Engineering applications of polymers and composites Books

Book SynopsisThe book introduces the reader to the concepts of Scientific Molding and Scientific Processing for Injection Molding, geared towards developing a robust, repeatable, and reproducible (3Rs) molding process.The effects of polymer morphology, thermal transitions, drying, and rheology on the injection molding process are explained in detail. The development of a robust molding process is broken down into two sections and is described as the Cosmetic Process and the Dimensional Process. Scientific molding procedures to establish a 3R process are provided.The concept of Design of Experiments (DOEs) for and in injection molding is explained, providing an insight into the cosmetic and dimensional process windows. A plan to release qualified molds into production with troubleshooting tips is also provided. Topics that impact a robust process such as the use of regrind, mold cooling, and venting are also described.Readers will be able to utilize the knowledge gained from the book in their day-to-day operations immediately.The second edition includes a completely new chapter on Quality Concepts, as well as much additional material throughout the book, covering fountain flow, factors affecting post mold shrinkage, and factor selections for DOEs. There are also further explanations on several topics, such as in-mold rheology curves, cavity imbalances, intensification ratios, gate seal studies, holding time optimization of hot runner molds, valve gated molds, and parts with large gates. A troubleshooting guide for common molded defects is also provided.With the purchase of this book, you also receive a free personal access code to download the eBook.

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Book SynopsisDr. Joel R. Fried is professor and chair of the department of chemical and biomedical engineering at Florida State University. Previously, he was professor and the Wright Brothers Endowed Chair in Nanomaterials at the University of Dayton. He is also professor emeritus of chemical engineering and fellow of the graduate school at the University of Cincinnati, where he directed the Polymer Research Center and led the department of chemical engineering. He holds B.S. degrees in biology and chemical engineering, and an M.E. degree in chemical engineering from Rensselaer Polytechnic Institute. He also holds M.S. and Ph.D. degrees in polymer science and engineering from the University of Massachusetts, Amherst.  Table of Contents Chapter 1: Introduction to Polymer Science Chapter 2: Polymer Synthesis Chapter 3: Conformation, Solutions, and Molecular Weight Chapter 4: Solid-State Properties Chapter 5: Viscoelasticity and Rubber Elasticity Chapter 6: Polymer Degradation and the Environment Chapter 7: Additives, Blends, Block Copolymers, and Composites Chapter 8: Biopolymers, Natural Polymers, and Fibers Chapter 9: Thermoplastics, Elastomers, and Thermosets Chapter 10: Engineering and Specialty Polymers Chapter 11: Polymer Processing and Rheology Chapter 12: Polymers for Advanced Technologies Chapter 13: Correlations and Simulations in Polymer Science Appendix A: Polymer Abbreviations Appendix B Representative Properties of Some Important Commercial Polymers Appendix C ASTM Standards for Plastics and Rubber Appendix D SI Units and Physical Constants Appendix E Mathematical Relationships Appendix F The Major Elements

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Book SynopsisPresents the latest strategies in the development and use of composite materials for large structures and the effects of defects Practical Design and Validation of Composites Structures: Effects of Defects offers an important guide to the use of fiber-reinforced composites and how they affect the durability and safety of engineering structures such as aircraft, ships, bridges, wind turbines as well as sporting equipment. The text draws on the authors' direct experience in industry and academia to cover the most recent strategies in the development of composite structures and uniquely integrates the assessment of the effects of defects introduced during production. This comprehensive resource builds on an essential introduction to the characteristics of composites and the most common types of defects encountered in production. The authors review the recent manufacturing methods and technologies used for inspecting composite structures and the design issuesTable of ContentsPreface xi 1 Characteristics of Composites 1 1.1 Introduction to Behavior 1 1.2 Introduction to Composite Analysis 3 1.3 Failure and Strength Methodologies 5 1.3.1 Lamina Failure Modes and their Influence upon Catastrophic Failure of Multidirectional Laminates 5 1.3.2 Design Values and Environmental Sensitivity 8 1.3.3 Design Values for Unnotched Multidirectional Laminates 11 1.3.4 Design Values for Notched Multidirectional Laminates 12 1.3.5 Material Variability 14 1.3.6 Strain-Based Failure Methodology 15 1.3.7 Composite Fatigue Behavior 15 References 16 2 DesignMethodology and Regulatory Requirements 19 2.1 Regulatory Requirements 19 2.2 Material and Process Specifications 22 2.3 Design Methodology 23 2.4 Design Values for Notched Multidirectional Laminates 24 2.5 Design Values for Bolted Joints 28 2.5.1 Determination of Fastener Loading 29 2.5.2 Failure Analysis at a Loaded and Unloaded Hole 29 2.6 Design Values for Bonded Joints and Bondlines 33 2.7 Design Values for Sandwich Structure 36 2.7.1 Facesheet Tension Design Values 36 2.7.2 Facesheet Compression Design Values 36 2.7.3 Sandwich Flexural Design Values 37 2.7.4 Out-of-Plane Loading 37 2.8 Statistical Allowables 37 2.9 Simulation of Temperature and Moisture Content 39 References 40 3 Material, Manufacturing, and Service Defects 43 3.1 Introduction 43 3.1.1 Differentiating Cosmetic from Structural Defects 46 3.2 Defects by Stage of Occurrence 46 3.2.1 Material Precure Defects 46 3.2.1.1 Fiber Damage and Defects 50 3.2.2 Manufacturing Defects 51 3.2.3 Service Defects 54 3.3 Defects by Location: Matrix-Dominated Defects 60 3.3.1 Matrix Degradation Due to Porosity and Voids 60 3.3.2 Matrix Degradation Due to Aged Material 63 3.3.3 Matrix Degradation Due to Errors in Curing (Pressure and Temperature) 64 3.3.4 Matrix Damage with No Fiber Breakage from Impact 67 3.3.5 Matrix Cracking and Crazing 67 3.3.6 Matrix Degradation Due to Anomalous Moisture Absorption 68 3.3.7 Matrix Degradation Due to UV Radiation or Surface Contamination 69 3.3.8 Matrix Degradation Due to High Temperature Exposure 70 3.3.9 Blisters 72 3.3.10 Matrix Degradation Due to Resin Mixture Error 73 3.4 Defects by Location: Fiber-Dominated Process Defects 73 3.4.1 Fiber Misalignment orWrinkles 73 3.4.1.1 In-PlaneWaviness 73 3.4.1.2 Out-of-PlaneWaviness 74 3.4.2 Excessive Ply Drops and Gaps 76 3.4.3 Fiber Damage 78 3.5 Defects by Location: Sandwich Composite Defects 78 3.5.1 Core Defect: Over-Expanded or Blown Core 79 3.5.2 Core Defect: Core Crushing or Movement 79 3.5.3 Core Defect: Core-Splice Spacing Exceeding Limits 80 3.5.4 Core Defect: Incorrect or Variable CoreThickness 80 3.5.5 Core Defect: Core Degradation Due to Core Defect –Water Entrapment in Core 81 3.5.6 Core Defect: Incorrect Core Density 81 3.5.7 Core Defect: Misaligned Nodes or Unbonded Nodes in Core Cell 81 3.5.8 Core Defect: Mismatched Nodes or Corrugations 82 3.5.9 Core Defect: Corrosion 82 3.5.10 Facesheet Defect: Pillowing,Wrinkling, or Orange Peel 82 3.5.11 Facesheet Defect: Dents in Facesheet 83 3.5.12 Facesheet/Core Disbond 83 3.5.13 Defects in Adhesive Fillets 84 3.5.14 Edge-Closeout Defects 84 3.6 Defects by Location: Mixed-Mode Fiber and Matrix Defects 86 3.6.1 Impact Damage with Fiber Breakage 86 3.6.2 Bearing Damage 87 3.6.3 Edge Cracking and Crushing 88 3.6.4 Cuts, Scratches, and Gouges 89 3.6.5 Composite Damage from Lightning Strikes 89 3.6.6 Misdrilled Holes 90 3.6.7 Mismatched Parts 90 3.6.8 Incorrect Fiber Orientation or Missing Plies 91 3.6.9 Galvanic Corrosion 91 3.6.10 Resin Migration and Uneven Fiber Volume Fraction 92 3.6.11 Residual Stresses and Dimensional Conformance 94 3.6.12 Delaminations 96 3.6.13 Composite Degradation Due to Excessive Temperature and Chemical Exposure 98 3.6.13.1 Fibers 98 3.6.13.2 Matrix 98 3.7 Defects by Location: Fastened and Bonded Joint Defects 98 3.7.1 Fastened Joints 98 3.7.1.1 Bearing Damage 99 3.7.1.2 Hole Delamination/Fraying 99 3.7.1.3 Hole Elongation or Out-of-Round Holes 99 3.7.1.4 Fastener Seating 99 3.7.1.5 Fastener Over-Torque 99 3.7.1.6 Fastener Under-Torque 100 3.7.1.7 Missing Fastener 100 3.7.1.8 Porosity Near the Fastener 100 3.7.1.9 Resin-Starved Bearing Surface 100 3.7.1.10 Insufficient Edge Margins 100 3.7.1.11 Tilted Hole 100 3.7.2 Bonded Joints 100 3.7.2.1 Poor Cure Due to Improper Material Chemistry: Mixing of Two-Part Resins or Material Past Shelf- or Out Life 103 3.7.2.2 Incorrect Bondline Thickness, Scarf, or Overlap Length 103 3.7.2.3 Zero-Volume Disbond or Long-Term Bond Failure Due to Contamination or Incorrect Surface Preparation 103 3.7.2.4 Bondline Degradation Due to Moisture or Incorrect Pressure During Processing 103 3.7.2.5 Bondline Degradation Due to Incorrect Heating Procedures 104 3.8 Future Directions 104 References 104 4 InspectionMethods 111 4.1 Introduction 111 4.2 Mechanical Vibration NDT Methods 117 4.2.1 Low Frequency Methods 117 4.2.1.1 Tap Testing 117 4.2.1.2 Mechanical Impedance 117 4.2.1.3 Membrane Resonance 118 4.2.2 High Frequency Ultrasonic Methods 118 4.2.2.1 Pulse Echo andThru-Transmission 118 4.2.2.2 Pulse Echo Ultrasonics 119 4.2.2.3 Through-Transmission Ultrasonics 119 4.2.2.4 Phased Array Ultrasonics 120 4.2.2.5 Ultrasonic Spectroscopy for Zero-Volume Disbonds 120 4.2.2.6 Ultrasonic Methods for Fiber Distortion 120 4.2.2.7 Guided LambWaves 122 4.2.2.8 Air-Coupled Ultrasonics 122 4.2.3 Acoustic Emission 123 4.3 Visual and Enhanced Visual Methods 125 4.3.1 Visual Inspections 125 4.3.2 Verification or Pressure Film 125 4.3.3 Leak Testing 126 4.4 Electromagnetic Radiation (X-Ray, Gamma, and Neutron) 126 4.4.1 Radiography 126 4.4.2 Computed Tomography 127 4.4.3 Compton Scattering 130 4.4.4 Neutron Tomography 131 4.5 Optical Methods 131 4.5.1 Shearography 131 4.5.2 Digital Image Correlation (DIC) 133 4.5.3 Hyperspectral Near Infrared Method for Resin Migration and Fiber Distortion 135 4.5.4 Laser Profilometers and Image Processing 136 4.6 Strain Measurement 137 4.7 Thermography 138 4.7.1 ActiveThermography 139 4.7.1.1 Thermoelastic Stress Analysis 139 4.7.2 Passive Thermography 139 4.8 Destructive Methods 142 4.8.1 Physical Tests 142 4.8.2 Density and Porosity Measurements 144 4.8.3 Microscopy 145 4.9 NDT Standards 147 References 147 5 Effects of Defects – Design Values and Statistical Considerations 159 5.1 Introduction 159 5.2 Effects on Laminate Properties 162 5.2.1 Cure Cycle Anomalies 162 5.2.1.1 Porosity 162 5.2.1.2 Nonuniformly Distributed Voids (Stratified Porosity) 163 5.2.1.3 Stratified Porosity or Delamination in L-Shaped Details 163 5.2.1.4 In-Plane Fiber Misalignment 164 5.2.1.5 FiberWaviness (Out-of-Plane) 164 5.2.1.6 Waviness in Curved Parts 168 5.2.1.7 Ply Gaps and Overlaps 170 5.2.2 Cuts, Scratches, and Gouges 171 5.2.3 Edge Delaminations 172 5.2.4 Foreign Object Impact 172 5.3 Effects on Sandwich Composites Properties 174 5.3.1 Facesheet to Core Disbonding 174 5.3.2 Facesheet Pillowing 175 5.3.3 Node Disbonds 176 5.3.4 Core Splicing 176 5.4 Effects on Bolted Joint Properties 179 5.4.1 Delaminations at the Holes 180 5.4.2 Oversize Holes 182 5.4.3 Over-Torqued Fasteners 182 5.4.4 Porosity Near Fasteners 184 5.5 Effects on Bonded Joint Properties 184 5.5.1 Assessment of Defects in Design of Bonded Joints 185 5.6 Statistical Considerations 185 5.6.1 Mean versus Design Values 189 5.6.2 Simpson’s Paradox 189 5.6.3 Design of Experiments 189 5.7 Suggested Approach for Evaluation of Defects 191 5.8 Evaluation of Scaling and Multiple Defects 192 References 194 6 Selected Case Studies in Effects of Defects 201 6.1 Introduction 201 6.2 Case Study 1: The Ohio Timber Road IIWind Turbine Failure Due to Wrinkles 201 6.2.1 Event 201 6.2.2 Background 201 6.2.3 Investigation 202 6.2.4 Lessons Learned 202 6.3 Case Study 2: Faulty Repairs of Sandwich Core Structure 203 6.3.1 Event 203 6.3.2 Lessons Learned 203 6.4 Case Study 3: Bonded Repair Failure 205 6.4.1 Event 205 6.4.2 Investigation 205 6.4.3 Lessons Learned 205 6.5 Case Study 4: Air Transat 961 Sandwich-Composite Failure 206 6.5.1 Event 206 6.5.2 Investigation 206 6.5.3 Lessons Learned 207 6.6 Case Study 5: Debonding Failure of a Sandwich-Composite Cryogenic Fuel Tank 208 6.6.1 Event 208 6.6.2 Investigation 208 6.6.3 Lessons Learned 208 References 209 Glossary 211 Index 215

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Book SynopsisExplore the cutting-edge in self-healing polymers and composites In Extrinsic and Intrinsic Approaches to Self-Healing Polymers and Polymer Composites, a pair of distinguished materials scientists delivers an insightful and up-to-date exploration of the fundamentals, theory, design, fabrication, characterization, and application of self-healing polymers and polymer composites. The book discusses how to prepare self-healing polymeric materials, how to increase the speed of crack repair, high temperature applications, and how to broaden the spectrum of healing agent species. The authors emphasize the integration of existing techniques with novel synthetic approaches for target-oriented materials design and fabrication. They provide a comprehensive view of this emerging field, allowing new researchers to gather a firm understanding of the framework for creating new materials or applications. Additionally, the book includes: A thorough introduction to the fieTable of ContentsPreface Chapter 1 Basics of self-healing – state of the art 1.1 Background 1.1.1 Adhesive bonding for healing thermosetting materials 1.1.2 Fusion bonding for healing thermoplastic materials 1.1.3 Bioinspired self-healing 1.2 Intrinsic self-healing 1.2.1 Self-healing based on physical interactions 1.2.2 Self-healing based on chemical interactions 1.2.3 Self-healing based on supramolecular interactions 1.3 Extrinsic self-healing 1.3.1 Self-healing in terms of healant loaded pipelines 1.3.2 Self-healing in terms of healant loaded microcapsules 1.4 Insights for future work 1.5 References Chapter 2 Extrinsic self-healing via addition polymerization 2.1 Design and selection of healing system 2.2 Microencapsulation of mercaptan and epoxy by in-situ polymerization 2.2.1 Microencapsulation of mercaptan 2.2.2 Microencapsulation of epoxy 2.3 Filling polymeric tubes with mercaptan and epoxy 2.4 Characterization of self-healing functionality 2.4.1 Self-healing epoxy materials with embedded dual encapsulated healant – healing of crack due to monotonic fracture 2.4.2 Factors related to performance improvement 2.4.3 Self-healing epoxy materials with embedded dual encapsulated healant – healing of fatigue crack 2.4.4 Self-healing epoxy/glass fabric composites with embedded dual encapsulated healant – healing of impact damage 2.4.5 Self-healing epoxy/glass fabric composites with self-pressurized healing system 2.5 Concluding remarks 2.6 References Chapter 3 Extrinsic self-healing via cationic polymerization 3.1 Thermosetting 3.1.1 Microencapsulation of epoxy by UV irradiation-induced interfacial copolymerization 3.1.2 Encapsulation of boron-containing curing agent 3.1.2.1 Loading boron-containing curing agent onto porous media 3.1.2.2 Microencapsulation of boron-containing curing agent via hollow capsules approach 3.1.3 Characterization of self-healing functionality 3.1.3.1 Self-healing epoxy materials with embedded epoxy-loaded microcapsules and (C2H5)2O•BF3-loaded sisal 3.1.3.2 Self-healing epoxy materials with embedded dual encapsulated healant 3.1.4 Preparation of silica walled microcapsules containing SbF5•HOC2H5/HOC2H5 3.1.5 Self-healing epoxy materials with embedded epoxy-loaded microcapsules and SbF5•HOC2H5/HOC2H5-loaded silica capsules 3.1.6 Preparation of silica walled microcapsules containing TfOH 3.1.7 Self-healing epoxy materials with embedded epoxy-loaded microcapsules and TfOH-loaded silica capsules 3.2 Thermoplastics 3.2.1 Preparation of IBH/GMA-loaded microcapsules 3.2.2 Self-healing PS composites filled with IBH/GMA-loaded microcapsules and NaBH4 particles 3.3 Concluding remarks 3.4 References Chapter 4 Extrinsic self-healing via anionic polymerization 4.1 Preparation of epoxy-loaded microcapsules and latent hardener 4.1.1 Microencapsulation of epoxy by in-situ condensation 4.1.2 Preparation of imidazole latent hardener 4.2 Self-healing epoxy materials with embedded epoxy-loaded microcapsules and latent hardener 4.3 Self-healing epoxy/woven glass fabric composites with embedded epoxy-loaded microcapsules and latent hardener – healing of interlaminar failure 4.4 Durability of healing ability 4.5 Self-healing epoxy/woven glass fabric composites with embedded epoxy-loaded microcapsules and latent hardener – healing of impact damage 4.6 Concluding remarks 4.7 References Chapter 5 Extrinsic self-healing via miscellaneous reactions 5.1 Extrinsic self-healing via nucleophilic addition and ring-opening reactions 5.1.1 Microencapsulation of GMA by in-situ polymerization 5.1.2 Self-healing epoxy materials with embedded single-component healant 5.2 Extrinsic self-healing via living polymerization 5.2.1 Preparation of living PMMA and its composites with GMA-loaded microcapsules 5.2.2 Self-healing performance of living PMMA composites filled with GMA-loaded microcapsules 5.2.3 Preparation of GMA-loaded multilayered microcapsules and their PS based composites 5.2.4 Self-healing performance of PS composites filled with GMA-loaded multilayered microcapsules 5.3 Extrinsic self-healing via free radical polymerization 5.3.1 Microencapsulation of styrene and BPO 5.3.2 Self-healing performance of epoxy composites filled with the dual capsules 5.4 Concluding remarks 5.5 References Chapter 6 Intrinsic self-healing via Diels-Alder reaction 6.1 Molecular design and synthesis 6.1.1 Synthesis and characterization of DGFA 6.1.2 Reversibility of DA bonds and crack remendability of DGFA based polymer 6.1.3 Synthesis and characterization of FGE 6.1.4 Reversibility of DA bonds and crack remendability of FGE based polymer 6.2 Blends of DGFA and FGE 6.2.1 Reversibility of DA bonds 6.2.2 Crack remendability of cured DGFA/FGE blends 6.3 Concluding remarks 6.4 References Chapter 7 Intrinsic self-healing via synchronous fission/radical recombination of C-ON bond 7.1 Thermal reversibility of alkoxyamine in polymer solids 7.2 Self-healing crosslinked polystyrene 7.2.1 Synthesis 7.2.2 Characterization 7.3 Self-healing epoxy 7.3.1 Synthesis 7.3.2 Characterization 7.4 Self-healing polymers containing alkoxyamine with oxygen insensitivity and reduced homolysis temperature 7.4.1 Synthesis 7.4.2 Characterization 7.5 Reversible shape memory polyurethane network with intrinsic self-healability of wider crack 7.5.1 Synthesis 7.5.2 Characterization 7.6 Concluding remarks 7.7 References Chapter 8 Intrinsic self-healing via exchange reaction of disulfide bond 8.1 Room-temperature self-healable and remoldable crosslinked polysulfide 8.2 Sunlight driven self-healing polymers containing disulfide bond 8.2.1 Crosslinked polyurethane 8.2.1.1 Bulk polymer 8.2.1.2 Composites with silver nanowires as strain sensor 8.2.2 Commercial silicone elastomer 8.3 Self-healing and reclaiming of vulcanized rubber 8.4 Concluding remarks 8.5 References

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Book SynopsisThe book provides an extensive coverage of conjugated polymer based nano-composite coatings with advanced anti-corrosive properties. The book gives detailed explanation of corrosion testing methods and techniques to evaluate the corrosion resistance of the coatings. It includes elaborate discussion on classification of corrosion, electrochemistry of corrosion process, theories explaining the mechanism of corrosion and various corrosion testing standards. Electrochemical studies like open circuit potential (OCP) variation with time, potentiodynamic polarization, Electrochemical Impedance Spectroscopy (EIS) and accelerated corrosion testing are highlighted as important tools to extract information about the behavior of coatings under corrosive conditions. The book discusses epoxy-conjugated polymer based novel composite coating formulations, including aniline and o-toluidine, o-anisidine, phenetidine and pentafluoroaniline with appropriate fillers like SiO2, flyash, ZrOTable of ContentsIntroduction to Corrosion. Conducting Polymers. Poly(Aniline-co-Pentafluoroaniline)/SiO2 Composite Based Anticorrosive Coating. Poly(Aniline-co-Pentafluoroaniline)/ZrO2 Nanocomposite Based Anticorrosive Coating. Polypyrrole-Based Composite Coatings. Polypyrrole/Biopolymer Hybrid Coatings. Future Scope and Directions.

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Book SynopsisSustainable Packaging Materials provides a concise introduction to the principles and practices of packaging sustainability. It addresses the important issues that concern packaging professionals, decision makers, managers, CTOs, legislators, researchers, and students, including the viability and future of recycling, bio- and oxo-degradable materials, and plastics alternatives such as paper, glass, and metal. Also covered are new regulations such as the extended producer responsibility (EPR) laws, their consequences as to what materials are likely to be banned, and whether microplastics should be a concern for packaging companies.Written by an experienced professor, educator, author, inventor, and entrepreneur, this book offers uniquely clear answers to these challenges, helping readers to identify packaging materials that are likely to be phased out to meet new regulations, and to find alternatives to benefit their research and businesses. They will also be equipped to follow guidelines on the use of various packaging materials to stay ahead of the demands of the industry, and to make informed choices about packaging materials by considering sustainability, performance, and cost. Furthermore, they will be informed of the emerging packaging trends in both academia and industry, and understand the issues associated with microplastic pollution, and the actions recommended to mitigate these challenges.

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Book SynopsisThis easy-to-understand guide provides the necessary information to implement a scientific molding program. It is a hands-on reference for people on the molding floor, including those previously lacking theoretical background or formal education.The book covers how the injection molding machine prepares the plastic and understanding of plastic flow. The functions of the main machine components are explained and understanding of correct procedures and testing is developed. Each step of the process is clearly explained in a step-by-step manner, and simple examples of important calculations are provided. The practical approach is augmented by useful guides for troubleshooting and machine set-up. An Excel spreadsheet with a process test and a machine performance test is available as bonus material. The 2nd edition has various updates, improvements, and corrections throughout.Table of Contents 1. Injection Unit: Screw 2. Injection Unit: Barrel 3. Clamping Unit 4. Ejectors/Controllers, Human Machine Interface (HMI) 5. Machine Performance Testing 6. Process Development Test 7. Plastic Temperature 8. Plastic Flow 9. Plastic Pressure (Pack/Hold) 10. Cooling 11. Benchmarking the Injection Molding Process 12. Process Troubleshooting 13. What is Important on a Set-Up Sheet? 14. Commonly Used Conversion Factors and Formulas 15. Machine Set-Up 16. Things That Hurt the Bottom Line of a Company 17. Terms and Definitions

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Book SynopsisThe first book to shed light on the critical role the melt delivery system plays in successful injection molding has received a major update in its 3rd edition. This successful book will give you an immediate leg up by reducing mold commissioning times, increasing productivity, improving customer satisfaction, and achieving quality goals such as Six Sigma.How do you determine the optimum design of your runners and gates; what type of runner system (hot or cold variations) do you use for a specific application; how do you identify molding problems generated by the gate and runner vs. those stemming from other molding issues; what should you consider when selecting a gating location? The “Runner and Gate Design Handbook” will give you the means to get to the bottom of these issues as well as provide specific guidelines for process optimization and troubleshooting.Highlights among the numerous new updates include coverage and analyses of critical shear induced melt variations that are developed in the runners of all injection molds, expanded content on hot runners, and a new subchapter on injection molding process development.

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Book SynopsisThe ‘system level’ knowledge and design skills needed to create good snap-fit interfaces existed in the minds of self-taught snap-fit experts but was not captured in the literature.New designers of plastic parts wishing to use snap-fit had nowhere to turn unless they were fortunate enough to have access to an experienced snap-fit designer. This book organizes and presents all design aspects of snap-fits with an emphasis on the systems level thinking required to create world-class attachments. Beginning, as well as experienced, product designers will find the information they need to develop snap-fits more efficiently and avoid many common snap-fit problems.The third edition has been thoroughly revised to include new case histories and applications. The text has been extensively rewritten for clarity and user-friendliness and there are many new figures with expert explanations.With the purchase of this book, you also receive a free personal access code to download the eBook.

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Book SynopsisRecent advances in polymer science have made it possible to relate quantitatively molecular structure to rheological behavior. At the same time, new methods of synthesis and characterization allow the preparation and structural verification of samples having a range of branched polymeric structures. This book unites this knowledge to enable production of polymers with prescribed processability and end-product properties.Methods of polymer synthesis and characterization are described, starting from fundamentals. The foundations of linear viscoelasticity are introduced, and then the linear behavior of entangled polymers is described in detail. This is followed by a discussion of the molecular modeling of linear behavior. Tube models for both linear and branched polymers are presented. The final two chapters deal with nonlinear rheological behavior and tube models to describe nonlinearity.In this second edition, each chapter has been significantly rewritten to account for recent advances in experimental methods and theoretical modeling. It includes new and updated material on developments in polymer synthesis and characterization, computational algorithms for linear and nonlinear rheology prediction, measurement of nonlinear viscoelasticity, entanglement detection algorithms in molecular dynamics, nonlinear constitutive equations, and instabilities.Table of Contents Introduction Structure of Polymers Polymerization Reactions and Processes Linear Viscoelasticity--Fundamentals Linear Viscoelasticity--Behavior of Molten Polymers Tube Models for Linear Polymers--Fundamentals Tube Models for Linear Polymers--Advanced Topics Determination of Molecular Weight Distribution Using Rheology Tube Models for Branched Polymers Nonlinear Viscoelasticity Tube Models for Nonlinear Viscoelasticity of Linear and Branched Polymers

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Book SynopsisPractical Rubber Rheology and Dynamic Properties provides a unique overview of rubber rheology from a practical perspective. Written by expert authors with many years of experience in the rubber industry, it focuses on applications of rubber rheology testing to solving industrial problems, rubber compound development, predicting changes in processability in the plant, quality assurance, and research and development. However, basic principles are also covered.Aimed at practitioners in the rubber industry, this book promotes understanding of the material to support efficient production of the high-quality rubber products demanded in today's market. It is also suitable for students and their instructors on rubber courses taught in universities.

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Book SynopsisThe intent of all technological advancements in the machining universe is to increase productivity and precision with less involvement of the endangered species known as the Machinist. Connectivity, data, and digitization are providing opportunities for significant improvements in modeling, programming, simulation, machine/people productivity, and real-time decision making. Advances in chip technology and processing speeds yield more sophisticated controls. Software enhancements create advanced CAM systems which interpret more complex models and produce higher precision programs.This book demonstrates how to integrate these technological advancements with Lean /Six Sigma, CNC Programming, Quality, and machining best practices to create an agile machining organization capable of winning against competition anywhere in the world.While most publications are written for executives the author has deliberately designed this publication for the entire organization. The role of everyone on the organizational chart or in the shop is discussed and reviewed. The premise of the book is that the demands of global competition on the modern machining organization are so great that success requires a foundation of Leadership, People, Equipment, Quality, IT, robust processes, and all employees executing to yield exceptional quality, delivery, and profits. The author provides the architecture and blueprint for high performance.With the purchase of this book, you also receive a free personal access code to download the eBook.

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Book SynopsisDie Design for Extrusion of Plastic Tubes and Pipes covers this topic from a uniquely practical perspective. The content draws on the author's over 50 years of experience in the plastics processing industry, most recently as head of the successful extrusion die manufacturing company he established in 1995. His approach is oriented toward solving production problems at the design stage using computer aided techniques for design and simulation of the plastic flow.The book provides a step-by-step guide to extrusion die design, with worked examples to illustrate problem solving. It is shown how important melt flow variables (e.g., pressure drop, shear stress, shear rate, temperature variations, and distribution variations, etc.) of key materials are determined using FEM software. The detailed drawings of complete dies for various applications that are provided constitute a rare and valuable resource. Both mono- and multilayer pipes are covered.Using the proven methods and examples from this book, the reader is well-equipped to understand dies for successful manufacture of tubes and pipes of many types.With the purchase of this book, you also receive a free personal access code to download the eBook.Table of Contents Basic Considerations Project Planning Design of a Simple Die Simulation of Melt Flow Spiral Die Monolayer Die for Tubes 1 mm t6 mm Monolayer Die for Tubes 4 mm t16 mm Monolayer Die for Pipes 50 mm t125 mm Monolayer Die for Pipes 140 mm t315 mm Coextrusion Pipe Dies Coextrusion Die (5 mm t16 mm) Coextrusion Three-Layer Die (20 mm t65 mm) Three-Layer-Plus-Striping Die for 25 mm t110 mm Pipes Materials for Extrusion Dies.

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Book SynopsisDiscontinuous long fiber-reinforced polymer structures with local continuous fiber reinforcements represent an important class of lightweight materials with broad design possibilities and various technical applications, eg, in vehicle construction. However, in contrast to continuous fiber-reinforced composites, extensively used in the aircraft industry, there is still a lack of integrated and experimentally proven concepts for manufacture, modeling, and dimensioning of combinations of discontinuously and continuously reinforced polymer structures. This is partly ascribed to the complexity of the manufacturing processes of discontinuously reinforced polymers, heterogeneous, anisotropic, and nonlinear material and structural properties, but also to the resulting bonding problem of both material types.This book addresses these issues, including both continuous and discontinuous fiber processing strategies. Specific design strategies for advanced composite reinforcement are provided with an integrated and holistic approach for composites material selection, product design, and mechanical properties. Characterization, simulation, technology, design, future research, and implementation directions are also included.In the field of application of three-dimensional load-bearing structures, this book provides an excellent foundation for the enhancement of scientific methods and engineers who need an interdisciplinary understanding of process and materials techniques, as well as simulation and product development methods.

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Book SynopsisSpecialty thermoplastics command a US$3 billion market worldwide. Their use is proliferating in aerospace and transportation, medical applications including implants, electrical and electronics, textiles and general engineering, and the oil and gas industries. This book provides the key details of all specialty thermoplastics in one volume, uncluttered by information on other commodity and engineering plastics. It covers the spectrum of manufacturing methods, major properties, processing, and applications.The extraordinary resistance of specialty thermoplastics to high temperature, oxidation, hydrolysis, other chemicals, and radiation, as well as outstanding mechanical properties at temperatures from -40 to 300 °C make them attractive materials for challenging applications. R&D scientists will appreciate the coverage here of different polymer structures for specialty plastics and why certain structures are technically and commercially preferred. Plastics engineers and product design engineers are empowered to select the right plastic in the right grade for the desired applications.Guidance on processing of specialty plastics using injection and compression molding, extrusion, and coating is provided, together with a wealth of details regarding applications, including aspects that are not readily visible, such as touch and feel.In addition to users in industry and academic research, this work is also applicable as a textbook for special courses on polymer science and engineering for graduate and undergraduate students.

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Book SynopsisUnderstanding of polymer interactions is important for effective processing of plastics and their blends, mixing with nanoparticles, and understanding of their mechanical and physical (e.g., electrical) properties. This book describes a new physics of interactions in polymers that challenges existing theories, and explains the concept of entanglement in a very different way.Rheology is formulated with different parameters defi ning the physics of dual-phase and cross-dual-phase. The rubbery behavior of thermoplastics is explained quite differently to conventional theory.Rheo-fluidification experiments which are applicable to industry (injection molding, extrusion, sheet forming, etc.) are described and analyzed, including molding under conditions of reduced viscosity (up to several hundred percent). The application of this theory to industry has already been proven by a number of successful derived inventions.

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Book SynopsisThis is an introductory textbook on polymer science aimed at lecturers/professors, undergraduate and graduate students of polymer science and technology courses as well as engineering (materials, chemical, civil, food, etc.), chemistry, and physics. It is also aimed at engineers and technologists.Each chapter is written starting from simple concepts and progressively getting more complex towards its end, to help the reader decide how deep to go into each topic. Each chapter also presents the solution of many proposed problems, guiding the reader to solve numerically the everyday problems polymer technologists face, by applying theoretical concepts. Additionally, at every chapter’s end there is a list of problems for the reader to check his/her understanding of the topics.The book contains a list of more than 10 experiments to perform in the laboratory, linked to some of the concepts discussed in the book. It also serves as a long-term reference with many figures, diagrams, tables, chemical equations containing frequently needed information. It contains as well an appendix with a long list of chemical structures of the main commercially available polymers.

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Book SynopsisThis introductory book covers the entire spectrum of the plastics technology/engineering, from raw material to finished plastic products. It is intended not just for university/college students in plastics technology and other engineering disciplines but also for beginners to the field in general.The interconnectivity between the different relevant knowledge areas of plastics technology, such as materials engineering, processing technology, and product development, is emphasized. A chapter “Plastics and the Environment” is also included, covering a topic (rightly) often of great concern to students and newcomers to the field.Also includes numerous videos, conveniently linked via QR codes, to better demonstrate key processes visually.

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Book SynopsisReliable and meaningful methods of polymer testing are necessary to support the plastics industry, being essential for understanding material and part properties, and evaluating materials for a part design, with important implications for product safety as well as operating conditions and lifetime. This book covers all the most important testing methods, from long-established basic techniques to recent developments, including the latest polymer testing standards. By means of examples for the optimization of materials as well as for the evaluation of part properties, an insight into modern polymer testing and its interdisciplinary character is provided. Included in this third edition is an all-new chapter on the testing of polymer films; additionally, many small updates and corrections have been made throughout the book. Numerous tables and figures are included, providing structures and physico-chemical data. A special section for beginners is dedicated to guiding formulations and test methods. A relatively short section deals with development trends in Europe. Sustainability is a major theme, and it is demonstrated that PVC has a strong potential to develop into a fully sustainable material. Another section deals with the everyday problems in the processing of PVC, such as the formation of specks, photo-effects, and plate-out. Plate-out is a common problem in the processing of PVC but only relatively few publications cover it. The causes, influencing factors, and mechanisms are still poorly understood. This section, unique in the literature, provides assistance in the selection and dosage of raw materials to PVC processor, based on the influencing factors during processing.

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Book SynopsisMeasurement uncertainty is an important component of modern materials analysis: it indicates the boundaries within which the test results can be trusted. Such results are necessary for understanding of, for example, material and product tolerances and lifetimes, vital for plastic product reliability and safety.Determination of measurement uncertainty is normally quite laborious, but this book shows how the available interlaboratory test data for plastics can be used to calculate measurement uncertainty much more simply. It contains many interlaboratory test results in the fields of thermoanalysis, molar mass determination, and quantitative analysis of the composition of material, presented in tables and graphical charts, discussed in the text, and elaborated by practical examples.In addition to the evaluation by means of the presented data (top-down approach), the relationship to the bottom-up approach specified in the Guide to the Expression of Uncertainty in Measurement (GUM) is explained based on an example. Further sections deal with sampling, and the issue of whether or not the difference between analytical results is significant.

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Book SynopsisThis book provides a necessary bridge between the values of engineering end-use parameters of polyethylene resins and their scientific molecular and structural characteristics. The main goal is to translate such common parameters, such as the melt index of a resin or the dart impact strength of a film sample, into the universal language of polymer science. After this translation is completed, many facets of the resin properties become transparent and easily explainable.The second edition is brought up to date with coverage of new types of catalysts and polymerization processes, and a new section on PE recycling. The chapter on melt indexes is modified and simplified, that on stress cracking has a significant update, and a new chapter on the nature of LLDPE extractables is added. Contents: Educational Minimum: Manufacture, Structure, and Mechanical Properties of Polyethylene Resins Melt Index and Melt Flow Ratio of Polyethylene Resin Melting Point of Polyethylene Resin Crystallinity Degree and Density of Polyethylene Resins End-Use Mechanical Properties of Polyethylene Film End-Use Testing of High Molecular Weight HDPE and MDPE Resins Nature of LLDPE Extractables

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Book SynopsisThis highly practical troubleshooting guide solves problems at the machine systematically and quickly. Drawing on a wealth of hands-on experience from the authors, who have built strong reputations in the field, the book is structured by type of problem/solution. Thus, it is an ideal reference to be consulted at the machine. Included is valuable information on robust process windows, cycle time evaluations, scrap savings, and runners/gates with no existing standard in the industry. No other book provides the unique insights found here.

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Book SynopsisPlastics production comprises the main process steps ""synthesis (reaction)"", ""preparation/compounding"" at the raw material manufacturer and compounder, and ""processing"" (shaping into semi-finished or finished products). In this handbook, the central middle step, preparation and compounding, is discussed. The preparation tasks include the removal of components, the incorporation of additives, and the change of particle size. Compounding is the incorporation of additives into a polymer or plastic. The process engineering fundamentals and the specific equipment and machines used are described. The specialist authors impart their knowledge from the fields of research, polymer production, and equipment/machine production with applications in plastics technology.

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Book SynopsisThis book shows the true and often-underestimated market potential of plastics recycling, with analysis from economic, ecological, and technical perspectives. It is aimed at both technical and non-technical readers, including decision makers in material suppliers, plastic product manufacturers, governmental agencies, educators, and anyone with a general interest in plastics recycling.An overview of waste handling systems with a focus on the U.S. market is provided. Different methods of waste handling are compared from both economic and ecological perspectives.Since plastic waste recycling is essential from an ecological point of view, common strategies and new approaches to both increase the recycling rate and improve recycling economically and technically are presented. This includes processing and material properties of recycled plastics.Finally, a worldwide outlook of plastic recycling is provided with analysis of additional worldwide markets, encompassing highly developed, fast-developing, and less developed countries.Bonus HanserPLUS content: all the data and calculations presented in the book are provided as downloadable spreadsheets for the reader’s own analysis and updates.

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Book SynopsisSuccessful coloration of plastics is a challenging exercise, requiring deep understanding of chemical, physical, and technological factors, as well as national and international regulations. Customer and regulatory demands are often very high, concerning toxicity, environmental factors, color specification/matching, stability, and cost, among others. This book enables the reader to identify the right color preparation for a particular product application, accounting for material and design.

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Book SynopsisPlastics have a very important role to play in energy-efficient and low-carbon technologies of the present and future, but for them to be classified as sustainable materials, there is a great need for practical and economic recycling methods and infrastructure. This book fills the gap for a modern comprehensive technical guide to recycling of plastics, covering the whole value chain from raw materials to recycled materials.All important recycling technologies (mechanical, chemical/feedstock, dissolution) are discussed and compared to each other and alternative disposal methods such as energy recovery and gasification. Collecting, sorting, and purification methods are also covered, as are economic, legal, and political aspects.A strong emphasis is placed on data comparability, e.g. by standardized methods in measuring data. Although this is a challenge to implement, comparing data across technologies, regions, and stakeholders along the value chain yields important benefits. Key instruments for such a target are lifecycle assessments (LCAs), which are calculated in a standard way across the chapters to "calibrate" the messages among the numerous expert co-authors.Table of Contents 1. Introduction 2. Recycling technologies in overview 3. Value chain (EU, Americas, Asia) 4. Analytics and consumer safety 5. Properties of recycled materials 6. Design for recycling 7. Future developments

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Book SynopsisThis practical introductory guide to injection molding simulation is aimed at both practicing engineers and students. It will help the reader to innovate and improve part design and molding processes, essential for efficient manufacturing.A user-friendly, case-study-based approach is applied, enhanced by many illustrations in full color. The book is conceptually divided into three parts:Chapters 1–5 introduce the fundamentals of injection molding, focusing the factors governing molding quality and how molding simulation methodology is developed. As they are essential to molding quality, the rheological, thermodynamic, thermal, mechanical, kinetic properties of plastics are fully elaborated in this part, as well as curing kinetics for thermoset plastics.Chapters 6–11 introduce CAE verification of design, a valuable tool for both part and mold designers toward avoiding molding problems in the design stage and to solve issues encountered in injection molding. This part covers design guidelines of part, gating, runner, and cooling channel systems. Temperature control in hot runner systems, prediction and control of warpage, and fiber orientation are also discussed.Chapters 12–17 introduce research and development in innovative molding, illustrating how CAE is applied to advanced molding techniques, including co-/bi-Injection molding, gas-/water-assisted injection molding, foam injection molding, powder injection molding, resin transfer molding, and integrated circuit packaging.The authors come from the creative simulation team at CoreTech System (Moldex3D), winner of the PPS James L. White Innovation Award 2015. Several CAE case study exercises for execution in the Moldex3D software are included to allow readers to practice what they have learned and test their understanding.In the 2nd edition, the concept of Cyber-Physical Systems (CPS) in injection molding is introduced. In order to integrate molding simulation and injection machines, the workflow of machine response characterization is illustrated. By taking into account the real-world machine response, users can more accurately reflect the real-world manufacturing conditions in simulations. The optimized processing conditions obtained from the simulation can then be directly applied on the shop floor, bridging the gap between simulation and manufacturing. In addition, a new flow-fiber coupling model, i.e., the informed-isotropic (IISO) viscosity developed by Dr. Favaloro and Prof. Pipes of Purdue University, to simulate the anisotropic flow for fiber-reinforced thermoplastics is introduced. The IISO coupling is available to simulate some peculiar, irregular filling patterns for fiber-reinforced melts at high fiber concentrations: the free surface advances faster along the side cavity walls.

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Book SynopsisFor 30 years, Designing Plastic Parts for Assembly has been the definitive guide for both seasoned part designers and novices to the field, facilitating cost-effective design decisions and ensuring that the plastic parts and products will stand up under use.The detailed yet simplified discussion of material selection, manufacturing techniques, and assembly procedures enables the reader to evaluate plastic materials and design plastic parts with confidence. Good joint design and implementation, the geometry and nature of the component parts, the types of load involved, and other fundamental information necessary for a successful outcome are all included. Throughout, the treatment is practice-oriented and focused on everyday problems and situations.The 10th edition includes an extensive revision of the chapter on welding techniques for plastics, including a new subchapter on hot gas welding. There are also many more minor updates, improvements, and corrections throughout.

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Book SynopsisThe use of adhesives is widespread and growing. There are few modern artefacts, from simple food packing to complex jumbo jets, that are without this means of adhesive joining. Fully updated and revised, Adhesion Science 2nd Edition provides an illuminating account of the science underlying the use of adhesives; technology fundamental to the science of coatings and composite materials, and to the performance of all types of bonded structures. This book guides the reader through essential polymer science to the chemistry of adhesives currently in use. It discusses surface preparation for adhesive bonding, the use of primers and coupling agents and includes a simple guide on stress distribution joints and considerations for testing. Adhesion Science also examines the interaction of adhesives and the environment, including an analysis of the resistance of joints to water, oxygen and ultra-violet light. This book is a comprehensive introduction to the chemistry of adhesives ideal not only for chemists, but any students with a background in physical or materials science.Table of ContentsIntroduction to Adhesion and Adhesives; Surface Treatment for Adhesion and for Abhesion; Primers and Coupling Agents; Chemistry of Adhesives which Harden by Chemical Reaction; Chemistry of Adhesives which Harden Without Chemical Reaction; Pressure-sensitive Adhesives; Surface Analysis; Contact Angles in the Study of Adhesion; Testing of Adhesive Joints; Adhesive Joints and the Environment; Bioadhesion; Recommended Reading.

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