws. The optimization was carried out by investigating the process factors such as coolant temperature, mold temperature, melt temperature, packing time, injection time, and packing pressure. A response surface methodology (RSM), based on the central composite design (CCD), was used to determine the effects of the process factors on the PLA based bone screws. Upon applying the method of maximizing the desirability function, optimization of the factors gave the lowest warpage and shrinkage for nanocomposite PLA bone screw (PLA9). Moreover, PLA9 has the greatest desirability among the selected materials for bone screw injection molding. Meanwhile, a finite element analysis (FE analysis) was also performed to determine the force values and concentration points which cause yielding of the screws under certain conditions. The Von-Mises stress distribution showed that PLA9 screw is more resistant against the highest loads as compared to the other ones. Finally, according to the results of injection molding simulations, the design of experiments (DOE) and structural analysis, PLA9 screw is recommended as the best candidate for the production of biomedical materials among all the three types of screws. Copyright © 2016 Elsevier Ltd. All rights reserved.

Research study demonstrates computer simulation can predict warpage and assist in its elimination

NASA Astrophysics Data System (ADS)

Glozer, G.; Post, S.; Ishii, K.

1994-10-01

Programs for predicting warpage in injection molded parts are relatively new. Commercial software for simulating the flow and cooling stages of injection molding have steadily gained acceptance; however, warpage software is not yet as readily accepted. This study focused on gaining an understanding of the predictive capabilities of the warpage software. The following aspects of this study were unique. (1) Quantitative results were found using a statistically designed set of experiments. (2) Comparisons between experimental and simulation results were made with parts produced in a well-instrumented and controlled injection molding machine. (3) The experimental parts were accurately measured on a coordinate measuring machine with a non-contact laser probe. (4) The effect of part geometry on warpage was investigated.

Selection of UV Resins for Nanostructured Molds for Thermal-NIL.

PubMed

Jia, Zheng; Choi, Junseo; Park, Sunggook

2018-06-18

Nanoimprint molds made of soft polymeric materials have advantages of low demolding force and low fabrication cost over Si or metal-based hard molds. However, such advantages are often sacrificed by their reduced replication fidelity associated with the low mechanical strength. In this paper, we studied replication fidelity of different UV-resin molds copied from a Si master mold via UV nanoimprint lithography (NIL) and their thermal imprinting performance into a thermoplastic polymer. Four different UV resins were studied: two were high surface energy UV resins based on tripropyleneglycol diacrylate (TPGDA resin) and polypropyleneglycol diacrylate (PPGDA resin), and the other two were commercially available, low surface energy poly-urethane acrylate (PUA resin) and fluorine-containing (MD 700) UV resins. The replication fidelity among the four UV-resins during UV nanoimprint lithograph from a Si master with sharp nanostructures was in the increasing order of (poorest) PUA resin < MD 700 < PPGDA resin < TPGDA resin (best). The results show that the high surface energy and small monomer size are keys to achieving good UV resin filling into sharp nanostructures over the viscosity of the resin solution. When the four UV-resin molds were used for thermal-NIL into a thermoplastic polymer, the replication fidelity was in the increasing order of (poorest) MD 700 < TPGDA resin < PUA resin (best), which follows the same order of their Young's moduli. Our results indicate that the selection of an appropriate UV resin for NIL molds requires consideration of the replication fidelities in the mold fabrication and the subsequent thermal-NIL into thermoplastic polymers. © 2018 IOP Publishing Ltd.

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.

Compression molded energy storage flywheels

NASA Astrophysics Data System (ADS)

Burdick, P. A.

Materials choices, manufacturing processes, and benefits of flywheels as an effective energy storage device are discussed. Tests at the LL Laboratories have indicated that compressing molding of plies of structural sheet molding compound (SMC) filled with randomly oriented fibers produces a laminated disk with transversely isotropic properties. Good performance has been realized with a carbon/epoxy system, which displays satisfactory stiffness and strength in flywheel applications. A core profile has been selected, consisting of a uniform 1 in cross sectional thickness and a 21 in diam. Test configurations using three different resin paste formulations were compared after being mounted elastomerically on aluminum hubs. Further development was found necessary on accurate balancing and hub bonding. It was concluded that the SMC flywheels display the low-cost, sufficient energy densities, suitable dynamic stability characteristics, and acceptably benign failure modes for automotive applications.

Factors influencing microinjection molding replication quality

NASA Astrophysics Data System (ADS)

Vera, Julie; Brulez, Anne-Catherine; Contraires, Elise; Larochette, Mathieu; Trannoy-Orban, Nathalie; Pignon, Maxime; Mauclair, Cyril; Valette, Stéphane; Benayoun, Stéphane

2018-01-01

In recent years, there has been increased interest in producing and providing high-precision plastic parts that can be manufactured by microinjection molding: gears, pumps, optical grating elements, and so on. For all of these applications, the replication quality is essential. This study has two goals: (1) fabrication of high-precision parts using the conventional injection molding machine; (2) identification of robust parameters that ensure production quality. Thus, different technological solutions have been used: cavity vacuuming and the use of a mold coated with DLC or CrN deposits. AFM and SEM analyses were carried out to characterize the replication profile. The replication quality was studied in terms of the process parameters, coated and uncoated molds and crystallinity of the polymer. Specific studies were processed to quantify the replicability of injection molded parts (ABS, PC and PP). Analysis of the Taguchi experimental designs permits prioritization of the impact of each parameter on the replication quality. A discussion taking into account these new parameters and the thermal and spreading properties on the coatings is proposed. It appeared that, in general, increasing the mold temperature improves the molten polymer fill in submicron features except for the steel insert (for which the presence of a vacuum is the most important factor). Moreover, the DLC coating was the best coating to increase the quality of the replication. This result could be explained by the lower thermal diffusivity of this coating. We noted that the viscosity of the polymers is not a primordial factor of the replication quality.

33. BENCH CORE STATION, GREY IRON FOUNDRY CORE ROOM WHERE ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

33. BENCH CORE STATION, GREY IRON FOUNDRY CORE ROOM WHERE CORE MOLDS WERE HAND FILLED AND OFTEN PNEUMATICALLY COMPRESSED WITH A HAND-HELD RAMMER BEFORE THEY WERE BAKED. - Stockham Pipe & Fittings Company, Grey Iron Foundry, 4000 Tenth Avenue North, Birmingham, Jefferson County, AL

Low noise wing slat system with rigid cove-filled slat

NASA Technical Reports Server (NTRS)

Shmilovich, Arvin (Inventor); Yadlin, Yoram (Inventor)

2013-01-01

Concepts and technologies described herein provide for a low noise aircraft wing slat system. According to one aspect of the disclosure provided herein, a cove-filled wing slat is used in conjunction with a moveable panel rotatably attached to the wing slat to provide a high lift system. The moveable panel rotates upward against the rear surface of the slat during deployment of the slat, and rotates downward to bridge a gap width between the stowed slat and the lower wing surface, completing the continuous outer mold line shape of the wing, when the cove-filled slat is retracted to the stowed position.

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.

Ring-mold craters in lineated valley fill and lobate debris aprons on Mars: Evidence for subsurface glacial ice

NASA Astrophysics Data System (ADS)

Kress, Ailish M.; Head, James W.

2008-12-01

Ring-mold craters (RMCs), concentric crater forms shaped like a truncated torus and named for their similarity to the cooking implement, are abundant in lobate debris aprons (LDA) and lineated valley fill (LVF) in the northern mid-latitudes on Mars, but are not seen in surrounding terrain. LDA and LVF have been interpreted to form by flow of debris, but uncertainty remains concerning the mechanism of flow, with hypotheses ranging from pore-ice-assisted creep of talus to debris-covered glaciers. RMCs average less than a few hundred meters in diameter and occur in association with normal bowl-shaped impact craters whose average diameters are commonly less than RMCs. On the basis of their morphologic similarities to laboratory impact craters formed in ice and the physics of impact cratering into layered material, we interpret the unusual morphology of RMCs to be the result of impact into a relatively pure ice substrate below a thin regolith, with strength-contrast properties, spallation, viscous flow and sublimation being factors in the development of the ring-mold shape. Associated smaller bowl-shaped craters are interpreted to have formed within a layer of regolith-like sublimation till overlying the ice substrate. Estimates of crater depths of excavation between populations of bowl-shaped and ring-mold craters suggest that the debris layer is relatively thin. These results support the hypothesis that LDA and LVF formed as debris-covered glaciers and predict that many hundreds of meters of ice remain today in LDA and LVF deposits, beneath a veneer of sublimation till. RMCs can be used in other parts of Mars to predict and assess the presence of ancient ice-related deposits.

Corrosion sealing of amalgam restorations in vitro.

PubMed

Mahler, David B; Pham, Bao V; Adey, Jerry D

2009-01-01

Amalgam restorations, when first placed, have been shown to exhibit a gap at the amalgam/tooth interface. With time in service, this gap fills with corrosion products that have the potential to "seal" the restoration. With the advent of high-copper, more corrosion-resistant amalgams, there has been concern that the time required to create this seal would be increased significantly when compared with low-copper traditional amalgams. The current study was designed to address this concern. Amalgam was condensed into a MACOR mold, simulating a Class I cavity form and then immersed into a 1.0% NaCl solution to simulate oral conditions. Using an air pressure test, the sealing was monitored over time. The results showed that the sealing was influenced by the size of the initial gap prior to immersion as well as corrosion resistance of the amalgam and that a corrosion-resistant amalgam with a small initial gap size can seal as quickly as a corrosion-prone amalgam. Therefore, it is not possible to predict sealing behavior based on corrosion resistance, alone. Furthermore, the presence of zinc in the amalgam alloy has been shown to result in the formation of zinc corrosion products in the amalgam/mold margin, which contributes to more rapid sealing. Analysis of a tooth extracted after 16 years of clinical service that had been restored with an amalgam-containing zinc was also shown to contain zinc corrosion products in the occlusal marginal area. This could explain the reported reduction in marginal fracture of clinically placed amalgam restorations made from zinc-containing alloys.

Energy Saving Melting and Revert Reduction Technology (Energy-SMARRT): Clean Steel Casting Production

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

Kuyucak, Selcuk; Li, Delin

2013-12-31

Inclusions in steel castings can cause rework, scrap, poor machining, and reduced casting performance, which can obviously result in excess energy consumption. Significant progress in understanding inclusion source, formation and control has been made. Inclusions can be defined as non-metallic materials such as refractory, sand, slag, or coatings, embedded in a metallic matrix. This research project has focused on the mold filling aspects to examine the effects of pouring methods and gating designs on the steel casting cleanliness through water modeling, computer modeling, and melting/casting experiments. Early in the research project, comprehensive studies of bottom-pouring water modeling and low-alloy steelmore » casting experiments were completed. The extent of air entrainment in bottom-poured large castings was demonstrated by water modeling. Current gating systems are designed to prevent air aspiration. However, air entrainment is equally harmful and no prevention measures are in current practice. In this study, new basin designs included a basin dam, submerged nozzle, and nozzle extension. The entrained air and inclusions from the gating system were significantly reduced using the new basin method. Near the end of the project, there has been close collaboration with Wescast Industries Inc., a company manufacturing automotive exhaust components. Both computer modeling using Magma software and melting/casting experiments on thin wall turbo-housing stainless steel castings were completed in this short period of time. Six gating designs were created, including the current gating on the pattern, non-pressurized, partially pressurized, naturally pressurized, naturally pressurized without filter, and radial choke gating without filter, for Magma modeling. The melt filling velocity and temperature were determined from the modeling. Based on the simulation results, three gating designs were chosen for further melting and casting experiments on the same casting pattern using the lip pouring method. It was observed again that gating designs greatly influenced the melt filling velocity and the number of inclusion defects. The radial choked gating showed improvements in casting cleanliness and yield over the other gatings, even though no mold filters were used in the gating system.« less

Influence of mold surface temperature on polymer part warpage in rapid heat cycle molding

NASA Astrophysics Data System (ADS)

Berger, G. R.; Pacher, G. A.; Pichler, A.; Friesenbichler, W.; Gruber, D. P.

2014-05-01

Dynamic mold surface temperature control was examined for its influence on the warpage. A test mold, featuring two different rapid heat cycle molding (RHCM) technologies was used to manufacture complex plate-shaped parts having different ribs, varying thin-wall regions, and both, circular and rectangular cut-outs. The mold's nozzle side is equipped with the areal heating and cooling technology BFMOLD®, where the heating/cooling channels are replaced by a ball-filled slot near the cavity surface flooded through with hot and cold water sequentially. Two local electrical ceramic heating elements are installed into the mold's ejection side. Based on a 23 full-factorial design of experiments (DoE) plan, varying nozzle temperature (Tnozzle), rapid heat cycle molding temperature (TRHCM) and holding pressure (pn), specimens of POM were manufactured systematically. Five specimens were examined per DoE run. The resulting warpage was measured at 6 surface line scans per part using the non-contact confocal topography system FRT MicroProf®. Two warpage parameters were calculated, the curvature of a 2nd order approximation a, and the vertical deflection at the profile center d. Both, the influence strength and the acting direction of the process parameters and their interactions on a and d were calculated by statistical analysis. Linear mathematical process models were determined for a and d to predict the warpage as a function of the process parameter settings. Finally, an optimum process setting was predicted, based on the process models and Microsoft Excel GRG solver. Clear and significant influences of TRHCM, pn, Tnozzle, and the interaction of TRHCM and pn were determined. While TRHCM was dominant close to the gate, pn became more effective as the flow length increased.

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.

A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing, Part II: Additive Manufacturing and Characterization of Polymer Composites

NASA Technical Reports Server (NTRS)

Chuang, Kathy C.; Grady, Joseph E.; Arnold, Steven M.; Draper, Robert D.; Shin, Eugene; Patterson, Clark; Santelle, Tom; Lao, Chao; Rhein, Morgan; Mehl, Jeremy

2015-01-01

This publication is the second part of the three part report of the project entitled "A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing" funded by NASA Aeronautics Research Institute (NARI). The objective of this project was to conduct additive manufacturing to produce aircraft engine components by Fused Deposition Modeling (FDM), using commercially available polyetherimides-Ultem 9085 and experimental Ultem 1000 mixed with 10% chopped carbon fiber. A property comparison between FDM-printed and injection molded coupons for Ultem 9085, Ultem 1000 resin and the fiber-filled composite Ultem 1000 was carried out. Furthermore, an acoustic liner was printed from Ultem 9085 simulating conventional honeycomb structured liners and tested in a wind tunnel. Composite compressor inlet guide vanes were also printed using fiber-filled Ultem 1000 filaments and tested in a cascade rig. The fiber-filled Ultem 1000 filaments and composite vanes were characterized by scanning electron microscope (SEM) and acid digestion to determine the porosity of FDM-printed articles which ranged from 25 to 31%. Coupons of Ultem 9085, experimental Ultem 1000 composites and XH6050 resin were tested at room temperature and 400F to evaluate their corresponding mechanical properties. A preliminary modeling was also initiated to predict the mechanical properties of FDM-printed Ultem 9085 coupons in relation to varied raster angles and void contents, using the GRC-developed MAC/GMC program.

Casting inorganic structures with DNA molds

DOE PAGES

Sun, Wei; Boulais, Etienne; Hakobyan, Yera; ...

2014-10-09

Here we report a general strategy for designing and synthesizing inorganic nanostructures with arbitrarily prescribed three-dimensional shapes. Computationally designed DNA strands self-assemble into a stiff “nano-mold” that contains a user-specified three-dimensional cavity and encloses a nucleating gold “seed”. Under mild conditions, this seed grows into a larger cast structure that fills and thus replicates the cavity. We synthesized a variety of nanoparticles with three nanometer resolution: three distinct silver cuboids with three independently tunable dimensions, silver and gold nanoparticles with diverse cross sections, and composite structures with homo-/heterogeneous components. The designer equilateral silver triangular and spherical nanoparticles exhibited plasmonic propertiesmore » consistent with electromagnetism-based simulations. Our framework is generalizable to more complex geometries and diverse inorganic materials, offering a range of applications in biosensing, photonics, and nanoelectronics.« less

Casting inorganic structures with DNA molds.

PubMed

Sun, Wei; Boulais, Etienne; Hakobyan, Yera; Wang, Wei Li; Guan, Amy; Bathe, Mark; Yin, Peng

2014-11-07

We report a general strategy for designing and synthesizing inorganic nanostructures with arbitrarily prescribed three-dimensional shapes. Computationally designed DNA strands self-assemble into a stiff "nanomold" that contains a user-specified three-dimensional cavity and encloses a nucleating gold "seed." Under mild conditions, this seed grows into a larger cast structure that fills and thus replicates the cavity. We synthesized a variety of nanoparticles with 3-nanometer resolution: three distinct silver cuboids with three independently tunable dimensions, silver and gold nanoparticles with diverse cross sections, and composite structures with homo- and heterogeneous components. The designer equilateral silver triangular and spherical nanoparticles exhibited plasmonic properties consistent with electromagnetism-based simulations. Our framework is generalizable to more complex geometries and diverse inorganic materials, offering a range of applications in biosensing, photonics, and nanoelectronics. Copyright © 2014, American Association for the Advancement of Science.

Determination of Machining Parameters of Corn Byproduct Filled Plastics

USDA-ARS?s Scientific Manuscript database

In a collaborative project between the USDA and Northern Illinois University, the use of ethanol corn processing by-products as bio-filler materials in the compression molding of phenolic plastics has been studied. This paper reports on the results of a machinability study in the milling of various ...

Determining Machining Parameters of Corn Byproduct Filled Plastics

USDA-ARS?s Scientific Manuscript database

In a collaborative project between the USDA and Northern Illinois University, the use of corn ethanol processing byproducts (i.e., DDGS) as bio-filler materials in the compression molding of phenolic plastics has been studied. This paper reports on the results of a machinability study in the milling...

40 CFR 63.5714 - How do I demonstrate compliance if I use filled resins?

Code of Federal Regulations, 2010 CFR

2010-07-01

... (CONTINUED) AIR PROGRAMS (CONTINUED) NATIONAL EMISSION STANDARDS FOR HAZARDOUS AIR POLLUTANTS FOR SOURCE CATEGORIES National Emission Standards for Hazardous Air Pollutants for Boat Manufacturing Standards for Open... of PV i in equation 2 of § 63.5710. Demonstrating Compliance for Open Molding Operations Controlled...

Effect of incremental filling technique on adhesion of light-cured resin composite to cavity floor.

PubMed

Chikawa, Hirokazu; Inai, Norimichi; Cho, Eitetsu; Kishikawa, Ryuzo; Otsuki, Masayuki; Foxton, Richard M; Tagami, Junji

2006-09-01

The purpose of this study was to evaluate the effect of various incremental filling techniques on adhesion between composite and cavity floor using light-cured resin composite. Black ABS resin and hybrid resin composite were used as mold materials--instead of dentin--for the preparation of cavities, and standardized to 5x5x5 mm. Each cavity was then treated with a bonding system (Clearfil SE bond). Resin composite (Clearfil Photo Core) was placed on the bonding resin using different incremental filling techniques or in bulk and irradiated for a total of 80 seconds using a halogen light unit. Specimens were subjected to the micro-tensile bond test at a crosshead speed of 1 mm/min. Data were analyzed by two-way ANOVA. The results indicated that an incremental filling technique was more effective in improving adhesion to the cavity floor than a bulk filling technique.

20. SIMILAR TO THE SYSTEM INSTALLED IN THE GREY IRON ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

20. SIMILAR TO THE SYSTEM INSTALLED IN THE GREY IRON FOUNDRY, MALLEABLE WORKERS FILLED MOLDS TRAVELING ON A CONVEYOR FROM LADLES ATTACHED TO OVERHEAD RAILS WHILE THEY STOOD ON A PLATFORM MOVING AT THE SAME SPEED AS THE CONVEYOR, CA. 1950 - Stockham Pipe & Fittings Company, 4000 Tenth Avenue North, Birmingham, Jefferson County, AL

The Simulation of Magnesium Wheel Low Pressure Die Casting Based on PAM-CAST™

NASA Astrophysics Data System (ADS)

Peng, Yinghong; Wang, Yingchun; Li, Dayong; Zeng, Xiaoqin

2004-06-01

Magnesium is the lightest metal commonly used in engineering, with various excellent characteristics such as high strength and electromagnetic interference shielding capability. Particularly, the usage of magnesium in automotive industry can meet better the need to reduce fuel consumption and CO2 emissions. Nowadays, most current magnesium components in automobiles are made by die casting. In this paper, commercial software for die casting, PAM-CAST™, was utilized to simulate the low pressure die casting process of magnesium wheel. Through calculating temperature field and velocity field during filling and solidification stages, the evolution of temperature distribution and liquid fraction was analyzed. Then, the potential defects including the gas entrapments in the middle of the spokes, shrinkages between the rim and the spokes were forecasted. The analytical results revealed that the mold geometry and die casting parameters should be improved in order to get the sound magnesium wheel. The reasons leading to these defects were also analyzed and the solutions to eliminate them were put forward. Furthermore, through reducing the pouring velocity, the air gas entrapments and partial shrinkages were eliminated effectively.

Predicting shrinkage and warpage in injection molding: Towards automatized mold design

NASA Astrophysics Data System (ADS)

Zwicke, Florian; Behr, Marek; Elgeti, Stefanie

2017-10-01

It is an inevitable part of any plastics molding process that the material undergoes some shrinkage during solidification. Mainly due to unavoidable inhomogeneities in the cooling process, the overall shrinkage cannot be assumed as homogeneous in all volumetric directions. The direct consequence is warpage. The accurate prediction of such shrinkage and warpage effects has been the subject of a considerable amount of research, but it is important to note that this behavior depends greatly on the type of material that is used as well as the process details. Without limiting ourselves to any specific properties of certain materials or process designs, we aim to develop a method for the automatized design of a mold cavity that will produce correctly shaped moldings after solidification. Essentially, this can be stated as a shape optimization problem, where the cavity shape is optimized to fulfill some objective function that measures defects in the molding shape. In order to be able to develop and evaluate such a method, we first require simulation methods for the diffierent steps involved in the injection molding process that can represent the phenomena responsible for shrinkage and warpage ina sufficiently accurate manner. As a starting point, we consider the solidification of purely amorphous materials. In this case, the material slowly transitions from fluid-like to solid-like behavior as it cools down. This behavior is modeled using adjusted viscoelastic material models. Once the material has passed a certain temperature threshold during cooling, any viscous effects are neglected and the behavior is assumed to be fully elastic. Non-linear elastic laws are used to predict shrinkage and warpage that occur after this point. We will present the current state of these simulation methods and show some first approaches towards optimizing the mold cavity shape based on these methods.

Simulation for grinding balls production using sand mold-gravity casting

NASA Astrophysics Data System (ADS)

Nurjaman, F.; Shofi, A.; Herlina, U.; Prilitasari, N. M.; Triapriani, Y.

2018-01-01

In this present work, the grinding balls from high chromium white cast iron (ASTM A-532) were produced by using sand mold-gravity casting. The simulation casting process was conducted before making these grinding balls by using SOLIDCast™ version 8.2.0. The gating system design and the pouring temperature of hot metal were investigated clearly to obtain grinding balls with no-defect. The sound casting of grinding balls was resulted by using the proper gating system with the addition of vent air on the top of each grinding ball’s mold. The dimension of vent air was reduced by the increasing of pouring temperature, thus it resulted on the increasing of the yield production of grinding balls.

A Parametric Study of Slag Skin Formation in Electroslag Remelting

NASA Astrophysics Data System (ADS)

Yanke, Jeff; Krane, Matthew John M.

In electroslag remelting (ESR), the slag generates heat, chemically refines the melting electrode material, and forms frozen skin on the mold. An axisymmetric model is used to simulate fluid flow, heat transfer, solidification, and electromagnetics and their interaction with slag skin formation in ESR. A volume of fluid (VOF) method is used to track the slag/metal interface, allowing simulation of slag freezing to the mold. Mold diameter and applied current are varied to determine how these parameters affect melt rate and formation of slag skin during ESR. Variations in the slag skin thickness within the slag cap are found to have a significant impact on melt rate and depth of metal sump. Changes in slag cap volume resulted in small changes in melt rate.

[Effect of Radii barrier sleeves on cure depth of composite resin].

PubMed

Wang, Binping; DU, Yongxiu

2009-01-01

To explore the effect of Radii barrier sleeves on the cure depth of composite resin. Cylinder mold was prepared, and the resin was filled strictly into the mold. The surface was flattened and then cured with plastic engraver's knife.The depth of composite resin which was cured by QHL75TM with or without Radii barrier sleeves was compared. The cure depth of composite resin which were cured by QHL75TM with or without Radii barrier sleeves of photo-curing machine was 4.38 mm and 4.27 mm respectively,with no statistical difference. The cure depth of composite resin is not influenced by Radii barrier sleeves under the same light condition.

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.

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.

Digital Twin concept for smart injection molding

NASA Astrophysics Data System (ADS)

Liau, Y.; Lee, H.; Ryu, K.

2018-03-01

Injection molding industry has evolved over decades and became the most common method to manufacture plastic parts. Monitoring and improvement in the injection molding industry are usually performed separately in each stage, i.e. mold design, mold making and injection molding process. However, in order to make a breakthrough and survive in the industrial revolution, all the stages in injection molding need to be linked and communicated with each other. Any changes in one stage will cause a certain effect in other stage because there is a correlation between each other. Hence, the simulation should not only based on the input of historical data, but it also needs to include the current condition of equipment and prediction of future events in other stages to make the responsive decision. This can be achieved by implementing the concept of Digital Twin that models the entire process as a virtual model and enables bidirectional control with the physical process. This paper presented types of data and technology required to build the Digital Twin for the injection molding industry. The concept includes Digital Twin of each stage and integration of these Digital Twin model as a thoroughgoing model of the injection molding industry.

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

NASA Astrophysics Data System (ADS)

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

2014-05-01

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

Moisture Durability Assessment of Selected Well-insulated Wall Assemblies

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

Pallin, Simon B.; Boudreaux, Philip R.; Kehrer, Manfred

2015-12-01

This report presents the results from studying the hygrothermal performance of two well-insulated wall assemblies, both complying with and exceeding international building codes (IECC 2015 2014, IRC 2015). The hygrothermal performance of walls is affected by a large number of influential parameters (e.g., outdoor and indoor climates, workmanship, material properties). This study was based on a probabilistic risk assessment in which a number of these influential parameters were simulated with their natural variability. The purpose of this approach was to generate simulation results based on laboratory chamber measurements that represent a variety of performances and thus better mimic realistic conditions.more » In total, laboratory measurements and 6,000 simulations were completed for five different US climate zones. A mold growth indicator (MGI) was used to estimate the risk of mold which potentially can cause moisture durability problems in the selected wall assemblies. Analyzing the possible impact on the indoor climate due to mold was not part of this study. The following conclusions can be reached from analyzing the simulation results. In a hot-humid climate, a higher R-value increases the importance of the airtightness because interior wall materials are at lower temperatures. In a cold climate, indoor humidity levels increase with increased airtightness. Air leakage must be considered in a hygrothermal risk assessment, since air efficiently brings moisture into buildings from either the interior or exterior environment. The sensitivity analysis of this study identifies mitigation strategies. Again, it is important to remark that MGI is an indicator of mold, not an indicator of indoor air quality and that mold is the most conservative indicator for moisture durability issues.« less

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.

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.

New tools for sculpting cranial implants in a shared haptic augmented reality environment.

PubMed

Ai, Zhuming; Evenhouse, Ray; Leigh, Jason; Charbel, Fady; Rasmussen, Mary

2006-01-01

New volumetric tools were developed for the design and fabrication of high quality cranial implants from patient CT data. These virtual tools replace time consuming physical sculpting, mold making and casting steps. The implant is designed by medical professionals in tele-immersive collaboration. Virtual clay is added in the virtual defect area on the CT data using the adding tool. With force feedback the modeler can feel the edge of the defect and fill only the space where no bone is present. A carving tool and a smoothing tool are then used to sculpt and refine the implant. To make a physical evaluation, the skull with simulated defect and the implant are fabricated via stereolithography to allow neurosurgeons to evaluate the quality of the implant. Initial tests demonstrate a very high quality fit. These new haptic volumetric sculpting tools are a critical component of a comprehensive tele-immersive system.

A new class of sonic composites

NASA Astrophysics Data System (ADS)

Munteanu, Ligia; Chiroiu, Veturia; Donescu, Ştefania; Brişan, Cornel

2014-03-01

Transformation acoustics opens a new avenue towards the architecture, modeling and simulation of a new class of sonic composites with scatterers made of various materials and having various shapes embedded in an epoxy matrix. The design of acoustic scatterers is based on the property of Helmholtz equations to be invariant under a coordinate transformation, i.e., a specific spatial compression is equivalent to a new material in a new space. In this paper, the noise suppression for a wide full band-gap of frequencies is discussed for spherical shell scatterers made of auxetic materials (materials with negative Poisson's ratio). The original domain consists of spheres made from conventional foams with positive Poisson's ratio. The spatial compression is controlled by the coordinate transformation, and leads to an equivalent domain filled with an auxetic material. The coordinate transformation is strongly supported by the manufacturing of auxetics which is based on the pore size reduction through radial compression molds.

Development of a CFD code for casting simulation

NASA Technical Reports Server (NTRS)

Murph, Jesse E.

1992-01-01

The task of developing a computational fluid dynamics (CFD) code to accurately model the mold filling phase of a casting operation was accomplished in a systematic manner. First the state-of-the-art was determined through a literature search, a code search, and participation with casting industry personnel involved in consortium startups. From this material and inputs from industry personnel, an evaluation of the currently available codes was made. It was determined that a few of the codes already contained sophisticated CFD algorithms and further validation of one of these codes could preclude the development of a new CFD code for this purpose. With industry concurrence, ProCAST was chosen for further evaluation. Two benchmark cases were used to evaluate the code's performance using a Silicon Graphics Personal Iris system. The results of these limited evaluations (because of machine and time constraints) are presented along with discussions of possible improvements and recommendations for further evaluation.

Numerically design the injection process parameters of parts fabricated with ramie fiber reinforced green composites

NASA Astrophysics Data System (ADS)

Chen, L. P.; He, L. P.; Chen, D. C.; Lu, G.; Li, W. J.; Yuan, J. M.

2017-01-01

The warpage deformation plays an important role on the performance of automobile interior components fabricated with natural fiber reinforced composites. The present work investigated the influence of process parameters on the warpage behavior of A pillar trim made of ramie fiber (RF) reinforced polypropylene (PP) composites (RF/PP) via numerical simulation with orthogonal experiment method and range analysis. The results indicated that fiber addition and packing pressure were the most important factors affecting warpage. The A pillar trim can achieved the minimum warpage value as of 2.124 mm under the optimum parameters. The optimal process parameters are: 70% percent of the default value of injection pressure for the packing pressure, 20 wt% for the fiber addition, 185 °C for the melt °C for the mold temperature, 7 s for the filling time and 17 s for the packing time.

Bioengineered 3D Scaffolds in Cancer Research: Focus on Epithelial to Mesenchymal Transition and Drug Screening.

PubMed

Xu, Xiaoli; Tang, LiLing

2017-01-01

The living environment of cancer cells is complicated and information-rich. Thus, traditional 2D culture mold in vitro cannot mimic the microenvironment of cancer cells exactly. Currently, bioengineered 3D scaffolds have been developed which can better simulate the microenvironment of tumors and fill the gap between 2D culture and clinical application. In this review, we discuss the scaffold materials used for fabrication techniques, biological behaviors of cancer cells in 3D scaffolds and the scaffold-based drug screening. A major emphasis is placed on the description of scaffold-based epithelial to mesenchymal transition and drug screening in 3D culture. By overcoming the defects of traditional 2D culture, 3D scaffolds culture can provide a simpler, safer and more reliable approach for cancer research. Copyright© Bentham Science Publishers; For any queries, please email at epub@benthamscience.org.

All plastic ultra-small size imaging lens unit fabrication and evaluation for endoscope

NASA Astrophysics Data System (ADS)

Ishii, Kenta; Okamoto, Dai; Ushio, Makoto; Tai, Hidetoshi; Nishihara, Atsuhiko; Tokuda, Kimio; Kawai, Shinsuke; Kitagawa, Seiichiro

2017-02-01

There is demand for small-size lens units for endoscope and industrial applications. Polished glass lenses with a diameter of 1 - 2mm exist, however plastic lenses similar in size are not commonplace. For low-cost, light-weight, and mass production, plastic lens fabrication is extremely beneficial. Especially, in the medical field, there is strong demand for disposable lens unit for endoscopes which prevent contamination due to reuse of the lens. Therefore, high mass producible and low cost becomes increasingly important. This paper reports our findings on injection-molded ultra-small size plastic lens units with a diameter of 1.3mm and total thickness of 1.4mm. We performed optical design, injection molding, and lens unit assembly for injection moldable, high imaging performance ultra-small sized lens units. We prioritize a robust product design, considering injection molding properties and lens unit assembly, with feedback from molding simulations reflected into the optical design. A mold capable of high precision lens positioning is used to fabricate the lenses and decrease the variability of the assembly. The geometric dimensions of the resulting lenses, are measured and used in the optical simulation to validate the optical performance, and a high agreement is reported. The injection molding of the lens and the assembly of the lens unit is performed with high precision, and results in high optical performance.

Replicative manufacturing of complex lighting optics by non-isothermal glass molding

NASA Astrophysics Data System (ADS)

Kreilkamp, Holger; Vu, Anh Tuan; Dambon, Olaf; Klocke, Fritz

2016-09-01

The advantages of LED lighting, especially its energy efficiency and the long service life have led to a wide distribution of LED technology in the world. However, in order to make fully use of the great potential that LED lighting offers, complex optics are required to distribute the emitted light from the LED efficiently. Nowadays, many applications use polymer optics which can be manufactured at low costs. However, due to ever increasing luminous power, polymer optics reach their technological limits. Due to its outstanding properties, especially its temperature resistance, resistance against UV radiation and its long term stability, glass is the alternative material of choice for the use in LED optics. This research is introducing a new replicative glass manufacturing approach, namely non-isothermal glass molding (NGM) which is able to manufacture complex lighting optics in high volumes at competitive prices. The integration of FEM simulation at the early stage of the process development is presented and helps to guarantee a fast development cycle. A coupled thermo-mechanical model is used to define the geometry of the glass preform as well as to define the mold surface geometry. Furthermore, simulation is used to predict main process outcomes, especially in terms of resulting form accuracy of the molded optics. Experiments conducted on a commercially available molding machine are presented to validate the developed simulation model. Finally, the influence of distinct parameters on important process outcomes like form accuracy, surface roughness, birefringence, etc. is discussed.

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.

Polymeric waveguide array with 45 degree slopes fabricated by bottom side tilted exposure

NASA Astrophysics Data System (ADS)

Lin, Xiaohui; Dou, Xinyuan; Wang, Alan X.; Chen, Ray T.

2011-01-01

This paper demonstrated a practical fabrication process of polymeric waveguide array (12 channels) with 50μm(W)×50μm(H)×23mm(L) dimension and mirror embedded 45° degree slopes for vertical coupling purpose. The entire process contained three main parts: a SU8 pre-mold with 45° slope, a PDMS mold and the final waveguide array device. The key step of fabricating the pre-mold included a bottom side tilted exposure of SU8 photo resist. By placing the sample upside down, tilting by 58.7° and immersing into DI water, the ultraviolet (UV) beam that shined vertically was directed to go through from the bottom of the glass substrate into top side SU8 resist with 45° angle to form the surface. This method was able to guarantee no-gap contact between the mask pattern and the photo resist when exposing. By comparing the process complexity and achieved structure of the top and bottom side exposure, the later was proved to be a promising method for making high quality tilted structure without any tailing effect. The reversed PDMS mold was then fabricated on the SU8 pre-mold. The PDMS mold was used to imprint the cladding layer of the waveguide array. After metal deposition, core filling and top cladding layer coating, the final polymeric waveguide array device was achieved. For performance evaluation, 850nm laser beam from VCSEL was modulated to 10Gbps signals and vertically coupled into the waveguide array. The eye diagrams revealed high Q factor when transmitting signals along these waveguide array.

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.

Polymeric compositions and their method of manufacture. [forming filled polymer systems using cryogenics

NASA Technical Reports Server (NTRS)

Moser, B. G.; Landel, R. F. (Inventor)

1972-01-01

Filled polymer compositions are made by dissolving the polymer binder in a suitable sublimable solvent, mixing the filler material with the polymer and its solvent, freezing the resultant mixture, and subliming the frozen solvent from the mixture from which it is then removed. The remaining composition is suitable for conventional processing such as compression molding or extruding. A particular feature of the method of manufacture is pouring the mixed solution slowly in a continuous stream into a cryogenic bath wherein frozen particles of the mixture result. The frozen individual particles are then subjected to the sublimation.

Muffling Hammer Blows In A Workshop

NASA Technical Reports Server (NTRS)

Thiele, Alfred W.; Gilbert, Jeffrey L.; Gutow, David A.

1994-01-01

Sound-deadening bags placed on hammered workpieces. Useful in many workshop situations. Fabricated easily and inexpensively. Bags filled with particles of sand, metal shot, plastic, or glass, then sewn or molded shut. Tailored to fit special configurations of some workpieces. Devices used to deaden print rollers and to reduce vibrations in main-injector inlet manifold of rocket engine.

U.S. EPA, Pesticide Product Label, MONOPROP MOLD KILLER, 08/28/1986

EPA Pesticide Factsheets

2011-04-21

... The. 4t.poe. of e~t1 baa illl .... i- 1ary lan4fill or by iatineration. or. ... ( •• f ( I A,.Iy It poe"", 'Jlt!1' tGn 'Gf • 'r .. 4h 'nrage I>v 'fIr:lIln!l·~'t" fn .. "~ I. It !f<>f!lI. ...

Changes in wood flour/HDPE composites after accelerated weathering with and without water spray

Treesearch

Nicole M. Stark

2005-01-01

Wood-plastic lumber is promoted as a low-maintenance high-durability product. After weathering, however, wood-plasticcomposites (WPCs) often fide and lose mechanical properties. In the first part ofthis study, 50%wood-flour-filled high-density polyethylene (HDPE) composite samples were injection molded or extruded. Composites were exposed to two accelerated weathering...

High-Performance Synthetic Fibers for Composites

DTIC Science & Technology

1992-04-01

under evaluation today include polyether ether ketone , polyamide, 23 polyamideimide, polyimide, polysulfone, and polyphenylene sulfide. Epoxy resins...shrinkage under intense neutron radiation . This attribute, together with other properties of high-temperature strength, toughness, and low nuclear...and (2) liquid or solid resins cross-linked with other esters in chopped-fiber and mineral-filled molding compounds. Polyether ether ketone (PEEK) A

Study on thickness distribution of thermoformed medical PVC blister

NASA Astrophysics Data System (ADS)

Li, Yiping

2017-08-01

Vacuum forming has many advantages over other plastic forming processes due to its cost effectiveness, time efficiency, higher product precision, and more design flexibility. Nevertheless, when pressures greater than the atmospheric value are required to force the thermo-plastic into more intimate contact with the mold surface, pressure forming is a better choice. This paper studies the process of air-pressure thermoforming of plastic sheet, and focuses on medical blister PVC products. ANSYS POLYFLOW tool is used to simulate the process and analyze the wall thickness distribution of the blister. The influence of mold parameters on the wall thickness distribution of thermoformed part is thus obtained through simulation. Increasing radius between mold and side wall at the bottom of blister and draft prove to improve the wall thickness distribution.

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.

Finite element analysis and simulation of rheological properties of bulk molding compound (BMC)

NASA Astrophysics Data System (ADS)

Ergin, M. Fatih; Aydin, Ismail

2013-12-01

Bulk molding compound (BMC) is one of the important composite materials with various engineering applications. BMC is a thermoset plastic resin blend of various inert fillers, fiber reinforcements, catalysts, stabilizers and pigments that form a viscous, molding compound. Depending on the end-use application, bulk molding compounds are formulated to achieve close dimensional control, flame and scratch resistance, electrical insulation, corrosion and stain resistance, superior mechanical properties, low shrink and color stability. Its excellent flow characteristics, dielectric properties, and flame resistance make this thermoset material well-suited to a wide variety of applications requiring precision in detail and dimensions as well as high performance. When a BMC is used for these purposes, the rheological behavior and properties of the BMC is the main concern. In this paper, finite element analysis of rheological properties of bulk molding composite material was studied. For this purpose, standard samples of composite material were obtained by means of uniaxial hot pressing. 3 point flexural tests were then carried out by using a universal testing machine. Finite element analyses were then performed with defined material properties within a specific constitutive material behavior. Experimental and numerical results were then compared. Good correlation between the numerical simulation and the experimental results was obtained. It was expected with this study that effects of various process parameters and boundary conditions on the rheological behavior of bulk molding compounds could be determined by means of numerical analysis without detailed experimental work.

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

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

Nguyen Thi, T. B., E-mail: thanhbinh.skku@gmail.com, E-mail: yokoyama@kit.ac.jp; Yokoyama, A., E-mail: thanhbinh.skku@gmail.com, E-mail: yokoyama@kit.ac.jp; Ota, K., E-mail: kei-ota@toyobo.jp, E-mail: katsuhiro-kodama@toyobo.jp, E-mail: katsuhisa-yamashita@toyobo.jp, E-mail: yumiko-isogai@toyobo.jp, E-mail: kenji-furuichi@toyobo.jp, E-mail: chisato-nonomura@toyobo.jp

2014-05-15

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

Simulation of cracking cores when molding piston components

NASA Astrophysics Data System (ADS)

Petrenko, Alena; Soukup, Josef

2014-08-01

The article deals with pistons casting made from aluminum alloy. Pistons are casting at steel mold with steel core. The casting is provided by gravity casting machine. The each machine is equipped by two metal molds, which are preheated above temperature 160 °C before use. The steel core is also preheated by flame. The metal molds and cores are heated up within the casting process. The temperature of the metal mold raise up to 200 °C and temperature of core is higher. The surface of the core is treated by nitration. The mold and core are cooled down by water during casting process. The core is overheated and its top part is finally cracked despite its intensive water-cooling. The life time cycle of the core is decreased to approximately 5 to 15 thousands casting, which is only 15 % of life time cycle of core for production of other pistons. The article presents the temperature analysis of the core.

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

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

Nguyen, Ba Nghiep; Kunc, Vlastimil; Jin, Xiaoshi

2013-12-18

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

Thermosetting Fluoropolymer Foams

NASA Technical Reports Server (NTRS)

Lee, Sheng Yen

1987-01-01

New process makes fluoropolymer foams with controllable amounts of inert-gas fillings in foam cells. Thermosetting fluoropolymers do not require foaming additives leaving undesirable residues and do not have to be molded and sintered at temperatures of about 240 to 400 degree C. Consequently, better for use with electronic or other parts sensitive to high temperatures or residues. Uses include coatings, electrical insulation, and structural parts.

Characterization of weathered wood-plastic composite surfaces using FTIR spectroscopy, contact angle, and XPS

Treesearch

Nicole M. Stark; Laurent M. Matuana

2007-01-01

Much of the current growth of wood-plastic composites (WPCs) is due to increased penetration into the decking market; therefore it has become imperative to understand the durability of WPCs in outdoor applications. In this study, wood flour filled high-density polyethylene (HDPE) composites were manufactured through either injection molding or extrusion. A set of...

Injection molded plastic helical gear filled with carbon powder made from rice hull

NASA Astrophysics Data System (ADS)

Chen, Yen Chu; Itagaki, Takayoshi; Takahashi, Hideo; Takahashi, Mikio

2017-07-01

Natural materials are focused on the ecological responsibility, all over the world. The rice-hull contains natural silica about 20 wt.%. Therefore, a carbonized rice-hull; Rice-Hull-Silica-Carbon (RHSC) is focused as effective utilization of the discarded rice hull. In this study, test plastic helical gears were made form polyacetal copolymer filled with RHSC powder by injection molding. Test helical gears were operated on endurance test. The bulk temperature and noise of test gears were measured during gears operation. Then, the tooth damage of test gears were investigated by using optical microscope. It is clarified that difference of tooth damage by kind of test gears. Moreover, the transition of gear bulk temperature and noise during operation are investigated. Based on these results, the effect of RHSC powder is discussed. From the discussions, it seems reasonable to conclude : (1) The heat resistance of plastic gear is improved by adding the RHSC powder. (2) The fatigue life of plastic gear is improved by adding suitable amount of the RHSC powder. (3) The sound pressure level of plastic gear is reduced by adding the smaller median grain diameter of RHSC powder.

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

Experimental and Numerical Studies on Fiber Deformation and Formability in Thermoforming Process Using a Fast-Cure Carbon Prepreg: Effect of Stacking Sequence and Mold Geometry.

PubMed

Bae, Daeryeong; Kim, Shino; Lee, Wonoh; Yi, Jin Woo; Um, Moon Kwang; Seong, Dong Gi

2018-05-21

A fast-cure carbon fiber/epoxy prepreg was thermoformed against a replicated automotive roof panel mold (square-cup) to investigate the effect of the stacking sequence of prepreg layers with unidirectional and plane woven fabrics and mold geometry with different drawing angles and depths on the fiber deformation and formability of the prepreg. The optimum forming condition was determined via analysis of the material properties of epoxy resin. The non-linear mechanical properties of prepreg at the deformation modes of inter- and intra-ply shear, tensile and bending were measured to be used as input data for the commercial virtual forming simulation software. The prepreg with a stacking sequence containing the plain-woven carbon prepreg on the outer layer of the laminate was successfully thermoformed against a mold with a depth of 20 mm and a tilting angle of 110°. Experimental results for the shear deformations at each corner of the thermoformed square-cup product were compared with the simulation and a similarity in the overall tendency of the shear angle in the path at each corner was observed. The results are expected to contribute to the optimization of parameters on materials, mold design and processing in the thermoforming mass-production process for manufacturing high quality automotive parts with a square-cup geometry.

Experimental and Numerical Studies on Fiber Deformation and Formability in Thermoforming Process Using a Fast-Cure Carbon Prepreg: Effect of Stacking Sequence and Mold Geometry

PubMed Central

Bae, Daeryeong; Kim, Shino; Lee, Wonoh; Yi, Jin Woo; Um, Moon Kwang; Seong, Dong Gi

2018-01-01

A fast-cure carbon fiber/epoxy prepreg was thermoformed against a replicated automotive roof panel mold (square-cup) to investigate the effect of the stacking sequence of prepreg layers with unidirectional and plane woven fabrics and mold geometry with different drawing angles and depths on the fiber deformation and formability of the prepreg. The optimum forming condition was determined via analysis of the material properties of epoxy resin. The non-linear mechanical properties of prepreg at the deformation modes of inter- and intra-ply shear, tensile and bending were measured to be used as input data for the commercial virtual forming simulation software. The prepreg with a stacking sequence containing the plain-woven carbon prepreg on the outer layer of the laminate was successfully thermoformed against a mold with a depth of 20 mm and a tilting angle of 110°. Experimental results for the shear deformations at each corner of the thermoformed square-cup product were compared with the simulation and a similarity in the overall tendency of the shear angle in the path at each corner was observed. The results are expected to contribute to the optimization of parameters on materials, mold design and processing in the thermoforming mass-production process for manufacturing high quality automotive parts with a square-cup geometry. PMID:29883413

A Statistics-Based Cracking Criterion of Resin-Bonded Silica Sand for Casting Process Simulation

NASA Astrophysics Data System (ADS)

Wang, Huimin; Lu, Yan; Ripplinger, Keith; Detwiler, Duane; Luo, Alan A.

2017-02-01

Cracking of sand molds/cores can result in many casting defects such as veining. A robust cracking criterion is needed in casting process simulation for predicting/controlling such defects. A cracking probability map, relating to fracture stress and effective volume, was proposed for resin-bonded silica sand based on Weibull statistics. Three-point bending test results of sand samples were used to generate the cracking map and set up a safety line for cracking criterion. Tensile test results confirmed the accuracy of the safety line for cracking prediction. A laboratory casting experiment was designed and carried out to predict cracking of a cup mold during aluminum casting. The stress-strain behavior and the effective volume of the cup molds were calculated using a finite element analysis code ProCAST®. Furthermore, an energy dispersive spectroscopy fractographic examination of the sand samples confirmed the binder cracking in resin-bonded silica sand.

Wind turbine generator rotor blade concepts with low cost potential

NASA Technical Reports Server (NTRS)

Sullivan, T. L.; Cahill, T. P.; Griffee, D. G., Jr.; Gewehr, H. W.

1977-01-01

Four processed for producing blades are examined. Two use filament winding techniques and two involve filling a mold or form to produce all or part of a blade. The processes are described and a comparison is made of cost, material properties, design and free vibration characteristics. Conclusions are made regarding the feasibility of each process to produce low cost, structurally adequate blades.

Wind-turbine-generator rotor-blade concepts with low-cost potential

NASA Technical Reports Server (NTRS)

Sullivan, T. L.; Cahill, T. P.; Griffee, D. G., Jr.; Gewehr, H. W.

1978-01-01

Four processes for producing blades are examined. Two use filament winding techniques and two involve filling a mold or form to produce all or part of a blade. The processes are described and a comparison is made of costs, material properties, designs and free vibration characteristics. Conclusions are made regarding the feasibility of each process to produce low-cost, structurally adequate blades.

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.

Fatigue stipulation of bulk-fill composites: An in vitro appraisal.

PubMed

Vidhawan, Shruti A; Yap, Adrian U; Ornaghi, Barbara P; Banas, Agnieszka; Banas, Krzysztof; Neo, Jennifer C; Pfeifer, Carmem S; Rosa, Vinicius

2015-09-01

The aim of this study was to determine the Weibull and slow crack growth (SCG) parameters of bulk-fill resin based composites. The strength degradation over time of the materials was also assessed by strength-probability-time (SPT) analysis. Three bulk-fill [Tetric EvoCeram Bulk Fill (TBF); X-tra fil (XTR); Filtek Bulk-fill flowable (BFL)] and a conventional one [Filtek Z250 (Z250)] were studied. Seventy five disk-shaped specimens (12mm in diameter and 1mm thick) were prepared by inserting the uncured composites in a stainless steel split mold followed by photoactivation (1200mW/cm(2)/20s) and storage in distilled water (37°C/24h). Degree of conversion was evaluated in five specimens by analysis of FT-IR spectra obtained in the mid-IR region. The SCG parameters n (stress corrosion susceptibility coefficient) and σf0 (scaling parameter) were obtained by testing ten specimens in each of the five stress rates: 10(-2), 10(-1), 10(0), 10(1) and 10(2)MPa/s using a piston-on-three-balls device. Weibull parameter m (Weibull modulus) and σf0 (characteristic strength) were obtained by testing additional 20 specimens at 1MPa/s. Strength-probability-time (SPT) diagrams were constructed by merging SCG and Weibull parameters. BFL and TBF presented higher n values, respectively (40.1 and 25.5). Z250 showed the highest (157.02MPa) and TBF the lowest (110.90MPa) σf0 value. Weibull analysis showed m (Weibull modulus) of 9.7, 8.6, 9.7 and 8.9 for TBF, BFL, XTR and Z250, respectively. SPT diagram for 5% probability of failure showed strength decrease of 18% for BFL, 25% for TBF, 32% for XTR and 36% for Z250, respectively, after 5 years as compared to 1 year. The reliability and decadence of strength over time for bulk-fill resin composites studied are, at least, comparable to conventional composites. BFL shows the highest fatigue resistance under all simulations followed by TBF, while XTR was at par with Z250. Copyright © 2015 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

Thermally stable laminating resins

NASA Technical Reports Server (NTRS)

Jones, R. J.; Vaughan, R. W.; Burns, E. A.

1972-01-01

Improved thermally stable laminating resins were developed based on the addition-type pyrolytic polymerization. Detailed monomer and polymer synthesis and characterization studies identified formulations which facilitate press molding processing and autoclave fabrication of glass and graphite fiber reinforced composites. A specific resin formulation, termed P10P was utilized to prepare a Courtaulds HMS reinforced simulated airfoil demonstration part by an autoclave molding process.

Route 20, Autobahn 7, and Slime Mold: Approximating the Longest Roads in USA and Germany With Slime Mold on 3-D Terrains.

PubMed

Adamatzky, Andrew I

2014-01-01

A cellular slime mould Physarum polycephalum is a monstrously large single cell visible by an unaided eye. The slime mold explores space in parallel, is guided by gradients of chemoattractants, and propagates toward sources of nutrients along nearly shortest paths. The slime mold is a living prototype of amorphous biological computers and robotic devices capable of solving a range of tasks of graph optimization and computational geometry. When presented with a distribution of nutrients, the slime mold spans the sources of nutrients with a network of protoplasmic tubes. This protoplasmic network matches a network of major transport routes of a country when configuration of major urban areas is represented by nutrients. A transport route connecting two cities should ideally be a shortest path, and this is usually the case in computer simulations and laboratory experiments with flat substrates. What searching strategies does the slime mold adopt when exploring 3-D terrains? How are optimal and transport routes approximated by protoplasmic tubes? Do the routes built by the slime mold on 3-D terrain match real-world transport routes? To answer these questions, we conducted pioneer laboratory experiments with Nylon terrains of USA and Germany. We used the slime mold to approximate route 20, the longest road in USA, and autobahn 7, the longest national motorway in Europe. We found that slime mold builds longer transport routes on 3-D terrains, compared to flat substrates yet sufficiently approximates man-made transport routes studied. We demonstrate that nutrients placed in destination sites affect performance of slime mold, and show how the mold navigates around elevations. In cellular automaton models of the slime mold, we have shown variability of the protoplasmic routes might depends on physiological states of the slime mold. Results presented will contribute toward development of novel algorithms for sensorial fusion, information processing, and decision making, and will provide inspirations in design of bioinspired amorphous robotic devices.

A novel injection-molded capsular device for oral pulsatile delivery based on swellable/erodible polymers.

PubMed

Gazzaniga, Andrea; Cerea, Matteo; Cozzi, Alberto; Foppoli, Anastasia; Maroni, Alessandra; Zema, Lucia

2011-03-01

The feasibility of injection molding was explored in the preparation of a novel capsular device for oral pulsatile/delayed delivery based on swellable/erodible polymers. For this purpose, a mold intended to be coupled with a bench-top injection-molding press was designed. This was expected to enable the preparation of matching capsule cap and body items within a single manufacturing cycle and the selection of differing shell thicknesses (300, 600, and 900 μm). Hydroxypropylcellulose (Klucel(®) EF, LF, and GF) was employed as the release-controlling polymer in admixture with polyethylene glycol 1500 (10%, w/w) as the plasticizer. After preliminary trials aimed at the setup of operating conditions, Klucel(®) EF and LF capsule shells with satisfactory technological properties were manufactured. The performance of capsular devices filled with a tracer drug powder was studied by means of a modified USP31 disintegration apparatus. Typical in vitro delayed release patterns were thereby obtained, with lag time increasing as a function of the wall thickness. A good correlation was found between the latter parameter and t (10%), i.e., the time to 10% release, for both polymer grades employed. On the basis of the overall results, the investigated technique was proven suitable for the manufacturing of an innovative pulsatile release platform. © 2011 American Association of Pharmaceutical Scientists

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

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

Thi, Thanh Binh Nguyen; Morioka, Mizuki; Yokoyama, Atsushi

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

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

NASA Astrophysics Data System (ADS)

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

2015-05-01

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

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

NASA Astrophysics Data System (ADS)

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

2008-08-01

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

Optimization simulated injection molding process for ultrahigh molecular weight polyethylene nanocomposite hip liner using response surface methodology and simulation of mechanical behavior.

PubMed

Heidari, Behzad Shiroud; Davachi, Seyed Mohammad; Moghaddam, Amin Hedayati; Seyfi, Javad; Hejazi, Iman; Sahraeian, Razi; Rashedi, Hamid

2018-05-01

In this study, injection molding process of ultrahigh molecular weight polyethylene (UHMWPE) reinforced with nano-hydroxyapatite (nHA) was simulated and optimized through minimizing the shrinkage and warpage of the hip liners as an essential part of a hip prosthesis. Fractional factorial design (FFD) was applied to the design of the experiment, modeling, and optimizing the shrinkage and warpage of UHMWPE/nHA composite liners. The Analysis of variance (ANOVA) was applied to find the importance of operative parameters and their effects. In this experiment, seven input parameters were surveyed, including mold temperature (A), melt temperature (B), injection time (C), packing time (D), packing pressure (E), coolant temperature (F), and type of liner (G). Two models were capable of predicting warpage and volumetric shrinkage (%) in different conditions with R 2 of 0.9949 and 0.9989, respectively. According to the models, the optimized values of warpage and volumetric shrinkage are 0.287222 mm and 13.6613%, respectively. Meanwhile, a finite element analysis (FE analysis) was also carried out to examine the stress distribution in liners under the force values of demanding and daily activities. The Von-Mises stress distribution showed that both of the liners can be applied to all activities with no failure. However, UHMWPE/nHA liner is more resistant to the highest loads than UHMWPE liner due to the effect of nHA in the nanocomposite. Finally, according to the results of injection molding simulations, optimization, structural analysis as well as the tensile strength and wear resistance, UHMWPE/nHA liner is recommended for the production of a hip prosthesis. Copyright © 2018 Elsevier Ltd. All rights reserved.

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.

A coupled-oscillator model with a conservation law for the rhythmic amoeboid movements of plasmodial slime molds

NASA Astrophysics Data System (ADS)

Tero, A.; Kobayashi, R.; Nakagaki, T.

2005-06-01

Experiments on the fusion and partial separation of plasmodia of the true slime mold Physarum polycephalum are described, concentrating on the spatio-temporal phase patterns of rhythmic amoeboid movement. On the basis of these experimental results we introduce a new model of coupled oscillators with one conserved quantity. Simulations using the model equations reproduce the experimental results well.

Production of dissolvable microneedles using an atomised spray process: effect of microneedle composition on skin penetration.

PubMed

McGrath, Marie G; Vucen, Sonja; Vrdoljak, Anto; Kelly, Adam; O'Mahony, Conor; Crean, Abina M; Moore, Anne

2014-02-01

Dissolvable microneedles offer an attractive delivery system for transdermal drug and vaccine delivery. They are most commonly formed by filling a microneedle mold with liquid formulation using vacuum or centrifugation to overcome the constraints of surface tension and solution viscosity. Here, we demonstrate a novel microneedle fabrication method employing an atomised spray technique that minimises the effects of the liquid surface tension and viscosity when filling molds. This spray method was successfully used to fabricate dissolvable microneedles (DMN) from a wide range of sugars (trehalose, fructose and raffinose) and polymeric materials (polyvinyl alcohol, polyvinylpyrrolidone, carboxymethylcellulose, hydroxypropylmethylcellulose and sodium alginate). Fabrication by spraying produced microneedles with amorphous content using single sugar compositions. These microneedles displayed sharp tips and had complete fidelity to the master silicon template. Using a method to quantify the consistency of DMN penetration into different skin layers, we demonstrate that the material of construction significantly influenced the extent of skin penetration. We demonstrate that this spraying method can be adapted to produce novel laminate-layered as well as horizontally-layered DMN arrays. To our knowledge, this is the first report documenting the use of an atomising spray, at ambient, mild processing conditions, to create dissolvable microneedle arrays that can possess novel, laminate layering. Copyright © 2013 Elsevier B.V. All rights reserved.

The reference cube: A new ballistic model to generate staining in firearm barrels.

PubMed

Schyma, Christian; Bauer, Kristina; Brünig, Julia

2017-06-01

After contact shots to the head biological traces can be found inside firearm barrels. So far silicone coated, gelatin filled box models were used to generate such staining according to the triple contrast method (mixture of acrylic paint, barium sulfate and blood sealed in a thin foil bag). This study was conducted to develop a transparent ballistic model allowing contact shots. Gelatin filled polyethylene bottles with and without a silicone coat were tested in comparison to non-covered gelatin blocks. Finally, thin foil bags of 5 cm × 5 cm dimension were glued on a synthetic absorbent kitchen wipe on top of which 1 L 10% gelatin solution was molded to create blocks of 8.5 cm length. A kitchen wipe with a paint pad on its inside formed the front of the cube. Three contact shots each with a 9 mm Luger pistol and a .38 special revolver were performed on all model variations. The staining was documented by endoscopy and swabs gathered from both ends of the barrel were analyzed by quantitative PCR. Reliable staining was achieved using the front covered gelatin block with comparable results to the silicone coated box model used before. For further research using ballistic models to simulate a human head a symmetric form of the gelatin block such as a cube is recommended.

Foam injection molding of elastomers with iron microparticles

NASA Astrophysics Data System (ADS)

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

2015-12-01

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

Fuel cell assembly fluid flow plate having conductive fibers and rigidizing material therein

DOEpatents

Walsh, Michael M.

2000-01-01

A fluid flow plate is preferably formed with three initial sections, for instance, two layers of conductive (e.g., metal) fibers and a barrier material (e.g., metal foil) which is interposed between the two layers. For example, sintering of these three sections can provide electrical path(s) between outer faces of the two layers. Then, the sintered sections can be, for instance, placed in a mold for forming of flow channel(s) into one or more of the outer faces. Next, rigidizing material (e.g., resin) can be injected into the mold, for example, to fill and/or seal space(s) about a conductive matrix of the electrical path(s). Preferably, abrading of surface(s) of the outer face(s) serves to expose electrical contact(s) to the electrical path(s).

Influence of gating design on microstructure and fluidity of thin sections AA320.0 cast hypo-eutectic Al-Si alloy

NASA Astrophysics Data System (ADS)

Ramadan, Mohamed

2018-05-01

Influence of gating design especially number of ingrates on microstructure and fluidity of thin sections of 2, 4, 6 mm AA320.0 cast hypo-eutectic Al-Si alloy was evaluated for sand casting molding technique. Increasing the number of ingates improves the microstructe to be fine and more globular. About 87 μm of α-Al grain size, 0.6 α-Al grain sphericity and 37 μm dendrite arm spacing DAS are achieved by using 4 ingates in gating system. Increasing the number of ingates up to 3 increases hardness, filling area and related fluditiy of all cast samples. The minimum thickness of 2.5 mm for each ingate should be considered in order to successfully production of high quality light weight thin sections castings in sand mold.

Flow behavior in liquid molding

NASA Technical Reports Server (NTRS)

Hunston, D.; Phelan, F.; Parnas, R.

1992-01-01

The liquid molding (LM) process for manufacturing polymer composites with structural properties has the potential to significantly lower fabrication costs and increase production rates. LM includes both resin transfer molding and structural reaction injection molding. To achieve this potential, however, the underlying science base must be improved to facilitate effective process optimization and implementation of on-line process control. The National Institute of Standards and Technology (NIST) has a major program in LM that includes materials characterization, process simulation models, on-line process monitoring and control, and the fabrication of test specimens. The results of this program are applied to real parts through cooperative projects with industry. The key feature in the effort is a comprehensive and integrated approach to the processing science aspects of LM. This paper briefly outlines the NIST program and uses several examples to illustrate the work.

Quality changes of fresh filled pasta during storage: influence of modified atmosphere packaging on microbial growth and sensory properties.

PubMed

Sanguinetti, A M; Del Caro, A; Mangia, N P; Secchi, N; Catzeddu, P; Piga, A

2011-02-01

This study evaluated the shelf life of fresh pasta filled with cheese subjected to modified atmosphere packaging (MAP) or air packaging (AP). After a pasteurization treatment, fresh pasta was packaged under a 50/50 N(2)/CO(2) ratio or in air (air batch). Changes in microbial growth, in-package gas composition, chemical-physical parameters and sensory attributes were monitored for 42 days at 4 (°)C. The pasteurization treatment resulted in suitable microbiological reduction. MAP allowed a mold-free shelf life of the fresh filled pasta of 42 days, whereas air-packaged samples got spoilt between 7 and 14 days. The hurdle approach used (MAP and low storage temperature) prevented the growth of pathogens and alterative microorganisms. MAP samples maintained a high microbiological standard throughout the storage period. The panel judged MAP fresh pasta above the acceptability threshold throughout the shelf life.

Presurgical nasoalveolar molding for cleft lip and palate: the application of digitally designed molds.

PubMed

Shen, Congcong; Yao, Caroline A; Magee, William; Chai, Gang; Zhang, Yan

2015-06-01

The authors present a novel nasoalveolar molding protocol by prefabricating sets of nasoalveolar molding appliances using three-dimensional technology. Prospectively, 17 infants with unilateral complete cleft lip and palate underwent the authors' protocol before primary cheiloplasty. An initial nasoalveolar molding appliance was created based on the patient's first and only in-person maxillary cast, produced from a traditional intraoral dental impression. Thereafter, each patient's molding course was simulated using computer software that aimed to narrow the alveolar gap by 1 mm each week by rotating the greater alveolar segment. A maxillary cast of each predicted molding stage was created using three-dimensional printing. Subsequent appliances were constructed in advance, based on the series of computer-generated casts. Each patient had a total three clinic visits spaced 1 month apart. Anthropometric measurements and bony segment volumes were recorded before and after treatment. Alveolar cleft widths narrowed significantly (p < 0.01), soft-tissue volume of each segment expanded (p < 0.01), and the arc of the alveolus became more contiguous across the cleft (p < 0.01). One patient required a new appliance at the second visit because of bleeding and discomfort. Eleven patients had mucosal irritation and two experienced minor mucosal ulceration. Three-dimensional technology can precisely represent anatomic structures in pediatric clefts. Results from the authors' algorithm are equivalent to those of traditional nasoalveolar molding therapies; however, the number of required clinic visits and appliance adjustments decreased. As three-dimensional technology costs decrease, multidisciplinary teams may design customized nasoalveolar molding treatment with improved efficiency and less burden to medical staff, patients, and families. Therapeutic, IV.

Compensating additional optical power in the central zone of a multifocal contact lens forminimization of the shrinkage error of the shell mold in the injection molding process.

PubMed

Vu, Lien T; Chen, Chao-Chang A; Lee, Chia-Cheng; Yu, Chia-Wei

2018-04-20

This study aims to develop a compensating method to minimize the shrinkage error of the shell mold (SM) in the injection molding (IM) process to obtain uniform optical power in the central optical zone of soft axial symmetric multifocal contact lenses (CL). The Z-shrinkage error along the Z axis or axial axis of the anterior SM corresponding to the anterior surface of a dry contact lens in the IM process can be minimized by optimizing IM process parameters and then by compensating for additional (Add) powers in the central zone of the original lens design. First, the shrinkage error is minimized by optimizing three levels of four IM parameters, including mold temperature, injection velocity, packing pressure, and cooling time in 18 IM simulations based on an orthogonal array L 18 (2 1 ×3 4 ). Then, based on the Z-shrinkage error from IM simulation, three new contact lens designs are obtained by increasing the Add power in the central zone of the original multifocal CL design to compensate for the optical power errors. Results obtained from IM process simulations and the optical simulations show that the new CL design with 0.1 D increasing in Add power has the closest shrinkage profile to the original anterior SM profile with percentage of reduction in absolute Z-shrinkage error of 55% and more uniform power in the central zone than in the other two cases. Moreover, actual experiments of IM of SM for casting soft multifocal CLs have been performed. The final product of wet CLs has been completed for the original design and the new design. Results of the optical performance have verified the improvement of the compensated design of CLs. The feasibility of this compensating method has been proven based on the measurement results of the produced soft multifocal CLs of the new design. Results of this study can be further applied to predict or compensate for the total optical power errors of the soft multifocal CLs.

Finite Element Modeling of Reheat Stretch Blow Molding of PET

NASA Astrophysics Data System (ADS)

Krishnan, Dwarak; Dupaix, Rebecca B.

2004-06-01

Poly (ethylene terephthalate) or PET is a polymer used as a packaging material for consumer products such as beverages, food or other liquids, and in other applications including drawn fibers and stretched films. Key features that make it widely used are its transparency, dimensional stability, gas impermeability, impact resistance, and high stiffness and strength in certain preferential directions. These commercially useful properties arise from the fact that PET crystallizes upon deformation above the glass transition temperature. Additionally, this strain-induced crystallization causes the deformation behavior of PET to be highly sensitive to processing conditions. It is thus crucial for engineers to be able to predict its performance at various process temperatures, strain rates and strain states so as to optimize the manufacturing process. In addressing these issues; a finite element analysis of the reheat blow molding process with PET has been carried out using ABAQUS. The simulation employed a constitutive model for PET developed by Dupaix and Boyce et al.. The model includes the combined effects of molecular orientation and strain-induced crystallization on strain hardening when the material is deformed above the glass transition temperature. The simulated bottles were also compared with actual blow molded bottles to evaluate the validity of the simulation.

[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.

Mechanism of Void Prediction in Flip Chip Packages with Molded Underfill

NASA Astrophysics Data System (ADS)

Wu, Kuo-Tsai; Hwang, Sheng-Jye; Lee, Huei-Huang

2017-08-01

Voids have always been present using the molded underfill (MUF) package process, which is a problem that needs further investigation. In this study, the process was studied using the Moldex3D numerical analysis software. The effects of gas (air vent effect) on the overall melt front were also considered. In this isothermal process containing two fluids, the gas and melt colloid interact in the mold cavity. Simulation enabled an appropriate understanding of the actual situation to be gained, and, through analysis, the void region and exact location of voids were predicted. First, the global flow end area was observed to predict the void movement trend, and then the local flow ends were observed to predict the location and size of voids. In the MUF 518 case study, simulations predicted the void region as well as the location and size of the voids. The void phenomenon in a flip chip ball grid array underfill is discussed as part of the study.

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

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

Thi, Thanh Binh Nguyen, E-mail: nttbinh@kit.ac.jp; Yokoyama, Atsushi, E-mail: yokoyama@kit.ac.jp; Hamanaka, Senji

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

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

NASA Astrophysics Data System (ADS)

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

2016-03-01

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

Hybrid waste filler filled bio-polymer foam composites for sound absorbent materials

NASA Astrophysics Data System (ADS)

Rus, Anika Zafiah M.; Azahari, M. Shafiq M.; Kormin, Shaharuddin; Soon, Leong Bong; Zaliran, M. Taufiq; Ahraz Sadrina M. F., L.

2017-09-01

Sound absorption materials are one of the major requirements in many industries with regards to the sound insulation developed should be efficient to reduce sound. This is also important to contribute in economically ways of producing sound absorbing materials which is cheaper and user friendly. Thus, in this research, the sound absorbent properties of bio-polymer foam filled with hybrid fillers of wood dust and waste tire rubber has been investigated. Waste cooking oil from crisp industries was converted into bio-monomer, filled with different proportion ratio of fillers and fabricated into bio-polymer foam composite. Two fabrication methods is applied which is the Close Mold Method (CMM) and Open Mold Method (OMM). A total of four bio-polymer foam composite samples were produce for each method used. The percentage of hybrid fillers; mixture of wood dust and waste tire rubber of 2.5 %, 5.0%, 7.5% and 10% weight to weight ration with bio-monomer. The sound absorption of the bio-polymer foam composites samples were tested by using the impedance tube test according to the ASTM E-1050 and Scanning Electron Microscope to determine the morphology and porosity of the samples. The sound absorption coefficient (α) at different frequency range revealed that the polymer foam of 10.0 % hybrid fillers shows highest α of 0.963. The highest hybrid filler loading contributing to smallest pore sizes but highest interconnected pores. This also revealed that when highly porous material is exposed to incident sound waves, the air molecules at the surface of the material and within the pores of the material are forced to vibrate and loses some of their original energy. This is concluded that the suitability of bio-polymer foam filled with hybrid fillers to be used in acoustic application of automotive components such as dashboards, door panels, cushion and etc.

Additive Manufacturing of Parts and Tooling in Robotic Systems

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

Love, Lonnie J.; Hassen, Ahmed A.; Chesser, Phillip C.

ORNL worked with Transcend Robotics, LLC to explore additive manufacturing of the two-piece compression body for their ARTI mobile robot platform. Extrusion compression molding was identified as an effective means of manufacturing these parts. ORNL consulted on modifications to the housing design to accommodate the selected manufacturing process. Parts were printed using ORNL's FDM machines for testing and evaluation of the design as a precursor to molding the parts. The assembly and evaluation of the parts proved favorable and minor design changes to improve assembly and performance were identified.The goal is to develop a light weight and rugged two-part roboticmore » enclosure for an unmanned ground vehicle UGV) that will be used in search and rescue applications. The FDM parts fabricated by ORNL allowed Transcend Robotics to assemble a prototype robot and verify that the new parts will meet the performance requirements. ORNL fabricated enclosure parts out of ABS and Nylon 12 materials such that the design could be tested prior to fabricating tooling for compression molding of Nylon 6 with carbon fiber fill. The robot was performance tested and compared with the previous manufacturing techniques and found to have superior performance.« less

Advancement and Implementation of Integrated Computational Materials Engineering (ICME) for Aerospace Applications

DTIC Science & Technology

2010-03-01

of sub-routines Thermal history • Abaqus FEM engine mature applied within ABAQUS Residual stress & Distortion • Unknown maturity for HTC • Focused...investment. The committee’s ICME vision is comprehensive, expansive , and involves the entire materials community. The scope of this white paper is...Software • Continuum FEM for fluid flow, heat Mold Fill • FEM implementation mature flow and stress analysis Thermal & mushy zone history • Needs

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

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

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

2009-10-30

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

Numerical simulation of stress-strain state of electrophoretic shell molds

NASA Astrophysics Data System (ADS)

Sviridov, A. V.; Odinokov, V. I.; Dmitriev, E. A.; Evstigneev, A. I.; Bashkov, O. V.

2017-10-01

In the foundry engineering, castings obtained in one-piece non-gas-generating high-refractory electrophoretic shell molds (ShM) by investment patterns (IP) have an increased rejects percentage associated with low deformation resistance and crack resistance of the SM at different stages of their formation and manufacturing. Crack resistance of the ShM based on IP depends mainly on their stress-strain state (SSS) at various stages of mold forming. SSS decrease significantly improves their crack resistance and decreases their rejects percentage of castings occurring due to clogging and surface defects. In addition, the known methods of decreasing the SSS are still poorly understood. Thus, current research trends are to determine SSS at each stage of ShM forming and develop the ways to decrease it. Theoretical predicting of crack formation in multiple-layer axisymmetric shell molds is given in the work [1], and SSS of multiple-layer axisymmetric shell molds is given in the work [2]. Monolayer electrophoretic ShM had a lack of concern in this field, thus it became an argument for the present workMathematical Model of ShM SSS

Development of Metal Casting Molds By Sol-Gel Technology Using Planetary Resources

NASA Technical Reports Server (NTRS)

Sibille, L.; Sen, S.; Curreri, P.; Stefanescu, D.

2000-01-01

Metals extracted from planetary soils will eventually need to be casted and shaped in-situ to produce useful products. In response to this challenge, we propose to develop and demonstrate the manufacturing of a specific product using Lunar and Martian soil simulants, i.e. a mold for the casting of metal and alloy parts, which will be an indispensable tool for the survival of outposts on the Moon and Mars. Drawing from our combined knowledge of sol-gel and metal casting technologies, we set out to demonstrate the extraordinary potential of mesoporous materials such as aerogels to serve as efficient casting molds as well as fulfilling numerous other needs of an autonomous planetary outpost.

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

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

Demori, R.; Mauler, R. S., E-mail: raquel.mauler@ufrgs.br; Ashton, E.

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

Micromachined mold-type double-gated metal field emitters

NASA Astrophysics Data System (ADS)

Lee, Yongjae; Kang, Seokho; Chun, Kukjin

1997-12-01

Electron field emitters with double gates were fabricated using micromachining technology and the effect of the electric potential of the focusing gate (or second gate) was experimentally evaluated. The molybdenum field emission tip was made by filling a cusplike mold formed when a conformal film was deposited on the hole-trench that had been patterned on stacked metals and dielectric layers. The hole-trench was patterned by electron beam lithography and reactive ion etching. Each field emitter has a 0960-1317/7/4/009/img1 diameter extraction gate (or first gate) and a 0960-1317/7/4/009/img2 diameter focusing gate (or second gate). To make a path for the emitted electrons, silicon bulk was etched anisotropically in KOH and EDP (ethylene-diamine pyrocatechol) solution successively. The I - V characteristics and anode current change due to the focusing gate potential were measured.

On processing development for fabrication of fiber reinforced composite, part 2

NASA Technical Reports Server (NTRS)

Hou, Tan-Hung; Hou, Gene J. W.; Sheen, Jeen S.

1989-01-01

Fiber-reinforced composite laminates are used in many aerospace and automobile applications. The magnitudes and durations of the cure temperature and the cure pressure applied during the curing process have significant consequences for the performance of the finished product. The objective of this study is to exploit the potential of applying the optimization technique to the cure cycle design. Using the compression molding of a filled polyester sheet molding compound (SMC) as an example, a unified Computer Aided Design (CAD) methodology, consisting of three uncoupled modules, (i.e., optimization, analysis and sensitivity calculations), is developed to systematically generate optimal cure cycle designs. Various optimization formulations for the cure cycle design are investigated. The uniformities in the distributions of the temperature and the degree with those resulting from conventional isothermal processing conditions with pre-warmed platens. Recommendations with regards to further research in the computerization of the cure cycle design are also addressed.

Process simulations for manufacturing of thick composites

NASA Astrophysics Data System (ADS)

Kempner, Evan A.

The availability of manufacturing simulations for composites can significantly reduce the costs associated with process development. Simulations provide a tool for evaluating the effect of processing conditions on the quality of parts produced without requiring numerous experiments. This is especially significant in parts that have troublesome features such as large thickness. The development of simulations for thick walled composites has been approached by examining the mechanics of resin flow and fiber deformation during processing, applying these evaluations to develop simulations, and evaluating the simulation with experimental results. A unified analysis is developed to describe the three-dimensional resin flow and fiber preform deformation during processing regardless of the manufacturing process used. It is shown how the generic governing evaluations in the unified analysis can be applied to autoclave molding, compression molding, pultrusion, filament winding, and resin transfer molding. A comparison is provided with earlier models derived individually for these processes. The evaluations described for autoclave curing were used to produce a one-dimensional cure simulation for autoclave curing of thick composites. The simulation consists of an analysis for heat transfer and resin flow in the composite as well as bleeder plies used to absorb resin removed from the part. Experiments were performed in a hot press to approximate curing in an autoclave. Graphite/epoxy laminates of 3 cm and 5 cm thickness were cured while monitoring temperatures at several points inside the laminate and thickness. The simulation predicted temperatures fairly closely, but difficulties were encountered in correlation of thickness results. This simulation was also used to study the effects of prepreg aging on processing of thick composites. An investigation was also performed on filament winding with prepreg tow. Cylinders were wound of approximately 12 mm thickness with pressure gages at the mandrel-composite interface. Cylinders were hoop wound with tensions ranging from 13-34 N. An analytical model was developed to calculate change in stress due to relaxation during winding. Although compressive circumferential stresses occurred throughout each of the cylinders, the magnitude was fairly low.

Infiltration/cure modeling of resin transfer molded composite materials using advanced fiber architectures

NASA Technical Reports Server (NTRS)

Loos, Alfred C.; Weideman, Mark H.; Long, Edward R., Jr.; Kranbuehl, David E.; Kinsley, Philip J.; Hart, Sean M.

1991-01-01

A model was developed which can be used to simulate infiltration and cure of textile composites by resin transfer molding. Fabric preforms were resin infiltrated and cured using model generated optimized one-step infiltration/cure protocols. Frequency dependent electromagnetic sensing (FDEMS) was used to monitor in situ resin infiltration and cure during processing. FDEMS measurements of infiltration time, resin viscosity, and resin degree of cure agreed well with values predicted by the simulation model. Textile composites fabricated using a one-step infiltration/cure procedure were uniformly resin impregnated and void free. Fiber volume fraction measurements by the resin digestion method compared well with values predicted using the model.

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.

Electrical connector composite housing and method of making same

DOEpatents

Silva, Frank A.

1979-01-01

A sleeve-like insert of conductive elastomeric material of a type which serves as an internal shield in electrical connectors for connecting high voltage cables has an end portion folded upon itself, the enfolded portion being substantially permanently retained in its desired position by allowing insulative elastomeric material to fill apertures in the end portion and become bonded thereto in a void free manner, during molding of an insulating outer sleeve-like jacket about the insert.

Simulation of the Two Stages Stretch-Blow Molding Process: Infrared Heating and Blowing Modeling

NASA Astrophysics Data System (ADS)

Bordival, M.; Schmidt, F. M.; Le Maoult, Y.; Velay, V.

2007-05-01

In the Stretch-Blow Molding (SBM) process, the temperature distribution of the reheated perform affects drastically the blowing kinematic, the bottle thickness distribution, as well as the orientation induced by stretching. Consequently, mechanical and optical properties of the final bottle are closely related to heating conditions. In order to predict the 3D temperature distribution of a rotating preform, numerical software using control-volume method has been developed. Since PET behaves like a semi-transparent medium, the radiative flux absorption was computed using Beer Lambert law. In a second step, 2D axi-symmetric simulations of the SBM have been developed using the finite element package ABAQUS®. Temperature profiles through the preform wall thickness and along its length were computed and applied as initial condition. Air pressure inside the preform was not considered as an input variable, but was automatically computed using a thermodynamic model. The heat transfer coefficient applied between the mold and the polymer was also measured. Finally, the G'sell law was used for modeling PET behavior. For both heating and blowing stage simulations, a good agreement has been observed with experimental measurements. This work is part of the European project "APT_PACK" (Advanced knowledge of Polymer deformation for Tomorrow's PACKaging).

Design for the automation of composite wind turbine blade manufacture

NASA Astrophysics Data System (ADS)

Polcari, M. J.; White, K. D.; Sherwood, J. A.

2016-10-01

The majority of large wind turbine blades are manufactured from textile-reinforced resin-infused composites using an open mold. The placement of the textile reinforcements in the mold is traditionally accomplished by a manual process where dozens of workers hand place each dry fabric in the mold. Depending on the level of skill and experience of each worker and the relative complexity of the mold geometry, local areas may exhibit out-of-plane wrinkling and in-plane waviness. Fabric imperfections such as these can adversely impact the strength and stiffness of the blade, thereby compromising its durability in service. In an effort to reduce the variabilities associated with a manual-labor process, an automated piecewise shifting method has been proposed for fabric placement. This automated layup method saves time on the preform process and reduces variability from blade to blade. In the current research the automated shifting layup method is investigated using a robust and easy-to-use finite element modelling approach. User-defined material models utilizing a mesoscopic unit-cell modeling approach are linked with Abaqus to capture the evolution of the fabric shear stiffness and changes in the fiber orientations during the fabric-placement process. The simulation approach is demonstrated for the geometry of the trailing edge of a typical wind turbine blade. The simulation considers the mechanical behavior of the fabric and reliably predicts fabric deformation and failure zones.

Novel Approach for Modeling of Nonuniform Slag Layers and Air Gap in Continuous Casting Mold

NASA Astrophysics Data System (ADS)

Wang, Xudong; Kong, Lingwei; Yao, Man; Zhang, Xiaobing

2017-02-01

Various kinds of surface defects on the continuous casting slab usually originate from nonuniform heat transfer and mechanical behavior, especially during the initial solidification inside the mold. In this article, a model-coupled inverse heat transfer problem incorporating the effect of slag layers and air gap is developed to study the nonuniform distribution of liquid slag, solid slag, and air gap layers. The model considers not only the formation and evolution of slag layers and air gap but also the temperatures in the mold copper as measured by thermocouples. The simulation results from the model and the measured temperatures from experiments are shown to be in good agreement with each other. At the casting speed of 0.65 m/min, the liquid slag film disappears and transforms into solid slag entirely at about 400 mm away from meniscus, and an air gap begins to form. Until the mold exit, the maximum thickness of the solid slag layer and air gap gradually increases to 1.34 and 0.056 mm, respectively. The results illustrate that the magnitude and nonuniform distribution of the slag layers and air gap along the cross direction, correlating with heat flux between the shell and mold, eventually determine the temperature profiles of the mold hot face and slab surface. The proposed model may provide a convenient approach for analyzing nonuniform heat transfer and mechanical behaviors between the mold and slab in the real casting process.

Analysis of form deviation in non-isothermal glass molding

NASA Astrophysics Data System (ADS)

Kreilkamp, H.; Grunwald, T.; Dambon, O.; Klocke, F.

2018-02-01

Especially in the market of sensors, LED lighting and medical technologies, there is a growing demand for precise yet low-cost glass optics. This demand poses a major challenge for glass manufacturers who are confronted with the challenge arising from the trend towards ever-higher levels of precision combined with immense pressure on market prices. Since current manufacturing technologies especially grinding and polishing as well as Precision Glass Molding (PGM) are not able to achieve the desired production costs, glass manufacturers are looking for alternative technologies. Non-isothermal Glass Molding (NGM) has been shown to have a big potential for low-cost mass manufacturing of complex glass optics. However, the biggest drawback of this technology at the moment is the limited accuracy of the manufactured glass optics. This research is addressing the specific challenges of non-isothermal glass molding with respect to form deviation of molded glass optics. Based on empirical models, the influencing factors on form deviation in particular form accuracy, waviness and surface roughness will be discussed. A comparison with traditional isothermal glass molding processes (PGM) will point out the specific challenges of non-isothermal process conditions. Furthermore, the underlying physical principle leading to the formation of form deviations will be analyzed in detail with the help of numerical simulation. In this way, this research contributes to a better understanding of form deviations in non-isothermal glass molding and is an important step towards new applications demanding precise yet low-cost glass optics.

Simulative design and process optimization of the two-stage stretch-blow molding process

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

Hopmann, Ch.; Rasche, S.; Windeck, C.

2015-05-22

The total production costs of PET bottles are significantly affected by the costs of raw material. Approximately 70 % of the total costs are spent for the raw material. Therefore, stretch-blow molding industry intends to reduce the total production costs by an optimized material efficiency. However, there is often a trade-off between an optimized material efficiency and required product properties. Due to a multitude of complex boundary conditions, the design process of new stretch-blow molded products is still a challenging task and is often based on empirical knowledge. Application of current CAE-tools supports the design process by reducing development timemore » and costs. This paper describes an approach to determine optimized preform geometry and corresponding process parameters iteratively. The wall thickness distribution and the local stretch ratios of the blown bottle are calculated in a three-dimensional process simulation. Thereby, the wall thickness distribution is correlated with an objective function and preform geometry as well as process parameters are varied by an optimization algorithm. Taking into account the correlation between material usage, process history and resulting product properties, integrative coupled simulation steps, e.g. structural analyses or barrier simulations, are performed. The approach is applied on a 0.5 liter PET bottle of Krones AG, Neutraubling, Germany. The investigations point out that the design process can be supported by applying this simulative optimization approach. In an optimization study the total bottle weight is reduced from 18.5 g to 15.5 g. The validation of the computed results is in progress.« less

Simulation Based Low-Cost Composite Process Development at the US Air Force Research Laboratory

NASA Technical Reports Server (NTRS)

Rice, Brian P.; Lee, C. William; Curliss, David B.

2003-01-01

Low-cost composite research in the US Air Force Research Laboratory, Materials and Manufacturing Directorate, Organic Matrix Composites Branch has focused on the theme of affordable performance. Practically, this means that we use a very broad view when considering the affordability of composites. Factors such as material costs, labor costs, recurring and nonrecurring manufacturing costs are balanced against performance to arrive at the relative affordability vs. performance measure of merit. The research efforts discussed here are two projects focused on affordable processing of composites. The first topic is the use of a neural network scheme to model cure reaction kinetics, then utilize the kinetics coupled with simple heat transport models to predict, in real-time, future exotherms and control them. The neural network scheme is demonstrated to be very robust and a much more efficient method that mechanistic cure modeling approach. This enables very practical low-cost processing of thick composite parts. The second project is liquid composite molding (LCM) process simulation. LCM processing of large 3D integrated composite parts has been demonstrated to be a very cost effective way to produce large integrated aerospace components specific examples of LCM processes are resin transfer molding (RTM), vacuum assisted resin transfer molding (VARTM), and other similar approaches. LCM process simulation is a critical part of developing an LCM process approach. Flow simulation enables the development of the most robust approach to introducing resin into complex preforms. Furthermore, LCM simulation can be used in conjunction with flow front sensors to control the LCM process in real-time to account for preform or resin variability.

Simulative design and process optimization of the two-stage stretch-blow molding process

NASA Astrophysics Data System (ADS)

Hopmann, Ch.; Rasche, S.; Windeck, C.

2015-05-01

The total production costs of PET bottles are significantly affected by the costs of raw material. Approximately 70 % of the total costs are spent for the raw material. Therefore, stretch-blow molding industry intends to reduce the total production costs by an optimized material efficiency. However, there is often a trade-off between an optimized material efficiency and required product properties. Due to a multitude of complex boundary conditions, the design process of new stretch-blow molded products is still a challenging task and is often based on empirical knowledge. Application of current CAE-tools supports the design process by reducing development time and costs. This paper describes an approach to determine optimized preform geometry and corresponding process parameters iteratively. The wall thickness distribution and the local stretch ratios of the blown bottle are calculated in a three-dimensional process simulation. Thereby, the wall thickness distribution is correlated with an objective function and preform geometry as well as process parameters are varied by an optimization algorithm. Taking into account the correlation between material usage, process history and resulting product properties, integrative coupled simulation steps, e.g. structural analyses or barrier simulations, are performed. The approach is applied on a 0.5 liter PET bottle of Krones AG, Neutraubling, Germany. The investigations point out that the design process can be supported by applying this simulative optimization approach. In an optimization study the total bottle weight is reduced from 18.5 g to 15.5 g. The validation of the computed results is in progress.

Optimization and Simulation of Plastic Injection Process using Genetic Algorithm and Moldflow

NASA Astrophysics Data System (ADS)

Martowibowo, Sigit Yoewono; Kaswadi, Agung

2017-03-01

The use of plastic-based products is continuously increasing. The increasing demands for thinner products, lower production costs, yet higher product quality has triggered an increase in the number of research projects on plastic molding processes. An important branch of such research is focused on mold cooling system. Conventional cooling systems are most widely used because they are easy to make by using conventional machining processes. However, the non-uniform cooling processes are considered as one of their weaknesses. Apart from the conventional systems, there are also conformal cooling systems that are designed for faster and more uniform plastic mold cooling. In this study, the conformal cooling system is applied for the production of bowl-shaped product made of PP AZ564. Optimization is conducted to initiate machine setup parameters, namely, the melting temperature, injection pressure, holding pressure and holding time. The genetic algorithm method and Moldflow were used to optimize the injection process parameters at a minimum cycle time. It is found that, an optimum injection molding processes could be obtained by setting the parameters to the following values: T M = 180 °C; P inj = 20 MPa; P hold = 16 MPa and t hold = 8 s, with a cycle time of 14.11 s. Experiments using the conformal cooling system yielded an average cycle time of 14.19 s. The studied conformal cooling system yielded a volumetric shrinkage of 5.61% and the wall shear stress was found at 0.17 MPa. The difference between the cycle time obtained through simulations and experiments using the conformal cooling system was insignificant (below 1%). Thus, combining process parameters optimization and simulations by using genetic algorithm method with Moldflow can be considered as valid.

Study on Hydroforming of Magnesium Alloy Tube under Temperature Condition

NASA Astrophysics Data System (ADS)

Wang, Xinsong; Wang, Shouren; Zhang, Yongliang; Wang, Gaoqi; Guo, Peiquan; Qiao, Yang

2018-01-01

First of all, under 100 °C, 150 °C, 200 °C, 250 °C, 300 °C and 350 °C, respectively do the test of magnesium alloy AZ31B temperature tensile and the fracture of SEM electron microscopic scanning, studying the plastic forming ability under six different temperature. Secondly, observe and study the real stress-strain curves and fracture topography. Through observation and research can concluded that with the increase of temperature, the yield strength and tensile strength of AZ31B was increased, and the elongation rate and the plastic deformation capacity are increased obviously. Taking into account the actual production, energy consumption, and mold temperature resistance, 250 °Cwas the best molding temperature. Finally, under the temperature condition of 250 °C, the finite element simulation and simulation of magnesium alloy profiled tube were carried out by Dynaform, and the special wall and forming limit diagram of magnesium alloy were obtained. According to the forming wall thickness and forming limit diagram, the molding experiment can be optimized continuously.

Applications of thin carbon coatings and films in injection molding

NASA Astrophysics Data System (ADS)

Cabrera, Eusebio Duarte

In this research, the technical feasibility of two novel applications of thin carbon coatings is demonstrated. The first application consists of using thin carbon coatings on molds for molding ultra-thin plastic parts (<0.5 mm thickness) with lower pressures by promoting wall slip. The second application consists of a new approach to provide electromagnetic interference (EMI) shielding for plastic parts using in mold coated nanoparticle thin films or nanopapers to create a conductive top layer. During this research, the technical feasibility of a new approach was proven which provides injection molding of ultra-thin parts at lower pressures, without the need of fast heating/fast cooling or other expensive mold modification. An in-house developed procedure by other members of our group, was employed for coating the mold surface using chemical vapor deposition (CVD) resulting in a graphene coating with carbide bonding to the mold surface. The coating resulted in a significant decrease of surface friction and consequently easiness of flow when compared to their uncoated counterparts. Thermoplastic polymers and their composites are a very attractive alternative but are hindered by the non-conductive nature of polymers. There are two general approaches used to date to achieve EMI shielding for plastic products. One is to spray a conductive metal coating onto the plastic surface forming a layer that must maintain its shielding effectiveness (SE), and its adhesion to the plastic throughout the expected life of the product. However, metal coatings add undesirable weight and tend to corrode over time. Furthermore, scratching the coating may create shielding failure; therefore, a protective topcoat may be required. The other approach is to use polymer composites filled with conductive fillers such as carbon black (CB), carbon nanofiber (CNF), and carbon nanotube (CNT). While conductive fillers may increase the electrical conductivity of polymer composites, the loading of such fillers often cannot reach a high level (<10 wt. %) due to the dispersion difficulty and exponential increase in viscosity. In this research, the technical feasibility of a new approach to EMI shielding of plastic parts was proven using in mold coated nanoparticle thin films or nanopapers to create a conductive top layer. For many years, in-mold coating (IMC) has been commercially applied to Sheet Molding Compound (SMC) compression molded parts, as an environmentally friendly approach to improve its surface quality and provide the required conductivity for electrostatic painting using carbon black (CB). Such process can also be applied to injection molding for creating a top conductive layer. Increasing the amount of CB will increase the surface conductivity of the coated part, thus improving the paint transfer efficiency. However the CB levels needed to achieve the conductivity levels required for achieving EMI shielding would make the coating viscosity too large for proper coating. Nanopaper based composites are excellent candidates for EMI shielding because of the nanopaper's high concentration of carbon nanofibers (CNFs) (~2 wt% to 10 wt% depending on nanopaper/thermoplastic thickness and 71wt.% to 79wt.% in the nanopaper itself after resin infusion) and high conductivity of the nanopaper. Instead of premixing nanoparticles with IMC coating, nanopapers enable the use of low viscosity IMC without CB coating to impregnate the CNF network in order to reach high electrical conductivity and EMI shielding values. (Abstract shortened by UMI.).

Study of Hygrothermal Processes in External Walls with Internal Insulation

NASA Astrophysics Data System (ADS)

Biseniece, Edite; Freimanis, Ritvars; Purvins, Reinis; Gravelsins, Armands; Pumpurs, Aivars; Blumberga, Andra

2018-03-01

Being an important contributor to the final energy consumption, historic buildings built before 1945 have high specific heating energy consumption compared to current energy standards and norms. However, they often cannot be insulated from the outside due to their heritage and culture value. Internal insulation is an alternative. However internal insulation faces challenges related to hygrothermal behaviour leading to mold growth, freezing, deterioration and other risks. The goal of this research is to link hygrothermal simulation results with experimental results for internally insulated historic brick masonry to assess correlation between simulated and measured data as well as the most influential parameters. The study is carried out by both a mathematical simulation tool and laboratory tests of historic masonry with internal insulation with four insulation materials (mineral wool, EPS, wood fiber and granulated aerogel) in a cold climate (average 4000 heating degree days). We found disparity between measured and simulated hygrothermal performance of studied constructions due to differences in material parameters and initial conditions of materials. The latter plays a more important role than material parameters. Under a steady state of conditions, the condensate tolerating system varies between 72.7 % and 80.5 % relative humidity, but in condensate limiting systems relative humidity variates between 73.3 % and 82.3 %. The temperature between the masonry wall and all insulation materials has stabilized on average at +10 °C. Mold corresponding to Mold index 3 was discovered on wood fiber mat.

Verification of a two-dimensional infiltration model for the resin transfer molding process

NASA Technical Reports Server (NTRS)

Hammond, Vincent H.; Loos, Alfred C.; Dexter, H. Benson; Hasko, Gregory H.

1993-01-01

A two-dimensional finite element model for the infiltration of a dry textile preform by an injected resin was verified. The model, which is based on the finite element/control volume technique, determines the total infiltration time and the pressure increase at the mold inlet associated with the RTM process. Important input data for the model are the compaction and permeability behavior of the preform along with the kinetic and rheological behavior of the resin. The compaction behavior for several textile preforms was determined by experimental methods. A power law regression model was used to relate fiber volume fraction to the applied compaction pressure. Results showed a large increase in fiber volume fraction with the initial application of pressure. However, as the maximum fiber volume fraction was approached, the amount of compaction pressure required to decrease the porosity of the preform rapidly increased. Similarly, a power law regression model was used to relate permeability to the fiber volume fraction of the preform. Two methods were used to measure the permeability of the textile preform. The first, known as the steady state method, measures the permeability of a saturated preform under constant flow rate conditions. The second, denoted the advancing front method, determines the permeability of a dry preform to an infiltrating fluid. Water, corn oil, and an epoxy resin, Epon 815, were used to determine the effect of fluid type and viscosity on the steady state permeability behavior of the preform. Permeability values measured with the different fluids showed that fluid viscosity had no influence on the permeability behavior of 162 E-glass and TTI IM7/8HS preforms. Permeabilities measured from steady state and advancing front experiments for the warp direction of 162 E-glass fabric were similar. This behavior was noticed for tests conducted with corn oil and Epon 815. Comparable behavior was observed for the warp direction of the TTI IM7/8HS preform and corn oil. Mold filling and flow visualization experiments were performed to verify the analytical computer model. Frequency dependent electromagnetic sensors were used to monitor the resin flow front as a function of time. For the flow visualization tests, a video camera and high resolution tape recorder were used to record the experimental flow fronts. Comparisons between experimental and model predicted flow fronts agreed well for all tests. For the mold filling tests conducted at constant flow rate injection, the model was able to accurately predict the pressure increase at the mold inlet during the infiltration process. A kinetics model developed to predict the degree of cure as a function of time for the injected resin accurately calculated the increase in the degree of cure during the subsequent cure cycle.

Thermoplastic composites for veneering posterior teeth-a feasibility study.

PubMed

Gegauff, Anthony G; Garcia, Jose L; Koelling, Kurt W; Seghi, Robert R

2002-09-01

This pilot study was conducted to explore selected commercially-available thermoplastic composites that potentially had physical properties superior to currently available dental systems for restoring esthetic posterior crowns. Polyurethane, polycarbonate, and poly(ethylene/tetrafluoroethylene) (ETFE) composites and unfilled polyurethane specimens were injection molded to produce shapes adaptive to five standardized mechanical tests. The mechanical testing included abrasive wear rate, yield strength, apparent fracture toughness (strength ratio), flexural strength, and compressive strength. Compared to commercially available dental composites, abrasion wear rates were lower for all materials tested, yield strength was greater for the filled polycarbonates and filled polyurethane resins, fracture toughness testing was invalid (strength ratios were calculated for comparison of the pilot test materials), flexural strength was roughly similar except for the filled ETFE which was significantly greater, and compressive strength was lower. Commercially available thermoplastic resin composites, such as polyurethane, demonstrate the potential for development of an artificial crown material which exceeds the mechanical properties of currently available esthetic systems, if compressive strength can be improved.

Solubility of a new calcium silicate-based root-end filling material

PubMed Central

Singh, Shishir; Podar, Rajesh; Dadu, Shifali; Kulkarni, Gaurav; Purba, Rucheet

2015-01-01

Introduction: The purpose of this study was to compare solubility of a new calcium silicate-based cement, Biodentine with three commonly used root-end filling materials viz. glass-ionomer cement (GIC), intermediate restorative material (IRM), and mineral trioxide aggregate (MTA). Materials and Methods: Twenty stainless steel ring molds were filled with cements corresponding to four groups (n = 5). The weight of 20 dried glass bottles was recorded. Samples were transferred to bottles containing 5 ml of distilled water and stored for 24 h. The bottles were dried at 105΀C and weighed. This procedure was repeated for 3, 10, 30, and 60 days. Data was analyzed with one-way analysis of variance (ANOVA) test (P < 0.05). Results: Biodentine demonstrated significantly higher solubility than MTA for 30- and 60-day immersion periods. Statistical difference was noted between the solubility values of Biodentine samples amongst each of the five time intervals. Conclusions: Biodentine exhibited higher solubility in comparison with all other cements. PMID:25829696

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.

Development of Aerogel Molds for Metal Casting Using Lunar and Martian Regolith

NASA Technical Reports Server (NTRS)

2003-01-01

In the last few years NASA has set new priorities for research and development of technologies necessary to enable long-term presence on the Moon and Mars. Among these key technologies is what is known as in situ resource utilization, which defines all conceivable usage of mineral, liquid, gaseous, or biological resources on a visited planet. In response to this challenge, we have been focusing on developing and demonstrating the manufacturing of a specific product using Lunar and Martian soil simulants (i.e., a mold for the casting of metal and alloy parts) which will be an indispensable tool for the survival of outposts on the Moon and Mars. In addition, our purpose is to demonstrate the feasibility of using mesoporous materials such as aerogels to serve as efficient casting molds for high quality components in propulsion and other aerospace applications. The first part of the project consists of producing aerogels from the in situ resources available in Martian and Lunar soil. The approach we are investigating is to use chemical processes to solubilize silicates using organic reagents at low temperatures and then use these as precursors in the formation of aerogels for the fabrication of metal casting molds. One set of experiments consists of dissolving silica sources in basic ethylene glycol solution to form silicon glycolates. When ground silica aerogel was used as source material, a clear solution of silicon glycolate was obtained and reacted to form a gel thus proving the feasibility of this approach. The application of this process to Lunar and Martian simulants did not result in the formation of a gel; further study is in progress. In the second method acidified alcohol is reacted with the simulants to form silicate esters. Preliminary results indicate the presence of silicon alkoxide in the product distillation. However, no gel has been obtained so further characterization is ongoing. In the second part of the project, the focus has been on developing a series of aerogel plates suitable for thin plate metal casting and ingot metal castings. The influence of aerogels on thin wall metal castings was studied by placing aerogel plates into the cavities of thin sections of resin bonded sand molds. An 1 based commercial alloy ( 356) containing 7 percent Si was poured into these molds. Post-solidification studies provide evidence that aerogel inserts significantly reduce the cooling rate during solidification. The advantage of a lower rate using aerogel inserts was reflected in the reduction of casting defects such as shrinkage porosity. Quantitative results support the hypothesis that using aerogels as a mold material can offer definite advantages when used as casting thin sections. As a separate effort, silica aerogel with cylindrical cavities have been prepared and will be evaluated for casting commercial alloys.

High strength particulate ceramics

DOEpatents

Liles, Kenneth J.; Hoyer, Jesse L.; Mlynarski, Kenneth W.

1991-01-01

This invention relates to new and useful hard, dense, composite materials made from metallic nitrides such as titanium nitride when combined with aluminum oxide and aluminum nitride and a process comprising the steps of: (1) mixing constituent materials using kerosene as a mixing medium; (2) screening, settling, filtering, and washing the mixture in acetone; (3) filling and sealing said materials in a latex mold; (4) isostatically pressing the material into a compacted powder; and (5) sintering the compacted powder in a gas atmosphere at 1,850.degree. C. for two hours.

Engineering and functional properties of biodegradable pellets developed from various agro-industrial wastes using extrusion technology.

PubMed

Jan, Kulsum; Riar, C S; Saxena, D C

2015-12-01

Different agro-industrial wastes were mixed with different plasticizers and extruded to form the pellets to be used further for development of biodegradable molded pots. Bulk density and macro-porosity are the important engineering properties used to determine the functional characteristics of the biodegradable pellets viz., expansion volume, water solubility, product colour, flowability and compactness. Significant differences in the functional properties of pellets with varying bulk densities (loose and tapped) and macro-porosities (loose, tapped) were observed. The observed mean bulk density of biodegradable pellets made from different formulations ranged between 0.213 and 0.560 g/ml for loose fill conditions and 0.248 to 0.604 g/ml for tapped fill conditions. Biodegradable pellets bear a good compaction for both loose and tapped fill methods. The mean macro-porosity of biodegradable pellets ranged between 1.19 and 54.48 % for loose fill condition and 0.29 to 53.35 % for tapped fill condition. Hausner ratio (HR) for biodegradable pellets varied from 1.026 to 1.328, indicating a good flowability of biodegradable pellets. Pearson's correlation between engineering properties and functional properties of biodegradable pellets revealed that from engineering properties functional properties can be predicted.

Thermochemical Ablation Analysis of the Orion Heatshield

NASA Technical Reports Server (NTRS)

Sixel, William

2015-01-01

The Orion Multi-Purpose Crew Vehicle will one day carry astronauts to the Moon and beyond, and Orion's heatshield is a critical component in ensuring their safe return to Earth. The Orion heatshield is the structural component responsible for absorbing the intense heating environment caused by re-entry to Earth's atmosphere. The heatshield is primarily composed of Avcoat, an ablative material that is consumed during the re-entry process. Ablation is primarily characterized by two processes: pyrolysis and recession. The decomposition of in-depth virgin material is known as pyrolysis. Recession occurs when the exposed surface of the heatshield reacts with the surrounding flow. The Orion heatshield design was changed from an individually filled Avcoat honeycomb to a molded block Avcoat design. The molded block Avcoat heatshield relies on an adhesive bond to keep it attached to the capsule. In some locations on the heatshield, the integrity of the adhesive bond cannot be verified. For these locations, a mechanical retention device was proposed. Avcoat ablation was modelled in CHAR and the in-depth virgin material temperatures were used in a Thermal Desktop model of the mechanical retention device. The retention device was analyzed and shown to cause a large increase in the maximum bondline temperature. In order to study the impact of individual ablation modelling parameters on the heatshield sizing process, a Monte Carlo simulation of the sizing process was proposed. The simulation will give the sensitivity of the ablation model to each of its input parameters. As part of the Monte Carlo simulation, statistical uncertainties on material properties were required for Avcoat. Several properties were difficult to acquire uncertainties for: the pyrolysis gas enthalpy, non-dimensional mass loss rate (B´c), and Arrhenius equation parameters. Variability in the elemental composition of Avcoat was used as the basis for determining the statistical uncertainty in pyrolysis gas enthalpy and B´c. A MATLAB program was developed to allow for faster, more accurate and automated computation of Arrhenius reaction parameters. These parameters are required for a material model to be used in the CHAR ablation analysis program. This MATLAB program, along with thermogravimetric analysis (TGA) data, was used to generate uncertainties on the Arrhenius parameters for Avcoat. In addition, the TGA fitting program was developed to provide Arrhenius parameters for the ablation model of the gap filler material, RTV silicone.

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

PubMed Central

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

2014-01-01

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

Laser-assisted photothermal imprinting of nanocomposite

NASA Astrophysics Data System (ADS)

Lu, Y.; Shao, D. B.; Chen, S. C.

2004-08-01

We report on a laser-assisted photothermal imprinting method for directly patterning carbon nanofiber-reinforced polyethylene nanocomposite. A single laser pulse from a solid state Nd :YAG laser (10ns pluse, 532 and 355nm wavelengths) is used to melt/soften a thin skin layer of the polymer nanocomposite. Meanwhile, a fused quartz mold with micro sized surface relief structures is pressed against the surface of the composite. Successful pattern transfer is realized upon releasing the quartz mold. Although polyethylene is transparent to the laser beam, the carbon nanofibers in the high density polyethylene (HDPE) matrix absorb the laser energy and convert it into heat. Numerical heat conduction simulation shows the HDPE matrix is partially melted or softened, allowing for easier imprinting of the relief pattern of the quartz mold.

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

PubMed

Rodríguez-Yáñez, Alicia Berenice; Méndez-Vázquez, Yaileen; Cabrera-Ríos, Mauricio

2014-01-01

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

Effect of surface preparation on the failure load of a highly filled composite bonded to the polymer-monomer matrix of a fiber-reinforced composite.

PubMed

Shimizu, Hiroshi; Tsue, Fumitake; Chen, Zhao-Xun; Takahashi, Yutaka

2009-04-01

The purpose of the present study was to evaluate the effect of surface preparation on the maximum fracture load value of a highly filled composite bonded to the polymer-monomer matrix of a fiber-reinforced composite. A polymer-monomer matrix was made by mixing urethane dimethacrylate and triethyleneglycol dimethacrylate at a ratio of 1:1 with camphorquinone and 2-dimethylaminoethyl methacrylate as a light initiator. The matrix was then polymerized in a disk-shaped silicone mold with a light-polymerizing unit. The flat surfaces of the polymer-monomer matrix disk were prepared in one of the following ways: (1) without preparation; (2) application of silane coupling agent; or (3) application of matrix liquid and prepolymerization. A highly filled composite material was applied and polymerized with a light-polymerizing unit. Additional test specimens made entirely of the polymer-monomer matrix were fabricated as references; the disk and cylinder were fabricated in one piece using a mold specially made for the present study (group 4). Half the specimens were thermocycled up to 10,000 times in water with a 1-minute dwell time at each temperature (5 degrees C and 55 degrees C). The maximum fracture load values were determined using a universal testing machine (n = 10). The maximum fracture loads for group 3 were significantly enhanced both before and after thermocycling, whereas the maximum fracture loads of group 2 were significantly enhanced before thermocycling (p < 0.05); however, the failure loads decreased for all groups after thermocycling (p < 0.05). All the specimens in groups 1 and 2 debonded during thermocycling. The failure load of group 3 was significantly lower than that of group 4 both before and after thermocycling (p < 0.05). Within the limitations of the current in vitro study, the application and prepolymerization of a mixed dimethacrylate resin liquid prior to the application of a highly filled composite was an effective surface preparation for the polymer-monomer matrix of a fiber-reinforced composite; however, the bond durability may be insufficient.

Large Eddy Simulation of Transient Flow, Solidification, and Particle Transport Processes in Continuous-Casting Mold

NASA Astrophysics Data System (ADS)

Liu, Zhongqiu; Li, Linmin; Li, Baokuan; Jiang, Maofa

2014-07-01

The current study developed a coupled computational model to simulate the transient fluid flow, solidification, and particle transport processes in a slab continuous-casting mold. Transient flow of molten steel in the mold is calculated using the large eddy simulation. An enthalpy-porosity approach is used for the analysis of solidification processes. The transport of bubble and non-metallic inclusion inside the liquid pool is calculated using the Lagrangian approach based on the transient flow field. A criterion of particle entrapment in the solidified shell is developed using the user-defined functions of FLUENT software (ANSYS, Inc., Canonsburg, PA). The predicted results of this model are compared with the measurements of the ultrasonic testing of the rolled steel plates and the water model experiments. The transient asymmetrical flow pattern inside the liquid pool exhibits quite satisfactory agreement with the corresponding measurements. The predicted complex instantaneous velocity field is composed of various small recirculation zones and multiple vortices. The transport of particles inside the liquid pool and the entrapment of particles in the solidified shell are not symmetric. The Magnus force can reduce the entrapment ratio of particles in the solidified shell, especially for smaller particles, but the effect is not obvious. The Marangoni force can play an important role in controlling the motion of particles, which increases the entrapment ratio of particles in the solidified shell obviously.

Lower sintering temperature of nanostructured dense ceramics compacted from dry nanopowders using powerful ultrasonic action

NASA Astrophysics Data System (ADS)

Khasanov, O.; Reichel, U.; Dvilis, E.; Khasanov, A.

2011-10-01

Nanostructured high dense zirconia ceramics have been sintered from dry nanopowders compacted by uniaxial pressing with simultaneous powerful ultrasonic action (PUA). Powerful ultrasound with frequency of 21 kHz was supplied from ultrasonic generator to the mold, which was the ultrasonic wave-guide. Previously the mold was filled by non-agglomerated zirconia nanopowder having average particle size of 40 nm. Any binders or plasticizers were excluded at nanopowder processing. Compaction pressure was 240 MPa, power of ultrasonic generator at PUA was 1 kW and 3 kW. The fully dense zirconia ceramics has been sintered at 1345°C and high-dense ceramics with a density of 99.1%, the most grains of which had the sizes Dgr <= 200 nm, has been sintered at low sintering temperature (1325°C). Applied approach prevents essential grain growth owing to uniform packing of nanoparticles under vibrating PU-action at pressing, which provides the friction forces control during dry nanopowder compaction without contaminating binders or plasticizers.

Experimental Investigation on Mechanical and Thermal Properties of Marble Dust Particulate-Filled Needle-Punched Nonwoven Jute Fiber/Epoxy Composite

NASA Astrophysics Data System (ADS)

Sharma, Ankush; Patnaik, Amar

2018-03-01

The present investigation evaluates the effects of waste marble dust, collected from the marble industries of Rajasthan, India, on the mechanical properties of needle-punched nonwoven jute fiber/epoxy composites. The composites with varying filler contents from 0 wt.% to 30 wt.% marble dust were prepared using vacuum-assisted resin-transfer molding. The influences of the filler material on the void content, tensile strength, flexural strength, interlaminar shear strength (ILSS), and thermal conductivity of the hybrid composites have been analyzed experimentally under the desired optimal conditions. The addition of marble dust up to 30 wt.% increases the flexural strength, ILSS, and thermal conductivity, but decreases the tensile strength. Subsequently, the fractured surfaces of the particulate-filled jute/epoxy composites were analyzed microstructurally by field-emission scanning electron microscopy.

Matrix Characterization and Development for the Vacuum Assisted Resin Transfer Molding Process

NASA Technical Reports Server (NTRS)

Grimsley, B. W.; Hubert, P.; Hou, T. H.; Cano, R. J.; Loos, A. C.; Pipes, R. B.

2001-01-01

The curing kinetics and viscosity of an epoxy resin system, SI-ZG-5A, have been characterized for application in the vacuum assisted resin transfer molding (VARTM) process. Impregnation of a typical carbon fiber perform provided the test bed for the characterization. Process simulations were carried out using the process model, COMPRO, to examine heat transfer and curing kinetics for a fully impregnated panel, neglecting resin flow. The predicted viscosity profile and final degree of cure were found to be in good agreement with experimental observations.

Cellulosic building insulation versus mineral wool, fiberglass or perlite: installer's exposure by inhalation of fibers, dust, endotoxin and fire-retardant additives.

PubMed

Breum, N O; Schneider, T; Jørgensen, O; Valdbjørn Rasmussen, T; Skibstrup Eriksen, S

2003-11-01

A task-specific exposure matrix was designed for workers installing building insulation materials. A priori, a matrix element was defined by type of task (installer or helper), type of work area (attic spaces or wall cavities) and type of insulation material (slabs from mineral wool, fiberglass or flax; loose-fill cellulosic material or perlite). In the laboratory a mock-up (full scale) of a one-family house was used for simulated installation of insulation materials (four replicates per matrix element). Personal exposure to dust and fibers was measured. The dust was analyzed for content of endotoxin and some trace elements (boron and aluminum) from fire-retardant or mold-resistant additives. Fibers were characterized as WHO fibers or non-WHO fibers. In support of the exposure matrix, the dustiness of all the materials was measured in a rotating drum tester. For installers in attic spaces, risk of exposure was low for inhalation of dust and WHO fibers from slab materials of mineral wool or fiberglass. Slab materials from flax may cause high risk of exposure to endotoxin. The risk of exposure by inhalation of dust from loose-fill materials was high for installers in attic spaces and for some of the materials risk of exposure was high for boron and aluminum. Exposure by inhalation of cellulosic WHO fibers was high but little is known about the health effects and a risk assessment is not possible. For the insulation of walls, the risk of installers' exposure by inhalation of dust and fibers was low for the slab materials, while a high risk was observed for loose-fill materials. The exposure to WHO fibers was positively correlated to the dust exposure. A dust level of 6.1 mg/m3 was shown to be useful as a proxy for screening exposure to WHO fibers in excess of 10(6) fibers/m3. In the rotating drum, slabs of insulation material from mineral wool or fiberglass were tested as not dusty. Cellulosic loose-fill materials were tested as very dusty, and perlite proved to be extremely dusty.

Oscillation-Mark Formation and Liquid-Slag Consumption in Continuous Casting Mold

NASA Astrophysics Data System (ADS)

Yang, Jie; Meng, Xiangning; Wang, Ning; Zhu, Miaoyong

2017-04-01

Traditional understanding on the complex multiphysics phenomenon of the meniscus in the oscillating mold for continuously cast steel, including oscillation-mark formation and liquid-slag consumption, has never considered the shape influence of the flux channel between the mold wall and the solidifying shell surface. Based on the reciprocating oscillation of mold, this study was carried out to calculate theoretically the periodic pressure and the liquid-slag layer thickness in the flux channel for the upper and the lower meniscus that possess different shapes in combination with a transient equilibrium profile of the flux channel as well as the sinusoidal and the nonsinusoidal oscillation modes of mold. The effect of flux channel shape on the multiphysics phenomenon in the meniscus was determined by the physical oscillation simulation by using an experimental cold model mold. The results show that the shape difference between the upper and the lower meniscus leads to the opposite direction of pressure in the flux channel. The pressure in the opposite direction plays a respective role in oscillation-mark formation and liquid-slag consumption in an oscillation cycle of mold, and thus, it makes a new mechanism for explaining the multiphysics phenomenon in the meniscus. The oscillation mark is initially formed by the rapid increase of positive channel pressure in the upper meniscus, and most of the liquid slag is infiltrated into the flux channel by the negative channel pressure in the lower meniscus from the end of a positive strip time to the beginning of the next positive strip time, including the negative strip time in between. Furthermore, the physical characteristics of the lubrication behavior in the meniscus are summarized, including liquid-slag infiltration, solidifying shell deformation, and the thickness change of the liquid-slag layer.

Identification and Quantitation of the Microbiological Flora of the Food Packet, Long Range Patrol under Simulated Field Conditions,

DTIC Science & Technology

MILITARY RATIONS, *MICROORGANISMS), (*FOOD, *BIOLOGICAL CONTAMINATION), DETECTION, IDENTIFICATION, STORAGE, PROCESSING, FREEZE DRYING, MICROCOCCUS , STREPTOCOCCUS, YEASTS, MOLDS(ORGANISMS), TEMPERATURE, HIGH ALTITUDE

DRAPING SIMULATION OF WOVEN FABRICS

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

Rodgers, William; Jin, Xiaoshi; Zhu, Jiang

2016-09-07

Woven fabric composites are extensively used in molding complex geometrical shapes due to their high conformability compared to other fabrics. Preforming is an important step in the overall process, where the two-dimensional fabric is draped to become the three-dimensional shape of the part prior to resin injection. During preforming, the orientation of the yarns may change significantly compared to the initial orientations. Accurate prediction of the yarn orientations after molding is important for evaluating the structural performance of the final part. This paper presents a systematic investigation of the angle changes during the preform operation for carbon fiber twill andmore » satin weave fabrics. Preforming experiments were conducted using a truncated pyramid mold geometry designed and fabricated at the General Motors Research Laboratories. Predicted results for the yarn orientations were compared with experimental results and good agreement was observed« less

Filling schemes of silver dots inkjet-printed on pixelated nanostructured surfaces

NASA Astrophysics Data System (ADS)

Alan, Sheida; Jiang, Hao; Shahbazbegian, Haleh; Patel, Jasbir N.; Kaminska, Bozena

2017-03-01

Recently, our group demonstrated an inkjet-based technique to enable high-throughput, versatile and full-colour printing of structural colours on generic pixelated nanostructures, termed as molded ink on nanostructured surfaces. The printed colours are controlled by the area of printed silver on the pixelated red, green and blue polymer nanostructure arrays. This paper investigates the behaviour of jetted silver ink droplets on nanostructured surfaces and the microscale dot patterns implemented during printing process, for achieving accurate and consistent colours in the printed images. The surface wettability and the schemes of filling silver dots inside the subpixels are crucial to the quality of printed images. Several related concepts and definitions are introduced, such as filling ratio, full dots per subpixel (DPSP), number of printable colours, colour leaking and dot merging. In our experiments, we first chemically modified the surface to control the wettability and dot size. From each type of modified surface, various filling schemes were experimented and the printed results were evaluated with comprehensive considerations on the number of printable colours and the negative effects of colour leaking and dot merging. Rational selection of the best filling scheme resulted in a 2-line filling scheme using 20 μm dot spacing and line spacing capable of printing 9261 different colours with 121 pixel per inch display resolution, on low-wettability surface. This study is of vital importance for scaling up the printing technique in industrial applications and provides meaningful insights for inkjet-printing on nanostructures.

Low-cost endoscopic third ventriculostomy simulator with mimetic endoscope.

PubMed

Garling, Richard Justin; Jin, Xin; Yang, Jianzhong; Khasawneh, Ahmad H; Harris, Carolyn Anne

2018-05-11

OBJECTIVE Hydrocephalus affects approximately 1 in 500 people in the US, yet ventricular shunting, the gold standard of treatment, has a nearly 85% failure rate. Endoscopic third ventriculostomy (ETV) is an alternative surgical approach for a specific subset of hydrocephalic patients, but can be limited by the inability of neurosurgical residents to practice prior to patient contact. The goal of this study was to create an affordable ETV model and endoscope for resident training. METHODS Open-source software was used to isolate the skull and brain from the CT and MR images of a 2-year-old boy with hydrocephalus. A 3D printer created the skull and a 3D mold of the brain. A mixture of silicone and silicone tactile mutator was used to cast the brain mold prior to subsequent compression and shearing modulus testing. A mimetic endoscope was then created from basic supplies and a 3D printed frame. A small cohort of neurosurgical residents and attending physicians evaluated the ETV simulator with mimetic endoscope. RESULTS The authors successfully created a mimetic endoscope and ETV simulator. After compression and shearing modulus testing, a silicone/Slacker ratio between 10:6 and 10:7 was found to be similar to that of human brain parenchyma. Eighty-seven percent of participants strongly agreed that the simulator was useful for resident training, and 93% strongly agreed that the simulator helped them understand how to orient themselves with the endoscope. CONCLUSIONS The authors created an affordable (US$123, excluding 3D printer), easy-to-use ETV simulator with endoscope. Previous models have required expensive software and costly operative endoscopes that may not be available to most residents. Instead, this attempt takes advantage of open-source software for the manipulation and fabrication of a patient-specific mold. This model can assist with resident development, allowing them to safely practice use of the endoscope in ETV.

Demineralized bone matrix fibers formable as general and custom 3D printed mold-based implants for promoting bone regeneration.

PubMed

Rodriguez, Rudy U; Kemper, Nathan; Breathwaite, Erick; Dutta, Sucharita M; Hsu, Erin L; Hsu, Wellington K; Francis, Michael P

2016-07-26

Bone repair frequently requires time-consuming implant construction, particularly when using un-formed implants with poor handling properties. We therefore developed osteoinductive, micro-fibrous surface patterned demineralized bone matrix (DBM) fibers for engineering both defect-matched and general three-dimensional implants. Implant molds were filled with demineralized human cortical bone fibers there were compressed and lyophilized, forming mechanically strong shaped DBM scaffolds. Enzyme linked immunosorbent assays and mass spectrometry confirmed that DBM fibers contained abundant osteogenic growth factors (bone morphogenetic proteins, insulin-like growth factor-I) and extracellular matrix proteins. Mercury porosimetry and mechanical testing showed interconnected pores within the mechanically stable, custom DBM fiber scaffolds. Mesenchymal stem cells readily attached to the DBM and showed increasing metabolic activity over time. DBM fibers further increased alkaline phosphatase activity in C2C12 cells. In vivo, DBM implants elicited osteoinductive potential in a mouse muscle pouch, and also promoted spine fusion in a rat arthrodesis model. DBM fibers can be engineered into custom-shaped, osteoinductive and osteoconductive implants with potential for repairing osseous defects with precise fitment, potentially reducing operating time. By providing pre-formed and custom implants, this regenerative allograft may improve patient outcomes following surgical bone repair, while further advancing personalized orthopedic and craniomaxillofacial medicine using three-dimensional-printed tissue molds.

Method for molding threads in graphite panels

DOEpatents

Short, W.W.; Spencer, C.

1994-11-29

A graphite panel with a hole having a damaged thread is repaired by drilling the hole to remove all of the thread and making a new hole of larger diameter. A bolt with a lubricated thread is placed in the new hole and the hole is packed with graphite cement to fill the hole and the thread on the bolt. The graphite cement is cured, and the bolt is unscrewed therefrom to leave a thread in the cement which is at least as strong as that of the original thread. 8 figures.

In-situ stabilization of radioactive zirconium swarf

DOEpatents

Hess, Clay C.

1999-01-01

The method for treating ignitable cutting swarf in accordance with the present invention involves collecting cutting swarf in a casting mold underwater and injecting a binder mixture comprising vinyl ester styrene into the vessel to fill void volume; and form a mixture comprising swarf and vinyl ester styrene; and curing the mixture. The method is especially useful for stabilizing the ignitable characteristics of radioactive zirconium cutting swarf, and can be used to solidify zirconium swarf, or other ignitable finely divided material, underwater. The process could also be performed out of water with other particulate wastes.

Virtual Reality and Simulation in Neurosurgical Training.

PubMed

Bernardo, Antonio

2017-10-01

Recent biotechnological advances, including three-dimensional microscopy and endoscopy, virtual reality, surgical simulation, surgical robotics, and advanced neuroimaging, have continued to mold the surgeon-computer relationship. For developing neurosurgeons, such tools can reduce the learning curve, improve conceptual understanding of complex anatomy, and enhance visuospatial skills. We explore the current and future roles and application of virtual reality and simulation in neurosurgical training. Copyright © 2017 Elsevier Inc. All rights reserved.

Analysis of roll-stamped light guide plate fabricated with laser-ablated stamper

NASA Astrophysics Data System (ADS)

Na, Hyunjun; Hong, Seokkwan; Kim, Jongsun; Hwang, Jeongho; Joo, Byungyun; Yoon, Kyunghwan; Kang, Jeongjin

2017-12-01

LGP (light guide plate) is one of the major components of LCD (liquid crystal display), and it makes surface illumination for LCD backlit. LGP is a transparent plastic plate usually produced by injection molding process. On the back of LGP there are micron size patterns for extraction of light. Recently a roll-stamping process has achieved the high mass productivity of thinner LGPs. In order to fabricate optical patterns on LGPs, a fabricating tool called as a stamper is used. Micro patterns on metallic stampers are made by several micro machining processes such as chemical etching, LIGA-reflow, and laser ablation. In this study, a roll-stamping process by using a laser ablated metallic stamper was dealt with in consideration of the compatibility with the roll-stamping process. LGP fabricating tests were performed using a roll-stamping process with four different roll pressures. Pattern shapes on the stamper fabricated by laser ablation and transcription ratios of the roll-stamping process were analyzed, and LGP luminance was evaluated. Based on the evaluation, optical simulation model for LGP was made and simulation accuracy was evaluated. Simulation results showed good agreements with optical performance of LGPs in the brightness and uniformity. It was also shown that the roll-stamped LGP has the possibility of better optical performance than the conventional injection molded LGP. It was also shown that the roll-stamped LGP with the laser ablated stamper is potential to have better optical performance than the conventional injection molded LGP.

Provenance and diagenesis of the evaporite-bearing Burns formation, Meridiani Planum, Mars

USGS Publications Warehouse

McLennan, S.M.; Bell, J.F.; Calvin, W.M.; Christensen, P.R.; Clark, B. C.; de Souza, P.A.; Farmer, J.; Farrand, W. H.; Fike, D.A.; Gellert, Ralf; Ghosh, A.; Glotch, T.D.; Grotzinger, J.P.; Hahn, B.; Herkenhoff, K. E.; Hurowitz, J.A.; Johnson, J. R.; Johnson, S.S.; Jolliff, B.; Klingelhofer, G.; Knoll, A.H.; Learner, Z.; Malin, M.C.; McSween, H.Y.; Pocock, J.; Ruff, S.W.; Soderblom, L.A.; Squyres, S. W.; Tosca, N.J.; Watters, W.A.; Wyatt, M.B.; Yen, A.

2005-01-01

Impure reworked evaporitic sandstones, preserved on Meridiani Planum, Mars, are mixtures of roughly equal amounts of altered siliciclastic debris, of basaltic provenance (40 ?? 10% by mass), and chemical constituents, dominated by evaporitic minerals (jarosite, Mg-, Ca-sulfates ?? chlorides ?? Fe-, Na-sulfates), hematite and possibly secondary silica (60 ?? 10%). These chemical constituents and their relative abundances are not an equilibrium evaporite assemblage and to a substantial degree have been reworked by aeolian and subaqueous transport. Ultimately they formed by evaporation of acidic waters derived from interaction with olivine-bearing basalts and subsequent diagenetic alteration. The rocks experienced an extended diagenetic history, with at least two and up to four distinct episodes of cementation, including stratigraphically restricted zones of recrystallization and secondary porosity, non-randomly distributed, highly spherical millimeter-scale hematitic concretions, millimeter-scale crystal molds, interpreted to have resulted from dissolution of a highly soluble evaporite mineral, elongate to sheet-like vugs and evidence for minor synsedimentary deformation (convolute and contorted bedding, possible teepee structures or salt ridge features). Other features that may be diagenetic, but more likely are associated with relatively recent meteorite impact, are meter-scale fracture patterns, veins and polygonal fractures on rock surfaces that cut across bedding. Crystallization of minerals that originally filled the molds, early cement and sediment deformation occurred syndepositionally or during early diagenesis. All other diagenetic features are consistent with formation during later diagenesis in the phreatic (fluid saturated) zone or capillary fringe of a groundwater table under near isotropic hydrological conditions such as those expected during periodic groundwater recharge. Textural evidence suggests that rapidly formed hematitic concretions post-date the primary mineral now represented by crystal molds and early pore-filling cements but pre-date secondary moldic and vug porosity. The second generation of cements followed formation of secondary porosity. This paragenetic sequence is consistent with an extended history of syndepositional through post-depositional diagenesis in the presence of a slowly fluctuating, chemically evolving, but persistently high ionic strength groundwater system. ?? 2005 Elsevier B.V. All rights reserved.

Provenance and diagenesis of the evaporite-bearing Burns formation, Meridiani Planum, Mars

NASA Astrophysics Data System (ADS)

McLennan, S. M.; Bell, J. F.; Calvin, W. M.; Christensen, P. R.; Clark, B. C.; de Souza, P. A.; Farmer, J.; Farrand, W. H.; Fike, D. A.; Gellert, R.; Ghosh, A.; Glotch, T. D.; Grotzinger, J. P.; Hahn, B.; Herkenhoff, K. E.; Hurowitz, J. A.; Johnson, J. R.; Johnson, S. S.; Jolliff, B.; Klingelhöfer, G.; Knoll, A. H.; Learner, Z.; Malin, M. C.; McSween, H. Y.; Pocock, J.; Ruff, S. W.; Soderblom, L. A.; Squyres, S. W.; Tosca, N. J.; Watters, W. A.; Wyatt, M. B.; Yen, A.

2005-11-01

Impure reworked evaporitic sandstones, preserved on Meridiani Planum, Mars, are mixtures of roughly equal amounts of altered siliciclastic debris, of basaltic provenance (40 ± 10% by mass), and chemical constituents, dominated by evaporitic minerals (jarosite, Mg-, Ca-sulfates ± chlorides ± Fe-, Na-sulfates), hematite and possibly secondary silica (60 ± 10%). These chemical constituents and their relative abundances are not an equilibrium evaporite assemblage and to a substantial degree have been reworked by aeolian and subaqueous transport. Ultimately they formed by evaporation of acidic waters derived from interaction with olivine-bearing basalts and subsequent diagenetic alteration. The rocks experienced an extended diagenetic history, with at least two and up to four distinct episodes of cementation, including stratigraphically restricted zones of recrystallization and secondary porosity, non-randomly distributed, highly spherical millimeter-scale hematitic concretions, millimeter-scale crystal molds, interpreted to have resulted from dissolution of a highly soluble evaporite mineral, elongate to sheet-like vugs and evidence for minor synsedimentary deformation (convolute and contorted bedding, possible teepee structures or salt ridge features). Other features that may be diagenetic, but more likely are associated with relatively recent meteorite impact, are meter-scale fracture patterns, veins and polygonal fractures on rock surfaces that cut across bedding. Crystallization of minerals that originally filled the molds, early cement and sediment deformation occurred syndepositionally or during early diagenesis. All other diagenetic features are consistent with formation during later diagenesis in the phreatic (fluid saturated) zone or capillary fringe of a groundwater table under near isotropic hydrological conditions such as those expected during periodic groundwater recharge. Textural evidence suggests that rapidly formed hematitic concretions post-date the primary mineral now represented by crystal molds and early pore-filling cements but pre-date secondary moldic and vug porosity. The second generation of cements followed formation of secondary porosity. This paragenetic sequence is consistent with an extended history of syndepositional through post-depositional diagenesis in the presence of a slowly fluctuating, chemically evolving, but persistently high ionic strength groundwater system.

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.

Modeling of magnetic particle orientation in magnetic powder injection molding

NASA Astrophysics Data System (ADS)

Doo Jung, Im; Kang, Tae Gon; Seul Shin, Da; Park, Seong Jin

2018-03-01

The magnetic micro powder orientation under viscous shear flow has been analytically understood and characterized into a new analytical orientation model for a powder injection molding process. The effects of hydrodynamic force from the viscous flow, external magnetic force and internal dipole-dipole interaction were considered to predict the orientation under given process conditions. Comparative studies with a finite element method proved the calculation validity with a partial differential form of the model. The angular motion, agglomeration and magnetic chain formation have been simulated, which shows that the effect of dipole-dipole interaction among powders on the orientation state becomes negligible at a high Mason number condition and at a low λ condition (the ratio of external magnetic field strength and internal magnetic moment of powder). Our developed model can be very usefully employed in the process analysis and design of magnetic powder injection molding.

Spiral optical designs for nonimaging applications

NASA Astrophysics Data System (ADS)

Zamora, Pablo; Benítez, Pablo; Miñano, Juan C.; Vilaplana, Juan; Buljan, Marina

2011-10-01

Manufacturing technologies as injection molding or embossing specify their production limits for minimum radii of the vertices or draft angle for demolding, for instance. In some demanding nonimaging applications, these restrictions may limit the system optical efficiency or affect the generation of undesired artifacts on the illumination pattern. A novel manufacturing concept is presented here, in which the optical surfaces are not obtained from the usual revolution symmetry with respect to a central axis (z axis), but they are calculated as free-form surfaces describing a spiral trajectory around z axis. The main advantage of this new concept lies in the manufacturing process: a molded piece can be easily separated from its mold just by applying a combination of rotational movement around axis z and linear movement along axis z, even for negative draft angles. Some of these spiral symmetry examples will be shown here, as well as their simulated results.

Spiral nonimaging optical designs

NASA Astrophysics Data System (ADS)

Zamora, Pablo; Benítez, Pablo; Miñano, Juan C.; Vilaplana, Juan

2011-10-01

Manufacturing technologies as injection molding or embossing specify their production limits for minimum radii of the vertices or draft angle for demolding, for instance. In some demanding nonimaging applications, these restrictions may limit the system optical efficiency or affect the generation of undesired artifacts on the illumination pattern. A novel manufacturing concept is presented here, in which the optical surfaces are not obtained from the usual revolution symmetry with respect to a central axis (z axis), but they are calculated as free-form surfaces describing a spiral trajectory around z axis. The main advantage of this new concept lies in the manufacturing process: a molded piece can be easily separated from its mold just by applying a combination of rotational movement around axis z and linear movement along axis z, even for negative draft angles. Some of these spiral symmetry examples will be shown here, as well as their simulated results.

A Simulation of Alternatives for Wholesale Inventory Replenishment

DTIC Science & Technology

2016-03-01

algorithmic details. The last method is a mixed-integer, linear optimization model. Comparative Inventory Simulation, a discrete event simulation model, is...simulation; event graphs; reorder point; fill-rate; backorder; discrete event simulation; wholesale inventory optimization model 15. NUMBER OF PAGES...model. Comparative Inventory Simulation, a discrete event simulation model, is designed to find fill rates achieved for each National Item

Numerical simulations - Some results for the 2- and 3-D Hubbard models and a 2-D electron phonon model

NASA Technical Reports Server (NTRS)

Scalapino, D. J.; Sugar, R. L.; White, S. R.; Bickers, N. E.; Scalettar, R. T.

1989-01-01

Numerical simulations on the half-filled three-dimensional Hubbard model clearly show the onset of Neel order. Simulations of the two-dimensional electron-phonon Holstein model show the competition between the formation of a Peierls-CDW state and a superconducting state. However, the behavior of the partly filled two-dimensional Hubbard model is more difficult to determine. At half-filling, the antiferromagnetic correlations grow as T is reduced. Doping away from half-filling suppresses these correlations, and it is found that there is a weak attractive pairing interaction in the d-wave channel. However, the strength of the pair field susceptibility is weak at the temperatures and lattice sizes that have been simulated, and the nature of the low-temperature state of the nearly half-filled Hubbard model remains open.

Dental Stem Cell Migration on Pulp Ceiling Cavities Filled with MTA, Dentin Chips, or Bio-Oss

PubMed Central

Lymperi, Stefania; Taraslia, Vasiliki; Tsatsoulis, Ioannis N.; Samara, Athina; Agrafioti, Anastasia; Anastasiadou, Ema; Kontakiotis, Evangelos

2015-01-01

MTA, Bio-Oss, and dentin chips have been successfully used in endodontics. The aim of this study was to assess the adhesion and migration of dental stem cells on human pulp ceiling cavities filled with these endodontic materials in an experimental model, which mimics the clinical conditions of regenerative endodontics. Cavities were formed, by a homemade mold, on untouched third molars, filled with endodontic materials, and observed with electron microscopy. Cells were seeded on cavities' surface and their morphology and number were analysed. The phenomenon of tropism was assessed in a migration assay. All three materials demonstrated appropriate microstructures for cell attachment. Cells grew on all reagents, but they showed a differential morphology. Moreover, variations were observed when comparing cells numbers on cavity's filling versus the surrounding dentine disc. The highest number of cells was recorded on dentin chips whereas the opposite was true for Bio-Oss. This was confirmed in the migration assay where a statistically significant lower number of cells migrated towards Bio-Oss as compared to MTA and dentin chips. This study highlights that MTA and dentin chips have a greater potential compared to Bio-Oss regarding the attraction of dental stem cells and are good candidates for bioengineered pulp regeneration. PMID:26146613

A novel tool to standardize rheology testing of molten polymers for pharmaceutical applications.

PubMed

Treffer, Daniel; Troiss, Alexander; Khinast, Johannes

2015-11-10

Melt rheology provides information about material properties that are of great importance for equipment design and simulations, especially for novel pharmaceutical manufacturing operations, including extrusion, injection molding or 3d printing. To that end, homogeneous samples must be prepared, most commonly via compression or injection molding, both of which require costly equipment and might not be applicable for shear- and heat-sensitive pharmaceutical materials. Our study introduces a novel vacuum compression molding (VCM) tool for simple preparation of thermoplastic specimens using standard laboratory equipment: a hot plate and a vacuum source. Sticking is eliminated by applying polytetrafluoroethylene (PTFE) coated separation foils. The evacuation of the tool leads to compression of the sample chamber, which is cost-efficient compared to conventional methods, such as compression molding or injection molding that require special equipment. In addition, this compact design reduces the preparation time and the heat load. The VCM tool was used to prepare samples for a rheological study of three pharmaceutical polymers (Soluplus(®), Eudragit(®)E, EVA Rowalit(®) 300-1/28). The prepared samples were without any air inclusions or voids, and the measurements had a high reproducibility. All relative standard deviations were below 3%. The obtained data were fitted to the Carreau-Yasuda model and time-temperature superposition was applied. Copyright © 2015 Elsevier B.V. All rights reserved.

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.

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.

Numerical natural rubber curing simulation, obtaining a controlled gradient of the state of cure in a thick-section part

NASA Astrophysics Data System (ADS)

El Labban, A.; Mousseau, P.; Bailleul, J. L.; Deterre, R.

2007-04-01

Although numerical simulation has proved to be a useful tool to predict the rubber vulcanization process, few applications in the process control have been reported. Because the end-use rubber properties depend on the state of cure distribution in the parts thickness, the prediction of the optimal distribution remains a challenge for the rubber industry. The analysis of the vulcanization process requires the determination of the thermal behavior of the material and the cure kinetics. A nonisothermal vulcanization model with nonisothermal induction time is used in this numerical study. Numerical results are obtained for natural rubber (NR) thick-section part curing. A controlled gradient of the state of cure in the part thickness is obtained by a curing process that consists not only in mold heating phase, but also a forced convection mold cooling phase in order to stop the vulcanization process and to control the vulcanization distribution. The mold design that allows this control is described. In the heating phase, the state of cure is mainly controlled by the chemical kinetics (the induction time), but in the cooling phase, it is the heat diffusion that controls the state of cure distribution. A comparison among different cooling conditions is shown and a good state of cure gradient control is obtained.

Novel fabrication technique of hybrid structure lens array for 3D images

NASA Astrophysics Data System (ADS)

Lee, Junsik; Kim, Junoh; Kim, Cheoljoong; Shin, Dooseub; Koo, Gyohyun; Won, Yong Hyub

2016-03-01

Tunable liquid lens arrays can produce three dimensional images by using electrowetting principle that alters surface tensions by applying voltage. This method has advantages of fast response time and low power consumption. However, it is challenging to fabricate a high fill factor liquid lens array and operate three dimensional images which demand high diopter. This study describes a hybrid structure lens array which has not only a liquid lens array but a solid lens array. A concave-shape lens array is unavoidable when using only the liquid lens array and some voltages are needed to make the lens flat. By placing the solid lens array on the liquid lens array, initial diopter can be positive. To fabricate the hybrid structure lens array, a conventional lithographic process in semiconductor manufacturing is needed. A negative photoresist SU-8 was used as chamber master molds. PDMS and UV adhesive replica molding are done sequentially. Two immiscible liquids, DI water and dodecane, are injected in the fabricated chamber, followed by sealing. The fabricated structure has a 20 by 20 pattern of cylindrical shaped circle array and the aperture size of each lens is 1mm. The thickness of the overall hybrid structure is about 2.8mm. Hybrid structure lens array has many advantages. Solid lens array has almost 100% fill factor and allow high efficiency. Diopter can be increased by more than 200 and negative diopter can be shifted to the positive region. This experiment showed several properties of the hybrid structure and demonstrated its superiority.

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

Over the last ten years, photonic band gap (PBG) theory and technology have become an important area of research because of the numerous possible applications ranging from high-efficiency laser diodes to optical circuitry. This research concentrates on reducing the length scale in the fabrication of layered photonic band gap structures and developing procedures to improve processing consistency. Various procedures and materials have been used in the fabrication of layered PBG structures. This research focused on an economical micro transfer molding approach to create the final PBG structure. A poly dimethylsiloxane (PDMS) rubber mold was created from a silicon substrate. Itmore » was filled with epoxy and built layer-by-layer to create a 3-D epoxy structure. This structure was infiltrated with nanoparticle titania or a titania sol-gel, then fired to remove the polymer mold, leaving a monolithic ceramic inverse of the epoxy structure. The final result was a lattice of titania rolds that resembles a face-centered tetragonal structure. The original intent of this research was to miniaturize this process to a bar size small enough to create a photonic band gap for wavelengths of visible electro-magnetic radiation. The factor limiting progress was the absence of a silicon master mold of small enough dimensions. The Iowa State Microelectronics Research Center fabricated samples with periodicities of 2.5 and 1.0 microns with the existing technology, but a sample was needed on the order of 0.3 microns or less. A 0.4 micron sample was received from Sandia National Laboratory, which was made through an electron beam lithography process, but it contained several defects. The results of the work are primarily from the 2.5 and 1.0 micron samples. Most of the work focused on changing processing variables in order to optimize the infiltration procedure for the best results. Several critical parameters were identified, ranging from the ambient conditions to the specifics of the procedure. It is believed that most critical for fabrication of high quality samples is control of the temperature of the sample during and after infiltration, and the rate and amount of time spent applying epoxy to the PDMS.« less

Anatomic Mesenchymal Stem Cell-Based Engineered Cartilage Constructs for Biologic Total Joint Replacement

PubMed Central

Saxena, Vishal; Kim, Minwook; Keah, Niobra M.; Neuwirth, Alexander L.; Stoeckl, Brendan D.; Bickard, Kevin; Restle, David J.; Salowe, Rebecca; Wang, Margaret Ye; Steinberg, David R.

2016-01-01

Cartilage has a poor healing response, and few viable options exist for repair of extensive damage. Hyaluronic acid (HA) hydrogels seeded with mesenchymal stem cells (MSCs) polymerized through UV crosslinking can generate functional tissue, but this crosslinking is not compatible with indirect rapid prototyping utilizing opaque anatomic molds. Methacrylate-modified polymers can also be chemically crosslinked in a cytocompatible manner using ammonium persulfate (APS) and N,N,N′,N′-tetramethylethylenediamine (TEMED). The objectives of this study were to (1) compare APS/TEMED crosslinking with UV crosslinking in terms of functional maturation of MSC-seeded HA hydrogels; (2) generate an anatomic mold of a complex joint surface through rapid prototyping; and (3) grow anatomic MSC-seeded HA hydrogel constructs using this alternative crosslinking method. Juvenile bovine MSCs were suspended in methacrylated HA (MeHA) and crosslinked either through UV polymerization or chemically with APS/TEMED to generate cylindrical constructs. Minipig porcine femoral heads were imaged using microCT, and anatomic negative molds were generated by three-dimensional printing using fused deposition modeling. Molded HA constructs were produced using the APS/TEMED method. All constructs were cultured for up to 12 weeks in a chemically defined medium supplemented with TGF-β3 and characterized by mechanical testing, biochemical assays, and histologic analysis. Both UV- and APS/TEMED-polymerized constructs showed increasing mechanical properties and robust proteoglycan and collagen deposition over time. At 12 weeks, APS/TEMED-polymerized constructs had higher equilibrium and dynamic moduli than UV-polymerized constructs, with no differences in proteoglycan or collagen content. Molded HA constructs retained their hemispherical shape in culture and demonstrated increasing mechanical properties and proteoglycan and collagen deposition, especially at the edges compared to the center of these larger constructs. Immunohistochemistry showed abundant collagen type II staining and little collagen type I staining. APS/TEMED crosslinking can be used to produce MSC-seeded HA-based neocartilage and can be used in combination with rapid prototyping techniques to generate anatomic MSC-seeded HA constructs for use in filling large and anatomically complex chondral defects or for biologic joint replacement. PMID:26871863

Studies on the injection molding of polyvinyl chloride: Analysis of viscous heating and degradation in simple geometries

NASA Astrophysics Data System (ADS)

Garcia, Jose Luis

2000-10-01

In injection molding processes, computer aided engineering (CAE) allows processors to evaluate different process parameters in order to achieve complete filling of a cavity and, in some cases, it predicts shrinkage and warpage. However, because commercial computational packages are used to design complex geometries, detail in the thickness direction is limited. Approximations in the thickness direction lead to the solution of a 2½-D problem instead of a 3-D problem. These simplifications drastically reduce computational times and memory requirements. However, these approximations hinder the ability to predict thermal and/or mechanical degradation. The goal of this study was to determine the degree of degradation during PVC injection molding and to compare the results with a computational model. Instead of analyzing degradation in complex geometries, the computational analysis and injection molding trials were performed on typical sections found in complex geometries, such as flow in a tube, flow in a rectangular channel, and radial flow. This simplification reduces the flow problem to a 1-D problem and allows one to develop a computational model with a higher level of detail in the thickness direction, essential for the determination of degradation. Two different geometries were examined in this study: a spiral mold, in order to approximate the rectangular channel, and a center gated plate for the radial flow. Injection speed, melt temperature, and shot size were varied. Parts varying in degree of degradation, from no to severe degradation, were produced to determine possible transition points. Furthermore, two different PVC materials were used, low and high viscosity, M3800 and M4200, respectively (The Geon Company, Avon Lake, OH), to correlate the degree of degradation with the viscous heating observed during injection. It was found that a good agreement between experimental and computational results was obtained only if the reaction was assumed to be more thermally sensitive than found in literature. The results from this study show that, during injection, the activation energy for degradation was 65 kcal/mol, compared to 17--30 kcal/mol found in literature for quiescent systems.

Three-Dimensional Flow Behavior Inside the Submerged Entry Nozzle

NASA Astrophysics Data System (ADS)

Real-Ramirez, Cesar Augusto; Carvajal-Mariscal, Ignacio; Sanchez-Silva, Florencio; Cervantes-de-la-Torre, Francisco; Diaz-Montes, Jesus; Gonzalez-Trejo, Jesus

2018-05-01

According to various authors, the surface quality of steel depends on the dynamic conditions that occur within the continuous casting mold's upper region. The meniscus, found in that upper region, is where the solidification process begins. The liquid steel is distributed into the mold through a submerged entry nozzle (SEN). In this paper, the dynamic behavior inside the SEN is analyzed by means of physical experiments and numerical simulations. The particle imaging velocimetry technique was used to obtain the vector field in different planes and three-dimensional flow patterns inside the SEN volume. Moreover, large eddy simulation was performed, and the turbulence model results were used to understand the nonlinear flow pattern inside the SEN. Using scaled physical and numerical models, quasi-periodic behavior was observed due to the interaction of two three-dimensional vortices that move inside the SEN lower region located between the exit ports of the nozzle.

Metallic Fuel Casting Development and Parameter Optimization Simulations

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

R.S. Fielding; J. Crapps; C. Unal

One of the advantages of metallic fuel is the abilility to cast the fuel slugs to near net shape with little additional processing. However, the high aspect ratio of the fuel is not ideal for casting. EBR-II fuel was cast using counter gravity injection casting (CGIC) but, concerns have been raised concerning the feasibility of this process for americium bearing alloys. The Fuel Cycle Research and Development program has begun developing gravity casting techniques suitable for fuel production. Compared to CGIC gravity casting does not require a large heel that then is recycled, does not require application of a vacuummore » during melting, and is conducive to re-usable molds. Development has included fabrication of two separate benchscale, approximately 300 grams, systems. To shorten development time computer simulations have been used to ensure mold and crucible designs are feasible and to identify which fluid properties most affect casting behavior and therefore require more characterization.« less

Study of the Mechanism of Liquid Slag Infiltration for Lubrication in Slab Continuous Casting

NASA Astrophysics Data System (ADS)

Zhang, Shaoda; Wang, Qiangqiang; He, Shengping; Wang, Qian

2018-04-01

Consistent and uniform lubrication of the solidifying shell, especially in the meniscus, is crucial for the smooth continuous casting operation and production of strands free of surface defects. Thus, the current study established a coupled model to study the inflow behavior of liquid slag to the mold-strand channel, taking the solidification of steel and slag and the periodic oscillation of mold into account. The difficulties and solutions for the simulation were described in detail. The predicted profiles of the slag rim and initial shell were in good agreement with the reports. The main results indicated that liquid slag could be squeezed out and back into the slag pool in a negative strip period while a large amount of liquid slag could infiltrate into the mold-strand channel. Thus, the amount of slag consumed in the negative strip period was relatively small compared with that in the positive strip period. The predicted variation of slag consumption during mold oscillation was periodic, and the average value was 0.274 kg/m2, which agreed well with the slag consumption in industrial practice. The current model can predict and optimize the oscillation parameters aiming at stable lubrication conditions.

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.

3D integrated HYDRA simulations of hohlraums including fill tubes

NASA Astrophysics Data System (ADS)

Marinak, M. M.; Milovich, J.; Hammel, B. A.; Macphee, A. G.; Smalyuk, V. A.; Kerbel, G. D.; Sepke, S.; Patel, M. V.

2017-10-01

Measurements of fill tube perturbations from hydro growth radiography (HGR) experiments on the National Ignition Facility show spoke perturbations in the ablator radiating from the base of the tube. These correspond to the shadow of the 10 μm diameter glass fill tube cast by hot spots at early time. We present 3D integrated HYDRA simulations of these experiments which include the fill tube. Meshing techniques are described which were employed to resolve the fill tube structure and associated perturbations in the simulations. We examine the extent to which the specific illumination geometry necessary to accommodate a backlighter in the HGR experiment contributes to the spoke pattern. Simulations presented include high resolution calculations run on the Trinity machine operated by the Alliance for Computing at Extreme Scale (ACES) partnership. This work was performed under the auspices of the Lawrence Livermore National Security, LLC, (LLNS) under Contract No. DE-AC52-07NA27344.

Modeling and Fault Simulation of Propellant Filling System

NASA Astrophysics Data System (ADS)

Jiang, Yunchun; Liu, Weidong; Hou, Xiaobo

2012-05-01

Propellant filling system is one of the key ground plants in launching site of rocket that use liquid propellant. There is an urgent demand for ensuring and improving its reliability and safety, and there is no doubt that Failure Mode Effect Analysis (FMEA) is a good approach to meet it. Driven by the request to get more fault information for FMEA, and because of the high expense of propellant filling, in this paper, the working process of the propellant filling system in fault condition was studied by simulating based on AMESim. Firstly, based on analyzing its structure and function, the filling system was modular decomposed, and the mathematic models of every module were given, based on which the whole filling system was modeled in AMESim. Secondly, a general method of fault injecting into dynamic system was proposed, and as an example, two typical faults - leakage and blockage - were injected into the model of filling system, based on which one can get two fault models in AMESim. After that, fault simulation was processed and the dynamic characteristics of several key parameters were analyzed under fault conditions. The results show that the model can simulate effectively the two faults, and can be used to provide guidance for the filling system maintain and amelioration.

Demonstration of UV LED versatility when paired with molded UV transmitting glass optics to produce unique irradiance patterns

NASA Astrophysics Data System (ADS)

Jasenak, Brian

2017-02-01

Ultraviolet light-emitting diode (UV LED) adoption is accelerating; they are being used in new applications such as UV curing, germicidal irradiation, nondestructive testing, and forensic analysis. In many of these applications, it is critically important to produce a uniform light distribution and consistent surface irradiance. Flat panes of fused quartz, silica, or glass are commonly used to cover and protect UV LED arrays. However, they don't offer the advantages of an optical lens design. An investigation was conducted to determine the effect of a secondary glass optic on the uniformity of the light distribution and irradiance. Glass optics capable of transmitting UV-A, UV-B, and UV-C wavelengths can improve light distribution, uniformity, and intensity. In this work, two simulation studies were created to illustrate distinct irradiance patterns desirable for potential real world applications. The first study investigates the use of a multi-UV LED array and optic to create a uniform irradiance pattern on the flat two dimensional (2D) target surface. The uniformity was improved by designing both the LED array and molded optic to produce a homogenous pattern. The second study investigated the use of an LED light source and molded optic to improve the light uniformity on the inside of a canister. The case study illustrates the requirements for careful selection of LED based on light distribution and subsequent design of optics. The optic utilizes total internal reflection to create optimized light distribution. The combination of the LED and molded optic showed significant improvement in uniformity on the inner surface of the canister. The simulations illustrate how the application of optics can significantly improve UV light distribution which can be critical in applications such as UV curing and sterilization.

Verification of a three-dimensional resin transfer molding process simulation model

NASA Technical Reports Server (NTRS)

Fingerson, John C.; Loos, Alfred C.; Dexter, H. Benson

1995-01-01

Experimental evidence was obtained to complete the verification of the parameters needed for input to a three-dimensional finite element model simulating the resin flow and cure through an orthotropic fabric preform. The material characterizations completed include resin kinetics and viscosity models, as well as preform permeability and compaction models. The steady-state and advancing front permeability measurement methods are compared. The results indicate that both methods yield similar permeabilities for a plain weave, bi-axial fiberglass fabric. Also, a method to determine principal directions and permeabilities is discussed and results are shown for a multi-axial warp knit preform. The flow of resin through a blade-stiffened preform was modeled and experiments were completed to verify the results. The predicted inlet pressure was approximately 65% of the measured value. A parametric study was performed to explain differences in measured and predicted flow front advancement and inlet pressures. Furthermore, PR-500 epoxy resin/IM7 8HS carbon fabric flat panels were fabricated by the Resin Transfer Molding process. Tests were completed utilizing both perimeter injection and center-port injection as resin inlet boundary conditions. The mold was instrumented with FDEMS sensors, pressure transducers, and thermocouples to monitor the process conditions. Results include a comparison of predicted and measured inlet pressures and flow front position. For the perimeter injection case, the measured inlet pressure and flow front results compared well to the predicted results. The results of the center-port injection case showed that the predicted inlet pressure was approximately 50% of the measured inlet pressure. Also, measured flow front position data did not agree well with the predicted results. Possible reasons for error include fiber deformation at the resin inlet and a lag in FDEMS sensor wet-out due to low mold pressures.

Numerical simulation of stress distribution in Inconel 718 components realized by metal injection molding during supercritical debinding

NASA Astrophysics Data System (ADS)

Agne, Aboubakry; Barrière, Thierry

2018-05-01

Metal injection molding (MIM) is a process combining advantages of thermoplastic injection molding and powder metallurgy process in order to manufacture components with complex and near net-shape geometries. The debinding of a green component can be performed in two steps, first by using solvent debinding in order to extract the organic part of the binder and then by thermal degradation of the rest of the binder. A shorter and innovative method for extracting an organic binder involves the use of supercritical fluid instead of a regular solvent. The debinding via a supercritical fluid was recently investigated to extract organic binders contained in components obtained by Metal Injection Molding. It consists to put the component in an enclosure subjected to high pressure and temperature. The supercritical fluid has various properties depending on these two conditions, e.g., density and viscosity. The high-pressure combined with the high temperature during the process affect the component structure. Three mechanisms contributing to the deformation of the component can been differentiated: thermal expansion, binder extraction and supercritical fluid effect on the outer surfaces of the component. If one supposes that, the deformation due to binder extraction is negligible, thermal expansion and the fluid effect are probably the main mechanisms that can produce several stress. A finite-element model, which couples fluid-structures interaction and structural mechanics, has been developed and performed on the Comsol Multiphysics® finite-element software platform allowed to estimate the stress distribution during the supercritical debinding of MIM component composed of Inconel 718 powders, polypropylene, polyethylene glycol and stearic acid as binder. The proposed numerical simulations allow the estimation of the stress distribution with respect to the processing parameters for MIM components during the supercritical debinding process using a stationary solver.

The mold integration method for the calculation of the crystal-fluid interfacial free energy from simulations

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

Espinosa, J. R.; Vega, C.; Sanz, E.

2014-10-07

The interfacial free energy between a crystal and a fluid, γ{sub cf}, is a highly relevant parameter in phenomena such as wetting or crystal nucleation and growth. Due to the difficulty of measuring γ{sub cf} experimentally, computer simulations are often used to study the crystal-fluid interface. Here, we present a novel simulation methodology for the calculation of γ{sub cf}. The methodology consists in using a mold composed of potential energy wells to induce the formation of a crystal slab in the fluid at coexistence conditions. This induction is done along a reversible pathway along which the free energy difference betweenmore » the initial and the final states is obtained by means of thermodynamic integration. The structure of the mold is given by that of the crystal lattice planes, which allows to easily obtain the free energy for different crystal orientations. The method is validated by calculating γ{sub cf} for previously studied systems, namely, the hard spheres and the Lennard-Jones systems. Our results for the latter show that the method is accurate enough to deal with the anisotropy of γ{sub cf} with respect to the crystal orientation. We also calculate γ{sub cf} for a recently proposed continuous version of the hard sphere potential and obtain the same γ{sub cf} as for the pure hard sphere system. The method can be implemented both in Monte Carlo and Molecular Dynamics. In fact, we show that it can be easily used in combination with the popular Molecular Dynamics package GROMACS.« less

Evaluation of effect of different disposable infection control barriers on light intensity of light-curing unit and microhardness of composite - An in vitro study.

PubMed

Khode, Rajiv Tarachand; Shenoi, Pratima Ramakrishna; Kubde, Rajesh R; Makade, Chetana S; Wadekar, Kanchan D; Khode, Priyanka Tarachand

2017-01-01

This study evaluated effect of infection control barriers on light intensity (LI) of light-curing unit (LCU) and microhardness of composite. Four different disposable barriers ( n = 30) were tested against the control. LI for each barrier was measured with Lux meter. One hundred and fifty Teflon molds were equally divided into five groups of thirty each. Composite was filled in bulk in these molds and cured without and with barrier. Microhardness was evaluated on top and bottom surface of composite specimen with microhardness testing machine and hardness ratio (HR) was derived. One-way analysis of variance, Tukey's honestly significant difference test, and paired t -test using SPSS version 18 software. All barriers had significantly reduced the baseline LI of LCU ( P < 0.0001), but only Cure Elastic Steri-Shield and latex cut glove pieces (LCGP) significantly reduced the microhardness of the composite ( P < 0.05). However, HR determined inadequate curing only with LCGP. Although entire tested barrier significantly reduced the LI; none, except LCGP markedly affected the degree of cure of the composite.

An improved method for field extraction and laboratory analysis of large, intact soil cores

USGS Publications Warehouse

Tindall, J.A.; Hemmen, K.; Dowd, J.F.

1992-01-01

Various methods have been proposed for the extraction of large, undisturbed soil cores and for subsequent analysis of fluid movement within the cores. The major problems associated with these methods are expense, cumbersome field extraction, and inadequate simulation of unsaturated flow conditions. A field and laboratory procedure is presented that is economical, convenient, and simulates unsaturated and saturated flow without interface flow problems and can be used on a variety of soil types. In the field, a stainless steel core barrel is hydraulically pressed into the soil (30-cm diam. and 38 cm high), the barrel and core are extracted from the soil, and after the barrel is removed from the core, the core is then wrapped securely with flexible sheet metal and a stainless mesh screen is attached to the bottom of the core for support. In the laboratory the soil core is set atop a porous ceramic plate over which a soil-diatomaceous earth slurry has been poured to assure good contact between plate and core. A cardboard cylinder (mold) is fastened around the core and the empty space filled with paraffin wax. Soil cores were tested under saturated and unsaturated conditions using a hanging water column for potentials ???0. Breakthrough curves indicated that no interface flow occurred along the edge of the core. This procedure proved to be reliable for field extraction of large, intact soil cores and for laboratory analysis of solute transport.

Saturation measurement accuracy in clinical near-infrared cerebral oximeters with a 3D-printed channel array phantom

NASA Astrophysics Data System (ADS)

Afshari, Ali; Ghassemi, Pejhman; Halprin, Molly; Lin, Jonathan; Weininger, Sandy; Gandjbakhche, Amir H.; Wang, Jianting; Pfefer, Joshua

2018-02-01

Clinical cerebral oximeters based on near-infrared spectroscopy (NIRS) are a commonly used, non-invasive tool for intraoperative monitoring of hemoglobin saturation. Research to verify performance of cerebral oximeters in human subject trials has shown differences between commercially available devices. Test methods based on tissue-simulating phantoms have been proposed to augment clinical findings. While prior studies have focused on liquid phantoms, this work is aimed at developing methods based on solid polymer phantoms that are stable. Specifically, we have designed and fabricated a neonatal/pediatric head mimicking layered phantoms based on a 3D-printed cerebral matrix incorporating an array of vessel-simulating linear channels. Superficial layers incorporating homogeneous molded polydimethylsiloxane (PDMS) slabs were fabricated to represent CSF, scalp and skull regions. The cerebral matrix was filled with bovine blood desaturated with sodium dithionite to achieve oxygenation levels across the 40-90% range. Measurements were performed with a commercially available cerebral oximeter using two probes with different illumination-collection geometries, as designed for neonatal and pediatric patients. Reference measurements of samples were performed with a CO-oximeter before injection and after extraction. Results from applied cerebral oximeters indicate a strong sensitivity to the thickness of the superficial layer of the phantom. Better correlation with the reference CO-oximeter results were obtained in the superficial layer thickness of 0.8-2.5 mm range. Channel array phantoms with modular superficial layers represent a promising approach for performance testing of NIRS-based cerebral oximeters.

Identification of a thermo-elasto-viscoplastic behavior law for the simulation of thermoforming of high impact polystyrene

NASA Astrophysics Data System (ADS)

Atmani, O.; Abbès, B.; Abbès, F.; Li, Y. M.; Batkam, S.

2018-05-01

Thermoforming of high impact polystyrene sheets (HIPS) requires technical knowledge on material behavior, mold type, mold material, and process variables. Accurate thermoforming simulations are needed in the optimization process. Determining the behavior of the material under thermoforming conditions is one of the key parameters for an accurate simulation. The aim of this work is to identify the thermomechanical behavior of HIPS in the thermoforming conditions. HIPS behavior is highly dependent on temperature and strain rate. In order to reproduce the behavior of such material, a thermo-elasto-viscoplastic constitutive law was implement in the finite element code ABAQUS. The proposed model parameters are considered as thermo-dependent. The strain-dependence effect is introduced using Prony series. Tensile tests were carried out at different temperatures and strain rates. The material parameters were then identified using a NSGA-II algorithm. To validate the rheological model, experimental blowing tests were carried out on a thermoforming pilot machine. To compare the numerical results with the experimental ones the thickness distribution and the bubble shape were investigated.

Effects of simulated ice on the performance of price type-AA current meter rotors

USGS Publications Warehouse

Fulford, Janice M.

1994-01-01

Slush ice readily adheres to the standard metal rotor of the winter Price type-AA current meter and affects the ability of the meter to measure the flow velocity accurately. Tests conducted at the U.S. Geological Survey Hydraulics Laboratory at Stennis Space Center, Mississippi, attempt to quantify the effects of slush ice on the performance of standard Price type-AA meter metal rotors. Test data obtained for rotors filled with simulated slush are compared with data for solid-cup polymer and standard hollow-cup metal rotors. Partial filling of the cups only marginally affects rotor performance at velocities greater than 15.24 centimeters per second. However, when cups are filled or over-filled with simulated slush, rotor performance is noticeably affected. Errors associated with slush over-filling and filling of cups are also significant when flows are angled vertically.

Method for molding threads in graphite panels

DOEpatents

Short, William W.; Spencer, Cecil

1994-01-01

A graphite panel (10) with a hole (11) having a damaged thread (12) is repaired by drilling the hole (11) to remove all of the thread and make a new hole (13) of larger diameter. A bolt (14) with a lubricated thread (17) is placed in the new hole (13) and the hole (13) is packed with graphite cement (16) to fill the hole and the thread on the bolt. The graphite cement (16) is cured, and the bolt is unscrewed therefrom to leave a thread (20) in the cement (16) which is at least as strong as that of the original thread (12).

Pitch-based carbon foam heat sink with phase change material

DOEpatents

Klett, James W.; Burchell, Timothy D.

2004-08-24

A process for producing a carbon foam heat sink is disclosed which obviates the need for conventional oxidative stabilization. The process employs mesophase or isotropic pitch and a simplified process using a single mold. The foam has a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts. The foam material can be made into a composite which is useful in high temperature sandwich panels for both thermal and structural applications. The foam is encased and filled with a phase change material to provide a very efficient heat sink device.

Pitch-based carbon foam heat sink with phase change material

DOEpatents

Klett, James W.; Burchell, Timothy D.

2007-01-02

A process for producing a carbon foam heat sink is disclosed which obviates the need for conventional oxidative stabilization. The process employs mesophase or isotropic pitch and a simplified process using a single mold. The foam has a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts. The foam material can be made into a composite which is useful in high temperature sandwich panels for both thermal and structural applications. The foam is encased and filled with a phase change material to provide a very efficient heat sink device.

Pitch-based carbon foam heat sink with phase change material

DOEpatents

Klett, James W.; Burchell, Timothy D.

2006-03-21

A process for producing a carbon foam heat sink is disclosed which obviates the need for conventional oxidative stabilization. The process employs mesophase or isotropic pitch and a simplified process using a single mold. The foam has a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts. The foam material can be made into a composite which is useful in high temperature sandwich panels for both thermal and structural applications. The foam is encased and filled with a phase change material to provide a very efficient heat sink device.

Pitch-based carbon foam heat sink with phase change material

DOEpatents

Klett, James W.; Burchell, Timothy D.

2002-01-01

A process for producing a carbon foam heat sink is disclosed which obviates the need for conventional oxidative stabilization. The process employs mesophase or isotropic pitch and a simplified process using a single mold. The foam has a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts. The foam material can be made into a composite which is useful in high temperature sandwich panels for both thermal and structural applications. The foam is encased and filled with a phase change material to provide a very efficient heat sink device.

Pitch-based carbon foam heat sink with phase change material

DOEpatents

Klett, James W.; Burchell, Timothy D.

2000-01-01

A process for producing a carbon foam heat sink is disclosed which obviates the need for conventional oxidative stabilization. The process employs mesophase or isotropic pitch and a simplified process using a single mold. The foam has a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts. The foam material can be made into a composite which is useful in high temperature sandwich panels for both thermal and structural applications. The foam is encased and filled with a phase change material to provide a very efficient heat sink device.

Pitch-based carbon foam heat sink with phase change material

DOEpatents

Klett, James W.; Burchell, Timothy D.

2007-01-23

A process for producing a carbon foam heat sink is disclosed which obviates the need for conventional oxidative stabilization. The process employs mesophase or isotropic pitch and a simplified process using a single mold. The foam has a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts. The foam material can be made into a composite which is useful in high temperature sandwich panels for both thermal and structural applications. The foam is encased and filled with a phase change material to provide a very efficient heat sink device.

Development of 3D out-of-plane SU-8 microlenses using modified micromolding in capillaries (MIMIC) technology

NASA Astrophysics Data System (ADS)

Llobera, A.; Wilke, R.; Johnson, D. W.; Büttgenbach, S.

2006-04-01

This paper describes a modification of the standard MIMIC technology, solving its main drawbacks, to define arrays of spherical or ellipsoidal microlenses. Perfectly symmetrical meniscuses have been obtained by using a XP SU-8 NO-2 layer beneath the PDMS mold. Moreover, the photostructurable properties of this polymer allow obtaining self-alignment structures for adequate fiber optics positioning. Microchannels ended with these meniscuses have been filled with standard SU-8 to obtain 3D microlenses. Agreement between theory and experimental results allows confirming the validity of the proposed technology.

In-situ stabilization of radioactive zirconium swarf

DOEpatents

Hess, C.C.

1999-08-31

The method for treating ignitable cutting swarf in accordance with the present invention involves collecting cutting swarf in a casting mold underwater and injecting a binder mixture comprising vinyl ester styrene into the vessel to fill void volume; and form a mixture comprising swarf and vinyl ester styrene; and curing the mixture. The method is especially useful for stabilizing the ignitable characteristics of radioactive zirconium cutting swarf, and can be used to solidify zirconium swarf, or other ignitable finely divided material, underwater. The process could also be performed out of water with other particulate wastes. 6 figs.

Effect of Flow Rate Controller on Liquid Steel Flow in Continuous Casting Mold using Numerical Modeling

NASA Astrophysics Data System (ADS)

Gursoy, Kadir Ali; Yavuz, Mehmet Metin

2014-11-01

In continuous casting operation of steel, the flow through tundish to the mold can be controlled by different flow rate control systems including stopper rod and slide-gate. Ladle changes in continuous casting machines result in liquid steel level changes in tundishes. During this transient event of production, the flow rate controller opening is increased to reduce the pressure drop across the opening which helps to keep the mass flow rate at the desired level for the reduced liquid steel level in tundish. In the present study, computational fluid dynamic (CFD) models are developed to investigate the effect of flow rate controller on mold flow structure, and particularly to understand the effect of flow controller opening on meniscus flow. First, a detailed validation of the CFD models is conducted using available experimental data and the performances of different turbulence models are compared. Then, the constant throughput casting operations for different flow rate controller openings are simulated to quantify the opening effect on meniscus region. The results indicate that the meniscus velocities are significantly affected by the flow rate controller and its opening level. The steady state operations, specified as constant throughput casting, do not provide the same mold flow if the controller opening is altered. Thus, for quality and castability purposes, adjusting the flow controller opening to obtain the fixed mold flow structure is proposed. Supported by Middle East Technical University (METU) BAP (Scientific Research Projects) Coordination.

Tissue-Simulating Gel For Medical Research

NASA Technical Reports Server (NTRS)

Companion, John A.

1992-01-01

Nonhardening, translucent gel more nearly simulates soft human or animal tissue. Modified to be softer or harder by altering proportions of ingredients. Fillers added to change electrical, mechanical, heat-conducting, or sound-conducting/scattering properties. Molded to any desired shape and has sufficient mechanical strength to maintain shape without supporting shell. Because of its thermal stability, gel especially useful for investigation of hyperthermia as treatment for cancer.

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.

Side-entry laser-beam zigzag irradiation of multiple channels in a microchip for simultaneous and highly sensitive detection of fluorescent analytes.

PubMed

Anazawa, Takashi; Yokoi, Takahide; Uchiho, Yuichi

2015-09-01

A simple and highly sensitive technique for laser-induced fluorescence detection on multiple channels in a plastic microchip was developed, and its effectiveness was demonstrated by laser-beam ray-trace simulations and experiments. In the microchip, with refractive index nC, A channels and B channels are arrayed alternately and respectively filled with materials with refractive indexes nA for electrophoresis analysis and nB for laser-beam control. It was shown that a laser beam entering from the side of the channel array traveled straight and irradiated all A channels simultaneously and effectively because the refractive actions by the A and B channels were counterbalanced according to the condition nA < nC < nB. This technique is thus called "side-entry laser-beam zigzag irradiation". As a demonstration of the technique, when nC = 1.53, nA = 1.41, nB = 1.66, and the cross sections of both eight A channels and seven B channels were the same isosceles trapezoids with 97° base angle, laser-beam irradiation efficiency on the eight A channels by the simulations was 89% on average and coefficient of variation was 4.4%. These results are far superior to those achieved by other conventional methods such as laser-beam expansion and scanning. Furthermore, fluorescence intensity on the eight A channels determined by the experiments agreed well with that determined by the simulations. Therefore, highly sensitive and uniform fluorescence detection on eight A channels was achieved. It is also possible to fabricate the microchips at low cost by plastic-injection molding and to make a simple and compact detection system, thereby promoting actual use of the proposed side-entry laser-beam zigzag irradiation in various fields.

Analysis of Monolith Cores from an Engineering Scale Demonstration of a Prospective Cast Stone Process

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

Crawford, C. L.; Cozzi, A. D.; Hill, K. A.

2016-06-01

The primary disposition path of Low Activity Waste (LAW) at the DOE Hanford Site is vitrification. A cementitious waste form is one of the alternatives being considered for the supplemental immobilization of the LAW that will not be treated by the primary vitrification facility. Washington River Protection Solutions (WRPS) has been directed to generate and collect data on cementitious or pozzolanic waste forms such as Cast Stone. This report documents the coring and leach testing of monolithic samples cored from an engineering-scale demonstration (ES Demo) with non-radioactive simulants. The ES Demo was performed at SRNL in October of 2013 usingmore » the Scaled Continuous Processing Facility (SCPF) to fill an 8.5 ft. diameter x 3.25 ft. high container with simulated Cast Stone grout. The Cast Stone formulation was chosen from the previous screening tests. Legacy salt solution from previous Hanford salt waste testing was adjusted to correspond to the average LAW composition generated from the Hanford Tank Waste Operation Simulator (HTWOS). The dry blend materials, ordinary portland cement (OPC), Class F fly ash, and ground granulated blast furnace slag (GGBFS or BFS), were obtained from Lafarge North America in Pasco, WA. In 2014 core samples originally obtained approximately six months after filling the ES Demo were tested along with bench scale molded samples that were collected during the original pour. A latter set of core samples were obtained in late March of 2015, eighteen months after completion of the original ES Demo. Core samples were obtained using a 2” diameter x 11” long coring bit. The ES Demo was sampled in three different regions consisting of an outer ring, a middle ring and an inner core zone. Cores from these three lateral zones were further segregated into upper, middle and lower vertical segments. Monolithic core samples were tested using the Environmental Protection Agency (EPA) Method 1315, which is designed to provide mass transfer rates (release rates) of inorganic analytes contained in monolithic material under diffusion controlled release conditions as a function of leaching time. Compressive strength measurements and drying tests were also performed on the 2015 samples. Leachability indices reported are based on analyte concentrations determined from dissolution of the dried samples.« less

Space-filling designs for computer experiments: A review

DOE PAGES

Joseph, V. Roshan

2016-01-29

Improving the quality of a product/process using a computer simulator is a much less expensive option than the real physical testing. However, simulation using computationally intensive computer models can be time consuming and therefore, directly doing the optimization on the computer simulator can be infeasible. Experimental design and statistical modeling techniques can be used for overcoming this problem. This article reviews experimental designs known as space-filling designs that are suitable for computer simulations. In the review, a special emphasis is given for a recently developed space-filling design called maximum projection design. Furthermore, its advantages are illustrated using a simulation conductedmore » for optimizing a milling process.« less

Space-filling designs for computer experiments: A review

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

Joseph, V. Roshan

Improving the quality of a product/process using a computer simulator is a much less expensive option than the real physical testing. However, simulation using computationally intensive computer models can be time consuming and therefore, directly doing the optimization on the computer simulator can be infeasible. Experimental design and statistical modeling techniques can be used for overcoming this problem. This article reviews experimental designs known as space-filling designs that are suitable for computer simulations. In the review, a special emphasis is given for a recently developed space-filling design called maximum projection design. Furthermore, its advantages are illustrated using a simulation conductedmore » for optimizing a milling process.« less

Effects of Fibers on Color and Translucency Changes of Bulk-Fill and Anterior Composites after Accelerated Aging

PubMed Central

Güven, Mehmet Esad

2018-01-01

The aim of this study was to determine the effects of glass and polyethylene fibers on the color and translucency change of bulk-fill and anterior composites before and after artificial accelerated aging (AAA). Two types of teflon molds were used to fabricate samples which were 13 mm in diameter and, respectively, 2 mm and 4 mm in height. Polyethylene fiber (PF) and glass fiber (GF) were incorporated in the middle of the composite samples. Color and translucency changes of each composite were evaluated before and after AAA with spectrophotometer. ANOVA and Tukey's HSD post hoc statistical analysis were used at a significance level of 0.05. Before AAA (for anterior composites), there were no significant differences in L* and b* parameters among the three groups (p > 0.05); there were no significant differences in L* parameter between PF and GF groups or in TP between GF and control groups (p > 0.05) (for bulk-fill composites). After AAA, there were no significant differences in L* parameter between GF and control groups, in a* parameter between PF and control groups, in b* parameter among all groups, or in TP parameter between GF and control groups (p > 0.05). Fiber reinforcement led to color and TP change in both anterior and bulk-fill resin composites. PMID:29850499

Performance of an ablator for Space Shuttle inorbit repair in an arc-plasma airstream

NASA Technical Reports Server (NTRS)

Stewart, D. A.; Cuellar, M.; Flowers, O.

1983-01-01

An ablator patch material performed well in an arc plasma environment simulating nominal Earth entry conditions for the Space Shuttle. Ablation tests using vacuum molded cones provided data to optimize the formulation of a two part polymer system for application under space conditions. The blunt cones were made using a Teflon mold and a state of the art caulking gun. Char stability of formulations with various amounts of catalyst and diluent were investigated. The char was found to be unstable in formulations with low amounts of catalyst and high amounts of diluent. The best polymer system determined by these tests was evaluated using a half tile patch in a multiple High Temperature Reusable surface Insulation tile model. It was demonstrated that this ablator could be applied in a space environment using a state of the art caulking gun, would maintain the outer mold line of the thermal protection system during entry, and would keep the bond line temperature at the aluminum tile interface below the design limit.

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

Smith, F. G.; Daniels, E. J.

This report summarizes an assessment conducted by Environmental Technologies Alternatives, Inc., under a subcontract to Argonne National Laboratory. The project was conducted in two phases. An assessment of alternative technologies for recycling of prompt non-tire rubber was conducted in the first phase, and an experimental program focusing on a new technology called the catalytic Regeneration Process offered the greatest opportunity for recovery of high-value recyclable rubber material. An experimental and large-scale test program was undertaken to further delineate the economic potential as an essential step leading to commercial deployment and to determine the course of continued development of the technologymore » by the private sector. The experimental program defined process-operating conditions for the technology and verified the degree of devulcanisation achievable for two rubber compounds: ethylene-propylene-nonconjugated-diene monomer (EPDM) and neoprene. To determine product acceptance, samples of devulcanized EPDM and neoprene were prepared and used in factory trials for the production of automotive moldings (EPDM) and fiber-filled belting (neoprene). The factory trials indicated that the physical properties of the products were acceptable in both cases. The appearance of molded and calendared surface finishes was acceptable, while that of extruded finishes was unsatisfactory. The fiber-filled neoprene belting application offers the greatest economic potential. Process costs were estimated at $0.34/lb for neoprene waste rubber relative to a value of $0.57/lb. The results of the experimental program led to the decision to continue development of this technology is being planned, subject to the availability of about $3 million in financing from private-sector investors. The ability to recycle non-tire rubber scrap could conserve as much as 90,000 Btu/lb, thus yielding an estimated energy savings potential of about 0.25 quad/yr.« less

A novel model for through-silicon via (TSV) filling process simulation considering three additives and current density effect

NASA Astrophysics Data System (ADS)

Wang, Fuliang; Zhao, Zhipeng; Wang, Feng; Wang, Yan; Nie, Nantian

2017-12-01

Through-silicon via (TSV) filling by electrochemical deposition is still a challenge for 3D IC packaging, and three-component additive systems (accelerator, suppressor, and leveler) were commonly used in the industry to achieve void-free filling. However, models considering three additive systems and the current density effect have not been fully studied. In this paper, a novel three-component model was developed to study the TSV filling mechanism and process, where the interaction behavior of the three additives (accelerator, suppressor, and leveler) were considered, and the adsorption, desorption, and consumption coefficient of the three additives were changed with the current density. Based on this new model, the three filling types (seam void, ‘V’ shape, and key hole) were simulated under different current density conditions, and the filling results were verified by experiments. The effect of the current density on the copper ion concentration, additives surface coverage, and local current density distribution during the TSV filling process were obtained. Based on the simulation and experimental results, the diffusion-adsorption-desorption-consumption competition behavior between the suppressor, the accelerator, and the leveler were discussed. The filling mechanisms under different current densities were also analyzed.

The Real-World Connection.

ERIC Educational Resources Information Center

Estes, Charles R.

1994-01-01

Discusses theoretical versus applied science and the use of the scientific method for analysis of social issues. Topics addressed include the use of simulation and modeling; the growth in computer power, including nanotechnology; distributed computing; self-evolving programs; spiritual matters; human engineering, i.e., molding individuals;…

3D printing to simulate laparoscopic choledochal surgery.

PubMed

Burdall, Oliver C; Makin, Erica; Davenport, Mark; Ade-Ajayi, Niyi

2016-05-01

Laparoscopic simulation has transformed skills acquisition for many procedures. However, realistic nonbiological simulators for complex reconstructive surgery are rare. Life-like tactile feedback is particularly difficult to reproduce. Technological innovations may contribute novel solutions to these shortages. We describe a hybrid model, harnessing 3D technology to simulate laparoscopic choledochal surgery for the first time. Digital hepatic anatomy images and standard laparoscopic trainer dimensions were employed to create an entry level laparoscopic choledochal surgery model. The information was fed into a 3D systems project 660pro with visijet pxl core powder to create a free standing liver mold. This included a cuboid portal in which to slot disposable hybrid components representing hepatic and pancreatic ducts and choledochal cyst. The mold was used to create soft silicone replicas with T28 resin and T5 fast catalyst. The model was assessed at a national pediatric surgery training day. The 10 delegates that trialed the simulation felt that the tactile likeness was good (5.6/10±1.71, 10=like the real thing), was not too complex (6.2/10±1.35; where 1=too simple, 10=too complicated), and generally very useful (7.36/10±1.57, 10=invaluable). 100% stated that they felt they could reproduce this in their own centers, and 100% would recommend this simulation to colleagues. Though this first phase choledochal cyst excision simulation requires further development, 3D printing provides a useful means of creating specific and detailed simulations for rare and complex operations with huge potential for development. Copyright © 2016. Published by Elsevier Inc.

Simulation Analysis and Performance Study of CoCrMo Porous Structure Manufactured by Selective Laser Melting

NASA Astrophysics Data System (ADS)

Guoqing, Zhang; Junxin, Li; Jin, Li; Chengguang, Zhang; Zefeng, Xiao

2018-04-01

To fabricate porous implants with improved biocompatibility and mechanical properties that are matched to their application using selective laser melting (SLM), flow within the mold and compressive properties and performance of the porous structures must be comprehensively studied. Parametric modeling was used to build 3D models of octahedron and hexahedron structures. Finite element analysis was used to evaluate the mold flow and compressive properties of the parametric porous structures. A DiMetal-100 SLM molding apparatus was used to manufacture the porous structures and the results evaluated by light microscopy. The results showed that parametric modeling can produce robust models. Square structures caused higher blood cell adhesion than cylindrical structures. "Vortex" flow in square structures resulted in chaotic distribution of blood elements, whereas they were mostly distributed around the connecting parts in the cylindrical structures. No significant difference in elastic moduli or compressive strength was observed in square and cylindrical porous structures of identical characteristics. Hexahedron, square and cylindrical porous structures had the same stress-strain properties. For octahedron porous structures, cylindrical structures had higher stress-strain properties. Using these modeling and molding results, an important basis for designing and the direct manufacture of fixed biological implants is provided.

Simulation Analysis and Performance Study of CoCrMo Porous Structure Manufactured by Selective Laser Melting

NASA Astrophysics Data System (ADS)

Guoqing, Zhang; Junxin, Li; Jin, Li; Chengguang, Zhang; Zefeng, Xiao

2018-05-01

To fabricate porous implants with improved biocompatibility and mechanical properties that are matched to their application using selective laser melting (SLM), flow within the mold and compressive properties and performance of the porous structures must be comprehensively studied. Parametric modeling was used to build 3D models of octahedron and hexahedron structures. Finite element analysis was used to evaluate the mold flow and compressive properties of the parametric porous structures. A DiMetal-100 SLM molding apparatus was used to manufacture the porous structures and the results evaluated by light microscopy. The results showed that parametric modeling can produce robust models. Square structures caused higher blood cell adhesion than cylindrical structures. "Vortex" flow in square structures resulted in chaotic distribution of blood elements, whereas they were mostly distributed around the connecting parts in the cylindrical structures. No significant difference in elastic moduli or compressive strength was observed in square and cylindrical porous structures of identical characteristics. Hexahedron, square and cylindrical porous structures had the same stress-strain properties. For octahedron porous structures, cylindrical structures had higher stress-strain properties. Using these modeling and molding results, an important basis for designing and the direct manufacture of fixed biological implants is provided.

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

NASA Astrophysics Data System (ADS)

Öktem, H.

2012-01-01

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

Nanomechanical properties of dental resin-composites.

PubMed

El-Safty, S; Akhtar, R; Silikas, N; Watts, D C

2012-12-01

To determine by nanoindentation the hardness and elastic modulus of resin-composites, including a series with systematically varied filler loading, plus other representative materials that fall into the categories of flowable, bulk-fill and conventional nano-hybrid types. Ten dental resin-composites: three flowable, three bulk-fill and four conventional were investigated using nanoindentation. Disc specimens (15mm×2mm) were prepared from each material using a metallic mold. Specimens were irradiated in the mold at top and bottom surfaces in multiple overlapping points (40s each) with light curing unit at 650mW/cm(2). Specimens were then mounted in 3cm diameter phenolic ring forms and embedded in a self-curing polystyrene resin. After grinding and polishing, specimens were stored in distilled water at 37°C for 7 days. Specimens were investigated using an Agilent Technologies XP nanoindenter equipped with a Berkovich diamond tip (100nm radius). Each specimen was loaded at one loading rate and three different unloading rates (at room temperature) with thirty indentations, per unloading rate. The maximum load applied by the nanoindenter to examine the specimens was 10mN. Dependent on the type of the resin-composite material, the mean values ranged from 0.73GPa to 1.60GPa for nanohardness and from 14.44GPa to 24.07GPa for elastic modulus. There was a significant positive non-linear correlation between elastic modulus and nanohardness (r(2)=0.88). Nonlinear regression revealed a significant positive correlation (r(2)=0.62) between elastic moduli and filler loading and a non-significant correlation (r(2)=0.50) between nanohardness and filler loading of the studied materials. Varying the unloading rates showed no consistent effect on the elastic modulus and nanohardness of the studied materials. For a specific resin matrix, both elastic moduli and nanohardness correlated positively with filler loading. For the resin-composites investigated, the group-average elastic moduli and nanohardnesses for bulk-fill and flowable materials were lower than those for conventional nano-hybrid composites. Copyright © 2012 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

Freeform fabrication of tissue-simulating phantom for potential use of surgical planning in conjoined twins separation surgery.

PubMed

Shen, Shuwei; Wang, Haili; Xue, Yue; Yuan, Li; Zhou, Ximing; Zhao, Zuhua; Dong, Erbao; Liu, Bin; Liu, Wendong; Cromeens, Barrett; Adler, Brent; Besner, Gail; Xu, Ronald X

2017-09-08

Preoperative assessment of tissue anatomy and accurate surgical planning is crucial in conjoined twin separation surgery. We developed a new method that combines three-dimensional (3D) printing, assembling, and casting to produce anatomic models of high fidelity for surgical planning. The related anatomic features of the conjoined twins were captured by computed tomography (CT), classified as five organ groups, and reconstructed as five computer models. Among these organ groups, the skeleton was produced by fused deposition modeling (FDM) using acrylonitrile-butadiene-styrene. For the other four organ groups, shell molds were prepared by FDM and cast with silica gel to simulate soft tissues, with contrast enhancement pigments added to simulate different CT and visual contrasts. The produced models were assembled, positioned firmly within a 3D printed shell mold simulating the skin boundary, and cast with transparent silica gel. The produced phantom was subject to further CT scan in comparison with that of the patient data for fidelity evaluation. Further data analysis showed that the produced model reassembled the geometric features of the original CT data with an overall mean deviation of less than 2 mm, indicating the clinical potential to use this method for surgical planning in conjoined twin separation surgery.

Bond strength of resin-modified glass ionomer restorative materials using a no-rinse conditioner.

PubMed

Suihkonen, Rian W; Vandewalle, Kraig S; Dossett, Jon M

2012-01-01

A paste-paste resin-modified glass ionomer (RMGI) restorative material has been introduced recently with a new conditioner that requires no rinsing. The purpose of this study was to compare the shear bond strength of an encapsulated RMGI (Fuji II LC) and a new paste-paste RMGI (Fuji Filling LC) to dentin conditioned with 20% polyacrylic acid (Cavity Conditioner), a new no-rinse conditioner (Self Conditioner,), or no conditioner. Mounted human third molars were flattened and the dentin surface was conditioned. The RMGI restorative materials were mixed and incrementally inserted into a mold and photocured. The specimens were loaded until failure in a universal testing machine after 24 hours of storage in distilled water. Fuji II LC had significantly greater bond strength to dentin than Fuji Filling LC. The use of Cavity Conditioner or Self Conditioner resulted in bond strengths that were not significantly different from each other; however, both produced greater bond strengths than those in the non-conditioned groups.

Preparation process and properties of exfoliated graphite nanoplatelets filled Bisphthalonitrile nanocomposites

NASA Astrophysics Data System (ADS)

Lei, Yajie; Hu, Guo-Hua; Zhao, Rui; Guo, Heng; Zhao, Xin; Liu, Xiaobo

2012-11-01

Exfoliated graphite nanoplatelets (xGnP) filled 4,4'-Bis (3,4-dicyanophenoxy) biphenyl (BPh) nanocomposites were prepared by a resin transfer molding process. The rheological behavior of the BPh pre-polymer, and the morphology and electrical, mechanical and thermal properties of the xGnP/BPh nanocomposites were systematically investigated. The results showed that the xGnP/BPh pre-polymer possessed a higher complex viscosity and storage modulus than the pure BPh and that the xGnP could significantly enhance the mechanical and electrical properties of the resulted nanocomposites. The electrical percolation threshold of the xGnP/BPh nanocomposites was between 5 and 10 wt% xGnP. The flexural strength and modulus of the xGnP/BPh nanocomposites with 10 wt% xGnP exhibited maximum values and their thermal stabilities were greatly improved. Those novel xGnP/BPh nanocomposites could have advanced applications in areas like aerospace and military industry.

Injection molding lens metrology using software configurable optical test system

NASA Astrophysics Data System (ADS)

Zhan, Cheng; Cheng, Dewen; Wang, Shanshan; Wang, Yongtian

2016-10-01

Optical plastic lens produced by injection molding machine possesses numerous advantages of light quality, impact resistance, low cost, etc. The measuring methods in the optical shop are mainly interferometry, profile meter. However, these instruments are not only expensive, but also difficult to alignment. The software configurable optical test system (SCOTS) is based on the geometry of the fringe refection and phase measuring deflectometry method (PMD), which can be used to measure large diameter mirror, aspheric and freeform surface rapidly, robustly, and accurately. In addition to the conventional phase shifting method, we propose another data collection method called as dots matrix projection. We also use the Zernike polynomials to correct the camera distortion. This polynomials fitting mapping distortion method has not only simple operation, but also high conversion precision. We simulate this test system to measure the concave surface using CODE V and MATLAB. The simulation results show that the dots matrix projection method has high accuracy and SCOTS has important significance for on-line detection in optical shop.

Inactivation of dust mites, dust mite allergen, and mold from carpet.

PubMed

Ong, Kee-Hean; Lewis, Roger D; Dixit, Anupma; MacDonald, Maureen; Yang, Mingan; Qian, Zhengmin

2014-01-01

Carpet is known to be a reservoir for biological contaminants, such as dust mites, dust mite allergen, and mold, if it is not kept clean. The accumulation of these contaminants in carpet might trigger allergies or asthma symptoms in both children and adults. The purpose of this study is to compare methods for removal of dust mites, dust mite allergens, and mold from carpet. Carpets were artificially worn to simulate 1 to 2 years of wear in a four-person household. The worn carpets were inoculated together with a common indoor mold (Cladosporium species) and house dust mites and incubated for 6 weeks to allow time for dust mite growth on the carpet. The carpets were randomly assigned to one of the four treatment groups. Available treatment regimens for controlling carpet contaminants were evaluated through a literature review and experimentation. Four moderately low-hazard, nondestructive methods were selected as treatments: vacuuming, steam-vapor, Neem oil (a natural tree extract), and benzalkonium chloride (a quaternary ammonium compound). Steam vapor treatment demonstrated the greatest dust mite population reduction (p < 0.05) when compared to other methods. The two physical methods, steam vapor and vacuuming, have no statistically significant efficacy in inactivating dust mite allergens (p = 0.084), but have higher efficacy when compared to the chemical method on dust mite allergens (p = 0.002). There is no statistically significant difference in the efficacy for reducing mold in carpet (p > 0.05) for both physical and chemical methods. The steam-vapor treatment effectively killed dust mites and denatured dust mite allergen in the laboratory environment.

Engineering solutions for polymer composites solar water heaters production

NASA Astrophysics Data System (ADS)

Frid, S. E.; Arsatov, A. V.; Oshchepkov, M. Yu.

2016-06-01

Analysis of engineering solutions aimed at a considerable decrease of solar water heaters cost via the use of polymer composites in heaters construction and solar collector and heat storage integration into a single device representing an integrated unit results are considered. Possibilities of creating solar water heaters of only three components and changing welding, soldering, mechanical treatment, and assembly of a complicate construction for large components molding of polymer composites and their gluing are demonstrated. Materials of unit components and engineering solutions for their manufacturing are analyzed with consideration for construction requirements of solar water heaters. Optimal materials are fiber glass and carbon-filled plastics based on hot-cure thermosets, and an optimal molding technology is hot molding. It is necessary to manufacture the absorbing panel as corrugated and to use a special paint as its selective coating. Parameters of the unit have been optimized by calculation. Developed two-dimensional numerical model of the unit demonstrates good agreement with the experiment. Optimal ratio of daily load to receiving surface area of a solar water heater operating on a clear summer day in the midland of Russia is 130‒150 L/m2. Storage tank volume and load schedule have a slight effect on solar water heater output. A thermal insulation layer of 35‒40 mm is sufficient to provide an efficient thermal insulation of the back and side walls. An experimental model layout representing a solar water heater prototype of a prime cost of 70‒90/(m2 receiving surface) has been developed for a manufacturing volume of no less than 5000 pieces per year.

Real-Time Monitoring of Scada Based Control System for Filling Process

NASA Astrophysics Data System (ADS)

Soe, Aung Kyaw; Myint, Aung Naing; Latt, Maung Maung; Theingi

2008-10-01

This paper is a design of real-time monitoring for filling system using Supervisory Control and Data Acquisition (SCADA). The monitoring of production process is described in real-time using Visual Basic.Net programming under Visual Studio 2005 software without SCADA software. The software integrators are programmed to get the required information for the configuration screens. Simulation of components is expressed on the computer screen using parallel port between computers and filling devices. The programs of real-time simulation for the filling process from the pure drinking water industry are provided.

PROTOCOL TO EVALUATE THE MOISTURE DURABILITY OF ENERGY-EFFICIENT WALLS

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

Boudreaux, Philip R; Pallin, Simon B; Hun, Diana E

Walls account for about 8% of the energy used in residential buildings. This energy penalty can be reduced with higher insulation levels and increased airtightness. However, these measures can compromise the moisture durability and long-term performance of wall assemblies because they can lead to lower moisture tolerance due to reduced drying potential. To avert these problems, a moisture durability protocol was developed to evaluate the probability that an energy-efficient wall design will experience mold growth. This protocol examines the effects of moisture sources in walls through a combination of simulations and lab experiments, uses the mold growth index as themore » moisture durability indicator, and is based on a probabilistic approach that utilizes stochastically varying input parameters. The simulation tools used include a new validated method for taking into account the effects of air leakage in wall assemblies This paper provides an overview of the developed protocol, discussion of the probabilistic simulation approach and describes results from the evaluation of two wall assemblies in Climate Zones 2, 4, and 6. The protocol will be used to supply builders with wall designs that are energy efficient, moisture durable and cost-effective.« less

Experimental Characterization of the Energy Absorption of Functionally Graded Foam Filled Tubes Under Axial Crushing Loads

NASA Astrophysics Data System (ADS)

Ebrahimi, Saeed; Vahdatazad, Nader; Liaghat, Gholamhossein

2018-03-01

This paper deals with the energy absorption characterization of functionally graded foam (FGF) filled tubes under axial crushing loads by experimental method. The FGF tubes are filled axially by gradient layers of polyurethane foams with different densities. The mechanical properties of the polyurethane foams are firstly obtained from axial compressive tests. Then, the quasi-static compressive tests are carried out for empty tubes, uniform foam filled tubes and FGF filled tubes. Before to present the experimental test results, a nonlinear FEM simulation of the FGF filled tube is carried out in ABAQUS software to gain more insight into the crush deformation patterns, as well as the energy absorption capability of the FGF filled tube. A good agreement between the experimental and simulation results is observed. Finally, the results of experimental test show that an FGF filled tube has excellent energy absorption capacity compared to the ordinary uniform foam-filled tube with the same weight.

A mock heart engineered with helical aramid fibers for in vitro cardiovascular device testing.

PubMed

Jansen-Park, So-Hyun; Hsu, Po-Lin; Müller, Indra; Steinseifer, Ulrich; Abel, Dirk; Autschbach, Rüdiger; Rossaint, Rolf; Schmitz-Rode, Thomas

2017-04-01

Mock heart circulation loops (MHCLs) serve as in-vitro platforms to investigate the physiological interaction between circulatory systems and cardiovascular devices. A mock heart (MH) engineered with silicone walls and helical aramid fibers, to mimic the complex contraction of a natural heart, has been developed to advance the MHCL previously developed in our group. A mock aorta with an anatomical shape enables the evaluation of a cannulation method for ventricular assist devices (VADs) and investigation of the usage of clinical measurement systems like pressure-volume catheters. Ventricle and aorta molds were produced based on MRI data and cast with silicone. Aramid fibers were layered in the silicone ventricle to reproduce ventricle torsion. A rotating hollow shaft was connected to the apex enabling the rotation of the MH and the connection of a VAD. Silicone wall thickness, aramid fiber angle and fiber pitch were varied to generate different MH models. All MH models were placed in a tank filled with variable amounts of water and air simulating the compliance. In this work, physiological ventricular torsion angles (15°-26°) and physiological pressure-volume loops were achieved. This MHCL can serve as a comprehensive testing platform for cardiovascular devices, such as artificial heart valves and cannulation of VADs.

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.

Evaluation of effect of different disposable infection control barriers on light intensity of light-curing unit and microhardness of composite - An in vitro study

PubMed Central

Khode, Rajiv Tarachand; Shenoi, Pratima Ramakrishna; Kubde, Rajesh R.; Makade, Chetana S.; Wadekar, Kanchan D.; Khode, Priyanka Tarachand

2017-01-01

Aims: This study evaluated effect of infection control barriers on light intensity (LI) of light-curing unit (LCU) and microhardness of composite. Materials and Methods: Four different disposable barriers (n = 30) were tested against the control. LI for each barrier was measured with Lux meter. One hundred and fifty Teflon molds were equally divided into five groups of thirty each. Composite was filled in bulk in these molds and cured without and with barrier. Microhardness was evaluated on top and bottom surface of composite specimen with microhardness testing machine and hardness ratio (HR) was derived. Statistical Analysis Used: One-way analysis of variance, Tukey's honestly significant difference test, and paired t-test using SPSS version 18 software. Results: All barriers had significantly reduced the baseline LI of LCU (P < 0.0001), but only Cure Elastic Steri-Shield and latex cut glove pieces (LCGP) significantly reduced the microhardness of the composite (P < 0.05). However, HR determined inadequate curing only with LCGP. Conclusions: Although entire tested barrier significantly reduced the LI; none, except LCGP markedly affected the degree of cure of the composite. PMID:29279622

Effect of coal filler on the properties of soy protein plastics

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

Wang, G.H.; Zhou, A.N.; Hu, M.B.

2006-11-15

The influence of ultrafine coal filler (UFC) content on tensile properties, water absorption, and biodegradability of soy protein plastics were investigated. The addition of UFC in the soy protein plastics, with different content of glycerol as a plasticizer, was at different ratio varying from 10:0 to 6:4. Blend sheets of the soy protein composites were prepared by the compression molding processing. The results show that, with 23.08 wt % glycerol, the tensile strength and elongation at break for the soy protein sheet with coal filler (range from 5 to 30 parts) can be enhanced as compared with nonfilled soy proteinmore » plastics. Water resistance of the soy protein plastics improves with the increase in UFC content. The derivative thermogravimetry (DTG) curves indicate a double-stage degradation process for defatted soy flour (SPF), while three-stage degradation process for soy plastics and the soy protein composites. FT-IR, XPS, and SEM were applied to study the interfacial interaction between coal macromolecules and soy protein molecules in UFC filled soy protein plastics. The results demonstrated that there is strong interfacial interaction in the soy protein plastics caused by the compression molding processing.« less

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

Diagenesis and late-stage porosity development in the pennsylvanian strawn formation, val verde basin, Texas, U.S.A

USGS Publications Warehouse

Newell, K. David; Goldstein, R.H.; Burdick, C.J.

2005-01-01

The Middle Pennsylvanian (Desmoinesian) Strawn Formation in the Trans-Pecos area of Texas was deposited during relative tectonic quiescence that prevailed before rapid infilling of the Val Verde Basin. It represents one of a series of backstepping carbonate ramps formed on the craton side of this foreland basin. Strawn Formation carbonate rocks in three cores - Conoco Anna McClung #3-1, Alex Mitchell S2-1R, and Creek Ranch #10-1 - show several shallowing-up ward sequences, each a few meters thick. The Creek Ranch core displays the deepest-water characteristics of the three cores; the lower part of this core is dominated by graded bedding. The Mitchell and McClung cores contain skeletal-rich carbonates. Both of these cores display characteristics of shallow-water bank or lagoonal environments. All three cores have approximately the same diagenetic history. Primary fluid inclusions indicate early porosity-occluding interparticle and mold-filling calcite precipitated from water with a narrow range of salinities. Modal salinities are that of seawater, but slightly lesser salinities (indicating mixing of seawater and meteoric water) and slightly greater salinities (indicating evaporative concentration of seawater) are also indicated. The influence of meteoric groundwater can be detected by stable-isotope analyses of the early cements at stratigraphic levels that correlate to the tops of the major shallowing-upward depositional sequences. However, subaerial exposure surfaces are not demonstrated in these cores but were likely to be present updip. Most porosity is cement-reduced vugs, dissolution-enlarged (and cement-reduced) molds (> 1/16 mm, < 4 mm), and fractures. Minor intraparticle, intercrystalline, and shelter porosity is also present. Reservoir porosity is caused by fracturing and a late-stage dissolution event. Dissolution in the Creek Ranch core is not as pronounced as in the other cores because of a dearth of skeletal material. Porous zones in the McClung and Mitchell cores are associated with open fractures spatially, which commonly interconnect with nearby molds and vugs. This complex porosity system occurred after stylolitization, as evidenced by "cuticles" of insoluble styloliticresidue thatbridge across small dissolution-enlarged fractures. Porosity detected by wireline logs therefore is mostly effective porosity. The open-fracture network may have been caused by thrusting of the Strawn Formation, most likely in Permian time. Late-stage cement reduction of porosity occurs in two stages-first by calcite spar, then saddle dolomite. These cements are unevenly distributed. Both of these cements contain primary oil-filled fluid inclusions. Homogenization temperatures of primary aqueous fluid inclusions in saddle dolomites indicate that the Strawn Formation has been subjected to a temperature of at least 136??C (roughly 45??C over present formation temperature), which correlates to a vitrinite reflectance equivalent of 1.22%. Homogenization temperatures, in conjunction with oxygen isotope compositions, indicate that fracture-filling calcite spars and the later saddle dolomites precipitated from isotopically positive fluids, which were probably connate waters that had undergone extensive rock-water interaction. These observations suggest that thrusting of carbonate shelf strata, in a proximal foreland setting, was responsible for creation of latestage fracture porosity. In turn, tectonic expulsion of undersaturated, heated, connate water into the Strawn Formation enhanced the porosity. As this expulsed water cooled, it reached saturation with respect to calcite and dolomite, and these cements partly filled the available porosity. These processes of reservoir creation might be expected in other proximal foreland settings.

Experiments and numerical simulations of flow field and heat transfer coefficients inside an autoclave model

NASA Astrophysics Data System (ADS)

Ghamlouch, T.; Roux, S.; Bailleul, J.-L.; Lefèvre, N.; Sobotka, V.

2017-10-01

Today's aerospace industrial first priority is the quality improvement of the composite material parts with the reduction of the manufacturing time in order to increase their quality/cost ratio. A fabrication method that could meet these specifications especially for large parts is the autoclave curing process. In fact the autoclave molding ensures the thermal control of the composite parts during the whole curing cycle. However the geometry of the tools as well as their positioning in the autoclave induce non uniform and complex flows around composite parts. This heterogeneity implies non-uniform heat transfers which can directly impact on part quality. One of the main challenges is therefore to describe the flow field inside an autoclave as well as the convective heat transfer from the heated pressurized gas to the composite part and the mold. For this purpose, and given the technical issues associated with instrumentation and measurements in actual autoclaves, an autoclave model was designed and then manufactured based on similarity laws. This tool allows the measurement of the flow field around representative real industrial molds using the PIV technique and the characterization of the heat transfer thanks to thermal instrumentation. The experimental results are then compared with those derived from numerical simulations using a commercial RANS CFD code. This study aims at developing a semi-empirical approach for the prediction of the heat transfer coefficient around the parts and therefore predicts its thermal history during the process with a view of optimization.

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.

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.

Heat Transfer Coefficient at Cast-Mold Interface During Centrifugal Casting: Calculation of Air Gap

NASA Astrophysics Data System (ADS)

Bohacek, Jan; Kharicha, Abdellah; Ludwig, Andreas; Wu, Menghuai; Karimi-Sibaki, Ebrahim

2018-06-01

During centrifugal casting, the thermal resistance at the cast-mold interface represents a main blockage mechanism for heat transfer. In addition to the refractory coating, an air gap begins to form due to the shrinkage of the casting and the mold expansion, under the continuous influence of strong centrifugal forces. Here, the heat transfer coefficient at the cast-mold interface h has been determined from calculations of the air gap thickness d a based on a plane stress model taking into account thermoelastic stresses, centrifugal forces, plastic deformations, and a temperature-dependent Young's modulus. The numerical approach proposed here is rather novel and tries to offer an alternative to the empirical formulas usually used in numerical simulations for a description of a time-dependent heat transfer coefficient h. Several numerical tests were performed for different coating thicknesses d C, rotation rates Ω, and temperatures of solidus T sol. Results demonstrated that the scenario at the interface is unique for each set of parameters, hindering the possibility of employing empirical formulas without a preceding experiment being performed. Initial values of h are simply equivalent to the ratio of the coating thermal conductivity and its thickness ( 1000 Wm-2 K-1). Later, when the air gap is formed, h drops exponentially to values at least one order of magnitude smaller ( 100 Wm-2 K-1).

Ease fabrication of PCR modular chip for portable DNA detection kit

NASA Astrophysics Data System (ADS)

Whulanza, Yudan; Aditya, Rifky; Arvialido, Reyhan; Utomo, Muhammad S.; Bachtiar, Boy M.

2017-02-01

Engineering a lab-on-a-chip (LoC) to perform the DNA polymerase chain reaction (PCR) for malaria detection is the ultimate goal of this study. This paper investigates the ability to fabricate an LoC kit using conventional method to achieve the lowest production cost by using existing fabrication process. It has been known that majority of LoC was made of polydimethylsiloxane (PDMS) which in this study was realized through a contact mold process. CNC milling process was utilized to create channel features in the range of 150-250 µm on the mold. Characterization on the milling process was done to understand the shrinkage/contraction between mold to product, roughness and also angle of contact of PDMS surface. Ultimately, this paper also includes analysis on flow measurement and heat distribution of an assembled LoC PCR kit. The results show that the achieved dimension of microchannel is 227 µm wide with a roughness of 0.01 µm. The flow measurement indicates a deviation with simulation in the range of 10%. A heat distribution through the kit is achieved following the three temperature zones as desired.

Microbial volatile organic compounds in moldy interiors: a long-term climate chamber study.

PubMed

Schuchardt, Sven; Strube, Andrea

2013-06-01

The present study simulated large-scale indoor mold damage in order to test the efficiency of air sampling for the detection of microbial volatile organic compounds (MVOCs). To do this, a wallpaper damaged by condensation was stored in a climate chamber (representing a hypothetical test room of 40 m(3) volume) and was inoculated with 14 typical indoor fungal strains. The chamber ventilation conditions were adjusted to common values found in moldy homes, and the mold growth was allowed to continue to higher than average values. The MVOC content of the chamber air was analyzed daily for a period of 105 days using coupled gas chromatography/mass spectrometry (GC-MS). This procedure guarantees MVOC profiling without external factors such as outdoor air, building materials, furniture, and occupants. However, only nine MVOCs could be detected during the sampling period, which indicates that the very low concentrated MVOCs are hardly accessible, even under these favorable conditions. Furthermore, most of the MVOCs that were detected cannot be considered as reliable indicators of mold growth in indoor environments. © 2013 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

[Presurgical alveolar molding using computer aided design in infants with unilateral complete cleft lip and palate].

PubMed

Zgong, Xin; Yu, Quan; Yu, Zhe-yuan; Wang, Guo-min; Qian, Yu-fen

2012-04-01

To establish a new method of presurgical alveolar molding using computer aided design(CAD) in infants with complete unilateral cleft lip and palate (UCLP). Ten infants with complete UCLP were recruited. A maxillary impression was taken at the first examination after birth. The study model was scanned by a non-contact three-dimensional laser scanner and a digital model was constructed and analyzed to simulate the alveolar molding procedure with reverse engineering software (RapidForm 2006). The digital geometrical data were exported to produce a scale model using rapid prototyping technology. The whole set of appliances was fabricated based on these solid models. The digital model could be viewed and measured from any direction by the software. By the end of the NAM treatment before surgical lip repair, the cleft was narrowed and the malformation of alveolar segments was aligned normally, significantly improving nasal symmetry and nostril shape. Presurgical NAM using CAD could simplify the treatment procedure and estimate the treatment objective, which enabled precise control of the force and direction of the alveolar segments movement.

Warpage Characteristics and Process Development of Through Silicon Via-Less Interconnection Technology.

PubMed

Shen, Wen-Wei; Lin, Yu-Min; Wu, Sheng-Tsai; Lee, Chia-Hsin; Huang, Shin-Yi; Chang, Hsiang-Hung; Chang, Tao-Chih; Chen, Kuan-Neng

2018-08-01

In this study, through silicon via (TSV)-less interconnection using the fan-out wafer-level-packaging (FO-WLP) technology and a novel redistribution layer (RDL)-first wafer level packaging are investigated. Since warpage of molded wafer is a critical issue and needs to be optimized for process integration, the evaluation of the warpage issue on a 12-inch wafer using finite element analysis (FEA) at various parameters is presented. Related parameters include geometric dimension (such as chip size, chip number, chip thickness, and mold thickness), materials' selection and structure optimization. The effect of glass carriers with various coefficients of thermal expansion (CTE) is also discussed. Chips are bonded onto a 12-inch reconstituted wafer, which includes 2 RDL layers, 3 passivation layers, and micro bumps, followed by using epoxy molding compound process. Furthermore, an optical surface inspector is adopted to measure the surface profile and the results are compared with the results from simulation. In order to examine the quality of the TSV-less interconnection structure, electrical measurement is conducted and the respective results are presented.

Alloy Shrinkage factors for the investment casting of 17-4PH stainless steel parts

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

Sabau, Adrian S; Porter, Wallace D

2008-01-01

In this study, the alloy shrinkage factors were obtained for the investment casting of 17-4PH stainless steel parts. For the investment casting process, unfilled wax and fused silica with a zircon prime coat were used for patterns and shell molds, respectively. Dimensions of the die tooling, wax pattern, and casting were measured using a Coordinate Measurement Machine. For all the properties, the experimental data available in the literature did not cover the entire temperature range necessary for process simulation. A comparison between the predicted material property data measured property data is made. It was found that most material properties weremore » accurately predicted over the most of the temperature range of the process. Several assumptions were made in order to obtain a complete set of mechanical property data at high temperatures. Thermal expansion measurements for the 17-4PH alloy were conducted at heating and cooling. As a function of temperature, the thermal expansion for both the alloy and shell mold materials showed different evolution at heating and cooling. Thus, one generic simulation were performed with thermal expansion obtained at heating and another one with thermal expansion obtained at cooling. The alloy dimensions were obtained from numerical simulation results of solidification, heat transfer, and deformation phenomena. As compared with experimental results, the numerical simulation results for the shrinkage factors were slightly over-predicted.« less

Alloy Shrinkage Factors for the Investment Casting of 17-4PH Stainless Steel Parts

NASA Astrophysics Data System (ADS)

Sabau, Adrian S.; Porter, Wallace D.

2008-04-01

In this study, alloy shrinkage factors were obtained for the investment casting of 17-4PH stainless steel parts. For the investment casting process, unfilled wax and fused silica with a zircon prime coat were used for patterns and shell molds, respectively. The dimensions of the die tooling, wax pattern, and casting were measured using a coordinate measurement machine (CMM). For all the properties, the experimental data available in the literature did not cover the entire temperature range necessary for process simulation. A comparison between the predicted material property data and measured property data is made. It was found that most material properties were accurately predicted over most of the temperature range of the process. Several assumptions were made, in order to obtain a complete set of mechanical property data at high temperatures. Thermal expansion measurements for the 17-4PH alloy were conducted during heating and cooling. As a function of temperature, the thermal expansion for both the alloy and shell mold materials showed a different evolution on heating and cooling. Thus, one generic simulation was performed with thermal expansion obtained on heating, and another one was performed with thermal expansion obtained on cooling. The alloy dimensions were obtained from the numerical simulation results of the solidification, heat transfer, and deformation phenomena. As compared with experimental results, the numerical simulation results for the shrinkage factors were slightly overpredicted.

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.

Theoretical prediction and experimental determination of the effect of mold characteristics on temperature and monomer conversion fraction profiles during polymerization of a PMMA-based bone cement.

PubMed

Vallo, Claudia I

2002-01-01

The present work is concerned with applications of a kinetic model for free-radical polymerization of a polymethylmethacrylate-based bone cement. Autocatalytic behavior at the first part of the reaction as well as a diffusion control phenomenon near vitrification are described by the model. Comparison of theoretical computations with experimental measurements for the temperature evolution during batch casting demonstrated the capacity of the proposed model to represent the kinetic behavior of the polymerization reaction. Temperature evolution and monomer conversion were simulated for the cure of the cement in molds made of different materials. The maximum monomer conversion fraction was markedly influenced by the physical properties of the mold material. The unreacted monomer acts as a plasticizer that influences the mechanical behavior of the cement. Hence, the same cement formulation cured in molds of different materials may result in different mechanical response because of the differences in the amounts of residual monomer. Standardization of the mold type to prepare specimens for the mechanical characterization of bone cements is recommended. Theoretical prediction of temperature evolution during hip replacement indicated that for cement thickness lower than 6 mm the peak temperature at the bone-cement interface was below the limit stated for thermal injury (50 degrees C for more than 1 min). The use of thin cement layers is recommended to diminish the risk of thermal injury; however, it is accompanied by an increase in the amount of unreacted monomer present in the cured material. Copyright 2002 Wiley Periodicals, Inc. J Biomed Mater Res (Appl Biomater) 63: 627-642, 2002

A revised model of fluid transport optimization in Physarum polycephalum.

PubMed

Bonifaci, Vincenzo

2017-02-01

Optimization of fluid transport in the slime mold Physarum polycephalum has been the subject of several modeling efforts in recent literature. Existing models assume that the tube adaptation mechanism in P. polycephalum's tubular network is controlled by the sheer amount of fluid flow through the tubes. We put forward the hypothesis that the controlling variable may instead be the flow's pressure gradient along the tube. We carry out the stability analysis of such a revised mathematical model for a parallel-edge network, proving that the revised model supports the global flow-optimizing behavior of the slime mold for a substantially wider class of response functions compared to previous models. Simulations also suggest that the same conclusion may be valid for arbitrary network topologies.

HFIR Fuel Casting Support

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

Imhoff, Seth D.; Gibbs, Paul Jacob; Solis, Eunice Martinez

Process exploration for fuel production for the High Flux Isotope Reactor (HFIR) using cast LEU-10wt.%Mo as an initial processing step has just begun. This project represents the first trials concerned with casting design and quality. The studies carried out over the course of this year and information contained in this report address the initial mold development to be used as a starting point for future operations. In broad terms, the final billet design is that of a solid rolling blank with an irregular octagonal cross section. The work covered here is a comprehensive view of the initial attempts to producemore » a sound casting. This report covers the efforts to simulate, predict, cast, inspect, and revise the initial mold design.« less

The tunable mechanical property of water-filled carbon nanotubes under an electric field

NASA Astrophysics Data System (ADS)

Ye, Hongfei; Zhang, Zhongqiang; Zhang, Hongwu; Chen, Zhen; Zong, Zhi; Zheng, Yonggang

2014-03-01

The spring-induced compression of water-filled carbon nanotubes (CNTs) under an electric field is investigated by molecular dynamics simulations. Due to the incompressibility and polarity of water, the mechanical property of CNTs can be tuned through filling with water molecules and applying an electric field. To explore the variation of the mechanical property of water-filled CNTs, the effects of the CNT length, the filling density and the electric field intensity are examined. The simulation results indicate that the water filling and electric field can result in a slight change in the elastic property (the elastic modulus and Poisson's ratio) of water-filled CNTs. However, the yield stress and average post-buckling stress exhibit a significant response to the water density and electric field intensity. As compared to hollow CNTs, the increment in yield stress of the water-filled CNTs under an electric field of 2.0 V Å-1 is up to 35.29%, which is even higher than that resulting from metal filling. The findings from this study provide a valuable theoretical basis for designing and fabricating the controlling units at the nanoscale.

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.

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

NASA Astrophysics Data System (ADS)

Moritzer, Elmar; Martin, Yannick

2016-03-01

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

COMPARATIVE ANALYSIS OF THE SHRINKAGE STRESS OF COMPOSITE RESINS

PubMed Central

Pereira, Rosana Aparecida; de Araujo, Paulo Amarante; Castañeda-Espinosa, Juan Carlos; Mondelli, Rafael Francisco Lia

2008-01-01

The aim of this study was to compare the shrinkage stress of composite resins by three methods. In the first method, composites were inserted between two stainless steel plates. One of the plates was connected to a 20 kgf load cell of a universal testing machine (EMIC-DL-500). In the second method, disk-shaped cavities were prepared in 2-mm-thick Teflon molds and filled with the different composites. Gaps between the composites and molds formed after polymerization were evaluated microscopically. In the third method, the wall-to-wall shrinkage stress of the resins that were placed in bovine dentin cavities was evaluated. The gaps were measured microscopically. Data were analyzed by one-way ANOVA and Tukey's test (α=0.05). The obtained contraction forces were: Grandio = 12.18 ± 0.428N; Filtek Z 250 = 11.80 ± 0.760N; Filtek Supreme = 11.80 ± 0.707 N; and Admira = 11.89 ± 0.647 N. The gaps obtained between composites and Teflon molds were: Filtek Z 250 = 0.51 ± 0.0357%; Filtek Supreme = 0.36 ± 0.0438%; Admira = 0.25 ± 0.0346% and Grandio = 0.16 ± 0.008%. The gaps obtained in wall-to-wall contraction were: Filtek Z 250 = 11.33 ± 2.160 μm; Filtek Supreme = 10.66 ± 1.211μm; Admira = 11.16 ± 2.041 μm and Grandio = 10.50 ± 1.224 μm. There were no significant differences among the composite resins obtained with the first (shrinkage stress generated during polymerization) and third method (wall-to-wall shrinkage). The composite resins obtained with the second method (Teflon method) differed significantly regarding gap formation. PMID:19089286

Preparation and properties of an internal mold release for rigid urethane foam

NASA Astrophysics Data System (ADS)

Paker, B. G.

1980-08-01

Most mold release agents used in the molding of rigid polyurethane foam are applied to the internal surfaces of the mold. These materials form a thin layer between the surface of the mold and the foam, allowing for easy release of the molded parts. This type of mold release must be applied prior to each molding operation; and, after repeated use, cleaning of the mold is required. Small amounts of this mold release are transferred to the molded part, resulting in a part with poor surface bondability characteristics. An internal release agent, which can be mixed in a urethane foam resin was investigated. The internal mold release provided good releasability and resulted in urethane foam that has excellent surface bondability. No compatibility problems are expected from the use of this type of release agent.

Design of the liquefied natural gas (LNG) vehicle gas cylinder filling semi-physical simulation training and assessment system

NASA Astrophysics Data System (ADS)

Gao, Jie; Zheng, Jianrong; Zhao, Yinghui

2017-08-01

With the rapid development of LNG vehicle in China, the operator's training and assessment of the operating skills cannot operate on material objects, because of Vehicle Gas Cylinder's high pressure, flammable and explosive characteristics. LNG Vehicle Gas Cylinder's filling simulation system with semi-physical simulation technology presents the overall design and procedures of the simulation system, and elaborates the realization of the practical analog machine, data acquisition and control system and the computer software, and introduces the design process of equipment simulation model in detail. According to the designed assessment system of the Vehicle Gas Cylinder, it can obtain the operation on the actual cylinder filling and visual effects for the operator, and automatically record operation, the results of real operation with its software, and achieve the operators' training and assessment of operating skills on mobile special equipment.

Fabrication of Achromatic Infrared Wave Plate by Direct Imprinting Process on Chalcogenide Glass

NASA Astrophysics Data System (ADS)

Yamada, Itsunari; Yamashita, Naoto; Tani, Kunihiko; Einishi, Toshihiko; Saito, Mitsunori; Fukumi, Kouhei; Nishii, Junji

2012-07-01

An achromatic infrared wave plate was fabricated by forming a subwavelength grating on the chalcogenide glass using direct imprint lithography. A low toxic chalcogenide glass (Sb-Ge-Sn-S system) substrate was imprinted with a grating of 1.63-µm depth, a fill factor of 0.7, and 3-µm period using glassy carbon as a mold at 253 °C and 3.8 MPa. Phase retardation of the element reached around 30° at 8.5-10.5 µm wavelengths, and the transmittance exceeded that of a flat substrate over 8 µm wavelength. Fabrication of the mid-infrared wave plate is thereby less expensive than that of conventional crystalline wave plates.

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

Improving mixing efficiency of a polymer micromixer by use of a plastic shim divider

NASA Astrophysics Data System (ADS)

Li, Lei; Lee, L. James; Castro, Jose M.; Yi, Allen Y.

2010-03-01

In this paper, a critical modification to a polymer based affordable split-and-recombination static micromixer is described. To evaluate the improvement, both the original and the modified design were carefully investigated using an experimental setup and numerical modeling approach. The structure of the micromixer was designed to take advantage of the process capabilities of both ultraprecision micromachining and microinjection molding process. Specifically, the original and the modified design were numerically simulated using commercial finite element method software ANSYS CFX to assist the re-designing of the micromixers. The simulation results have shown that both designs are capable of performing mixing while the modified design has a much improved performance. Mixing experiments with two different fluids were carried out using the original and the modified mixers again showed a significantly improved mixing uniformity by the latter. The measured mixing coefficient for the original design was 0.11, and for the improved design it was 0.065. The developed manufacturing process based on ultraprecision machining and microinjection molding processes for device fabrication has the advantage of high-dimensional precision, low cost and manufacturing flexibility.

Experimental and Numerical Modeling of Fluid Flow Processes in Continuous Casting: Results from the LIMMCAST-Project

NASA Astrophysics Data System (ADS)

Timmel, K.; Kratzsch, C.; Asad, A.; Schurmann, D.; Schwarze, R.; Eckert, S.

2017-07-01

The present paper reports about numerical simulations and model experiments concerned with the fluid flow in the continuous casting process of steel. This work was carried out in the LIMMCAST project in the framework of the Helmholtz alliance LIMTECH. A brief description of the LIMMCAST facilities used for the experimental modeling at HZDR is given here. Ultrasonic and inductive techniques and the X-ray radioscopy were employed for flow measurements or visualizations of two-phase flow regimes occurring in the submerged entry nozzle and the mold. Corresponding numerical simulations were performed at TUBAF taking into account the dimensions and properties of the model experiments. Numerical models were successfully validated using the experimental data base. The reasonable and in many cases excellent agreement of numerical with experimental data allows to extrapolate the models to real casting configurations. Exemplary results will be presented here showing the effect of electromagnetic brakes or electromagnetic stirrers on the flow in the mold or illustrating the properties of two-phase flows resulting from an Ar injection through the stopper rod.

Replication of the nano-scale mold fabricated with focused ion beam

NASA Astrophysics Data System (ADS)

Gao, J. X.; Chan-Park, M. B.; Xie, D. Z.; Ngoi, Bryan K. A.

2004-12-01

Silicon mold fabricated with Focused Ion Beam lithography (FIB) was used to make silicone elastomer molds. The silicon mold is composed of lattice of holes which the diameter and depth are about 200 nm and 60 nm, respectively. The silicone elastomer material was then used to replicate slavery mold. Our study show the replication process with the elastomer mold had been performed successfully and the diameter of humps on the elastomer mold is near to that of holes on the master mold. But the height of humps in the elastomer mold is only 42 nm and it is different from the depth of holes in the master mold.

Allergies, asthma, and molds

MedlinePlus

Reactive airway - mold; Bronchial asthma - mold; Triggers - mold; Allergic rhinitis - pollen ... Things that make allergies or asthma worse are called triggers. Mold is a common trigger. When your asthma or allergies become worse due to mold, you are ...

Dosimetric effects of endorectal balloons on intensity-modulated radiation therapy plans for prostate cancer

NASA Astrophysics Data System (ADS)

Kim, Jae-Sung; Chung, Jin-Beom; Kim, In-Ah; Eom, Keun-Yong

2013-10-01

We used an endorectal balloon (ERB) for prostate immobilization during intensity-modulated radiotherapy (IMRT) for prostate cancer treatment. To investigate the dosimetric effects of ERB-filling materials, we changed the ERB Hounsfield unit (HU) from 0 to 1000 HU in 200-HU intervals to simulate the various ERB fillings; 0 HU simulated a water-filled ERB, and 1000 HU simulated the densest material-filled ERB. Dosimetric data (coverage, homogeneity, conformity, maximal dose, and typical volume dose) for the tumor and the organs at risk (OARs) were evaluated in prostate IMRT treatment plans with 6-MV and 15-MV beams. The tumor coverage appeared to differ by approximately 1%, except for the clinical target volume (CTV) V100% and the planning target volume (PTV) V100%. The largest difference for the various ERB fillings was observed in the PTV V100%. In spite of increasing HU, the prostate IMRT plans at both energies had relatively low dosimetric effects on the PTV and the CTV. However, the maximal and the typical volume doses (D25%, D30%, and D50%) to the rectal wall and the bladder increased with increasing HU. For an air-filled ERB, the maximal doses to the rectal wall and the monitor units were lower than the corresponding values for the water-filled and the densest material-filled ERBs. An air-filled ERB spared the rectal wall because of its dosimetric effect. Thus, we conclude that the use of an air-filled ERB provides a dosimetric benefit to the rectal wall without a loss of target coverage and is an effective option for prostate IMRT treatment.

Precision Casting via Advanced Simulation and Manufacturing

NASA Technical Reports Server (NTRS)

1997-01-01

A two-year program was conducted to develop and commercially implement selected casting manufacturing technologies to enable significant reductions in the costs of castings, increase the complexity and dimensional accuracy of castings, and reduce the development times for delivery of high quality castings. The industry-led R&D project was cost shared with NASA's Aerospace Industry Technology Program (AITP). The Rocketdyne Division of Boeing North American, Inc. served as the team lead with participation from Lockheed Martin, Ford Motor Company, Howmet Corporation, PCC Airfoils, General Electric, UES, Inc., University of Alabama, Auburn University, Robinson, Inc., Aracor, and NASA-LeRC. The technical effort was organized into four distinct tasks. The accomplishments reported herein. Task 1.0 developed advanced simulation technology for core molding. Ford headed up this task. On this program, a specialized core machine was designed and built. Task 2.0 focused on intelligent process control for precision core molding. Howmet led this effort. The primary focus of these experimental efforts was to characterize the process parameters that have a strong impact on dimensional control issues of injection molded cores during their fabrication. Task 3.0 developed and applied rapid prototyping to produce near net shape castings. Rocketdyne was responsible for this task. CAD files were generated using reverse engineering, rapid prototype patterns were fabricated using SLS and SLA, and castings produced and evaluated. Task 4.0 was aimed at developing technology transfer. Rocketdyne coordinated this task. Casting related technology, explored and evaluated in the first three tasks of this program, was implemented into manufacturing processes.

Spectroscopic and Mechanical Properties of a New Generation of Bulk Fill Composites

PubMed Central

Monterubbianesi, Riccardo; Orsini, Giovanna; Tosi, Giorgio; Conti, Carla; Librando, Vito; Procaccini, Maurizio; Putignano, Angelo

2016-01-01

Objectives: The aims of this study were to in vitro evaluate the degree of conversion and the microhardness properties of five bulk fill resin composites; in addition, the performance of two curing lamps, used for composites polymerization, was also analyzed. Materials and Methods: The following five resin-based bulk fill composites were tested: SureFil SDR®, Fill Up!™, Filtek™, SonicFill™, and SonicFill2™. Samples of 4 mm in thickness were prepared using Teflon molds filled in one increment and light-polymerized using two LED power units. Ten samples for each composite were cured using Elipar S10 and 10 using Demi Ultra. Additional samples of SonicFill2, (3 and 5 mm-thick) were also tested. The degree of conversion (DC) was determined by Raman spectroscopy, while the Vickers microhardness (VMH) was evaluated using a microhardness tester. The experimental evaluation was carried out on top and bottom sides, immediately after curing (t0), and, on bottom, after 24 h (t24). Two-ways analysis of variance was applied to evaluate DC and VMH-values. In all analyses, the level of significance was set at p < 0.05. Results: All bulk fill resin composites recorded satisfactory DCs on top and bottom sides. At t0, the top of SDR and SonicFill2 showed the highest DCs-values (85.56 ± 9.52 and 85.47 ± 1.90, respectively), when cured using Elipar S10; using Demi Ultra, SonicFill2 showed the highest DCs-values (90.53 ± 2.18). At t0, the highest DCs-values of bottom sides were recorded by SDR (84.64 ± 11.68), when cured using Elipar S10, and Filtek (81.52 ± 4.14), using Demi Ultra. On top sides, Demi Ultra lamp showed significant higher DCs compared to the Elipar S10 (p < 0.05). SonicFill2 reached suitable DCs also on bottom of 5 mm-thick samples. At t0, VMH-values ranged between 24.4 and 69.18 for Elipar S10, and between 26.5 and 67.3 for Demi Ultra. Using both lamps, the lowest VMH-values were shown by SDR, while the highest values by SonicFill2. At t24, all DC and VMH values significantly increased. Conclusions: Differences in DC and VMH among materials are suggested to be material and curing lamp dependent. Even at t0, the three high viscosity bulk composites showed higher VMH than the flowable or dual curing composites. PMID:28082918

Spectroscopic and Mechanical Properties of a New Generation of Bulk Fill Composites.

PubMed

Monterubbianesi, Riccardo; Orsini, Giovanna; Tosi, Giorgio; Conti, Carla; Librando, Vito; Procaccini, Maurizio; Putignano, Angelo

2016-01-01

Objectives: The aims of this study were to in vitro evaluate the degree of conversion and the microhardness properties of five bulk fill resin composites; in addition, the performance of two curing lamps, used for composites polymerization, was also analyzed. Materials and Methods: The following five resin-based bulk fill composites were tested: SureFil SDR®, Fill Up!™, Filtek™, SonicFill™, and SonicFill2™. Samples of 4 mm in thickness were prepared using Teflon molds filled in one increment and light-polymerized using two LED power units. Ten samples for each composite were cured using Elipar S10 and 10 using Demi Ultra. Additional samples of SonicFill2, (3 and 5 mm-thick) were also tested. The degree of conversion (DC) was determined by Raman spectroscopy, while the Vickers microhardness (VMH) was evaluated using a microhardness tester. The experimental evaluation was carried out on top and bottom sides, immediately after curing (t0), and, on bottom, after 24 h (t24). Two-ways analysis of variance was applied to evaluate DC and VMH-values. In all analyses, the level of significance was set at p < 0.05. Results: All bulk fill resin composites recorded satisfactory DCs on top and bottom sides. At t0, the top of SDR and SonicFill2 showed the highest DCs-values (85.56 ± 9.52 and 85.47 ± 1.90, respectively), when cured using Elipar S10; using Demi Ultra, SonicFill2 showed the highest DCs-values (90.53 ± 2.18). At t0, the highest DCs-values of bottom sides were recorded by SDR (84.64 ± 11.68), when cured using Elipar S10, and Filtek (81.52 ± 4.14), using Demi Ultra. On top sides, Demi Ultra lamp showed significant higher DCs compared to the Elipar S10 ( p < 0.05). SonicFill2 reached suitable DCs also on bottom of 5 mm-thick samples. At t0, VMH-values ranged between 24.4 and 69.18 for Elipar S10, and between 26.5 and 67.3 for Demi Ultra. Using both lamps, the lowest VMH-values were shown by SDR, while the highest values by SonicFill2. At t24, all DC and VMH values significantly increased. Conclusions: Differences in DC and VMH among materials are suggested to be material and curing lamp dependent. Even at t0, the three high viscosity bulk composites showed higher VMH than the flowable or dual curing composites.

SEMICONDUCTOR TECHNOLOGY Dummy fill effect on CMP planarity

NASA Astrophysics Data System (ADS)

Junxiong, Zhou; Lan, Chen; Wenbiao, Ruan; Zhigang, Li; Weixiang, Shen; Tianchun, Ye

2010-10-01

With the use of a chemical-mechanical polishing (CMP) simulator verified by testing data from a foundry, the effect of dummy fill characteristics, such as fill size, fill density and fill shape, on CMP planarity is analyzed. The results indicate that dummy density has a significant impact on oxide erosion, and copper dishing is in proportion to dummy size. We also demonstrate that cross shape dummy fill can have the best dishing performance at the same density.

Prompt remediation of water intrusion corrects the resultant mold contamination in a home.

PubMed

Rockwell, William

2005-01-01

More patients are turning to their allergists with symptoms compatible with allergic rhinitis, allergic sinusitis, and/or bronchial asthma after exposure to mold-contaminated indoor environments. These patients often seek guidance from their allergists in the remediation of the contaminated home or office. The aim of this study was to determine baseline mold spore counts for noncontaminated homes and report a successful mold remediation in one mold-contaminated home. Indoor air quality was tested using volumetric spore counts in 50 homes where homeowners reported no mold-related health problems and in one mold-contaminated home that was remediated. The health of the occupant of the mold-contaminated home also was assessed. Indoor volumetric mold spore counts ranged from 300 to 1200 spores/m3 in the baseline homes. For the successful remediation, the mold counts started at 300 spores/m3, increased to 2800 spores/m3 at the height of the mold contamination, and then fell to 800 spores/m3 after remediation. The occupant's allergic symptoms ceased on complete remediation of the home. Indoor volumetric mold counts taken with the Allergenco MK-3 can reveal a potential indoor mold contamination, with counts above 1000 spores/m3 suggesting indoor mold contamination. Once the presence of indoor mold growth is found, a prompt and thorough remediation can bring mold levels back to near-baseline level and minimize negative health effects for occupants.

Transferability of glass lens molding

NASA Astrophysics Data System (ADS)

Katsuki, Masahide

2006-02-01

Sphere lenses have been used for long time. But it is well known that sphere lenses theoretically have spherical aberration, coma and so on. And, aspheric lenses attract attention recently. Plastic lenses are molded easily with injection machines, and are relatively low cost. They are suitable for mass production. On the other hand, glass lenses have several excellent features such as high refractive index, heat resistance and so on. Many aspheric glass lenses came to be used for the latest digital camera and mobile phone camera module. It is very difficult to produce aspheric glass lenses by conventional process of curve generating and polishing. For the solution of this problem, Glass Molding Machine was developed and is spreading through the market. High precision mold is necessary to mold glass lenses with Glass Molding Machine. The mold core is ground or turned by high precision NC aspheric generator. To obtain higher transferability of the mold core, the function of the molding machine and the conditions of molding are very important. But because of high molding temperature, there are factors of thermal expansion and contraction of the mold and glass material. And it is hard to avoid the factors. In this session, I introduce following items. [1] Technology of glass molding and the machine is introduced. [2] The transferability of glass molding is analyzed with some data of glass lenses molded. [3] Compensation of molding shape error is discussed with examples.

Mold Allergy

MedlinePlus

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

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

Howell, Caitlin; Vu, Thy L.; Lin, Jennifer J.

Inspired by the long-term effectiveness of living antifouling materials, we have developed a method for the selfreplenishment of synthetic biofouling-release surfaces. These surfaces are created by either molding or directly embedding 3D vascular systems into polydimethylsiloxane (PDMS) and filling them with a silicone oil to generate a nontoxic oil-infused material. When replenished with silicone oil from an outside source, these materials are capable of self-lubrication and continuous renewal of the interfacial fouling-release layer. Under accelerated lubricant loss conditions, fully infused vascularized samples retained significantly more lubricant than equivalent nonvascularized controls. Tests of lubricant-infused PDMS in static cultures of the infectiousmore » bacteria Staphylococcus aureus and Escherichia coli as well as the green microalgae Botryococcus braunii, Chlamydomonas reinhardtii, Dunaliella salina, and Nannochloropsis oculata showed a significant reduction in biofilm adhesion compared to PDMS and glass controls containing no lubricant. Further experiments on vascularized versus nonvascularized samples that had been subjected to accelerated lubricant evaporation conditions for up to 48 h showed significantly less biofilm adherence on the vascularized surfaces. These results demonstrate the ability of an embedded lubricant-filled vascular network to improve the longevity of fouling-release surfaces.« less

Advantage of using high strength self compacting concrete for precast product

NASA Astrophysics Data System (ADS)

Murdono, Ferryandy; Agustin, Winda; Soeprapto, Gambiro; Sunarso, Mukhlis

2017-11-01

According to the development in the world of construction, the need for precast concrete also increases. Now the day there are many products with narrow range reinforcement and difficult dimensions. The ordinary concrete is difficult to pour in a mold with narrow range reinforcement inside without vibrator because the concrete can't fill in the gaps between the bars. SCC (Self Compacting Concrete) is a concrete that precast concrete industry needs to. The using of SCC also supports the green construction through the cement reducing and reducing the use of vibrator that requires not less energy. This research is using EFNARC standard as a condition of admission SCC (filling ability, passing ability, segregation resistance), and performed well against the application of the product by the production of Railway Sleeper without using a vibrator. The results of this study, the LB-2 and LB-3 qualified as SCC and compressive strength is expected that greater than 70 MPa, as well as products quality, is equal to standard and can be mass produced with the efficiency of the price of concrete up to 11%.

Fabrication of Wood-Rubber Composites Using Rubber Compound as a Bonding Agent Instead of Adhesives

PubMed Central

Shao, Dongwei; Xu, Min; Cai, Liping; Shi, Sheldon Q.

2016-01-01

Differing from the hot-pressing method in the manufacturing of traditional wood-rubber composites (WRCs), this study was aimed at fabricating WRCs using rubber processing to improve water resistance and mechanical properties. Three steps were used to make WRCs, namely, fiber-rubber mixing, tabletting, and the vulcanization molding process. Ninety-six WRC panels were made with wood fiber contents of 0%–50% at rotor rotational speeds of 15–45 rpm and filled coefficients of 0.55–0.75. Four regression equations, i.e., the tensile strength (Ts), elongation at break (Eb), hardness (Ha) and rebound resilience (Rr) as functions of fiber contents, rotational speed and filled coefficient, were derived and a nonlinear programming model were developed to obtain the optimum composite properties. Although the Ts, Eb and Rr of the panels were reduced, Ha was considerably increased by 17%–58% because of the wood fiber addition. Scanning electron microscope images indicated that fibers were well embedded in rubber matrix. The 24 h water absorption was only 1%–3%, which was much lower than commercial wood-based composites. PMID:28773591

Anisotropic mechanical behavior of an injection molded short fiber reinforced thermoplastic

NASA Astrophysics Data System (ADS)

Lopez, Delphine; Thuillier, Sandrine; Bessières, Nicolas; Grohens, Yves

2016-10-01

A short fiber reinforced thermoplastic was injected into a rectangular mold, in order to prepare samples to characterize the mechanical behavior of the material. The injection process was simulated with Moldflow and a cutting pattern was deduced from the predicted fiber orientation, leading to samples with several well-defined orientations with respect to the injection direction. Monotonic tensile tests up to rupture, as well as complex cycles made of loading steps followed by relaxation steps at different strain levels were performed, in order to check the reproducibility for a given orientation. Moreover, the fiber orientation in the central part of the tensile samples was also analyzed with X-ray tomography. The results show that the mechanical behavior for each orientation (among 6) was rather reproducible, thus validating the cutting pattern.

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

NASA Astrophysics Data System (ADS)

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

2007-05-01

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

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.

Simulation of beam-induced plasma in gas-filled rf cavities

DOE PAGES

Yu, Kwangmin; Samulyak, Roman; Yonehara, Katsuya; ...

2017-03-07

Processes occurring in a radio-frequency (rf) cavity, filled with high pressure gas and interacting with proton beams, have been studied via advanced numerical simulations. Simulations support the experimental program on the hydrogen gas-filled rf cavity in the Mucool Test Area (MTA) at Fermilab, and broader research on the design of muon cooling devices. space, a 3D electromagnetic particle-in-cell (EM-PIC) code with atomic physics support, was used in simulation studies. Plasma dynamics in the rf cavity, including the process of neutral gas ionization by proton beams, plasma loading of the rf cavity, and atomic processes in plasma such as electron-ion andmore » ion-ion recombination and electron attachment to dopant molecules, have been studied. Here, through comparison with experiments in the MTA, simulations quantified several uncertain values of plasma properties such as effective recombination rates and the attachment time of electrons to dopant molecules. Simulations have achieved very good agreement with experiments on plasma loading and related processes. Lastly, the experimentally validated code space is capable of predictive simulations of muon cooling devices.« less

An oil-based model of inhalation anesthetic uptake and elimination.

PubMed

Loughlin, P J; Bowes, W A; Westenskow, D R

1989-08-01

An oil-based model was developed as a physical simulation of inhalation anesthetic uptake and elimination. It provides an alternative to animal models in testing the performance of anesthesia equipment. A 7.5-1 water-filled manometer simulates pulmonary mechanics. Nitrogen and carbon dioxide flowing into the manometer simulate oxygen consumption and carbon dioxide production. Oil-filled chambers (180 ml and 900 ml) simulate the uptake and washout of halothane by the vessel-rich and muscle tissue groups. A 17.2-1 air-filled chamber simulates uptake by the lung group. Gas circulates through the chambers (3.7, 13.8, and 25 l/min) to simulate the transport of anesthetic to the tissues by the circulatory system. Results show that during induction and washout, the rate of rise in endtidal halothane fraction simulated by the model parallels that measured in patients. The model's end-tidal fraction changes correctly with changes in cardiac output and alveolar ventilation. The model has been used to test anesthetic controllers and to evaluate gas sensors, and should be useful in teaching principles underlying volatile anesthetic uptake.

53. PRODUCTION MOLDS. THESE MOLDS ARE COPIES OF THE ORIGINAL ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

53. PRODUCTION MOLDS. THESE MOLDS ARE COPIES OF THE ORIGINAL MOLDS IN THE MORAVIAN POTTERY AND TILE WORKS COLLECTION, AND ARE USED TO PRESS TILES. THE FACTORY KEEPS TEN PRODUCTION MOLDS FOR EACH IMAGE. THE ORIGINAL MOLDS ARE NOT USED IN PRODUCTION. - Moravian Pottery & Tile Works, Southwest side of State Route 313 (Swamp Road), Northwest of East Court Street, Doylestown, Bucks County, PA

Saliva secretory IgA antibodies against molds and mycotoxins in patients exposed to toxigenic fungi.

PubMed

Vojdani, Aristo; Kashanian, Albert; Vojdani, Elroy; Campbell, Andrew W

2003-11-01

Upper respiratory exposure to different environmental antigens results first in the activation of mucosal immunity and production of IgA antibodies in different secretions including saliva. Despite this there is no study, which addresses secretory antibodies against molds and mycotoxins. The purpose of this study was to evaluate mold-specific salivary IgA in individuals exposed to molds and mycotoxins in a water-damaged building environment. Saliva IgA antibody levels against seven different molds and two mycotoxins were studied in 40 patients exposed to molds and in 40 control subjects. Mold-exposed patients showed significantly higher levels of salivary IgA antibodies against one or more mold species. A majority of patients with high IgA antibodies against molds exhibited elevation in salivary IgA against mycotoxins, as well. These IgA antibodies against molds and mycotoxins are specific, since using molds and mycotoxins in immune absorption could reduce antibody levels, significantly. Detection of high counts of molds in water-damaged buildings, strongly suggests the existence of a reservoir of mold spores in the environment. This viable microbial activity with specific mold and mycotoxin IgA in saliva may assist in the diagnosis of mold exposure. Whether mold and mycotoxin specific IgA antibodies detected in saliva are indicative of the role of IgA antibodies in the late phase of type-1 hypersensitivity reaction or in type-2 and type-3 delayed sensitivities is a matter that warrants further investigation.

Resin film infusion mold tooling and molding method

NASA Technical Reports Server (NTRS)

Burgess, Roger (Inventor); Grossheim, Brian (Inventor); Mouradian, Karbis (Inventor); Thrash, Patrick J. (Inventor)

1999-01-01

A mold apparatus and method for resin film infusion molding including an outer mold tool having a facing sheet adapted to support a resin film and preform assembly. The facing sheet includes attachment features extending therefrom. An inner mold tool is positioned on the facing sheet to enclose the resin film and preform assembly for resin film infusion molding. The inner mold tool includes a plurality of mandrels positioned for engagement with the resin film and preform assembly. Each mandrel includes a slot formed therein. A plurality of locating bars cooperate with the slots and with the attachment features for locating the mandrels longitudinally on the outer mold tool.

The mitochondrial genome of the ethanol-metabolizing, wine cellar mold Zasmidium cellare is the smallest for a filamentous ascomycete.

PubMed

Goodwin, Stephen B; McCorison, Cassandra B; Cavaletto, Jessica R; Culley, David E; LaButti, Kurt; Baker, Scott E; Grigoriev, Igor V

2016-08-01

Fungi in the class Dothideomycetes often live in extreme environments or have unusual physiology. One of these, the wine cellar mold Zasmidium cellare, produces thick curtains of mycelia in cellars with high humidity, and its ability to metabolize volatile organic compounds is thought to improve air quality. Whether these abilities have affected its mitochondrial genome is not known. To fill this gap, the circular-mapping mitochondrial genome of Z. cellare was sequenced and, at only 23 743 bp, is the smallest reported for a filamentous fungus. Genes were encoded on both strands with a single change of direction, different from most other fungi but consistent with the Dothideomycetes. Other than its small size, the only unusual feature of the Z. cellare mitochondrial genome was two copies of a 110-bp sequence that were duplicated, inverted and separated by approximately 1 kb. This inverted-repeat sequence confused the assembly program but appears to have no functional significance. The small size of the Z. cellare mitochondrial genome was due to slightly smaller genes, lack of introns and non-essential genes, reduced intergenic spacers and very few ORFs relative to other fungi rather than a loss of essential genes. Whether this reduction facilitates its unusual biology remains unknown. Published by Elsevier Ltd.

A fluid-filled soft robot that exhibits spontaneous switching among versatile spatiotemporal oscillatory patterns inspired by the true slime mold.

PubMed

Umedachi, Takuya; Idei, Ryo; Ito, Kentaro; Ishiguro, Akio

2013-01-01

Behavioral diversity is an essential feature of living systems, enabling them to exhibit adaptive behavior in hostile and dynamically changing environments. However, traditional engineering approaches strive to avoid, or suppress, the behavioral diversity in artificial systems to achieve high performance in specific environments for given tasks. The goals of this research include understanding how living systems exhibit behavioral diversity and using these findings to build lifelike robots that exhibit truly adaptive behaviors. To this end, we have focused on one of the most primitive forms of intelligence concerning behavioral diversity, namely, a plasmodium of true slime mold. The plasmodium is a large amoeba-like unicellular organism that does not possess any nervous system or specialized organs. However, it exhibits versatile spatiotemporal oscillatory patterns and switches spontaneously between these. Inspired by the plasmodium, we built a mathematical model that exhibits versatile oscillatory patterns and spontaneously transitions between these patterns. This model demonstrates that, in contrast to coupled nonlinear oscillators with a well-designed complex diffusion network, physically interacting mechanosensory oscillators are capable of generating versatile oscillatory patterns without changing any parameters. Thus, the results are expected to shed new light on the design scheme for lifelike robots that exhibit amazingly versatile and adaptive behaviors.

Improved compression molding process

NASA Technical Reports Server (NTRS)

Heier, W. C.

1967-01-01

Modified compression molding process produces plastic molding compounds that are strong, homogeneous, free of residual stresses, and have improved ablative characteristics. The conventional method is modified by applying a vacuum to the mold during the molding cycle, using a volatile sink, and exercising precise control of the mold closure limits.

NASA Tech Briefs, September 2005

NASA Technical Reports Server (NTRS)

2005-01-01

Topivs include: Diamond-Coated Carbon Nanotubes for Efficient Field Emission; Improved Anode Coatings for Direct Methanol Fuel Cells; Advanced Ablative Insulators and Methods of Making Them; PETIs as High-Temperature Resin-Transfer-Molding Materials; Stable Polyimides for Terrestrial and Space Uses; Low-Density, Aerogel-Filled Thermal-Insulation Tiles; High-Performance Polymers Having Low Melt Viscosities; Nonflammable, Hydrophobic Aerogel Composites for Insulation; Front-Side Microstrip Line Feeding a Raised Antenna Patch; Medium-Frequency Pseudonoise Georadar; Facilitating Navigation Through Large Archives; Program for Weibull Analysis of Fatigue Data; Comprehensive Micromechanics-Analysis Code - Version 4.0; Component-Based Visualization System; Software for Engineering Simulations of a Spacecraft; LabVIEW Interface for PCI-SpaceWire Interface Card; Path Following with Slip Compensation for a Mars Rover; International Space Station Electric Power System Performance Code-SPACE; Software for Automation of Real-Time Agents, Version 2; Software for Optimizing Plans Involving Interdependent Goals; Computing Gravitational Fields of Finite-Sized Bodies; Custom Sky-Image Mosaics from NASA's Information Power Grid; ANTLR Tree Grammar Generator and Extensions; Generic Kalman Filter Software; Alignment Stage for a Cryogenic Dilatometer; Rugged Iris Mechanism; Treatments To Produce Stabilized Aluminum Mirrors for Cryogenic Uses; Making AlNx Tunnel Barriers Using a Low-Energy Nitrogen-Ion Beam; Making Wide-IF SIS Mixers with Suspended Metal-Beam Leads; Sol-Gel Glass Holographic Light-Shaping Diffusers; Automated Counting of Particles To Quantify Cleanliness; Phase Correction for GPS Antenna with Nonunique Phase Center; Compact Infrasonic Windscreen; Broadband External-Cavity Diode Laser; High-Efficiency Solar Cells Using Photonic-Bandgap Materials; Generating Solid Models from Topographical Data; Computationally Lightweight Air-Traffic-Control Simulation; Spool Valve for Switching Air Flows Between Two Beds; Partial Model of Insulator/ Insulator Contact Charging; Asymmetric Electrostatic Radiation Shielding for Spacecraft; and Reusable Hybrid Propellant Modules for Outer-Space Transport.

An in vitro investigation of wear resistance and hardness of composite resins.

PubMed

Cao, Liqun; Zhao, Xinyi; Gong, Xu; Zhao, Shouliang

2013-01-01

The aim of the present study was to investigate the wear resistance and hardness of five kinds of composite resins. Sixty-five specimens were fabricated with one nano-hybrid (Charisma Diamond), two micro-hybrid (3MZ250, Clearfil AP-X) and two packable (3MP60, Surefil) composite resins, according to a randomized complete block design (n=13, 8 for wear test; 5 for hardness test). The composites were filled in a rectangular mold, and light polymerization. After storage in 37°C deionized water for 24h, all specimens were tested with a custom-made toothbrush machine with a stainless-steel ball as antagonist (3N loads, 1Hz, 6×10(5) cycles) immersed in calcium fluoride slurry. Wear volume, hardness and surface structure of each tested material was examined by a three-dimensional non-contact optical profilometer, Vickers indentation technique and scanning electron microscope. The volume loss ranked from least to most as follows: Charisma Diamond, P60, Z250, Clearfil AP-X and Surefil. Regarding hardness, the rank from highest to lowest as follows: Clearfil AP-X, P60, Surefil, Z250, Charisma Diamond. The interactions between wear resistance and microhardness were not significant. The custom-made machine is considered suitable to simulate sliding of an antagonist cusp on an opposing occlusal composite restoration. Nanofilled composite may have superior wear compared to other composite resins.

Mold and Health

EPA Pesticide Factsheets

Molds have the potential to cause health problems. Molds produce allergens (substances that can cause allergic reactions) and irritants. Inhaling or touching mold or mold spores may cause allergic reactions in sensitive individuals.

MOLD-SPECIFIC QUANTITATIVE PCR: THE EMERGING STANDARD IN MOLD ANALYSIS

EPA Science Inventory

Molds can cause health problems like infections and allergies, destroy crops, and contaminate our food or pharmaceuticals. We can't avoid molds. Molds are essential players in the biological processes on earth, but we can now identify and quantify the molds that will be most pr...

Traditional Mold Analysis Compared to a DNA-based Method of Mold Analysis with Applications in Asthmatics' Homes

EPA Science Inventory

Traditional environmental mold analysis is based-on microscopic observations and counting of mold structures collected from the air on a sticky surface or culturing of molds on growth media for identification and quantification. A DNA-based method of mold analysis called mol...

92. PRODUCTION MOLDS. THESE MOLDS ARE COPIES OF THE ORIGINAL ...

Library of Congress Historic Buildings Survey, Historic Engineering Record, Historic Landscapes Survey

92. PRODUCTION MOLDS. THESE MOLDS ARE COPIES OF THE ORIGINAL MOLDS IN THE MORAVIAN POTTERY AND TILE WORKS COLLECTION, AND ARE USED TO PRESS TILES. THE FACTORY KEEPS TEN PRODUCTION MOLDS FOR EACH IMAGE. THE ORIGINAL MOLDS ARE NOT USED IN PRODUCTION. SAME VIEW AS PA-107-53. - Moravian Pottery & Tile Works, Southwest side of State Route 313 (Swamp Road), Northwest of East Court Street, Doylestown, Bucks County, PA

Testing the responses of four wheat crop models to heat stress at anthesis and grain filling.

PubMed

Liu, Bing; Asseng, Senthold; Liu, Leilei; Tang, Liang; Cao, Weixing; Zhu, Yan

2016-05-01

Higher temperatures caused by future climate change will bring more frequent heat stress events and pose an increasing risk to global wheat production. Crop models have been widely used to simulate future crop productivity but are rarely tested with observed heat stress experimental datasets. Four wheat models (DSSAT-CERES-Wheat, DSSAT-Nwheat, APSIM-Wheat, and WheatGrow) were evaluated with 4 years of environment-controlled phytotron experimental datasets with two wheat cultivars under heat stress at anthesis and grain filling stages. Heat stress at anthesis reduced observed grain numbers per unit area and individual grain size, while heat stress during grain filling mainly decreased the size of the individual grains. The observed impact of heat stress on grain filling duration, total aboveground biomass, grain yield, and grain protein concentration (GPC) varied depending on cultivar and accumulated heat stress. For every unit increase of heat degree days (HDD, degree days over 30 °C), grain filling duration was reduced by 0.30-0.60%, total aboveground biomass was reduced by 0.37-0.43%, and grain yield was reduced by 1.0-1.6%, but GPC was increased by 0.50% for cv Yangmai16 and 0.80% for cv Xumai30. The tested crop simulation models could reproduce some of the observed reductions in grain filling duration, final total aboveground biomass, and grain yield, as well as the observed increase in GPC due to heat stress. Most of the crop models tended to reproduce heat stress impacts better during grain filling than at anthesis. Some of the tested models require improvements in the response to heat stress during grain filling, but all models need improvements in simulating heat stress effects on grain set during anthesis. The observed significant genetic variability in the response of wheat to heat stress needs to be considered through cultivar parameters in future simulation studies. © 2016 John Wiley & Sons Ltd.

Superconducting electromechanical rotating device having a liquid-cooled, potted, one layer stator winding

DOEpatents

Dombrovski, Viatcheslav V.; Driscoll, David I.; Shovkhet, Boris A.

2001-01-01

A superconducting electromechanical rotating (SER) device, such as a synchronous AC motor, includes a superconducting field winding and a one-layer stator winding that may be water-cooled. The stator winding is potted to a support such as the inner radial surface of a support structure and, accordingly, lacks hangers or other mechanical fasteners that otherwise would complicate stator assembly and require the provision of an unnecessarily large gap between adjacent stator coil sections. The one-layer winding topology, resulting in the number of coils being equal to half the number of slots or other mounting locations on the support structure, allows one to minimize or eliminate the gap between the inner radial ends of adjacent straight sections of the stator coilswhile maintaining the gap between the coil knuckles equal to at least the coil width, providing sufficient room for electrical and cooling element configurations and connections. The stator winding may be potted to the support structure or other support, for example, by a one-step VPI process relying on saturation of an absorbent material to fill large gaps in the stator winding or by a two-step process in which small gaps are first filled via a VPI or similar operation and larger gaps are then filled via an operation that utilizes the stator as a portion of an on-site mold.

Influence of different final irrigation regimens and various endodontic filling materials on vertical root fracture resistance.

PubMed

Sungur, D D; Altundasar, E; Uzunoglu, E; Yilmaz, Z

2016-01-01

The aim of this study was to evaluate the influence of different endodontic materials and final irrigation regimens on vertical root fracture (VRF) resistance. Eighty human teeth were prepared then assigned into two groups (n = 40) according to the final irrigations. G1: 5 mL, 5.25% sodium hypochlorite (NaOCl), G2: 5 mL, 2% chlorhexidine gluconate (CHX). Each group was assigned into four subgroups according to the obturation system used (n = 10): A: iRoot SP/single gutta-percha cone (SGP), B: Only iRoot SP, C: Mineral trioxide aggregate (MTA)-Fillapex/SGP, D: AH26/SGP. The specimens were embedded in acrylic molds and subjected to compressive loading at a rate of 1 mm min until VRF occurred. Data were analyzed via three-way ANOVA tests. The statistically significant difference was found among groups (P < 0.05). The G1A and G1B and G1D revealed significantly higher-VRF values than G1C (P = 0.023). The roots filled with MTA-Fillapex revealed lower-VRF values than the other subgroups (P < 0.05). Groups irrigated with NaOCl had significantly lower-VRF values than the groups irrigated with CHX (P < 0.05). Final irrigation regimens could alter VRF resistance of root canals filled with different obturation technique and root canal sealers.

Study of Uneven Fills to Cure the Coupled-Bunch Instability in SRRC

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

Chao, Alex W.

2002-08-12

The performance of the 1.5-GeV storage ring light source TLS in SRRC has been limited by a longitudinal coupled-bunch beam instability. To improve the performance of the TLS, the beam instability has to be suppressed. One possible way considered for the TLS to suppress its coupled-bunch instability uses uneven filling patterns according to the theory of Prabhakar[1]. By knowing the harmful high-order-modes (HOMs), a special filling pattern can be designed to utilize either mode coupling or Landau damping to cure beam instability. In TLS the HOMs are contributed from the Doris RF cavity installed in the storage ring. The HOMsmore » of a 3-D Doris cavity was numerically analyzed. Filling patterns with equal bunch current according to theory had been calculated to cure the most harmful HOM. A longitudinal particle tracking program was used to simulate the coupled-bunch beam instability with both the uniform filling and the special designed filling. Filling pattern with unequal bunch current was also studied. The results of the simulation were discussed and compared to the theory.« less

Simulating human photoreceptor optics using a liquid-filled photonic crystal fiber.

PubMed

Rativa, Diego; Vohnsen, Brian

2011-02-11

We introduce a liquid-filled photonic crystal fiber to simulate a retinal cone photoreceptor mosaic and the directionality selective mechanism broadly known as the Stiles-Crawford effect. Experimental measurements are realized across the visible spectrum to study waveguide coupling and directionality at different managed waveguide parameters. The crystal fiber method is a hybrid tool between theory and a real biological sample and a valuable addition as a retina model for real eye simulations.

Curbing indoor mold growth with mold inhibitors

Treesearch

Carol A. Clausen; Vina W. Yang

2004-01-01

Environmentally acceptable mold inhibitors are needed to curb the growth of mold fungi in woodframe housing when moisture management measures fail. Excess indoor moisture can lead to rapid mold establishment which, in turn, can have deleterious affects on indoor air quality. Compounds with known mold inhibitory properties and low mammalian toxicity, such as food...

Indoor Molds and Respiratory Hypersensitivity: A Comparison of Selected Molds and House Dust Mite Induced Responses in a Mouse Model**

EPA Science Inventory

Molds are ubiquitous in the environment and exposures to molds contribute to various human diseases. Damp/moldy environments have been associated with asthma exacerbation, but mold's role in allergic asthma induction is less clear. The molds selected for these studies are commonl...

Method to Create Arbitrary Sidewall Geometries in 3-Dimensions Using Liga with a Stochastic Optimization Framework

NASA Technical Reports Server (NTRS)

Eyre, Francis B. (Inventor); Fink, Wolfgang (Inventor)

2011-01-01

Disclosed herein is a method of making a three dimensional mold comprising the steps of providing a mold substrate; exposing the substrate with an electromagnetic radiation source for a period of time sufficient to render the portion of the mold substrate susceptible to a developer to produce a modified mold substrate; and developing the modified mold with one or more developing reagents to remove the portion of the mold substrate rendered susceptible to the developer from the mold substrate, to produce the mold having a desired mold shape, wherein the electromagnetic radiation source has a fixed position, and wherein during the exposing step, the mold substrate is manipulated according to a manipulation algorithm in one or more dimensions relative to the electromagnetic radiation source; and wherein the manipulation algorithm is determined using stochastic optimization computations.

The Effect of modeled recharge distribution on simulated groundwater availability and capture

USGS Publications Warehouse

Tillman, Fred D.; Pool, Donald R.; Leake, Stanley A.

2015-01-01

Simulating groundwater flow in basin-fill aquifers of the semiarid southwestern United States commonly requires decisions about how to distribute aquifer recharge. Precipitation can recharge basin-fill aquifers by direct infiltration and transport through faults and fractures in the high-elevation areas, by flowing overland through high-elevation areas to infiltrate at basin-fill margins along mountain fronts, by flowing overland to infiltrate along ephemeral channels that often traverse basins in the area, or by some combination of these processes. The importance of accurately simulating recharge distributions is a current topic of discussion among hydrologists and water managers in the region, but no comparative study has been performed to analyze the effects of different recharge distributions on groundwater simulations. This study investigates the importance of the distribution of aquifer recharge in simulating regional groundwater flow in basin-fill aquifers by calibrating a groundwater-flow model to four different recharge distributions, all with the same total amount of recharge. Similarities are seen in results from steady-state models for optimized hydraulic conductivity values, fit of simulated to observed hydraulic heads, and composite scaled sensitivities of conductivity parameter zones. Transient simulations with hypothetical storage properties and pumping rates produce similar capture rates and storage change results, but differences are noted in the rate of drawdown at some well locations owing to the differences in optimized hydraulic conductivity. Depending on whether the purpose of the groundwater model is to simulate changes in groundwater levels or changes in storage and capture, the distribution of aquifer recharge may or may not be of primary importance.

No Vent Tank Fill and Transfer Line Chilldown Analysis by Generalized Fluid System Simulation Program (GFSSP)

NASA Technical Reports Server (NTRS)

Majumdar, Alok

2013-01-01

The purpose of the paper is to present the analytical capability developed to model no vent chill and fill of cryogenic tank to support CPST (Cryogenic Propellant Storage and Transfer) program. Generalized Fluid System Simulation Program (GFSSP) was adapted to simulate charge-holdvent method of Tank Chilldown. GFSSP models were developed to simulate chilldown of LH2 tank in K-site Test Facility and numerical predictions were compared with test data. The report also describes the modeling technique of simulating the chilldown of a cryogenic transfer line and GFSSP models were developed to simulate the chilldown of a long transfer line and compared with test data.

Mold Testing or Sampling

EPA Pesticide Factsheets

In most cases, if visible mold growth is present, sampling is unnecessary. Since no EPA or other federal limits have been set for mold or mold spores, sampling cannot be used to check a building's compliance with federal mold standards.

Method for making an elastomeric member with end pieces

DOEpatents

Hoppie, L.O.; McNinch, J.H. Jr.; Nowell, G.C.

1984-10-23

A molding process is described for molding an elongated elastomeric member with wire mesh sleeves bonded to the ends. A molding preform of elastomeric material is positioned within a seamless mold cylinder, and the open ends of the wire mesh sleeves are mounted to end plug assemblies slidably received into the mold cylinder and positioned against the ends of the preform. A specialized profile is formed into surfaces of the respective end plug assemblies and by heating of the mold, the ends of the elastomeric preform are molded to the profile, as well as bonded to the reinforcing wire mesh sleeves. Vacuum is applied to the interior of the mold to draw outgassing vapors through relief spaces there through. The completed elastomeric member is removed from the mold cylinder by stretching, the consequent reduction in diameter enabling ready separation from the mold cylinder and removal thereof. 9 figs.

High Cost/High Risk Components to Chalcogenide Molded Lens Model: Molding Preforms and Mold Technology

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

Bernacki, Bruce E.

2012-10-05

This brief report contains a critique of two key components of FiveFocal's cost model for glass compression molding of chalcogenide lenses for infrared applications. Molding preforms and mold technology have the greatest influence on the ultimate cost of the product and help determine the volumes needed to select glass molding over conventional single-point diamond turning or grinding and polishing. This brief report highlights key areas of both technologies with recommendations for further study.

Utilization of Network-Forming Block Copolymers and Ionomers in the Development of Novel Nanostructures and Responsive Media

NASA Astrophysics Data System (ADS)

Mineart, Kenneth

Network forming block copolymers, i.e. thermoplastic elastomers (TPEs), are one of the highest commodity forms of block copolymers due to their competitive elasticity and extendability as well as their ability to be melt and solution processed. TPEs owe many of their advantages to a combination of hard and soft blocks. The soft blocks, which must be covalently bound at both ends to hard blocks, connect adjacent hard domains resulting in physically cross-linked systems. Herein, simulations and theory are used to provide a molecular-level depiction of the evolution from diblock copolymers, which do not contain the ability to form physical cross-links, to network forming triblock copolymers. In addition, systems with high interblock incompatibility that are within the diblock-to-triblock transition (i.e. having high molecular asymmetry) are identified to form three component (ABC triblock copolymer) phases from copolymer containing only two chemically distinct blocks. Following this work, which emphasizes the fundamental principle of TPEs, the dissertation shifts focus to physically- and chemically-modified triblock and pentablock copolymer TPEs. Recent progress has sought to broaden TPEs to include properties that are above and beyond their inherent mechanical benefits, including responsiveness to external stimuli. The first examples presented here consist of TPEs prepared in combination with amorphous hydrocarbon additives to yield TPE gels (TPEGs). The resulting TPEGs, which maintain the beneficial processing properties of TPEs, are subsequently molded into 1- and 2-D arrays of microchannels that are filled with liquid metal. The final devices exhibit strain-sensitive electrical conductivity to at least 600% strain, have tunable compliance (ease of stretching), and are fully recyclable. The substitution of the amorphous hydrocarbon component for crystalline analogues with melting points <100 °C yield TPE composites (TPECs). The TPECs gain the added capability of thermally-triggered shape-memory actuation, which results in a number of design possibilities including: (i) multiple-transition shape-memory in single a composite, (ii) complex actuation in laminates and, (iii) thermally-responsive electrical conductivity in microchannel-molded composites filled with liquid metal. These shape-memory TPECs can also be tuned to have different shape-memory response rates through the addition of an amorphous hydrocarbon tackifier, which serves to dilute the crystalline content without altering TPE concentration. The second set of functionalized TPEs examined are midblock-sulfonated block copolymers, which have substantial ion and water transport abilities, but are often restricted in thermal processability. The casting solvent-dependent morphology of a midblock sulfonated pentablock copolymer highlights the impact of solvent templating on resulting film domain structures. It is shown that film deposition from a miscible mixture of toluene and isopropanol (TIPA) leads to spherical sulfonated domains within a nonpolar matrix whereas deposition from neat tetrahydrofuran (THF) produces a combination of lamellar and hexagonally-pack cylinder nanostructures. These morphologies can both be converted to the anticipated equilibrium morphology, alternating lamellae, using THF vapor-annealing. Further, the morphology resulting from each solvent-casting approach impacts the rate and overall capacity at which films absorb water. Specifically, THF-cast copolymers swell faster and to a greater extent. However, some intrigue lies in the transformation of the TIPA-cast copolymer upon swelling, which yields disordered, but continuous, hydrophilic domains. The disordered morphology outperforms ordered analogues in solar simulation experiments indicating higher ion conductivity.

Exploring the problem of mold growth and the efficacy of various mold inhibitor methods during moisture sorption isotherm measurements.

PubMed

Yu, X; Martin, S E; Schmidt, S J

2008-03-01

Mold growth is a common problem during the equilibration of food materials at high relative humidity values using the standard saturated salt slurry method. Exposing samples to toluene vapor and mixing samples with mold inhibitor chemicals are suggested methods for preventing mold growth while obtaining isotherms. However, no published research was found that examined the effect of mold growth on isotherm performance or the efficacy of various mold inhibitor methods, including their possible effect on the physicochemical properties of food materials. Therefore, the objectives of this study were to (1) explore the effect of mold growth on isotherm performance in a range of food materials, (2) investigate the effectiveness of 4 mold inhibitor methods, irradiation, 2 chemical inhibitors (potassium sorbate and sodium acetate), and toluene vapor, on mold growth on dent corn starch inoculated with A. niger, and (3) examine the effect of mold inhibitor methods on the physicochemical properties of dent corn starch, including isotherm performance, pasting properties, gelatinization temperature, and enthalpy. Mold growth was found to affect starch isotherm performance by contributing to weight changes during sample equilibration. Among the 4 mold inhibitor methods tested, irradiation and toluene vapor were found to be the most effective for inhibiting growth of A. niger on dent cornstarch. However, both methods exhibited a significant impact on the starches' physiochemical properties, suggesting the need to probe the efficacy of other mold inhibitor methods and explore the use of new rapid isotherm instruments, which hamper mold growth by significantly decreasing measurement time.

40 CFR Table 3 to Subpart Wwww of... - Organic HAP Emissions Limits for Existing Open Molding Sources, New Open Molding Sources Emitting...

Code of Federal Regulations, 2010 CFR

2010-07-01

... Existing Open Molding Sources, New Open Molding Sources Emitting Less Than 100 TPY of HAP, and New and... CATEGORIES National Emissions Standards for Hazardous Air Pollutants: Reinforced Plastic Composites... Existing Open Molding Sources, New Open Molding Sources Emitting Less Than 100 TPY of HAP, and New and...

21 CFR 133.184 - Roquefort cheese, sheep's milk blue-mold, and blue-mold cheese from sheep's milk.

Code of Federal Regulations, 2012 CFR

2012-04-01

... 21 Food and Drugs 2 2012-04-01 2012-04-01 false Roquefort cheese, sheep's milk blue-mold, and blue-mold cheese from sheep's milk. 133.184 Section 133.184 Food and Drugs FOOD AND DRUG ADMINISTRATION..., sheep's milk blue-mold, and blue-mold cheese from sheep's milk. (a) Description. (1) Roquefort cheese...

21 CFR 133.184 - Roquefort cheese, sheep's milk blue-mold, and blue-mold cheese from sheep's milk.

Code of Federal Regulations, 2014 CFR

2014-04-01

... 21 Food and Drugs 2 2014-04-01 2014-04-01 false Roquefort cheese, sheep's milk blue-mold, and blue-mold cheese from sheep's milk. 133.184 Section 133.184 Food and Drugs FOOD AND DRUG ADMINISTRATION..., sheep's milk blue-mold, and blue-mold cheese from sheep's milk. (a) Description. (1) Roquefort cheese...

21 CFR 133.184 - Roquefort cheese, sheep's milk blue-mold, and blue-mold cheese from sheep's milk.

Code of Federal Regulations, 2013 CFR

2013-04-01

... 21 Food and Drugs 2 2013-04-01 2013-04-01 false Roquefort cheese, sheep's milk blue-mold, and blue-mold cheese from sheep's milk. 133.184 Section 133.184 Food and Drugs FOOD AND DRUG ADMINISTRATION..., sheep's milk blue-mold, and blue-mold cheese from sheep's milk. (a) Description. (1) Roquefort cheese...

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

NASA Astrophysics Data System (ADS)

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

2011-02-01

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

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.

Assessment of solvent capsule-based healing for woven E-glass fibre-reinforced polymers

NASA Astrophysics Data System (ADS)

Manfredi, Erica; Cohades, Amaël; Richard, Inès; Michaud, Véronique

2015-01-01

Vacuum Assisted Resin Infusion Molding (VARIM) with low vacuum pressure difference was used to manufacture woven glass fibre-reinforced epoxy resin plates, with a fibre volume fraction of approx. 50 vol% and containing ethyl phenylacetate (EPA)-filled capsules for self-healing purposes. Capsules were introduced by functionalising the fabrics through manual dispersion. We investigated the capability of autonomously healing delaminations induced by static loading in Mode I and II. Healing did not take place for composite samples; this was attributed to the presence of bare fibres on the crack plane and to the reduction of EPA diffusion into the matrix in the presence of fibres both of which hinder the swelling mechanism responsible for healing the cracks.

Coating formulation and method for refinishing the surface of surface-damaged graphite articles

DOEpatents

Ardary, Z.L.; Benton, S.T.

1987-07-08

The described development is directed to a coating formulation for filling surface irregularities in graphite articles such as molds, crucibles, and matched die sets used in high-temperature metallurgical operations. The coating formulation of the present invention is formed of carbon black flour, thermosetting resin and a solvent for the resin. In affixing the coating to the article, the solvent is evaporated, the resin cured to bond the coating to the surface of the article and then pyrolyzed to convert the resin to carbon. Upon completion of the pyrolysis step, the coating is shaped and polished to provide the article with a surface restoration that is essentially similar to the original or desired surface finish without the irregularity.

Coating formulation and method for refinishing the surface of surface-damaged graphite articles

DOEpatents

Ardary, Zane L.; Benton, Samuel T.

1988-01-01

The described development is directed to a coating formulation for filling surface irregularities in graphite articles such as molds, crucibles, and matched die sets used in high-temperature metallurgical operations. The coating formulation of the present invention is formed of carbon black flour, thermosetting resin and a solvent for the resin. In affixing the coating to the article, the solvent is evaporated, the resin cured to bond the coating to the surface of the article and then pyrolyzed to convert the resin to carbon. Upon completion of the pyrolysis step, the coating is shaped and polished to provide the article with a surface restoration that is essentially similar to the original or desired surface finish without the irregularity.

Coating formulation and method for refinishing the surface of surface-damaged graphite articles

DOEpatents

Ardary, Z.L.; Benton, S.T.

1988-11-22

The described development is directed to a coating formulation for filling surface irregularities in graphite articles such as molds, crucibles, and matched die sets used in high-temperature metallurgical operations. The coating formulation of the present invention is formed of carbon black flour, thermosetting resin and a solvent for the resin. In affixing the coating to the article, the solvent is evaporated, the resin cured to bond the coating to the surface of the article and then pyrolyzed to convert the resin to carbon. Upon completion of the pyrolysis step, the coating is shaped and polished to provide the article with a surface restoration that is essentially similar to the original or desired surface finish without the irregularity.

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.

Soft 3D-Printed Phantom of the Human Kidney with Collecting System.

PubMed

Adams, Fabian; Qiu, Tian; Mark, Andrew; Fritz, Benjamin; Kramer, Lena; Schlager, Daniel; Wetterauer, Ulrich; Miernik, Arkadiusz; Fischer, Peer

2017-04-01

Organ models are used for planning and simulation of operations, developing new surgical instruments, and training purposes. There is a substantial demand for in vitro organ phantoms, especially in urological surgery. Animal models and existing simulator systems poorly mimic the detailed morphology and the physical properties of human organs. In this paper, we report a novel fabrication process to make a human kidney phantom with realistic anatomical structures and physical properties. The detailed anatomical structure was directly acquired from high resolution CT data sets of human cadaveric kidneys. The soft phantoms were constructed using a novel technique that combines 3D wax printing and polymer molding. Anatomical details and material properties of the phantoms were validated in detail by CT scan, ultrasound, and endoscopy. CT reconstruction, ultrasound examination, and endoscopy showed that the designed phantom mimics a real kidney's detailed anatomy and correctly corresponds to the targeted human cadaver's upper urinary tract. Soft materials with a tensile modulus of 0.8-1.5 MPa as well as biocompatible hydrogels were used to mimic human kidney tissues. We developed a method of constructing 3D organ models from medical imaging data using a 3D wax printing and molding process. This method is cost-effective means for obtaining a reproducible and robust model suitable for surgical simulation and training purposes.

Simulation on Effect of Preform Diameter in Injection Stretch Blow Molding

NASA Astrophysics Data System (ADS)

Tan, Z. Q.; Rosli, Nurrina; Oktaviandri, Muchamad

2018-03-01

Polyethylene terephthalate (PET) is the most common material of resin for manufacturing plastic bottle by injection stretch blow molding due to its excellent properties. As various issues of health and environmental hazards due to the PET use have risen, PET bottle manufacture may be improved by minimizing the wall thickness to reduce the PET use. One of the critical qualifications of the manufacturing process which lead to the wall thickness distribution is the initial preform diameter. In this project, we used the ANSYS Polyflow with aim to evaluate the wall thickness distribution of PET bottle for different diameter of initial preform. As a result, only 4 mm preform diameter presented wall thickness below than 1 mm. On the other hand, at least 6 mm preform diameter can permit the wall thickness 1.3 mm i.e. at the shoulder area.

Extended Eden model reproduces growth of an acellular slime mold.

PubMed

Wagner, G; Halvorsrud, R; Meakin, P

1999-11-01

A stochastic growth model was used to simulate the growth of the acellular slime mold Physarum polycephalum on substrates where the nutrients were confined in separate drops. Growth of Physarum on such substrates was previously studied experimentally and found to produce a range of different growth patterns [Phys. Rev. E 57, 941 (1998)]. The model represented the aging of cluster sites and differed from the original Eden model in that the occupation probability of perimeter sites depended on the time of occupation of adjacent cluster sites. This feature led to a bias in the selection of growth directions. A moderate degree of persistence was found to be crucial to reproduce the biological growth patterns under various conditions. Persistence in growth combined quick propagation in heterogeneous environments with a high probability of locating sources of nutrients.

Extended Eden model reproduces growth of an acellular slime mold

NASA Astrophysics Data System (ADS)

Wagner, Geri; Halvorsrud, Ragnhild; Meakin, Paul

1999-11-01

A stochastic growth model was used to simulate the growth of the acellular slime mold Physarum polycephalum on substrates where the nutrients were confined in separate drops. Growth of Physarum on such substrates was previously studied experimentally and found to produce a range of different growth patterns [Phys. Rev. E 57, 941 (1998)]. The model represented the aging of cluster sites and differed from the original Eden model in that the occupation probability of perimeter sites depended on the time of occupation of adjacent cluster sites. This feature led to a bias in the selection of growth directions. A moderate degree of persistence was found to be crucial to reproduce the biological growth patterns under various conditions. Persistence in growth combined quick propagation in heterogeneous environments with a high probability of locating sources of nutrients.

Staged mold for encapsulating hazardous wastes

DOEpatents

Unger, Samuel L.; Telles, Rodney W.; Lubowitz, Hyman R.

1990-01-01

A staged mold for stabilizing hazardous wastes for final disposal by molding an agglomerate of the hazardous wastes and encapsulating the agglomerate. Three stages are employed in the process. In the first stage, a first mold body is positioned on a first mold base, a mixture of the hazardous wastes and a thermosetting plastic is loaded into the mold, the mixture is mechanically compressed, heat is applied to cure the mixture to form a rigid agglomerate, and the first mold body is removed leaving the agglomerate sitting on the first mold base. In the second stage, a clamshell second mold body is positioned around the agglomerate and the first mold base, a powdered thermoplastic resin is poured on top of the agglomerate and in the gap between the sides of the agglomerate and the second mold body, the thermoplastic is compressed, heat is applied to melt the thermoplastic, and the plastic is cooled jacketing the agglomerate on the top and sides. In the third stage, the mold with the jacketed agglomerate is inverted, the first mold base is removed exposing the former bottom of the agglomerate, powdered thermoplastic is poured over the former bottom, the first mold base is replaced to compress the thermoplastic, heat is applied to melt the new thermoplastic and the top part of the jacket on the sides, the plastic is cooled jacketing the bottom and fusing with the jacketing on the sides to complete the seamless encapsulation of the agglomerate.

Staged mold for encapsulating hazardous wastes

DOEpatents

Unger, Samuel L.; Telles, Rodney W.; Lubowitz, Hyman R.

1988-01-01

A staged mold for stabilizing hazardous wastes for final disposal by molding an agglomerate of the hazardous wastes and encapsulating the agglomerate. Three stages are employed in the process. In the first stage, a first mold body is positioned on a first mold base, a mixture of the hazardous wastes and a thermosetting plastic is loaded into the mold, the mixture is mechanically compressed, heat is applied to cure the mixture to form a rigid agglomerate, and the first mold body is removed leaving the agglomerate sitting on the first mold base. In the second stage, a clamshell second mold body is positioned around the agglomerate and the first mold base, a powdered thermoplastic resin is poured on top of the agglomerate and in the gap between the sides of the agglomerate and the second mold body, the thermoplastic is compressed, heat is applied to melt the thermoplastic, and the plastic is cooled jacketing the agglomerate on the top and sides. In the third stage, the mold with the jacketed agglomerate is inverted, the first mold base is removed exposing the former bottom of the agglomerate, powdered thermoplastic is poured over the former bottom, the first mold base is replaced to compress the thermoplastic, heat is applied to melt the new thermoplastic and the top part of the jacket on the sides, the plastic is cooled jacketing the bottom and fusing with the jacketing on the sides to complete the seamless encapsulation of the agglomerate.

Method for encapsulating hazardous wastes using a staged mold

DOEpatents

Unger, Samuel L.; Telles, Rodney W.; Lubowitz, Hyman R.

1989-01-01

A staged mold and method for stabilizing hazardous wastes for final disposal by molding an agglomerate of the hazardous wastes and encapsulating the agglomerate. Three stages are employed in the process. In the first stage, a first mold body is positioned on a first mold base, a mixture of the hazardous wastes and a thermosetting plastic is loaded into the mold, the mixture is mechanically compressed, heat is applied to cure the mixture to form a rigid agglomerate, and the first mold body is removed leaving the agglomerate sitting on the first mold base. In the second stage, a clamshell second mold body is positioned around the agglomerate and the first mold base, a powdered thermoplastic resin is poured on top of the agglomerate and in the gap between the sides of the agglomerate and the second mold body, the thermoplastic is compressed, heat is applied to melt the thermoplastic, and the plastic is cooled jacketing the agglomerate on the top and sides. In the third stage, the mold with the jacketed agglomerate is inverted, the first mold base is removed exposing the former bottom of the agglomerate, powdered thermoplastic is poured over the former bottom, the first mold base is replaced to compress the thermoplastic, heat is applied to melt the new thermoplastic and the top part of the jacket on the sides, the plastic is cooled jacketing the bottom and fusing with the jacketing on the sides to complete the seamless encapsulation of the agglomerate.

Environmental Sustainability and Mold Hygiene in Buildings

PubMed Central

Ng, Tsz Wai; Lai, Ka Man

2018-01-01

Environmental sustainability is one of the key issues in building management. In Hong Kong, one of the initiatives is to reduce the operation hours of air-conditioning in buildings to cut down energy consumption. In this study, we reported a mold contamination case in a newly refurbished laboratory, in which the air-conditioner was switched from 24- to 18-h mode after refurbishment. In order to prevent mold recurrence, the air-conditioner was switched back to 24-h mode in the laboratory. During the mold investigation, visible mold patches in the laboratory were searched and then cultured, counted and identified. Building and environmental conditions were recorded, and used to deduce different causes of mold contamination. Eight contaminated sites including a wall, a bench, some metal and plastic surfaces and seven types of molds including two Cladosporium spp., two Aspergillus spp., one Rhizopus sp., one Trichoderma sp., and one Tritirachium sp. were identified. Cladosporium spp. were the most abundant and frequently found molds in the laboratory. The contaminated areas could have one to five different species on them. Based on the mold and environmental conditions, several scenarios causing the mold contamination were deduced, and different mold control measures were discussed to compare them with the current solution of using 24-h air-conditioning to control mold growth. This study highlights the importance of mold hygiene in sustainable building management. PMID:29617339

Environmental Sustainability and Mold Hygiene in Buildings.

PubMed

Wu, Haoxiang; Ng, Tsz Wai; Wong, Jonathan Wc; Lai, Ka Man

2018-04-04

Environmental sustainability is one of the key issues in building management. In Hong Kong, one of the initiatives is to reduce the operation hours of air-conditioning in buildings to cut down energy consumption. In this study, we reported a mold contamination case in a newly refurbished laboratory, in which the air-conditioner was switched from 24- to 18-h mode after refurbishment. In order to prevent mold recurrence, the air-conditioner was switched back to 24-h mode in the laboratory. During the mold investigation, visible mold patches in the laboratory were searched and then cultured, counted and identified. Building and environmental conditions were recorded, and used to deduce different causes of mold contamination. Eight contaminated sites including a wall, a bench, some metal and plastic surfaces and seven types of molds including two Cladosporium spp., two Aspergillus spp., one Rhizopus sp., one Trichoderma sp., and one Tritirachium sp. were identified. Cladosporium spp. were the most abundant and frequently found molds in the laboratory. The contaminated areas could have one to five different species on them. Based on the mold and environmental conditions, several scenarios causing the mold contamination were deduced, and different mold control measures were discussed to compare them with the current solution of using 24-h air-conditioning to control mold growth. This study highlights the importance of mold hygiene in sustainable building management.

Study of Shell-Mold Thermal Resistance: Laboratory Measurements, Estimation from Compact Strip Production Plant Data, and Observation of Simulated Flux-Mold Interface

NASA Astrophysics Data System (ADS)

González de la C., J. Manuel; Flores F., Tania M.; Castillejos E., A. Humberto

2016-08-01

The slag film that forms between the shell and mold in steel continuous casting is key in regulating the heat transfer between them. Generally, the mechanisms proposed are related to the phenomena associated with the formation of crystals in the solid layer of the film, such as the appearance of internal pores and surface roughness, which decrease phononic conduction through the layer and interfacial gap with the mold, respectively, and the emergence of crystals themselves, which reduce the transmissivity of infrared radiation across the layer. Due to the importance of the solid layer, this study investigates experimentally the effective thermal resistance, R T, between a hot Inconel surface and a cold Cu surface separated by an initially glassy slag disk, made from powders for casting low and medium-carbon steels, denoted as A and B, respectively. In the tests, an initially mirror-polished disk is sandwiched for 10,800 seconds while the Inconel temperature, away from the disk face, is maintained steady at a value, T c, between 973 K and 1423 K (700 °C and 1150 °C)-below the liquidus temperature of the slags. The disks have a thickness, d t, between ~0.7 and 3.2 mm. Over the range of conditions studied, mold slag B shows R T 33 pct larger than slag A, and microscopic observation of disks hints that the greater resistance arises from the larger porosity developed in B. This finding is supported by high-temperature confocal laser scanning microscope observations of the evolution of the surface of slag parallelepipeds encased between Pt sheets, which reveal that during devitrification the film surface moves outward not inward, contrary with what is widely claimed. This behavior would favor contact of the slag with the mold for both kinds of powders. However, in the case of slag A, the crystalline grains growing at or near the surface pack closely together, leaving only few and small empty spaces. In slag B, crystalline grains pack loosely and many and large empty spaces arise in and below the surface. Estimation from plant data shows R T values smaller than measured ones, suggesting that the process film slag thickness must be considerably thinner than those of laboratory disks. However, the difference in thermal resistance of both powders, averaged over the mold length, is close to the dissimilarity found in laboratory.

KSC-08pd3565

NASA Image and Video Library

2008-11-06

CAPE CANAVERAL, Fla. – Inside the Vehicle Assembly Building high bay 4 at NASA's Kennedy Space Center in Florida, these Ares I-X upper stage simulator segments have shed their protective blue shrink-wrapped covers used for shipping. The upper stage simulator will be used in the test flight identified as Ares I-X in 2009. The segments will simulate the mass and the outer mold line and will be more than 100 feet of the total vehicle height of 327 feet. The simulator comprises 11 segments that are approximately 18 feet in diameter. Most of the segments will be approximately 10 feet high, ranging in weight from 18,000 to 60,000 pounds, for a total of approximately 450,000 pounds. Photo credit: NASA/Troy Cryder

KSC-08pd3564

NASA Image and Video Library

2008-11-06

CAPE CANAVERAL, Fla. – Inside the Vehicle Assembly Building high bay 4 at NASA's Kennedy Space Center in Florida, these Ares I-X upper stage simulator segments have shed their protective blue shrink-wrapped covers used for shipping. The upper stage simulator will be used in the test flight identified as Ares I-X in 2009. The segments will simulate the mass and the outer mold line and will be more than 100 feet of the total vehicle height of 327 feet. The simulator comprises 11 segments that are approximately 18 feet in diameter. Most of the segments will be approximately 10 feet high, ranging in weight from 18,000 to 60,000 pounds, for a total of approximately 450,000 pounds. Photo credit: NASA/Troy Cryder

KSC-08pd3570

NASA Image and Video Library

2008-11-06

CAPE CANAVERAL, Fla. – Inside the Vehicle Assembly Building high bay 4 at NASA's Kennedy Space Center in Florida, these Ares I-X upper stage simulator segments have shed their protective blue shrink-wrapped covers used for shipping. The upper stage simulator will be used in the test flight identified as Ares I-X in 2009. The segments will simulate the mass and the outer mold line and will be more than 100 feet of the total vehicle height of 327 feet. The simulator comprises 11 segments that are approximately 18 feet in diameter. Most of the segments will be approximately 10 feet high, ranging in weight from 18,000 to 60,000 pounds, for a total of approximately 450,000 pounds. Photo credit: NASA/Troy Cryder

Effects of buried obstacles on penetration resistance in cohesionless soils

NASA Technical Reports Server (NTRS)

Deluca, E. W.; Carrasco, L. H.

1972-01-01

Recent experiments concerning penetration of cohesionless soils in special molds that include solid obstacles embedded within the soil matrix are reported. The relative effects of these obstacles with respect to the soil properties of relative density, texture, and gradation are also discussed. Because lunar soil is fairly cohesionless, special attention was given to the Apollo lunar simulant, AP-12.

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.

Dissolving Hydroxyolite: A DNA Molecule into Its Hydroxyapatite Mold.

PubMed

Bertran, Oscar; Revilla-López, Guillermo; Casanovas, Jordi; Del Valle, Luis J; Turon, Pau; Puiggalí, Jordi; Alemán, Carlos

2016-05-04

In spite of the clinical importance of hydroxyapatite (HAp), the mechanism that controls its dissolution in acidic environments remains unclear. Knowledge of such a process is highly desirable to provide better understanding of different pathologies, as for example osteoporosis, and of the HAp potential as vehicle for gene delivery to replace damaged DNA. In this work, the mechanism of dissolution in acid conditions of HAp nanoparticles encapsulating double-stranded DNA has been investigated at the atomistic level using computer simulations. For this purpose, four consecutive (multi-step) molecular dynamics simulations, involving different temperatures and proton transfer processes, have been carried out. Results are consistent with a polynuclear decalcification mechanism in which proton transfer processes, from the surface to the internal regions of the particle, play a crucial role. In addition, the DNA remains protected by the mineral mold and transferred proton from both temperature and chemicals. These results, which indicate that biomineralization imparts very effective protection to DNA, also have important implications in other biomedical fields, as for example in the design of artificial bones or in the fight against osteoporosis by promoting the fixation of Ca(2+) ions. © 2016 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

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

Bordival, M.; Schmidt, F. M.; Le Maoult, Y.

In the Stretch-Blow Molding (SBM) process, the temperature distribution of the reheated perform affects drastically the blowing kinematic, the bottle thickness distribution, as well as the orientation induced by stretching. Consequently, mechanical and optical properties of the final bottle are closely related to heating conditions. In order to predict the 3D temperature distribution of a rotating preform, numerical software using control-volume method has been developed. Since PET behaves like a semi-transparent medium, the radiative flux absorption was computed using Beer Lambert law. In a second step, 2D axi-symmetric simulations of the SBM have been developed using the finite element packagemore » ABAQUS registered . Temperature profiles through the preform wall thickness and along its length were computed and applied as initial condition. Air pressure inside the preform was not considered as an input variable, but was automatically computed using a thermodynamic model. The heat transfer coefficient applied between the mold and the polymer was also measured. Finally, the G'sell law was used for modeling PET behavior. For both heating and blowing stage simulations, a good agreement has been observed with experimental measurements. This work is part of the European project ''APT{sub P}ACK'' (Advanced knowledge of Polymer deformation for Tomorrow's PACKaging)« less

Development of eddy current probe for fiber orientation assessment in carbon fiber composites

NASA Astrophysics Data System (ADS)

Wincheski, Russell A.; Zhao, Selina

2018-04-01

Measurement of the fiber orientation in a carbon fiber composite material is crucial in understanding the load carrying capability of the structure. As manufacturing conditions including resin flow and molding pressures can alter fiber orientation, verification of the as-designed fiber layup is necessary to ensure optimal performance of the structure. In this work, the development of an eddy current probe and data processing technique for analysis of fiber orientation in carbon fiber composites is presented. A proposed directional eddy current probe is modeled and its response to an anisotropic multi-layer conductor simulated. The modeling results are then used to finalize specifications of the eddy current probe. Experimental testing of the fabricated probe is presented for several samples including a truncated pyramid part with complex fiber orientation draped to the geometry for resin transfer molding. The inductively coupled single sided measurement enables fiber orientation characterization through the thickness of the part. The fast and cost-effective technique can be applied as a spot check or as a surface map of the fiber orientations across the structure. This paper will detail the results of the probe design, computer simulations, and experimental results.

Radio-Frequency Tank Eigenmode Sensor for Propellant Quantity Gauging

NASA Technical Reports Server (NTRS)

Zimmerli, Gregory A.; Buchanan, David A.; Follo, Jeffrey C.; Vaden, Karl R.; Wagner, James D.; Asipauskas, Marius; Herlacher, Michael D.

2010-01-01

Although there are several methods for determining liquid level in a tank, there are no proven methods to quickly gauge the amount of propellant in a tank while it is in low gravity or under low-settling thrust conditions where propellant sloshing is an issue. Having the ability to quickly and accurately gauge propellant tanks in low-gravity is an enabling technology that would allow a spacecraft crew or mission control to always know the amount of propellant onboard, thus increasing the chances for a successful mission. The Radio Frequency Mass Gauge (RFMG) technique measures the electromagnetic eigenmodes, or natural resonant frequencies, of a tank containing a dielectric fluid. The essential hardware components consist of an RF network analyzer that measures the reflected power from an antenna probe mounted internal to the tank. At a resonant frequency, there is a drop in the reflected power, and these inverted peaks in the reflected power spectrum are identified as the tank eigenmode frequencies using a peak-detection software algorithm. This information is passed to a pattern-matching algorithm, which compares the measured eigenmode frequencies with a database of simulated eigenmode frequencies at various fill levels. A best match between the simulated and measured frequency values occurs at some fill level, which is then reported as the gauged fill level. The database of simulated eigenmode frequencies is created by using RF simulation software to calculate the tank eigenmodes at various fill levels. The input to the simulations consists of a fairly high-fidelity tank model with proper dimensions and including internal tank hardware, the dielectric properties of the fluid, and a defined liquid/vapor interface. Because of small discrepancies between the model and actual hardware, the measured empty tank spectra and simulations are used to create a set of correction factors for each mode (typically in the range of 0.999 1.001), which effectively accounts for the small discrepancies. These correction factors are multiplied to the modes at all fill levels. By comparing several measured modes with the simulations, it is possible to accurately gauge the amount of propellant in the tank. An advantage of the RFMG approach of applying computer simulations and a pattern-matching algorithm is that the Although there are several methods for determining liquid level in a tank, there are no proven methods to quickly gauge the amount of propellant in a tank while it is in low gravity or under low-settling thrust conditions where propellant sloshing is an issue. Having the ability to quickly and accurately gauge propellant tanks in low-gravity is an enabling technology that would allow a spacecraft crew or mission control to always know the amount of propellant onboard, thus increasing the chances for a successful mission. The Radio Frequency Mass Gauge (RFMG) technique measures the electromagnetic eigenmodes, or natural resonant frequencies, of a tank containing a dielectric fluid. The essential hardware components consist of an RF network analyzer that measures the reflected power from an antenna probe mounted internal to the tank. At a resonant frequency, there is a drop in the reflected power, and these inverted peaks in the reflected power spectrum are identified as the tank eigenmode frequencies using a peak-detection software algorithm. This information is passed to a pattern-matching algorithm, which compares the measured eigenmode frequencies with a database of simulated eigenmode frequencies at various fill levels. A best match between the simulated and measured frequency values occurs at some fill level, which is then reported as the gauged fill level. The database of simulated eigenmode frequencies is created by using RF simulation software to calculate the tank eigenmodes at various fill levels. The input to the simulations consists of a fairly high-fidelity tank model with proper dimensions and including internal tank harare, the dielectric properties of the fluid, and a defined liquid/vapor interface. Because of small discrepancies between the model and actual hardware, the measured empty tank spectra and simulations are used to create a set of correction factors for each mode (typically in the range of 0.999 1.001), which effectively accounts for the small discrepancies. These correction factors are multiplied to the modes at all fill levels. By comparing several measured modes with the simulations, it is possible to accurately gauge the amount of propellant in the tank. An advantage of the RFMG approach of applying computer simulations and a pattern-matching algorithm is that the

Method for making an elastomeric member with end pieces

DOEpatents

Hoppie, Lyle O.; McNinch, Jr., Joseph H.; Nowell, Gregory C.

1984-01-01

A molding process for molding an elongated elastomeric member (60) with wire mesh sleeves (16) bonded to the ends (14). A molding preform (10) of elastomeric material is positioned within a seamless mold cylinder (26), and the open ends of the wire mesh sleeves (16) are mounted to end plug assemblies (30) slidably received into the mold cylinder (26) and positioned against the ends (14) of the preform (10). A specialized profile is formed into surfaces (44) of the respective end plug assemblies (30) and by heating of the mold (26), the ends (14) of the elastomeric preform (10) are molded to the profile, as well as bonded to the reinforcing wire mesh sleeves (16). Vacuum is applied to the interior of the mold to draw outgassing vapors through relief spaces therethrough. The completed elastomeric member (60) is removed from the mold cylinder (26) by stretching, the consequent reduction in diameter enabling ready separation from the mold cylinder (26) and removal thereof.

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

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

Challenges in mold manufacturing for high precision molded diffractive optical elements

NASA Astrophysics Data System (ADS)

Pongs, Guido; Bresseler, Bernd; Schweizer, Klaus; Bergs, Thomas

2016-09-01

Isothermal precision glass molding of imaging optics is the key technology for mass production of precise optical elements. Especially for numerous consumer applications (e.g. digital cameras, smart phones, …), high precision glass molding is applied for the manufacturing of aspherical lenses. The usage of diffractive optical elements (DOEs) can help to further reduce the number of lenses in the optical systems which will lead to a reduced weight of hand-held optical devices. But today the application of molded glass DOEs is limited due to the technological challenges in structuring the mold surfaces. Depending on the application submicrometer structures are required on the mold surface. Furthermore these structures have to be replicated very precisely to the glass lens surface. Especially the micro structuring of hard and brittle mold materials such as Tungsten Carbide is very difficult and not established. Thus a multitude of innovative approaches using diffractive optical elements cannot be realized. Aixtooling has investigated in different mold materials and different suitable machining technologies for the micro- and sub-micrometer structuring of mold surfaces. The focus of the work lays on ultra-precision grinding to generate the diffractive pattern on the mold surfaces. This paper presents the latest achievements in diffractive structuring of Tungsten Carbide mold surfaces by ultra-precision grinding.

Feasibility of using Big Area Additive Manufacturing to Directly Manufacture Boat Molds

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

Post, Brian K.; Chesser, Phillip C.; Lind, Randall F.

The goal of this project was to explore the feasibility of using Big Area Additive Manufacturing (BAAM) to directly manufacture a boat mold without the need for coatings. All prior tooling projects with BAAM required the use to thick coatings to overcome the surface finish limitations of the BAAM process. While the BAAM process significantly lowers the cost of building the mold, the high cost element rapidly became the coatings (cost of the material, labor on coating, and finishing). As an example, the time and cost to manufacture the molds for the Wind Turbine project with TPI Composites Inc. andmore » the molds for the submarine project with Carderock Naval Warfare Systems was a fraction of the time and cost of the coatings. For this project, a catamaran boat hull mold was designed, manufactured, and assembled with an additional 0.15” thickness of material on all mold surfaces. After printing, the mold was immediately machined and assembled. Alliance MG, LLC (AMG), the industry partner of this project, experimented with mold release agents on the carbon-fiber reinforced acrylonitrile butadiene styrene (CF ABS) to verify that the material can be directly used as a mold (rather than needing a coating). In addition, for large molds (such as the wind turbine mold with TPI Composites Inc.), the mold only provided the target surface. A steel subframe had to be manufactured to provide structural integrity. If successful, this will significantly reduce the time and cost necessary for manufacturing large resin infusion molds using the BAAM process.« less

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

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

Nguyen, Ba Nghiep; Fifield, Leonard S.; Kijewski, Seth A.

2015-01-29

During the first quarter of FY 2015, the following technical progress has been made toward project milestones: 1) Autodesk delivered a new research version of ASMI to PNNL. This version includes the improved 3D fiber orientation solver, and the reduced order model (ROM) for fiber length distribution using the proper orthogonal decomposition (POD) implemented in the mid-plane, dual-domain and 3D solvers. 2) Autodesk coordinated a conference paper with PNNL reporting ASMI mid-plane fiber orientation predictions compared with the measured data for two PlastiComp plaques. This paper was accepted for presentation at the 2015 Society for Plastics Engineers (SPE) ANTEC conference.more » 3) The University of Illinois (Prof. Tucker) assisted team members from Purdue with fiber orientation measurement techniques, including interpretation of off-axis cross sections. 4) The University of Illinois assisted Autodesk team members with software implementation of the POD approach for fiber length modeling, and with fiber orientation modeling. 5) The University of Illinois co-authored in the SPE ANTEC paper, participated with the team in discussions of plaque data and model results, and participated in the definition of go/no-go experiments and data. 6) Purdue University (Purdue) conducted fiber orientation measurements for 3 PlastiComp plaques: fast-fill 30wt% LCF/PP center-gated, fast-fill 50wt% LCF/PA66 edge-gated and fast-fill 50wt% LCF/PA66 center-gated plaques, and delivered the fiber orientation data for these plaques at the selected locations (named A, B, and C) to PNNL. However, the data for the fast-fill 50wt% LCF/PA66 edge-gated plaque exhibited unusual variations and could not be used for the model validation. Purdue will re-measure fiber orientation for this plaque. 7) Based on discussions with the University of Illinois Purdue explained the ambiguity in the measurements of the fiber orientation components. 8) PNNL discussed with team members to establish a go/no-go decision plan for the project and submitted the established plan to DOE. 9) PNNL performed ASMI mid-plane analyses for the fast-fill center-gated 30wt% LCF/PP and 50wt% LCF/PA66 plaques and compared the predicted fiber orientations with the measured data provided by Purdue at Locations A, B, and C on these plaques. 10) Based on discussions with the University of Illinois and Autodesk, PNNL proposed a procedure to adjust fiber orientation data for Location A of the center-gated plaques so that the data can be expressed and interpreted in the flow/cross-flow direction coordinate system. 11) PNNL tested the new ASMI version received from Autodesk, examined and discussed 3D fiber orientation predictions for PlastiComp plaques. 12) PlastiComp, Inc. (PlastiComp), Toyota Research Institute North America (Toyota) and Magna Exteriors and Interiors Corp. (Magna) participated in discussions with team members on the go/no-go plan and the issues related to fiber length measurements. Toyota continued the discussion with Magna on tool modification for molding the complex part in order to achieve the target fiber length in the part.« less

The effect of modeled recharge distribution on simulated groundwater availability and capture.

PubMed

Tillman, F D; Pool, D R; Leake, S A

2015-01-01

Simulating groundwater flow in basin-fill aquifers of the semiarid southwestern United States commonly requires decisions about how to distribute aquifer recharge. Precipitation can recharge basin-fill aquifers by direct infiltration and transport through faults and fractures in the high-elevation areas, by flowing overland through high-elevation areas to infiltrate at basin-fill margins along mountain fronts, by flowing overland to infiltrate along ephemeral channels that often traverse basins in the area, or by some combination of these processes. The importance of accurately simulating recharge distributions is a current topic of discussion among hydrologists and water managers in the region, but no comparative study has been performed to analyze the effects of different recharge distributions on groundwater simulations. This study investigates the importance of the distribution of aquifer recharge in simulating regional groundwater flow in basin-fill aquifers by calibrating a groundwater-flow model to four different recharge distributions, all with the same total amount of recharge. Similarities are seen in results from steady-state models for optimized hydraulic conductivity values, fit of simulated to observed hydraulic heads, and composite scaled sensitivities of conductivity parameter zones. Transient simulations with hypothetical storage properties and pumping rates produce similar capture rates and storage change results, but differences are noted in the rate of drawdown at some well locations owing to the differences in optimized hydraulic conductivity. Depending on whether the purpose of the groundwater model is to simulate changes in groundwater levels or changes in storage and capture, the distribution of aquifer recharge may or may not be of primary importance. Published 2014. This article is a U.S. Government work and is in the public domain in the USA.

Fabrication of robust tooling for mass production of polymeric microfluidic devices

NASA Astrophysics Data System (ADS)

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

2010-08-01

Polymer microfluidic devices are gaining popularity for bio-applications. In both commonly used methods for the fabrication of polymer microfluidic devices, i.e. injection molding and hot-embossing, the quality of a mold insert is of high importance. Micro powder injection molding (μPIM) provides a suitable option for metal mold insert fabrication. In this paper, two mold inserts with micro-features of different patterns and sizes were produced using 316L stainless steel powder and an in-house binder system. The mold inserts were successfully used to produce cyclic olefin copolymer (COC, trade name TOPAS) micromixer plates with micro-channels of widths 100 µm and 50 µm. Compared with CNC-machined hot work steel mold inserts, the quality of the micro-channels is better as far as geometrical quality and dimensional tolerance are concerned. However, surface finish and flatness of the μPIM mold inserts are inferior to those of CNC-machined mold inserts.

Localized mold heating with the aid of selective induction for injection molding of high aspect ratio micro-features

NASA Astrophysics Data System (ADS)

Park, Keun; Lee, Sang-Ik

2010-03-01

High-frequency induction is an efficient, non-contact means of heating the surface of an injection mold through electromagnetic induction. Because the procedure allows for the rapid heating and cooling of mold surfaces, it has been recently applied to the injection molding of thin-walled parts or micro/nano-structures. The present study proposes a localized heating method involving the selective use of mold materials to enhance the heating efficiency of high-frequency induction heating. For localized induction heating, a composite injection mold of ferromagnetic material and paramagnetic material is used. The feasibility of the proposed heating method is investigated through numerical analyses in terms of its heating efficiency for localized mold surfaces and in terms of the structural safety of the composite mold. The moldability of high aspect ratio micro-features is then experimentally compared under a variety of induction heating conditions.

Evaluation of the microstructure, secondary dendrite arm spacing, and mechanical properties of Al-Si alloy castings made in sand and Fe-Cr slag molds

NASA Astrophysics Data System (ADS)

Narasimha Murthy, I.; Babu Rao, J.

2017-07-01

The microstructure and mechanical properties of as-cast A356 (Al-Si) alloy castings were investigated. A356 alloy was cast into three different molds composed of sand, ferrochrome (Fe-Cr) slag, and a mixture of sand and Fe-Cr. A sodium silicate-CO2 process was used to make the necessary molds. Cylindrical-shaped castings were prepared. Cast products with no porosity and a good surface finish were achieved in all of the molds. These castings were evaluated for their metallography, secondary dendrite arm spacing (SDAS), and mechanical properties, including hardness, compression, tensile, and impact properties. Furthermore, the tensile and impact samples were analyzed by fractography. The results show that faster heat transfer in the Fe-Cr slag molds than in either the silica sand or mixed molds led to lower SDAS values with a refined microstructure in the products cast in Fe-Cr slag molds. Consistent and enhanced mechanical properties were observed in the slag mold products than in the castings obtained from either sand or mixed molds. The fracture surface of the slag mold castings shows a dimple fracture morphology with a transgranular fracture nature. However, the fracture surfaces of the sand mold castings display brittle fracture. In conclusion, products cast in Fe-Cr slag molds exhibit an improved surface finish and enhanced mechanical properties compared to those of products cast in sand and mixed molds.

Using Theory and Simulation to Design Self-Healing Surfaces

DTIC Science & Technology

2007-11-16

blends, microcapsules Anna C. Balazs University of Pittsburgh Office of Sponsored Programs 3700 O’Hara St Pittsburgh, PA 15260 - REPORT DOCUMENTATION PAGE...novel computational approach (P5) to simulate the rolling motion of fluid-driven, particle-filled microcapsules along heterogeneous, adhesive substrates...established guidelines for designing particle-filled microcapsules that perform a “repair and go” function and could ultimately be used to restore

Materials for Advanced Ultrasupercritical Steam Turbines Task 4: Cast Superalloy Development

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

Thangirala, Mani

The Steam Turbine critical stationary structural components are high integrity Large Shell and Valve Casing heavy section Castings, containing high temperature steam under high pressures. Hence to support the development of advanced materials technology for use in an AUSC steam turbine capable of operating with steam conditions of 760°C (1400°F) and 35 Mpa (5000 psia), Casting alloy selection and evaluation of mechanical, metallurgical properties and castability with robust manufacturing methods are mandated. Alloy down select from Phase 1 based on producability criteria and creep rupture properties tested by NETL-Albany and ORNL directed the consortium to investigate cast properties of Haynesmore » 282 and Haynes 263. The goals of Task 4 in Phase 2 are to understand a broader range of mechanical properties, the impact of manufacturing variables on those properties. Scale up the size of heats to production levels to facilitate the understanding of the impact of heat and component weight, on metallurgical and mechanical behavior. GE Power & Water Materials and Processes Engineering for the Phase 2, Task 4.0 Castings work, systematically designed and executed casting material property evaluation, multiple test programs. Starting from 15 lbs. cylinder castings to world’s first 17,000 lbs. poured weight, heavy section large steam turbine partial valve Haynes 282 super alloy casting. This has demonstrated scalability of the material for steam Turbine applications. Activities under Task 4.0, Investigated and characterized various mechanical properties of Cast Haynes 282 and Cast Nimonic 263. The development stages involved were: 1) Small Cast Evaluation: 4 inch diam. Haynes 282 and Nimonic 263 Cylinders. This provided effects of liquidus super heat range and first baseline mechanical data on cast versions of conventional vacuum re-melted and forged Ni based super alloys. 2) Step block castings of 300 lbs. and 600 lbs. Haynes 282 from 2 foundry heats were evaluated which demonstrated the importance of proper heat treat cycles for Homogenization, and Solutionizing parameters selection and implementation. 3) Step blocks casting of Nimonic 263: Carried out casting solidification simulation analysis, NDT inspection methods evaluation, detailed test matrix for Chemical, Tensile, LCF, stress rupture, CVN impact, hardness and J1C Fracture toughness section sensitivity data and were reported. 4) Centrifugal Casting of Haynes 282, weighing 1400 lbs. with hybrid mold (half Graphite and half Chromite sand) mold assembly was cast using compressor casing production tooling. This test provided Mold cooling rates influence on centrifugally cast microstructure and mechanical properties. Graphite mold section out performs sand mold across all temperatures for 0.2% YS; %Elongation, %RA, UTS at 1400°F. Both Stress-LMP and conditional Fracture toughness plots data were in the scatter band of the wrought alloy. 5) Fundamental Studies on Cooling rates and SDAS test program. Evaluated the influence of 6 mold materials Silica, Chromite, Alumina, Silica with Indirect Chills, Zircon and Graphite on casting solidification cooling rates. Actual Casting cooling rates through Liquidus to Solidus phase transition were measured with 3 different locations based thermocouples placed in each mold. Compared with solidification simulation cooling rates and measurement of SDAS, microstructure features were reported. The test results provided engineered casting potential methods, applicable for heavy section Haynes 282 castings for optimal properties, with foundry process methods and tools. 6) Large casting of Haynes 282 Drawings and Engineering FEM models and supplemental requirements with applicable specifications were provided to suppliers for the steam turbine proto type feature valve casing casting. Molding, melting and casting pouring completed per approved Manufacturing Process Plan during 2014 Q4. The partial valve casing was successfully cast after casting methods were validated with solidification simulation analysis and the casting met NDT inspection and acceptance criteria. Heat treated and sectioned to extract trepan samples at different locations comparing with cast on coupons test data. Material properties requisite for design, such as tensile, creep/rupture, LCF, Fracture Toughness, Charpy V-notch chemical analysis testing were carried out. The test results will be presented in the final report. The typical Haynes 282 large size Steam Turbine production casting from Order to Delivery foundry schedule with the activity break up is shown in Figures 107 and 108. • From Purchase Order placement to Casting pouring ~ 26 weeks. 1. Sales and commercial review 3 2. Engineering Drawings/models review 4 3. Pattern and core box manufacturing 6 4. Casting process engineering review 4 5. FEM and solidification simulation analysis 4 6. Gating & Feeder Attachments, Ceramic tiling 2 7. Molding and coremaking production scheduling 6 8. Melting planning and schedule 3 9. Pouring, cooling and shake out 2 • From Pouring to casting Delivery ~ 29 weeks 10. Shot blast and riser cutting, gates removal 3 11. Homogenizing , solutionizing HT furnace prep 4 12. Grinding, Fettling 2 13. Aging HT Cycle, cooling 2 14. VT and LPT NDT inspections 2 15. Radiographic inspection 4 16. Mechanical testing, Chemical analysis test certs 4 17. Casting weld repair upgrades and Aging PWHT 4 18. NDT after weld repairs and casting upgrades 3 19. Casting Final Inspection and test certifications 3 20. Package and delivery 2 Hence the Total Lead time from P.O to Casting delivery is approximately 55 weeks. The Task 4.2 and Task 4.3 activities and reporting completed.« less

Semisolid Metal Processing Consortium

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

Apelian,Diran

Mathematical modeling and simulations of semisolid filling processes remains a critical issue in understanding and optimizing the process. Semisolid slurries are non-Newtonian materials that exhibit complex rheological behavior. There the way these slurries flow in cavities is very different from the way liquid in classical casting fills cavities. Actually filling in semisolid processing is often counter intuitive