Assessing a stepped sonotrode in ultrasonic molding technology

Grabalosa, J.; Ferrer, I.; Martínez-Romero, Óscar; Elı́as-Zúñiga, Alex; Plantà, Xavier; Rivillas, F.

doi:10.1016/j.jmatprotec.2015.10.023

Cited by 28 publications

(16 citation statements)

References 17 publications

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“…Recently, there has been growing interest in microparts of functional filler‐loaded polymer composites due to their potential applications in electronics and microelectromechanical systems. Therefore, several microprocessing methods, such as microinjection molding (μIM), hot embossing, injection‐compression molding, and thermoforming as well as ultrasonic molding , have been developed to meet the ever‐increasing demands of the above‐mentioned applications. Among these methods, μIM has been widely employed, thanks to its potential for mass production of microparts at a relatively low cost per part .…”

Section: Introductionmentioning

confidence: 99%

Properties of microinjection‐molded polypropylene/graphite composites

Zhou

Hrymak

Kamal

et al. 2019

Polymer Engineering & Sci

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In this study, polypropylene (PP) composites filled with two different types of graphite particles, that is, flake‐shaped synthetic graphite (SG) and low‐temperature expandable graphite (LTEG), were prepared by melt blending, followed by microinjection molding (μIM). The microparts had three consecutive zones with decreasing thickness along the flow direction (FD). Results showed that, in addition to the larger particle size, the in situ exfoliation of LTEG during melt processing is crucial to the overall enhancement of electrical conductivity when compared with their SG‐containing counterparts, as corroborated by morphology observations. Moreover, the preferential alignment of conductive particles favors the construction of conductive pathways along the FD. The melting and crystallization behavior for PP, PP/LTEG, and PP/SG materials, and samples from each section of the corresponding microparts were evaluated by differential scanning calorimetry. Results indicated that both the addition of graphite particles and the typical thermomechanical history of μIM (i.e., high shearing and cooling rates) experienced in different sections of the three‐step microparts influence the melting and crystallization behavior of the composites. POLYM. ENG. SCI., 59:1560–1569 2019. © 2019 Society of Plastics Engineers

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Section: Introductionmentioning

confidence: 99%

Properties of microinjection‐molded polypropylene/graphite composites

Zhou

Hrymak

Kamal

et al. 2019

Polymer Engineering & Sci

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“…On the other hand, the research works of Michaeli et al [7,15,16], Vazquez et al [17], Grabalosa et al [18], Sacristan et al [5], Diaz et al [19], Whiteside et al [6], Heredia et al [20], Masato et al [21], Sanchez-Sanchez et al [22] and Ferrer et al [23] were categorized as ultrasonic injection molding. In all of them, the raw material is directly poured into a plasticizing chamber prior to being injected into the mold cavity, compacted by the plunger, and plasticized by ultrasonic energy inside the plasticizing chamber (separated from the mold cavity).…”

Section: Standardization Of Terminology Used In Ultrasonic Moldingmentioning

confidence: 99%

“…Those and more characteristics made UIM a suitable process for manufacturing small and micro-parts. It comprises the following stages [18]. First, the thermoplastic material (feedstock) is introduced inside a plasticization chamber which is formed by the two halves of the mold used in the process.…”

Section: Ultrasonic Injection Moldingmentioning

confidence: 99%

Ultrasonic Molding Technology: Recent Advances and Potential Applications in the Medical Industry

2019

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Recently, ultrasonic molding (USM) has emerged as a promising replication technique for low and medium volume production of miniature and micro-scale parts. In a relatively short time cycle, ultrasonic molding can process a wide variety of polymeric materials without any noticeable thermal degradation into cost-effective molded parts. This research work reviews recent breakthroughs of the ultrasonic injection molding and ultrasonic compression molding process regarding the equipment and tooling development, materials processing and potential applications in the medical industry. The discussion is centered on the challenges of industrializing this technology, pointing out the need for improvement of the current process’s robustness and repeatability. Among the most important research areas that were identified are the processing of novel engineered and nanomaterials, the understanding and control of the ultrasonic plasticization process and the tooling and equipment development.

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“…where ω is the angular frequency of vibration, c is sound speed in the rod material, and ρ is the material's density. Depending to the cross sections, correction factors could be involved in calculating l1 and l2 at normal temperatures [25]. The input and the output diameters can be calculated by considering the diameter of the previous part (waveguide) and the required amplification [8]: Solving the model for a normal temperature and for a high temperature by changing the length after introducing the dependent properties on temperature (explained up); (c) manufacturing the sonotrode with some length tolerance for experimental analysis, taking into account that (d) the eigenfrequency at the wanted eigenmode (longitudinal vibration mode in the present study) can be reduced when the temperature increases and can be increased by reducing the length of the sonotrode.…”

Section: Fe Optimization Of the Sonotrodementioning

confidence: 99%

Section: The Impurities and The Associated Surface Porosity Contentmentioning

confidence: 99%

Ultrasonic Vibration as a Primary Mixing Tool in Accelerating Aluminum–Copper Alloys Preparation from Their Pure Elements

Muhrat

Puga

Barbosa

2019

Metals

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In this study, ultrasonic vibration (USV) was evaluated in preparation of Al–8wt.%Cu alloys at a lab-scale. Moreover, the role of Ti–6Al–4V sonotrode erosion and its contribution in grain refining were analyzed. Based on the experimental conditions/parameters, it was found that the amount of impurities and the associated porosity were significantly reduced in USV treated alloys. Furthermore, USV reduced the time needed for dissolving the alloying element Cu, nevertheless, the best dissolving of Cu in this study was not possible without introducing further holding time. As a result of using a titanium-based sonotrode, a noticeable content of Ti was found in the ultrasonically treated alloys due to sonotrode erosion under USV. The dispersion of TiAl3 promoted, as a main factor, a grain refining effect at relatively constant and high melt temperature, other possible mechanisms of grain refining have been discussed.

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Assessing a stepped sonotrode in ultrasonic molding technology

Cited by 28 publications

References 17 publications

Properties of microinjection‐molded polypropylene/graphite composites

Properties of microinjection‐molded polypropylene/graphite composites

Ultrasonic Molding Technology: Recent Advances and Potential Applications in the Medical Industry

Ultrasonic Vibration as a Primary Mixing Tool in Accelerating Aluminum–Copper Alloys Preparation from Their Pure Elements

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