Low Melting Temperature Research Articles

Vermicular and Chunky Graphite Nucleation during Chill Casting: Study on the Dynamics of Ductile Iron Recycling

AbstractThis investigation provides alternative insight into the dynamic behavior of spheroidal graphite structures throughout the remelting process during ductile cast iron recycling. Specifically, this study systematically analyzed the impact of the remelting process on graphite nucleation. Two approaches are included in this research: thermal analysis and the copper–mold chill casting method. Based on these results, different graphite structures nucleate in cast iron in response to the remelting and recasting processes, which correlate with the melting temperature, the cooling method, and the fading effect. Furthermore, it is indicated that the dissolution rate of spheroidal graphite is relatively slower than lamellar graphite, substantiated by the detection of residual graphite nodules in the case of low melting temperature applied during the remelting process. In addition, the formation of vermicular and potentially chunky graphite structures can also be observed to a certain extent during this set of investigations, thus providing further insight into their relation to the ductile cast iron production process. Graphical Abstract

Understanding melting behavior of aluminum clusters using machine learned deep neural network potential energy surfaces.

Deep neural network-based deep potentials (DP), developed by Tuo et al., have been used to compute the thermodynamic properties of free aluminum clusters with accuracy close to that of density functional theory. Although Jarrold and collaborators have reported extensive experimental measurements on the melting temperatures and heat capacities of free aluminum clusters, no reports exist for finite-temperature abinitio simulations on larger clusters (N > 55 atoms). We report the heat capacities and melting temperatures for 32 clusters in the size range of 48-342 atoms, computed using the multiple histogram technique. Extensive molecular dynamics (MD) simulations at twenty four temperatures have been performed for all the clusters. Our results are in very good agreement with the experimental melting temperatures for 19 clusters. Except for a few sizes, the interesting features in the heat capacities have been reproduced. To gain insight into the striking features reported in the experiments, we used structural and dynamical descriptors such as temperature-dependent mean squared displacements and the Lindemann index. Bimodal features observed in Al116 and the weak shoulder seen in Al52 are attributed to solid-solid structural transitions. In confirmation of the earlier reports, we observe that the behavior of the heat capacities is significantly influenced by the nature of the ground state geometries. Our findings show that the sharp drop in the melting temperature of the 56-atom cluster is a consequence of the change in the geometry of Al55. Mulliken population analysis of Al55 reveals that the charge-induced local electric field is responsible for the strong bonding between core and surface atoms, leading to the higher melting temperature. Our calculations do not support the lower melting temperature observed in experimental studies of Al69. Our results indicate that Al48 is in a liquid state above 600K and does not support the high melting temperature reported in the experiment. It turns out that the accuracy of the DP model by Tuo et al. is not reliable for MD simulations beyond 750K. We also report low-lying equilibrium geometries and thermodynamics of 11 larger clusters (N = 147-342) that have not been previously reported, and the melting temperatures of these clusters are in good agreement with the experimental ones.

Design and demonstration of a temperature-resistant aptamer structure for highly sensitive mercury ion detection with BioFETs

In this study, we developed a temperature-resistant aptamer coupled with extended gate electric double-layer Field-Effect Transistors (FETs) for highly sensitive mercury ion detection. The design of the temperature-resistant aptamer is based on the thermal and structural properties of the hairpin structure. Two aptamer sequences were designed with different melting temperatures (Tm) and compared for their sensitivity. The hairpin structure of the aptamer with a high melting temperature ensures the stable structure prior to the addition of the mercury ions, which allows the formation of thymine–mercury–thymine (T -Hg2+-T) complex in low concentrations of mercury ions. High sensitivity and low detection limit are achieved at elevated temperatures with the aptamer having a high melting temperature. The elevated temperature facilitates the reaction rate, resulting in high sensitivity and a low detection limit. The aptamer with a high melting temperature hairpin structure has shown a remarkable improvement in the limit of detection with a 4 orders of magnitude increase compared to the one with a low melting temperature. The sensor with the high melting temperature aptamer shows an extremely low detection limit of 4.68 × 10−12 M, surpassing previously reported results. The aptamer with a low melting temperature requires mercury ions to stabilize the hairpin structure by forming a T-Hg2+-T complex. The results show that if the melting temperature is lower than the ambient temperature, it is very difficult to detect low concentrations of mercury ions at the ambient temperature. The selectivity of this sequence was also tested against multiple heavy metals, including arsenic (As), lead (Pb), chromium (Cr), and cadmium (Cd) ions. This study has shown how the structural and thermal properties of the aptamer, and the ambient temperature affect the sensitivity. They are strongly correlated to the performance of the sensors and need to be considered in the design of the sequence.

Preparation of efficient all-inorganic perovskite solar cells from large grain via 1-heptanamine stabilised CsPbI2Br nanoparticles with NH4SCN additive

CsPbI2Br is a potential material for perovskite solar cells (PSCs) due to its better thermal stability and high efficiency. Centrifugal deposition for film formation greatly simplifies the steps of the conventional anti-solvent spin coating method, but there are still problems hindering progress, such as small grain size and poor photoelectric performance. In this work, NH4SCN was introduced as an additive during the preparation of heptylamine (C7H17N) stabilised CsPbI2Br nanoparticles (NCs) and the films were prepared by centrifugal deposition. The results show that the low melting temperature compounds which formed by thiourea from NH4SCN decomposition during annealing and unreacted PbX2 would link the small grains together by melting and flowing; after PbX2 precipitation and reaction with CsX, the grain size was significantly increased by about 95 % compared to that of the untreated film. Due to large grains, less defects and high crystallinity, the final power conversion efficiency and fill factor reached 12.25 % and 0.70, respectively.

Crystallization-Controlled Structure and Thermal Properties of Biobased Poly(Ethylene2,5-Furandicarboxylate).

Crystallization-controlled structure and thermal properties of biobased poly(ethylene 2,5-furandicarboxylate) (PEF) were studied. The cold-crystallization temperature controlled the structure and thermal properties of the biobased PEF. The melting was complex and evidenced the presence of a significant fraction of less-stable crystals with a low melting temperature that linearly increased with Tc, which formed already during the early stages of crystallization, together with those melting at a higher temperature. Low Tc resulted in the α'-phase formation, less crystallinity, and greater content of the rigid amorphous phase. At high Tc, the α-phase formed, higher crystallinity developed, the rigid amorphous phase content was lower, and the melting temperature of the less-stable crystals was higher; however, slight polymer degradation could have occurred. The applied thermal treatment altered the thermal behavior of PEF by shifting the melting of the less stable crystals to a significantly higher temperature. SEM examination revealed a spherulitic morphology. A lamellar order was evidenced with an average long period and small average lamella thickness, the latter about 3-3.5 nm, only slightly increasing with Tc.

A Melt-Processable Metal Halide Perovskite Ferroelectric.

Molecular ferroelectrics have increasingly garnered significant attention in both fundamental scientific research and technological applications due to their ease of processing, lightweight nature, and mechanical flexibility. Among these, metal halide perovskite ferroelectrics (MHP FEs), a subset of molecule-based ferroelectrics, exhibit diverse functionalities owing to their distinctive structures, thus emerging as a focal point of molecular ferroelectrics research. However, thin films, the predominant application form for MHP FEs, primarily rely on spin-coating, which presents considerable limitations. The development of melt-processable MHP FEs has been sparse, largely due to the challenge of integrating ferroelectricity with meltability. In this context, we propose a rational strategy for the successful synthesis of a melt-processable MHP FE, (MBPA)2PbBr4 (MBPA = N-methyl bromopropylammonium), featuring a notably low congruent melting temperature and excellent molten stability. The reversibility of solid and liquid states was demonstrated by X-ray diffraction and Raman and IR spectrum. Scanning electron microscopy examinations show a better quality of the melt-processed thin films compared to spin-coated ones. This study marks the successful implementation of integrating ferroelectricity and melt-processability into melt-processable MHP FEs, paving the way for a novel approach in processing MHP FEs and facilitating their future applications.

Entropy in catalyst dynamics under confinement.

Entropy during the dynamic structural evolution of catalysts has a non-trivial influence on chemical reactions. Confinement significantly affects the catalyst dynamics and thus impacts the reactivity. However, a full understanding has not been clearly established. To investigate catalyst dynamics under confinement, we utilize the active learning scheme to effectively train machine learning potentials for computing free energies of catalytic reactions. The scheme enables us to compute the reaction free energies and entropies of O2 dissociation on Pt clusters with different sizes confined inside a carbon nanotube (CNT) at the timescale of tens of nanoseconds while keeping ab initio accuracy. We observe an entropic effect owing to liquid-to-solid phase transitions of clusters at finite temperatures. More importantly, the confinement effect enhances the structural dynamics of the cluster and leads to a lower melting temperature than those of the bare cluster and cluster outside the CNT, consequently facilitating the reaction to occur at lower temperatures and preventing the catalyst from forming unfavorable oxides. Our work reveals the important influence of confinement on structural dynamics, providing useful insight into entropy in dynamic catalysis.

Frabrication of carboxymethylchitin nanofibers and fish gelatin hybrid gels with robust gel performance

Compared to animal gelatin, the application of fish gelatin (FG) in the food industry is limited due to its lower gel hardness, gelation temperature, and melting temperature. To address these issues, we developed hybrid gels using carboxymethyl chitin nanofibers (CMC-NFs) with FG to enhance its gel properties. The chitin was carboxymethylated by monochloroacetic acid, increasing the negative potential from −6 mV to −35 mV. This modified chitin was then defibrillated into CMC-NFs through high-pressure homogenization to improve its water dispersibility. The addition of 0.1% CMC-NFs significantly increased the hardness of FG gels from 533 g to 989 g, which was notably higher than the ∼600 g hardness of porcine gelatin. Additionally, the gelation and melting temperatures of FG reached 17 °C and 32 °C, respectively, which are very close to the 20 °C and 35 °C of porcine gelatin. Mechanistic studies revealed that FG and CMC-NFs (0.1%) molecules formed a synergistic gel network, facilitated by hydrogen bonding and hydrophobic interactions. This interaction significantly increased the α-helix content in the secondary structure of the FG protein from 15.26% to 21.18%, thereby enhancing the FG-dominated three-dimensional network structure with CMC-NF molecules. Increasing the concentration of CMC-NFs further elevated the gel's melting temperature while reducing its hardness due to phase separation. This study not only presents a viable method for enhancing the gelling properties of modified FG but also offers a feasible solution for expanding FG's applications in the food industry.

Diffusion coefficients of Al<sub>2</sub>Cl<sub>7</sub><sup>–</sup> in low temperature chloroaluminate melt based on triethylamine hydrochloride

With the growing demand for renewable energy sources, much of the research in the battery industry is focused on creating safe and high-capacity energy storage systems that can handle high current loads using inexpensive and readily available materials. The aluminum-ion batteries (AIB) are considered as one of the most promising systems. Such materials as aluminum metal, carbon materials and chloroaluminate ionic liquids are used as anode, cathode and electrolyte, respectively. A low-temperature chloroaluminate melt based on triethylamine hydrochloride (Et3NHCl) is promising and inexpensive electrolytes for AIBs. This melt has the ability to reversibly precipitate/dissolve aluminum metal due to the presence of the Al2Cl7– ion in it. However, the diffusion of Al2Cl7– ions in the Et3NHCl–AlCl3 system has not been studied previously. In the presented work, the concentration dependence of the diffusion coefficients of the Al2Cl7– anion was studied using chronopotentiometry in the concentration range N = 1.3–1.95 (where N is the molar ratio of aluminum chloride to organic salt). It was shown that diffusion coefficients increase with aluminum chloride content growth in the studied melt: from 1.71·10–7 (N = 1.3) to 4.50·10–7 cm2·s–1 (N = 1.95). This behavior can be caused by the viscosity decrease of the melts with Al2Cl7– concentration growth. Based on the obtained results it can be concluded that Et3NHCl–AlCl3 with N = 1.95 is the most suitable electrolyte for AIB. Moreover, it was established that the electrochemical reduction of the Al2Cl7– on the surface of the aluminum electrode is complicated by the nucleation process, which has the lowest overvoltage at N = 1.95.

Structural and Dynamical Effects of the CaO/SrO Substitution in Bioactive Glasses.

Silicate glasses containing silicon, sodium, phosphorous, and calcium have the ability to promote bone regeneration and biodegrade as new tissue is generated. Recently, it has been suggested that adding SrO can benefit tissue growth and silicate glass dissolution. Motivated by these recent developments, the effect of SrO/CaO-CaO/SrO substitution on the local structure and dynamics of Si-Na-P-Ca-O oxide glasses has been studied in this work. Differential thermal analysis has been performed to determine the thermal stability of the glasses after the addition of strontium. The local structure has been studied by neutron diffraction augmented by Reverse Monte Carlo simulation, and the local dynamics by neutron Compton scattering and Raman spectroscopy. Differential thermal analysis has shown that SrO-containing glasses have lower glass transition, melting, and crystallisation temperatures. Moreover, the addition of the Sr2+ ions decreased the thermal stability of the glass structure. The total neutron diffraction augmented by the RMC simulation revealed that Sr played a similar role as Ca in the glass structure when substituted on a molar basis. The bond length and the coordination number distributions of the network modifiers and network formers did not change when SrO (x = 0.125, 0.25) was substituted for CaO (25-x). However, the network connectivity increased in glass with 12.5 mol% CaO due to the increased length of the Si-O-Si interconnected chain. The analysis of Raman spectra revealed that substituting CaO with SrO in the glass structure dramatically enhances the intensity of the high-frequency band of 1110-2000 cm-1. For all glasses under investigation, the changes in the relative intensities of Raman bands and the distributions of the bond lengths and coordination numbers upon the SrO substitution were correlated with the values of the widths of nuclear momentum distributions of Si, Na, P, Ca, O, and Sr. The widths of nuclear momentum distributions were observed to soften compared to the values observed and simulated in their parent metal-oxide crystals. The widths of nuclear momentum distributions, obtained from fitting the experimental data to neutron Compton spectra, were related to the amount of disorder of effective force constants acting on individual atomic species in the glasses.

Black phosphorus modified wearable textile with excellent flame retardancy for personal thermal management and motion detection

A sandwich structure composite phase change textile material (CPCTM) was prepared by electrospinning. In the top and bottom layers, black phosphorus nanosheets (BPNs) was compounded into polyacrylonitrile (PAN). In the middle layer, the phase change thermal energy storage material polyethylene glycol (PEG) was well encapsulated by polyvinyl alcohol (PVA). By designing multilayer structure, the CPCTM exhibited excellent intensity with the tensile strength 62.65MPa and the elongation at break 1176%. The melting temperature and the crystallization temperature of CPCTM were 54.36 ℃ and 31.43 ℃ which were lower than pure PEG (55.87 ℃ and 35.55 ℃). The lower melting and crystallization temperature facilitated the storage of heat in CPCTM for body thermal management. Compared with that of pure PAN, the total heat release and total smoke production of the PAN@BP were respectively descended by 33.05% and 80.43%. During combustion, transfer of combustible gases and heat were hindered due to the formation of the expanded char layer by the BPNs. Meanwhile, the CPCTM showed excellent flexibility and ability of motion detection, which had broad application prospects in the fields of wearable electronic devices.

Microstructure of ternary Sn-Bi-xCu alloy on mechanical properties, current endurance and corrosion morphology via cycling corrosion test

Low melting temperature of Sn-58 wt.% Bi (SB) solders adding 0.5wt.% Cu (SB05C) and 1.7wt.% Cu (SB17C) concentrations were evaluated for the signal transmission in the 3D IC package. Microstructure combined with phase analysis and Pandat simulation were together with to explain the relationship among the mechanical property, electrical endurance and corrosion resistance. By Cu decoration, the presence Cu6Sn5 intermetallic compound (IMC) acts as heterogeneous nucleation sites to reduce surface free energy and generate fine Bi grain that resulted in higher hardness value. The power-law was used to explain the mechanism of interfacial IMC growth, both Cu6Sn5 and Cu3Sn formation were speculated to be volume diffusion control and surface reaction domination, respectively. The fracture morphology by shear testing indicates that earliest plastic deformation accompanied with brittle rupture were major factors due to the intergranular fracture and Cu6Sn5 compound induced bulk fracture. By cycling corrosion test (CCT), the lump shape of SnO2 by-product was found among solders at three cycling. After seven cycling, Sn phase has been completely corroded and Cu6Sn5 IMC began to be corroded forming circle shape of Cu2O but Bi phase still not be corroded among solders. In the electrical endurance, dense Cu6Sn5 dispersed in solder bulk and fine grain size were feasible to induce current crowding and joule heating, thus Cu deteriorated SB solders is easily failed.

Novel compositionally disordered (Pb,Sr)WO4 single-crystalline scintillation material for X- and gamma-ray scanners

Heavy, bright, and fast single-crystalline scintillation material (Pb,Sr)WO4 was produced and characterized for the first time. Incongruently melted material was obtained by the solution-melt method under the conditions of spontaneous crystallization. It has a density of 7.3 g/cm3 and an effective charge of Zeff = 71. The scintillation kinetics are characterized by a decay constant of 490 ns, while the light yield of scintillation is measured to be 13 500 ph/MeV, both at room temperature. A fabrication of the new low-temperature melting single crystalline tungstate family’s material opens the door for better and cheaper scintillators for X-ray and γ-ray detectors, in particular for radiographic scanners and medical imaging devices.

Nanoporous Aramid Nanofiber Separators with High Modulus and Thermal Stability for Safe Lithium-Ion Batteries.

Developing high-safety separators is a promising strategy to prevent thermal runaway in lithium-ion batteries (LIBs), which stems from the low melting temperatures and inadequate modulus of commercial polyolefin separators. However, achieving high modulus and thermal stability, along with uniform nanopores in these separators, poses significant challenges. Herein, the study presents ultrathin nanoporous aramid nanofiber (ANF) separators with high modulus and excellent thermal stability, enhancing the safety of LIBs. These separators are produced using a microfluidic-based continuous printing strategy, where the flow thickness can be meticulously controlled at the micrometer scale. This method allows for the continuous fabrication of nanoporous ANF separators with thicknesses ranging from 1.6 ± 0.1µm to 2.7 ± 0.1µm. Thanks to the double-side solvent diffusion, the separators exhibit controllably uniform pore sizes with a narrow distribution, spanning from 40 ± 5nm to 105 ± 9nm, and a high modulus of 3.3 ± 0.5GPa. These nanoporous ANF separators effectively inhibit lithium dendrite formation, resulting in a high-capacity retention rate for the LIBs (80% after 240 cycles). Most notably, their robust structural and mechanical stability at elevated temperatures significantly enhances LIB safety under transient thermal abuse conditions, thus addressing critical safety concerns associated with LIBs.

Entropy-Driven Reversible Melting and Recrystallization of Layered Hybrid Perovskites.

Typical layered 2D A2PbX4 (A: organic ammonium cation, X: Br, I) perovskites undergo irreversible decomposition at high temperatures. Can they be designed to melt at lower temperatures without decomposition? Which thermodynamic parameter drive the melting of layered perovskites? These questions are addressed by considering the melt of A2PbX4 as a mixture of ions (like ionic liquids), and hypothesized that the increase in the structural entropy of fusion (ΔSfus) will be the driving force to decrease their melting temperature. Then to increase structural ΔSfus, A-site cations are designed that are rigid in the solid crystal, and become flexible in the molten state. Different tail groups in the A-site cations form hydrogen-, halogen- and even covalent bonding-interactions, making the cation-layer rigid in the solid form. Additionally, the rotation of ─NH3 + head group is suppressed by replacing ─H with ─CH3, further enhancing the rigidity. Six A2PbX4 crystals with high ΔSfus and low melting temperatures are prepared using this approach. For example, [I-(CH2)3-NH2(CH3)]2PbI4 reversibly melts at 388 K (decomposition temperature 500 K), and then recrystallizes back upon cooling. Consequently, melt-pressed films are grown demonstrating the solvent- and vacuum-free perovskite films for future optoelectronic devices.

Reorganization of Poly(Butylene Succinate) Containing Crystals of Low Stability.

Poly(butylene succinate) (PBS) forms small and imperfect crystals of low melting temperature at high supercooling of the melt. Slow heating allows reorganization of the obtained semicrystalline structure with the changes of the crystallinity and of the size and perfection of crystals analyzed by differential scanning calorimetry (DSC) and temperature-resolved X-ray scattering techniques. Crystals generated at 20 °C begin to melt and reorganize at a few K higher temperature with their initial imperfection and thickness unchanged upon heating to 70-80 °C. Slow heating to temperatures higher than 70-80 °C yields a distinct exothermic peak in the DSC scan, paralleled by detection of crystals of larger size/higher perfection, beginning to melt at ≈100 °C. These observations suggest that below 70-80 °C, reorganization of the semicrystalline morphology is constrained such that only minor and local improvement of the structure of crystals are possible. The formation of both perfect and thicker crystal lamellae at higher temperature proceeds via melting of imperfect crystals followed by melt-recrystallization as for PBS solid-state thickening is impossible. The study shows the limit of low-temperature reorganization processes when not involving both complete melting of crystals and rearrangement of the lamellar-stack structure.

Water-Etched Porous Ti: Surface Manipulation of Ti Foam Fabricated by Liquid Metal Dealloying Technique.

The liquid metal dealloying (LMD) process enables the fabrication of porous metals with various chemical compositions. Despite its advantages, LMD still faces key challenges such as maintaining the high-temperature molten metal bath for a prolonged time, avoiding the use of toxic etchants, and so on. To overcome these challenges, the study develops a water-leachable and oxidation-resistant alloy melt (AM) in Ca-Mg binary system. Specifically, Ca72Mg28 eutectic AM is designed, which exhibits higher oxidation resistance and lower melting temperature compared to pure Mg, allowing LMD to be conducted in atmospheric conditions as well as temperatures >200K lower. The AM also enables an innovative process to fabricate Ti foams with a hexagonal faceted surface structure by carefully manipulating the etching rate during the water etching process. This approach allows for the creation of foam with a surface area over 13% larger than that of foams with smooth surfaces via normal acid etching, potentially enhancing efficiency in applications such as electrodes for electrochemical systems or biomedical materials where increased cell adhesion can be beneficial. This study paves the way for efficiently manipulating the LMD process to fabricate metal foams with customized compositions and enhanced surface properties.

Effect of Grafting Density on the Crystallization Behavior of Molecular Bottlebrushes.

A unique case of sterically constrained crystallization arises in bottlebrush polymers bearing semicrystalline side chains. Bottlebrushes with grafted side chains can form crystalline structures governed by the complex interplay between side chain packing and backbone confinement. The confinement effect can be readily tuned by varying the side chain grafting density, thus affording control over the crystallization behavior of these systems. In this work, the grafting density effect on the crystallization behavior of molecular bottlebrushes comprising poly(ethylene oxide) (PEO) side chains grafted to a methacrylate backbone was systematically studied. Thermal analysis using differential scanning calorimetry showed that the bottlebrush polymers displayed suppressed crystallization temperatures, lower melting temperatures, and reduced crystallinities compared to linear homopolymer PEO. The crystalline morphology was investigated using polarized light, atomic force, and scanning electron microscopy. Isothermal crystallization experiments revealed a nonmonotonous dependence of the nucleation density on the side chain grafting density. The grafting density effect was also investigated using self-seeding experiments, revealing an increased clearing temperature and memory retention at higher grafting densities. This work highlights how grafting density influences the crystallization behavior of semicrystalline bottlebrushes, providing information for the processing and application of these unique polymers.

Low temperature carbonization and synergistic flame retardancy of cotton fabric coated by phosphorus‑nitrogen flame retardants

To solve the problems of flammability and smoldering of cotton fabric, its flame-retardant finishing was executed with biomass wool keratin (WK) and cyclic phosphate ester (CPE) through the soaking and baking process. The synergistic mechanism of WK low-temperature melting and CPE catalytic dehydration prompted the formation of protective carbonization layer on cotton fabric surface, and this protective layer reduced its pyrolysis rate, inhibited the production of combustible materials and improved its flame retardancy. The results of synchronous thermal analysis indicate that the initial decomposition temperature of WK and CPE is lower than that of cotton fabric, and they precede the endothermic degradation before fabric main body. This effectively promotes the low-temperature carbonization of cotton fabric and inhibits its pyrolysis. The initial decomposition temperature of WK/CPE treated fabrics advances by 47.9 °C–97.8 °C, presenting significant low-temperature carbonization trend. Moreover, they form 3.0 %–20.0 % aromatic structural char before the pyrolysis of cotton cellulose due to the low-temperature dehydration and carbonization reactions. The damage length after vertical burning is only 4.0 cm for treated fabric with five layers, its after-flame and smoldering disappear, and its limiting oxygen index value increases to 28.7 %. This research provides an effective idea for the flammability and smoldering problems of cotton fabric.

Study of Injection Molding Process to Improve Geometrical Quality of Thick-Walled Polycarbonate Optical Lenses by Reducing Sink Marks.

This study investigates the challenges and potential of conventional injection molding for producing thick-walled optical components. The research primarily focuses on optimizing process parameters and mold design to enhance product quality. The methods include software simulations and experimental validation using polycarbonate test samples (optical lenses). Significant parameters such as melt temperature, mold temperature, injection pressure, and packing pressure were varied to assess their impact on geometric accuracy and visual properties. The results show that lower melt temperatures and higher mold temperatures significantly reduce the occurrence of dimensional defects. Additionally, the design of the gate system was found to be crucial in minimizing defects and ensuring uniform material flow. Effective packing pressure was essential in reducing volumetric shrinkage and sink marks. Furthermore, we monitored the deviation between the predicted and actual defects relative to the thickness of the sample wall. After optimization, the occurrence of obvious defects was eliminated across all sample thicknesses (lenses), and the impact of the critical defect, the sink mark on the planar side of the lens, was minimized. These findings demonstrate the substantial potential of conventional injection molding to produce high-quality thick-walled parts when these parameters are precisely controlled. This study provides valuable insights for the efficient design and manufacturing of optical components, addressing the growing demand for high-performance thick-walled plastic products.