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Plastics Discovery Tour

Fakuma

 is a platform for publication of results from current research in the field of Plastics Technology. The Journal`s aim is to broaden public access to scientifically qualified, German and English contributions from the fields of material, construction and processing of plastics. Downloads are free of charge.

An inline color measurement sensor shows promising potential for improvements in production efficiency and quality assurance in color measurement in the injection molding process.

Spritzgießen

Prozessoptimierung

Farbsensor

Inline-Messtechnik

Inline color measurement and analysis of the influence of machine parameters on the color of injection molded parts

Presentation of a new process technology for the inline integration of the Boss system into the polymer liner.

Faserverbundwerkstoffe

Blasformen

Novel Technique for the Integration of Boss during Blowmolding Process of Polymer-Liner Based Pressure Vessels

Mechanical investigation and evaluation of a reinforcement structure for CFRP pressure vessels conforming to the installation space on the basis of internal tension struts.

Behälter / Silos

Comprehensive parameter study and evaluation of a reinforcement concept for conformable CFRP tanks for hydrogen storage

Presentation of a novel method for placing wireless sensors in composite materials.

Sensoren / Messwertaufnehmer

Computer-Tomografie-Systeme

Finite Methoden

Shape Optimization of Wireless Sensor Body for Better Integration in Fibre Composites

When selecting an assessment method for the biaxial elongational viscosity that operates with extrusion-related temperatures and pressures, one has to make a choice.

Prüfgeräte für rheologische Eigenschaften

Polypropylen

Rheologie

Towards an inline rheometer – A novel approach for assessing biaxial elongation viscosity

In part two, the investigation focuses on short and continuous fiber reinforcements in a NaCl salt matrix.

Micrograph of a salt core with continuous natural fiber reinforcement

Kohlenstofffasern / -matten

Pressen

Recycling

Naturmaterialien

Werkstoffe für additive Verfahren

Towards a Robust, Water-Soluble, Lost Core Material – part two: Fiber-Reinforced Salt by Wet Compression Molding

In this paper, research results regarding the adhesion properties between metallic conductor track and plastic carrier are presented. In particular, the influence of thermally conductive plastics on the adhesion properties has not yet been investigated.

IMKS specimen for investigating the adhesive properties between plastic carrier and metallic conductor track

Elektronik

Mehrkomponenten-Spritzgießen

Werkstoffprüfung, mechanisch

Hybridwerkstoffe

Statistische Methoden

Characterisation of the adhesive properties in the IMKS

How can water-soluble salt cores be implemented in the composite process routes injection molding and automated fiber placement (AFP).

Slokav-Salzkern-Versuche: Vergleich umspritzter Salzkerne in der ersten Stufe: PA6 (erfolgreich) vs. CF-PEEK (fehlgeschlagen).

Polyetherketon

Polyamide

Towards a Robust, Water-Soluble, Lost Core Material – part one: Unreinforced, Binder-Free Salt

A newly developed compact µ-wave plasma source was utilized for activating the surfaces of several polymers. A remarkable improvement of the surface adhesion was achieved.

Plasmabehandlung

Oberflächeninspektion

Reinigen und Vorbehandeln

Oberflächentechnik

Polymer surface functionalization using a new µ-wave driven atmospheric pressure plasma-jet device

This article provides a comprehensive, holistic overview of the problem of scaling fibre composites in thickness direction.

Example of a thick-walled FKV component: hydraulic bladder accumulator with wall thicknesses up to 30 mm.

Zerstörungsfreie Werkstoffprüfung

Challenges of thick-walled fibre-reinforced thermosets in manufacturing, destructive and non-destructive testing – A review

The possibility of using thermally conductive plastics in combination with the integrated metal/plastic injection moulding (IMKS) has not been investigated, yet. In this article, guidelines are developed.

Elektrotechnik

Statistik

Wärmeleitfähigkeitsmessung

SPC, Statistische Prozesssteuerung

Influences of Material and Process Parameters in IMKS Using Thermally Conductive Plastics

In this work, foam injection molding is combined with the two-component co-injection molding process to produce hard-soft-combinations with TPS skin and a foamed polypropylene core.

Thermoplastische Elastomere

Co-Injektion (Barriere-/Sandwich-Spritzgießen)

Schäumwerkzeuge

Structure-property-relationships for Lightweight Parts Produced via Co-injection Molding and Foam Injection

Optically excited Lockin-Thermography is well suited for fast and robust detection of near-surface defects in isotropic and fiber-reinforced plastics. The resulting phase images are driven by the excitation frequency as a measurement parameter and can be analyzed in the one-dimensional case for depth-selective evaluation. For real test specimens, however, diffusive heat conduction processes overwhelm which makes accurate defect characterization from phase images much more difficult. Neural networks are used within this work to evaluate multiple phase values of different excitation frequencies with each other and thus implement for the first time a quantitative defect characterization in isotropic and fiber-reinforced plastics based on a LSTM-CNN hybrid model. It is shown that the already good prediction values of the neural network are again significantly improved by additional training data obtained from heat flow simulations.

Representation of the experimental setup: thermographic camera (bottom left), photodiode (top left), VCSEL array (right), CFRP test specimen (center).

Industrie 4.0 für die Qualitätssicherung

Künstliche Intelligenz für die Qualitätssicherung

Polymethylmethacrylat

Defect characterization in isotropic and fiber-reinforced plastics using active thermography and neural networks

This article describes a production process for environmentally friendly and resource-efficient molded parts consisting of innovative wood chip plastic composites (in German: Holz-Kunststoff-Verbunde, HKV).

HKV in a density-specific materials comparison

Duroplastische Werkstoffe

Thermoplaste

Produktentwicklung(sprozess)

Development of a production process for environmentally friendly and resource-efficient molded parts consisting of load-appropriate reinforced wood-plastic composites

A rotating mould core can induce shear in the tangential direction during injection, which superimposes the injection-induced shear. In the case of fibre-reinforced thermoplastics, this results in a reorientation of the fibres in tangential direction. This paper shows how a rotating mould core influences the fibre orientation and bursting strength of short-fibre-reinforced polypropylene and polyamide respectively. Furthermore, different wall thicknesses and fibre contents are investigated at varying rotational speeds. Regardless of the used material and the wall thickness, strength increases of more than 75 %are possible at the appropriate speed.

Schematic representation of the rotational shear rate due to the rotating tool core

Werkzeugkonstruktion

Influencing the fibre orientation of polypropylene and polyamide in the injection moulding process by a rotating mould core

Up to now, the relevant interactions between thermoplastics and metal surfaces at the interface have not been fully investigated. In this article, possible intermolecular interactions between plastics and metal surfaces are described and investigated on injection-moulded composite specimens made of polyamide 6 and polybutylene terephthalate with aluminum as a composite partner. The results of the investigation show that the composite adhesion is mainly based on intermolecular interactions between the composite partners and not on mechanical form-fit. If the polar surface of the aluminum is chemically inactivated without changing its surface topography, then no composite adhesion occurs.

Intermolecular interactions through hydrogen bonds between a carbonyl group in polyamide and a metal hydroxide surface.

Polybutylenterephthalat

Aluminium

Kupfer

Hybrid-Spritzgießen (Metall / Kunststoff)

Optische Mess- und Prüfverfahren

Intermolecular interactions and their influence on the adhesion between plastics and metal surfaces

With the help of CFD simulations, a nozzle system (top nozzle) for hot gas welding is developed, which encloses the weld seam during heating. The significantly more controlled flow behavior of the hot gas improves the processing window, increases the reproducibility and achieves a significantly more efficient heating time of the polymer weld seam. The CFD simulations used to develop the new nozzle system are validated by temperature measurements in the hot gas welding process with IR camera and thermocouples.

Hot gas welding station (left) and flow field of the investigated process (right)

Düsen, allgemein

Simulation Schweißen

Thermisches Fügeverfahren

Analysis of two different nozzle systems for hot gas welding using CFD simulations and measurement results

The occurrence of process-specific defects in the wet filament winding process requires an oversizing of the components which leads to high additional material costs, especially for 700 bar type-IV pressure vessels. This paper presents the development of a quality control together with an image processing algorithm based on an industrial camera with which manufacturing deviations in the cylindrical area of the vessels can be determined.

An industrial camera is used to inspect a pressure vessel for manufacturing deviations during the infeed of fiber slivers.

16:9

Bildverarbeitungs-Software

Qualitätssicherung

Wickelmaschinen

Qualitätssicherung Kunststoff

Use of an industrial camera for quality control in the production of the cylindrical area of type-IV pressure vessels in the wet filament winding process

This paper presents a new method for in situ deformation and wear measurement of polymer gears under operating loads. This new approach is based on the highly accurate measurement and tracking of time differences in the index pulses of encoders on the driving and driven side of a gear test rig.

Example pairing of two gears for the determination of elastic, plastic and wear deformation components

Zahnräder

Verschleißprüfgeräte

Tribologie

Getriebe

Test Rig for the In Situ Measurement of the Deformation Characteristics of Polymer Gears

In this research project an algorithm is developed and tested, which enables the automated optimization of dynamic mixing elements. For this purpose, selected geometry parameters are optimized by a genetic algorithm on a parameterized spiral shear mixer in such a way that flow conditions that favor mixing are established. In order to avoid manual evaluation of the flow results, quality criteria are introduced which are automatically calculated. A total of nine different quality criteria are used, which not only assess the potential of the flow field to implement distributive and dispersive mixing mechanisms, but also include processing aspects such as the fluid change effectiveness of the system. The results of the test show that an automated optimization can be carried out with the selected quality criteria and further improvement measures for the algorithm can be derived.

Automated optimization of dynamic mixing elements

In the present study, the pressure-dependent orientation relaxation was investigated by varying the mold temperature and cavity pressure in the context of a new injection-compression molding process with dynamic mold temperature control. For this purpose, isothermal pvT measurements were used to define a process window around the pressure-dependent glass transition region within which the injection-compression molding experiments were carried out. Initially, orientations were systematically introduced into the component via the filling phase, and their pressure- and temperature-dependent relaxation was observed during an isothermal and isobaric holding phase by means of photoelasticity images and path difference measurements. A clear pressure and temperature dependence of the orientation relaxation could be found, whereby with increasing mold temperature and decreasing cavity pressure, smaller path differences could be measured as a result of lower orientations.

Spritzprägen

Dynamische / variotherme Temperierung

Pressure-dependent orientation relaxation in injection compression molding with dynamic mold temperature control

Leakage in vacuum bags for fibre composite production is a frequently occurring defect, especially in the manufacture of components using the open mould process. The previous limit values for assessing the leak tightness of a vacuum set up are mostly historical and based on empirical values. In this paper, the effects of leaks that have been introduced in a defined manner into a vacuum bag are investigated. The physical processes that occur during curing within the leaking vacuum structure are analysed optically as well as by means of ultrasonic testing and thickness measurement and a better understanding of the effects on laminate quality is generated. It is found that there is a difference between leakages in the vacuum bag only and leakages that affect both the vacuum and release film.

Influence of leaky vacuum bags on the quality of composite parts made from prepreg material

Journal of Plastics Technology - Plastics Insights