Fabrication of Polyether–Ether–Ketone Foams with Superior Properties and Mitigated Weld Lines by Microcellular Injection Molding,Advanced Engineering Materials

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Fabrication of Polyether–Ether–Ketone Foams with Superior Properties and Mitigated Weld Lines by Microcellular Injection Molding
Advanced Engineering Materials ( IF 3.4 ) Pub Date : 2021-09-03 , DOI: 10.1002/adem.202100766
Yu-Teng Feng ₁ , Lin Wang ₁ , Hao-Yang Mi ₁ , Laifa Gu ₂ , Binbin Dong ₁ , Chuntai Liu ₁ , Changyu Shen ₁

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Polyether–ether–ketone (PEEK) as an engineering plastic with excellent mechanical properties requires strict processing conditions. Introducing microcells in PEEK parts is beneficial for reducing the material cost and improving their tenacity. Herein, foamed PEEK parts are fabricated using microcellular injection molding with supercritical nitrogen as the blowing agent. Using optimum processing conditions obtained from orthogonal array experiments based on finite-element simulation, the foamed PEEK parts achieve a 10% average weight reduction and display a typical sandwich structure with an average cell size of 30 μm in the core region. The cell size is larger, whereas the cell density and skin layer thickness are smaller in the region near the gate than the region far from the gate. The foamed PEEK parts show a slight drop in the tensile modulus and tensile strength but a significant improvement in the elongation at break when compared with the solid parts. Moreover, the foamed PEEK parts with weld lines exhibit less reduction in tensile properties than the solid counterparts, attributed to their tighter interfacial adhesion at the weld line. This study successfully produces foamed PEEK parts with high weight reduction and ductility and provides insights into the weld line mitigation through microcellular injection molding.

中文翻译：

微孔注塑法制备具有优异性能和减轻熔合线的聚醚-醚-酮泡沫

聚醚醚酮（PEEK）作为一种具有优异力学性能的工程塑料，对加工条件要求严格。在 PEEK 零件中引入微电池有利于降低材料成本并提高其韧性。在此，使用超临界氮作为发泡剂的微孔注塑成型制造发泡 PEEK 部件。使用基于有限元模拟的正交阵列实验获得的最佳加工条件，发泡 PEEK 部件实现了 10% 的平均减重，并在核心区域显示出平均孔尺寸为 30 μm 的典型夹层结构。单元尺寸较大，而靠近栅极的区域的单元密度和表层厚度小于远离栅极的区域。与实心部件相比，发泡 PEEK 部件的拉伸模量和拉伸强度略有下降，但断裂伸长率显着提高。此外，具有熔接线的发泡 PEEK 部件的拉伸性能比固体对应物的降低更少，这归因于它们在熔接线处的界面粘合更紧密。本研究成功地生产出具有高减重性和延展性的发泡 PEEK 部件，并为通过微孔注塑成型缓解熔接线提供了见解。

更新日期：2021-09-03

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