Polymers

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13 pages, 2988 KB

Open AccessArticle

Intelligent Modeling of Erosion-Corrosion in Polymer Composites: Integrating Fuzzy Logic and Machine Learning

by Hazzaa F. Alqurashi, Mohammed Y. Abdellah, Mubark Alshareef, Mohamed K. Hassan, Fadhel T. Alabdullah and Ahmed F. Moamed

Polymers 2026, 18(1), 9; https://doi.org/10.3390/polym18010009 - 19 Dec 2025

Cited by 1 | Viewed by 713

Abstract

This study presents a novel hybrid intelligent framework integrating fuzzy logic and artificial neural networks (ANN) to model the erosion-corrosion behavior of glass-fiber-reinforced pipes (GRP) under harsh operating conditions. Experimental data encompassing multiple operational parameters—including abrasive sand concentrations (250 g, 400 g, 500 [...] Read more.

This study presents a novel hybrid intelligent framework integrating fuzzy logic and artificial neural networks (ANN) to model the erosion-corrosion behavior of glass-fiber-reinforced pipes (GRP) under harsh operating conditions. Experimental data encompassing multiple operational parameters—including abrasive sand concentrations (250 g, 400 g, 500 g), flow rates (0.0067 m³/min, 0.01 m³/min, 0.015 m³/min), chlorine content (0–10 wt.%), and exposure times (1–5 h)—were utilized to develop the computational models. The fuzzy logic system effectively captured qualitative expert knowledge and uncertainty in material degradation processes, while ANN models provided quantitative predictions of erosion and corrosion rates. Results demonstrated good prediction accuracy, with R² values of 0.81 for corrosion rate and moderate prediction accuracy 0.56 for erosion rate. The analysis revealed that flow rate (correlation: 0.6) and fuzzy severity (0.6) were the most influential parameters, followed by chlorine content (0.41) and sand concentration (0.32). The hybrid model identified optimal operating conditions to minimize material degradation: low sand concentration (250 g), low flow rate (0.0067 m³/min), absence of chlorine, and shorter exposure times. This intelligent modeling approach provides a powerful tool for predictive maintenance, operational optimization, and service life prediction of GRP systems in aggressive environments, bridging the gap between experimental data and computational intelligence for enhanced material performance assessment. Full article

(This article belongs to the Special Issue Advances in Polymer Molding and Processing)

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41 pages, 12654 KB

Open AccessArticle

Study on Cooling Layer and Thin Insert Thickness Between Coolant and Cavity for Injection Mold with Bridge-Type Composite Product

by Tran Minh The Uyen, Pham Son Minh, Hung-Son Dang and Bui Chan Thanh

Polymers 2025, 17(21), 2823; https://doi.org/10.3390/polym17212823 - 23 Oct 2025

Viewed by 728

Abstract

This study focuses on the design and optimization of a cooling layer system integrated into a thin-thickness mold insert to enhance heat transfer efficiency, control mold temperature, and improve the quality of composite products during injection molding. The Taguchi method with an L25 [...] Read more.

This study focuses on the design and optimization of a cooling layer system integrated into a thin-thickness mold insert to enhance heat transfer efficiency, control mold temperature, and improve the quality of composite products during injection molding. The Taguchi method with an L25 (5⁴) orthogonal array was employed to investigate four key parameters: insert thickness, cooling layer thickness, water flow rate, and coolant temperature. Among 25 experimental combinations, five representative cases were selected for detailed analysis. The results indicate that the optimal configuration (0.5 mm insert, 10 mm cooling layer, 3.5 L/min flow rate, and 80 °C coolant temperature) successfully maintained a high and stable mold temperature, with a cavity temperature difference of only 3.6 °C at steady state and a simulation–experiment deviation ranging from 2.4% to 7.2%. This condition not only improved melt flowability and surface quality but also reduced defects such as weld lines, warpage, and shrinkage. In parallel, displacement measurements on PA6 and glass fiber-reinforced PA6 (PA6 + GF) composites revealed that increasing the fiber content from 0% to 30% reduced output displacement by more than 19% compared to neat PA6, highlighting the reinforcing effect of glass fibers and the relationship between temperature distribution and mechanical displacement behavior. The findings confirm that integrating a cooling layer into a thin-thickness mold, combined with Taguchi-based optimization, provides an effective approach to enhance through-thickness heat transfer, reduce deformation, and ensure the overall quality of composite injection-molded products in industrial applications. Full article

(This article belongs to the Special Issue Advances in Polymer Molding and Processing)

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20 pages, 2917 KB

Open AccessArticle

Multi-Objective Optimization and Reliability Assessment of Date Palm Fiber/Sheep Wool Hybrid Polyester Composites Using RSM and Weibull Analysis

by Mohammed Y. Abdellah, Ahmed H. Backar, Mohamed K. Hassan, Miltiadis Kourmpetis, Ahmed Mellouli and Ahmed F. Mohamed

Polymers 2025, 17(20), 2786; https://doi.org/10.3390/polym17202786 - 17 Oct 2025

Cited by 3 | Viewed by 746

Abstract

This study investigates date palm fiber (DPF) and sheep wool hybrid polyester composites with fiber loadings of 0%, 10%, 20%, and 30% by weight, fabricated by compression molding, to develop a sustainable and reliable material system. Experimental data from prior work were modeled [...] Read more.

This study investigates date palm fiber (DPF) and sheep wool hybrid polyester composites with fiber loadings of 0%, 10%, 20%, and 30% by weight, fabricated by compression molding, to develop a sustainable and reliable material system. Experimental data from prior work were modeled using Weibull analysis for reliability evaluation and response surface methodology (RSM) for multi-objective optimization. Weibull statistics fitted a two-parameter distribution to tensile strength and fracture toughness, extracting shape (η) and scale (

β

) parameters to quantify variability and failure probability. The analysis showed that 20% hybrid content achieved the highest scale values (

β

= 28.85 MPa for tensile strength and

β

= 15.03

M P a \sqrt{m}

for fracture toughness) and comparatively low scatter (η = 10.39 and 9.2, respectively), indicating superior reliability. RSM quadratic models were developed for tensile strength, fracture toughness, thermal conductivity, acoustic attenuation, and water absorption, and were combined using desirability functions. The RSM optimization was found at 18.97% fiber content with a desirability index of 0.673, predicting 25.89 MPa tensile strength, 14.23

M P a \sqrt{m}

fracture toughness, 0.08 W/m·K thermal conductivity, 20.49 dB acoustic attenuation, and 5.11% water absorption. Overlaying Weibull cumulative distribution functions with RSM desirability surfaces linked probabilistic reliability zones (90–95% survival) to the deterministic optimization peak. This integration establishes a unified framework for designing natural fiber composites by embedding reliability into multi-property optimization. Full article

(This article belongs to the Special Issue Advances in Polymer Molding and Processing)

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25 pages, 7359 KB

Open AccessArticle

Characterization and Comparison of Polymer Melt Fluidity Across Three Ultrasonic Plasticization Molding Technologies

by Shiyun Wu, Jianjun Du, Junfeng Liang, Likuan Zhu and Jianguo Lei

Polymers 2025, 17(19), 2576; https://doi.org/10.3390/polym17192576 - 24 Sep 2025

Viewed by 3128

Abstract

The influence of axial ultrasonic vibration (the dominant vibration mode) on the filling behavior of polymer melt in microcavities and its effect on microstructure formation remains inadequately understood. Based on the plasticization location and the extent to which the microcavity is covered by [...] Read more.

The influence of axial ultrasonic vibration (the dominant vibration mode) on the filling behavior of polymer melt in microcavities and its effect on microstructure formation remains inadequately understood. Based on the plasticization location and the extent to which the microcavity is covered by the ultrasonic sonotrode action surface, existing ultrasonic plasticization molding technologies were classified into three types—ultrasonic pressing (UP), ultrasonic plasticizing and pressing (UPP), and ultrasonic plasticization injection molding (UPIM). The effects of these configurations on melt fluidity and filling performance were evaluated and compared through slit flow tests. The interaction mechanisms between polymer melts and templates were elucidated based on melt pressure measurements and morphological changes in nickel micropillar arrays and silicon templates after molding. The results indicated that polymer melt exhibits improved flow behavior within microcavities when under the coverage area of the ultrasonic sonotrode action surface and subjected to the axial ultrasonic vibration. Continuous ultrasonic vibration contributed to sustaining melt fluidity during micropore filling. Among the three technologies, the most complex and intense mechanical interactions on the template microstructure were observed in UP, followed by UPP and then UPIM. Full article

(This article belongs to the Special Issue Advances in Polymer Molding and Processing)

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29 pages, 5212 KB

Open AccessArticle

Multi-Objective Optimization of an Injection Molding Process for an Alvarez Freeform Lens Using an Integrated Optical System and Mold Flow Analyses

by Po-Yu Yen, Chao-Ming Lin and I-Hsiu Chang Chien

Polymers 2025, 17(18), 2453; https://doi.org/10.3390/polym17182453 - 10 Sep 2025

Cited by 2 | Viewed by 1394

Abstract

This study optimizes the design and fabrication of an injection-molded Alvarez freeform lens using Moldex3D mold flow analysis and CODE V optical design simulations. The dual-software approach facilitates the transition between the manufacturing simulations and the optical design/verification process, thereby addressing the conversion [...] Read more.

This study optimizes the design and fabrication of an injection-molded Alvarez freeform lens using Moldex3D mold flow analysis and CODE V optical design simulations. The dual-software approach facilitates the transition between the manufacturing simulations and the optical design/verification process, thereby addressing the conversion issues between the two analysis modules. The optical quality of the designed lens is evaluated using spot diagram, distortion, and modulation transfer function (MTF) simulations. The Taguchi design methodology is first employed to identify the individual effects of the key injection molding parameters on the quality of the fabricated lens. The quality is then further improved by utilizing two multi-objective optimization methods, namely Gray Relational Analysis (GRA) and Robust Multi-Criteria Optimization (RMCO), to determine the optimal combination of the injection molding parameters. The results demonstrate that RMCO outperforms GRA, showing more substantial improvements in the optical quality of the lens. Overall, the proposed integrated method, incorporating Moldex3D, CODE V, Taguchi robust design, and RMCO analyses, provides an effective approach for optimizing the injection molding of Alvarez freeform lenses, thereby enhancing their quality. Future research could extend this methodology to other optical components and more complex optical systems. Full article

(This article belongs to the Special Issue Advances in Polymer Molding and Processing)

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17 pages, 6013 KB

Open AccessArticle

The Effect of Injection Molding Processing Parameters on Chrome-Plated Acrylonitrile Butadiene Styrene-Based Automotive Parts: An Industrial Scale

by Yunus Emre Polat, Mustafa Oksuz, Aysun Ekinci, Murat Ates and Ismail Aydin

Polymers 2025, 17(13), 1787; https://doi.org/10.3390/polym17131787 - 27 Jun 2025

Cited by 2 | Viewed by 1798

Abstract

In recent years, plastic decorative materials have been used in the automotive industry due to their advantages such as being environmentally friendly, aesthetic, light and economically affordable. Plastic decorative materials can exhibit high strength and metallic reflection with metal coatings. Chrome plating is [...] Read more.

In recent years, plastic decorative materials have been used in the automotive industry due to their advantages such as being environmentally friendly, aesthetic, light and economically affordable. Plastic decorative materials can exhibit high strength and metallic reflection with metal coatings. Chrome plating is generally preferred in the production of decorative plastic parts in the automotive industry. In this study, the effect of injection molding processing parameters on the metal–polymer adhesion of chrome-plated acrylonitrile butadiene styrene (ABS) was investigated. The ABS-based front grille frames are fabricated by means of using an industrial-scale injection molding machine. Then, the fabricated ABS-based front grille frame was plated with chrome by means of the electroplating method. The metal–polymer adhesion was investigated as a function of the injection molding processing parameters by means of a cross-cut test and scanning electron microscope (SEM). As a result, it was determined that the optimal injection process parameters, a cooling time of 18 s, a mold temperature of 70 °C, injection rates of 45-22-22-20-15-10 mm/s, and packing pressures of 110-100-100 bar, were effective in enhancing polymer–metal adhesion for the ABS-based front grille frame. Full article

(This article belongs to the Special Issue Advances in Polymer Molding and Processing)

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13 pages, 2360 KB

Open AccessArticle

Relation Between Injection Molding Conditions, Fiber Length, and Mechanical Properties of Highly Reinforced Long Fiber Polypropylene: Part II Long-Term Creep Performance

by Jon Haitz Badiola, U. Astobitza, M. Iturrondobeitia, A. Burgoa, J. Ibarretxe and A. Arriaga

Polymers 2025, 17(12), 1630; https://doi.org/10.3390/polym17121630 - 12 Jun 2025

Cited by 4 | Viewed by 1442

Abstract

This study investigates the long-term mechanical performance of highly reinforced long glass fiber thermoplastic polypropylene composites, focusing on the effects of processing parameters, fiber length, and skin–core structures. Dynamic mechanical and creep analyses were conducted to evaluate the impact of injection molding on [...] Read more.

This study investigates the long-term mechanical performance of highly reinforced long glass fiber thermoplastic polypropylene composites, focusing on the effects of processing parameters, fiber length, and skin–core structures. Dynamic mechanical and creep analyses were conducted to evaluate the impact of injection molding on the final microstructure and long-term mechanical properties. The findings confirm that a significant microstructural change occurs at a fiber length of 1000 µm, which strongly influences the material’s mechanical behavior. Samples with fiber lengths above this threshold reveal greater creep resistance due to the reduced flowability that leads to more entangled, three-dimensional fiber networks in the core. This structure limits chain mobility and consequently improves the resistance to long-term deformation under load. Conversely, fiber lengths below 1000 µm promote a planar arrangement of fibers, which enhances chain relaxation, fiber orientation, and creep strain. Specifically, samples with fiber lengths exceeding 1000 µm exhibited up to a 15% lower creep strain compared to shorter fiber samples. Additionally, a direct relationship is observed between the findings in the viscoelastic response and quasi-static tensile properties from previous studies. Finally, the impact of the microstructure is more pronounced at low temperatures and becomes nearly negligible at high temperatures, indicating that beyond the glass transition temperature, the microstructural effect diminishes gradually until it becomes almost non-existent. Full article

(This article belongs to the Special Issue Advances in Polymer Molding and Processing)

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16 pages, 4816 KB

Open AccessArticle

The Effect of Processing Methods and Nucleating Agents on the Wear Resistance and Crystallinity Behavior of Nylon 11

by Hu Lyu, Dongzhou Sun, Yue Li, Guoliang Yu, Shudi Liu, Pengfei Huo, Dawei Zhang and Xianzhi Kong

Polymers 2025, 17(8), 1073; https://doi.org/10.3390/polym17081073 - 16 Apr 2025

Viewed by 1386

Abstract

Nylon 11 is widely used in abrasion-resistant coatings due to its excellent wear resistance and processability. Here, the effects of different processing methods (pre-treatment temperatures, melting temperatures, and heating programs) and nucleating agents (silica, talcum powder, and montmorillonite) on the crystallinity behavior and [...] Read more.

Nylon 11 is widely used in abrasion-resistant coatings due to its excellent wear resistance and processability. Here, the effects of different processing methods (pre-treatment temperatures, melting temperatures, and heating programs) and nucleating agents (silica, talcum powder, and montmorillonite) on the crystallinity behavior and wear resistance of Nylon 11 were systematically analyzed. The results show that pre-treating Nylon 11 at 80–100 °C enhances its wear resistance, and its friction coefficient drops to ~0.16. Melting temperature influences both the processing flowability and wear resistance of Nylon 11. Specifically, when the melting temperature exceeds 195 °C, wear resistance improves significantly and its friction coefficient decreases from 0.32 to 0.17. Moreover, variations in the heating program also affect the wear resistance of Nylon 11. Optimal wear resistance is achieved when Nylon 11 is held at both 165 °C and 185 °C for 10 min (friction coefficient: ~0.17). The nucleating agents (silica, talcum powder, and montmorillonite) do not change the crystalline morphology of Nylon 11, which predominantly exhibits an orthorhombic α-phase. However, as the content of nucleating agents increases (0–1 wt%), the crystallinity first rises and then declines, with its highest value being 46.48%. This work emphasizes the critical role of processing methods and nucleating agents in the wear resistance and crystallinity behavior of Nylon 11, providing valuable insights for their performance optimization. Full article

(This article belongs to the Special Issue Advances in Polymer Molding and Processing)

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