Presentation File 534fe267 34cc 42cb 834d 1e0dac1029d2

Srikanth Pilla, Ph.D.

Department of Automotive Engineering Department of Materials Science and Engineering

Materials & Design Simulation and Modeling Manufacturing Life Cycle Assessment

Rigid Structural Composites Foams

High Back Pressure

(8-20 MPa)

Supercritical Fluid (e.g., N2 or CO2)

CavityCross Section

Single-PhasePolymer-Gas Solution

Special Reciprocating ScrewRapid Pressure Drop in Nozzle or Gate Triggers Cell Nucleation

Microstructure Near Surface Microstructure Near Core

High Back Pressure

(8-20 MPa)

Supercritical Fluid (e.g., N2 or CO2)

CavityCross Section

Single-PhasePolymer-Gas Solution

Special Reciprocating ScrewRapid Pressure Drop in Nozzle or Gate Triggers Cell Nucleation

Microstructure Near Surface Microstructure Near Core

§  Enhanced weight reduction §  Enhanced recyclability

§  Shorter cycle times

(min 15-20 sec less than conventional injection molding)

§  Dimensional stability & Reduced sink marks

§  Lower processing temperatures and pressures (energy efficient)

§  Potentially improved properties

§  Environmentally benign blowing agents such as N2 and CO2

Flexible Composite Foams

Polymer Process Simulation: MuCell Technology

Surface results of Cell Size and Cell Density at the end of Filling/Packing Source: Moldex3D

MuCell Simulation: Cell Analysis (Quantitative) > N2/LDPE

Source: Moldex3D

Thermoset ‘Structural’ Composites Processing

Vacuum Assisted Resin Transfer Molding

Heated Vacuum Assisted Resin Transfer Molding UV Curing of Laminated Composites

Integrated Long/Short-Fiber, Thermoset/Thermoplastic, Injection Molded Composite Structures & Foams

Composite Component Manufacturing

§  Enhanced weight reduction

§  Tailored (multi) functionality

§  Primary structural components

Foam injection molding (for skin)

High Back Pressure

(8-20 MPa)

Supercritical Fluid (e.g., N2 or CO2)

CavityCross Section

Single-PhasePolymer-Gas Solution

Special Reciprocating ScrewRapid Pressure Drop in Nozzle or Gate Triggers Cell Nucleation

Microstructure Near Surface Microstructure Near Core

High Back Pressure

(8-20 MPa)

Supercritical Fluid (e.g., N2 or CO2)

CavityCross Section

Single-PhasePolymer-Gas Solution

Special Reciprocating ScrewRapid Pressure Drop in Nozzle or Gate Triggers Cell Nucleation

Microstructure Near Surface Microstructure Near Core

High-speed Production

Stochastic Based Multiscale Modeling & Design

LENGTH

TIM

E

‘Lightweight’ Design

MACROSCALE

Simulation: Composites Sandwich Structure Optimization Process

Source: Schmueser et al.

Polymeric Nanocomposites

Plastics Recycling

Plastic pellets are fabricated with and without SCF

Non-SCF SCF

Melt-temperature 194°C 167°C

Melt-pressure 480-520 psi 480-520 psi

SCF used N/A Carbon-dioxide

SCF content N/A 7 ml/min

At same melt-pressure, we were able to reduce the melt-temperature by 27°C using SCF assisted process

Polypropylene Recycling Using SCF

Materials

Manufacturing

Packaging & Distribution

Assembly

Use

Disposal

Life Cycle Assessment

LCA refers to the process of compiling and evaluating the inputs, outputs and the

potential environmental impacts of a product system throughout its life cycle (cradle

to grave)

Life Cycle Assessment

Goal and Scope Definition

Inventory Analysis

Impact Assessment

Interpretation

Life Cycle Assessment Framework

Thank you! Srikanth Pilla

Office: (864) 283-7216

Mobile: (419) 320-1861

SPILLA@clemson.edu