Solid-State Foaming Process Optimization for the Production of Shape Memory Polymer Composite Foam

Tamem Salah,Aiman Ziout

doi:10.3390/app11083433

Abstract

This research examined the optimization of the sustainable manufacturing process for polyester-based polymers/Fe3O4 nanocomposite foaming. The foamed structure was achieved by using a solid-state foaming process, where the prepared foams were tested in order to ascertain the optimum foaming parameters with the highest foaming ratios and the lowest foaming densities. The foaming parameters used in this research were the polymer type, nanoparticle percentage, packing pressure, holding time, foaming temperature, and foaming time. Two levels were selected for each factor, and a Taguchi plan was designed to determine the number of experiments required to reach a conclusion. Further characterization techniques, namely, differential scanning calorimetry (DSC), Fourier transform infrared spectroscopy (FTIR), and X-ray diffraction (XRD) were used with the original samples to gain a better understanding of their structure and chemical composition. The data analysis showed that regardless of the parameters used, a high foaming ratio resulted in a low density. The introduction of nanoparticles (NPs) to the polymer structure resulted in higher foaming ratios. This increment in foaming ratio was noticeable on Corro-Coat PE Series 7® (CC) polymer more than Jotun Super Durable 2903® (JSD). The optimum parameters to prepare the highest foaming ratios were as follows: CC polymer with 2% NPs, compressed under a pressure of 10 K lbs. for a 3 min holding time and foamed at 290 °C for 15 min in the oven.

Highlights

Shape memory materials are stimuli-responsive materials with the ability to change their shape, after having been quasi-plastically distorted upon the application of an external stimulus
A solid-state foaming process with no foaming agent was tested on two different polymers, namely, Corro-Coat PE Series 7® (CC) and Jotun Super Durable 2903® (JSD)
The prepared tablets were foamed at different levels of foaming temperature and foaming time

Summary

Introduction

Shape memory materials are stimuli-responsive materials with the ability to change their shape, after having been quasi-plastically distorted upon the application of an external stimulus. Inadvertent triggering was the main obstacle for spreading of such joining methods. SMPs are distinguished from SMAs by unique properties, such as their light weight, ease of processing, low cost, and high shape recovery abilities. The shape memory effect can be observed in heat-activated SMPs when thermo-mechanical cycles are performed. These thermo-mechanical cycles consist of three main steps. The SMP is processed into a permanent shape, it is heated up beyond glass transition temperature (Tg) and deformed. It is heated to glass transition temperature (Tg) to trigger the shape recovery process, which returns it to its original permanent shape.

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Results

Conclusion