Development of glass microballoon/HDPE syntactic foams by compression molding

Jayavardhan, M.L.; Kumar, B. Rajesh; Doddamani, Mrityunjay; Singh, Ashish Kumar; Zeltmann, Steven E.; Gupta, Nïkhil

doi:10.1016/j.compositesb.2017.07.037

Cited by 95 publications

(42 citation statements)

References 35 publications

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“…Blending speed and temperature are set at 10 rpm and 160 °C, respectively, based on the pilot experiments with the objective of avoiding the GMB breakage to prepare H20, H40, and H60 compositions. 2 , 26 The representative image of the H60 blend is shown in Figure 2 a. Dynisco LMI5000 MFI equipment is used for measuring MFI (ASTM D1238) of H–H60 pellets, which helps in setting an appropriate multiplier in printing by isolating different temperature settings for different compositions. The study of rheological properties is essential to know the effect of the filler on manufacturing conditions.…”

Section: Methodsmentioning

confidence: 99%

“…In manufacturing low-cost lightweight thermoplastics without compromising the mechanical properties of the material, GMBs are candidate fillers exhibiting promising behavior. 2 GMB-based foams are shown to have better mechanical properties than fly ash-based composite foams. 7 , 48 Owing to better mechanical responses and biocompatibility, HDPE finds its application in chemical containers, milk jugs, household utilities, and other structural applications.…”

Section: Introductionmentioning

confidence: 99%

“… 25 Mechanical, surface, electrical, and magnetic properties can be altered using such fillers. 2 , 26 The most commonly used fillers are Al 2 O 3 , 27 glass, 28 iron particles, 29 carbon, and glass fibers. 30 Hollow spherical particles, such as fly ash and glass micro balloons (GMBs) as fillers in the matrix, were investigated using conventional processing methods wherein higher tooling cost and complex geometrical design restrictions pose many challenges.…”

Section: Introductionmentioning

confidence: 99%

“… 26 , 36 Achieving these properties depends on particle survival in these lightweight foams and processing methods used for synthesizing them. 2 , 37 Developing a lightweight filament with minimum to no particle breakage should significantly enhance specific properties in 3DP of the components for weight-sensitive applications such as in nose cones of remotely operated underwater vehicles or even printing the entire body in the tubular design form with all the internal structural details all at once. Automotive and aerospace components without any joints, if realized through printing, can add structural stability with enhanced performance.…”

Section: Introductionmentioning

confidence: 99%

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Three-Dimensional Printed Lightweight Composite Foams

et al. 2020

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The goal of this paper is to enable three-dimensional (3D) printed lightweight composite foams by blending hollow glass microballoons (GMBs) with high density polyethylene (HDPE). To that end, lightweight feedstock for printing syntactic foam composites is developed. The blend for this is prepared by varying the GMB content (20, 40, and 60 volume %) in HDPE for filament extrusion, which is subsequently used for 3D printing. The rheological properties and the melt flow index (MFI) of blends are investigated for identifying suitable printing parameters. It is observed that the storage and loss modulus, as well as complex viscosity, increase with increasing GMB content, whereas MFI decreases. Further, the coefficient of thermal expansion of HDPE and foam filaments decreases with increasing GMB content, thereby lowering the thermal stresses in prints, which promotes the reduction in warpage. The mechanical properties of filaments are determined by subjecting them to tensile tests, whereas 3D printed samples are tested under tensile and flexure tests. The tensile modulus of the filament increases with increasing GMB content (8–47%) as compared to HDPE and exhibit comparable filament strength. 3D printed foams show a higher specific tensile and flexural modulus as compared to neat HDPE, making them suitable candidate materials for weight-sensitive applications. HDPE having 60% by volume GMB exhibited the highest modulus and is 48.02% higher than the printed HDPE. Finally, the property map reveals a higher modulus and comparable strength against injection- and compression-molded foams. Printed foam registered 1.8 times higher modulus than the molded samples. Hence, 3D printed foams have the potential for replacing components processed through conventional manufacturing processes that have limitations on geometrically complex designs, lead time, and associated costs.

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Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Three-Dimensional Printed Lightweight Composite Foams

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“…Syntactic foams are composites formed by dispersing hollow particles in the matrix resin. Automobile, aerospace and marine applications extensively use such foams due to their excellent specific properties . Generally, reinforcements in polymers are used for a variety of reasons such as reducing the use of expensive resin, density control and tailoring optical, thermal, mechanical and electrical properties.…”

Section: Introductionmentioning

confidence: 99%

Effect of cenosphere filler surface treatment on the erosion behavior of epoxy matrix syntactic foams

et al. 2018

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Influence of cenosphere surface modification and volume fraction on the solid particle erosion of cenosphere/epoxy syntactic foams is investigated. Fly ash cenospheres are used as filler in both as received and silane surface modified configurations. Erosion behavior is studied at room temperature for different impact angles (30, 45, 60, and 90 ) and velocities (30, 45, and 60 m/s). Neat epoxy shows the highest erosion rate compared with that of the syntactic foams. Results show a strong dependence of impact angle and velocity on erosion rate of syntactic foams. With increasing cenosphere content erosion rate decreases for all impact angles. Erosion rate decreases with increasing impact angle and with decreasing velocity. Good interfacial bonding of treated cenospheres enhances the erosion resistance. All the samples exhibit ductile erosive behavior, with maximum erosion at 30 . The velocity exponent and erosion efficiency parameters confirm the ductile behavior of syntactic foams. POLYM. COMPOS., 40:2109-2118, 2019

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Ultralow Dielectric Constant Polyarylene Ether Nitrile/Polyhedral Oligomeric Silsesquioxanes Foams with High Thermal Stabilities and Excellent Mechanical Properties Prepared by Supercritical CO₂

et al. 2021

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Dielectric materials with ultralow dielectric constant, excellent mechanical properties, and good thermal stability have a broader application prospect in microelectronic devices with the rapid growth of 5G communication systems. On this basis, a series of lightweight polyarylene ether nitrile (PEN)/PSS‐octamethyl substituted (POSS) foams have been prepared by supercritical carbon dioxide foaming technique combining the strategy of low dielectric constant POSS doping and the introduction of bubbles. The effects of the introduction of POSS and foaming temperature on the foaming behavior of PEN/POSS composites are studied. The density of PEN/POSS foam with 5 wt% POSS is as low as 0.208 g cm−3 and the homologous porosity is up to 82.1%, which realizes the lightweight preparation of engineering plastics. Due to the introduction of POSS and pores, the PEN/POSS foam exhibits an ultralow dielectric constant of 1.83 at 1 kHz, while the dielectric loss is as low as 0.0036 and high thermal stability (Td5 > 453 °C). In addition, the specific modulus of PEN/POSS foam is up to 1.07 GPa cm−3 g−1 due to the high performance of the PEN. These excellent properties make PEN/POSS foams have great potential in the application of microelectronic devices.

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Development of glass microballoon/HDPE syntactic foams by compression molding

Cited by 95 publications

References 35 publications

Three-Dimensional Printed Lightweight Composite Foams

Three-Dimensional Printed Lightweight Composite Foams

Effect of cenosphere filler surface treatment on the erosion behavior of epoxy matrix syntactic foams

Ultralow Dielectric Constant Polyarylene Ether Nitrile/Polyhedral Oligomeric Silsesquioxanes Foams with High Thermal Stabilities and Excellent Mechanical Properties Prepared by Supercritical CO₂

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Development of glass microballoon/HDPE syntactic foams by compression molding

Cited by 95 publications

References 35 publications

Three-Dimensional Printed Lightweight Composite Foams

Three-Dimensional Printed Lightweight Composite Foams

Effect of cenosphere filler surface treatment on the erosion behavior of epoxy matrix syntactic foams

Ultralow Dielectric Constant Polyarylene Ether Nitrile/Polyhedral Oligomeric Silsesquioxanes Foams with High Thermal Stabilities and Excellent Mechanical Properties Prepared by Supercritical CO2

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Product

Resources

About

Ultralow Dielectric Constant Polyarylene Ether Nitrile/Polyhedral Oligomeric Silsesquioxanes Foams with High Thermal Stabilities and Excellent Mechanical Properties Prepared by Supercritical CO₂