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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
