Simulated Effect of Carbon Black on High Speed Laser Transmission Welding of Polypropylene With Low Line Energy

Laser welding is an important manufacturing tool for a wide variety of polymer products including consumer goods, automotive components and medical devices. The laser process parameters and polymer properties have a significant impact on weld quality. Due to higher heat density generated by the laser transmission welding (LTW) technique, defining a set of suitable parameters for LTW of thermoplastics and composites can be challenging. In this work the effect of carbon black along other control parameters has been investigated for high speed welding using a laser source of 980 nm wavelength with low line energy. In this work, the finite element method (FEM)-based software COMSOL Multiphysics is used to create a 3D transient thermal model for LTW of isotactic polypropylene (iPP) and its composites with carbon black (CB) of concentrations ranging from 0.5 wt% to 1.5 wt%. The design of experiments based on Box-Behnken design (BBD) is used to organize the simulation experiments and mathematical models are developed based on multiple curvilinear regression analysis on the simulation findings. Independent control variables include the laser power, welding speed, beam diameter, and carbon black content in the absorbent polymer. The maximum weld temperature, weld width, and weld depth within the transmissive and absorptive layers are considered as dependent response variables. Furthermore, sensitivity analysis is carried out to investigate the impact of carbon black along with other independent variables on the responses. The welding feasibility check was performed on the basis of melt and degradation temperature of the materials, and weld depths of transmissive and absorptive layers. It has been observed that the composites containing 0.5 wt% and 1 wt% of CB can be welded successfully with neat iPP. However, due to a degradation temperature problem, composites having a larger proportion of CB (>1 wt%) appear to be more difficult to weld

On the Application of Vickers Micro Hardness Testing to Isotactic Polypropylene

Hardness is a useful measure of a material’s resistance to permanent indentation; but for viscoelastic polymers, hardness data are highly dependent on the test type and the parameter set chosen. Vickers microhardness testing is used to leave small indents (<150 µm) and is shown to be applicable to polymers. A detailed investigation of the required steps for microhardness testing in isotactic polypropylene (iPP) is provided. Samples should be mounted in epoxy resin in order to maintain curing temperatures at room temperature. Mounted samples can be ground and polished in a semi-automatic polisher using graduated SiC paper (wet grinding) but progressing onto alumina suspension for polishing. Final polishing should be performed with 0.05-µm alumina suspension. The hardness measured was shown to be dependent on load and dwell time with a much greater dependency on dwell time. Strain recovery was shown to be completed after a time period equal to the dwell time. This study shows that indents can be measured thereafter, and it is recommended that they be measured within a 24 h period after the indent was created. After data fitting, the equation for hardness was shown to follow a power law with load and dwell time as the main variables. Fitting parameters were compared to those found in the literature, and it was found that parameters were significantly different to those reported elsewhere. Therefore, this study highlights the importance of calibrating on a case-by-case basis. Finally, to show the usefulness of the Vickers micro-hardness testing method, the calibrated test method was applied on iPP with additions of carbon black up to 3 wt.%. Comparisons were made with data from the literature, but the hardness data generated in our work were found to be at least twice that reported in the literature. The testing parameters were not cited in the literature: specifically, the dwell time was not provided, and this generated doubt on the usefulness of the cited data. Hence, this work is intended to serve as an exemplar of how to prepare and proceed with hardness testing of polymers

The Direct 3D Printing of Functional PEEK/Hydroxyapatite Composites via a Fused Filament Fabrication Approach

The manufacture of polyetheretherketone/hydroxyapatite (PEEK/HA) composites is seen as a viable approach to help enhance direct bone apposition in orthopaedic implants. A range of methods have been used to produce composites, including Selective Laser Sintering and injection moulding. Such techniques have drawbacks and lack flexibility to manufacture complex, custom-designed implants. 3D printing gets around many of the restraints and provides new opportunities for innovative solutions that are structurally suited to meet the needs of the patient. This work reports the direct 3D printing of extruded PEEK/HA composite filaments via a Fused Filament Fabrication (FFF) approach. In this work samples are 3D printed by a custom modified commercial printer Ultimaker 2+ (UM2+). SEM-EDX and µCT analyses show that HA particles are evenly distributed throughout the bulk and across the surface of the native 3D printed samples, with XRD highlighting up to 50% crystallinity and crystalline domains clearly observed in SEM and HR-TEM analyses. This highlights the favourable temperature conditions during 3D printing. The yield stress and ultimate tensile strength obtained for all the samples are comparable to human femoral cortical bone. The results show how FFF 3D printing of PEEK/HA composites up to 30 wt% HA can be achieved

Ultrasound sensors for process monitoring in injection moulding

Injection moulding is an extremely important industrial process, being one of the most commonly-used plastic formation techniques. However, the industry faces many current challenges associated with demands for greater product customisation, higher precision and most urgently a shift towards more sustainable materials and processing. Accurate real-time sensing of the material and part properties during processing is key to achieving rapid process optimisation and set-up, reducing downtimes, and reducing waste material and energy in the production of defective products. While most commercial processes rely on point measurements of pressure and temperature, ultrasound transducers represent a non-invasive and non-destructive source of rich information on the mould, the cavity, and the polymer melt and its morphology, which affect critical quality parameters such as shrinkage and warpage. In this paper, the relationship between polymer properties and the propagation of ultrasonic waves is described and the application of ultrasound measurements in injection moulding is evaluated. The principles and operation of both conventional and high-temperature ultrasound transducers are reviewed (HTUTs) together with their impact on improving the efficiency of the injection moulding process. The benefits and challenges associated with the recent development of sol-gel methods for HTUT fabrication are described together with a synopsis of further research and development needed to ensure greater industrial uptake of ultrasonic sensing in injection moulding

State estimators in soft sensing and sensor fusion for sustainable manufacturing

State estimators, including observers and Bayesian filters, are a class of model-based algorithms for estimating variables in a dynamical system given sensor measurements of related system states. They can be used to derive fast and accurate estimates of system variables which cannot be measured directly (’soft sensing’) or for which only noisy, intermittent, delayed, indirect or unreliable measurements are available, perhaps from multiple sources (’sensor fusion’). In this paper we introduce the concepts and main methods of state estimation and review recent applications in improving the sustainability of manufacturing processes. It is shown that state estimation algorithms can play a key role in manufacturing systems to accurately monitor and control processes to improve efficiencies, lower environmental impact, enhance product quality, improve the feasibility of processing more sustainable raw materials, and ensure safer working environments for humans. We discuss current and emerging trends in using state estimation as a framework for combining physical knowledge with other sources of data for monitoring and control of distributed manufacturing systems

Engineering Education Research: Reviewing Journal Manuscripts Fairly, Constructively, Effectively

Peer review is the mechanism for quality control in academic journals. When a manuscript is submitted to a journal, the editors invite other researchers – peers – to review it anonymously. The reviews should serve to support the journal editors in making decisions, and to support the authors in improving the manuscripts before publication. Therefore, reviews need to be fair and constructive. As reviewing can also take considerable effort, it is useful for the reviewer to consider how to do it effectively. Given the important role of peer review in a field, and the considerable effort it takes, it is valuable to jointly consider all these aspects of reviewing in a dialogue with reviewers, authors and editors. This paper presents the outcomes of such a dialogue with 49 participants in the field of engineering education research

The evolution and storage of primitive melts in the Eastern Volcanic Zone of Iceland: the 10 ka Grímsvötn tephra series (i.e. the Saksunarvatn ash)

Major, trace and volatile elements were measured in a suite of primitive macrocrysts and melt inclusions from the thickest layer of the 10 ka Grímsvötn tephra series (i.e. Saksunarvatn ash) at Lake Hvítárvatn in central Iceland. In the absence of primitive tholeiitic eruptions (MgO > 7 wt.%) within the Eastern Volcanic Zone (EVZ) of Iceland, these crystal and inclusion compositions provide an important insight into magmatic processes in this volcanically productive region. Matrix glass compositions show strong similarities with glass compositions from the AD 1783–84 Laki eruption, confirming the affinity of the tephra series with the Grímsvötn volcanic system. Macrocrysts can be divided into a primitive assemblage of zoned macrocryst cores (An_78–An_92, Mg#_cpx = 82–87, Fo_79.5–Fo_87) and an evolved assemblage consisting of unzoned macrocrysts and the rims of zoned macrocrysts (An_60–An_68, Mg#_cpx = 71–78, Fo_70–Fo_76). Although the evolved assemblage is close to being in equilibrium with the matrix glass, trace element disequilibrium between primitive and evolved assemblages indicates that they were derived from different distributions of mantle melt compositions. Juxtaposition of disequilibrium assemblages probably occurred during disaggregation of incompatible trace element-depleted mushes (mean La/Yb_melt = 2.1) into aphyric and incompatible trace element-enriched liquids (La/Yb_melt = 3.6) shortly before the growth of the evolved macrocryst assemblage. Post-entrapment modification of plagioclase-hosted melt inclusions has been minimal and high-Mg# inclusions record differentiation and mixing of compositionally variable mantle melts that are amongst the most primitive liquids known from the EVZ. Coupled high field strength element (HFSE) depletion and incompatible trace element enrichment in a subset of primitive plagioclase-hosted melt inclusions can be accounted for by inclusion formation following plagioclase dissolution driven by interaction with plagioclase-undersaturated melts. Thermobarometric calculations indicate that final crystal-melt equilibration within the evolved assemblage occurred at ~1140°C and 0.0–1.5 kbar. Considering the large volume of the erupted tephra and textural evidence for rapid crystallisation of the evolved assemblage, 0.0–1.5 kbar is considered unlikely to represent a pressure of long-term magma accumulation and storage. Multiple thermometers indicate that the primitive assemblage crystallised at high temperatures of 1240–1300°C. Different barometers, however, return markedly different crystallisation depth estimates. Raw clinopyroxene-melt pressures of 5.5–7.5 kbar conflict with apparent melt inclusion entrapment pressures of 1.4 kbar. After applying a correction derived from published experimental data, clinopyroxene-melt equilibria return mid-crustal pressures of 4±1.5 kbar, which are consistent with pressures estimated from the major element content of primitive melt inclusions. Long-term storage of primitive magmas in the mid-crust implies that low CO_2 concentrations measured in primitive plagioclase-hosted inclusions (262–800 ppm) result from post-entrapment CO_2 loss during transport through the shallow crust. In order to reconstruct basaltic plumbing system geometries from petrological data with greater confidence, mineral-melt equilibrium models require refinement at pressures of magma storage in Iceland. Further basalt phase equilibria experiments are thus needed within the crucial 1–7 kbar range.D.A.N. was supported by a Natural Environment Research Council studentship (NE/1528277/1) at the start of this project. SIMS analyses were supported by Natural Environment Research Council Ion Microprobe Facility award (IMF508/1013).This is the final version of the article. It first appeared from Springer via http://dx.doi.org/10.1007/s00410-015-1170-

Update on the use of aromatase inhibitors in early-stage breast cancer

Aromatase inhibitors are currently included in the 'optimal' management of early-stage breast cancer. Uncertainty remains, however, as to the most appropriate treatment strategy, particularly for newly diagnosed women as they seek to trade off the cost, toxicities and efficacy of the treatment options. Recent publications provide conflicting advice on the role of aromatase inhibitors in the treatment of postmenopausal patients with early-stage hormone receptor-positive breast cancer. This review provides updates on the clinical trials of aromatase inhibitors in early breast cancer and tries to provide practical clinical guidance on their optimal use