Search Results (17)

As critical infrastructure for carbon capture, utilization, and storage (CCUS) and large-scale energy storage, subsurface salt caverns are seriously challenged by fluid-induced sediment mobilization during the supplementary debrining. Conventional bulk resin consolidation often causes severe viscous fingering, uneven consolidation, and pore clogging under hypersaline conditions. Here, we develop a foam-templated hybrid polymer gel co-stabilized by silica nanoparticles, polyvinyl alcohol, and the zwitterionic surfactant. The key novelty is the use of foam as a transient transport template that redistributes the resin phase and promotes selective cementation at grain-contact points instead of indiscriminate pore filling. This nano-reinforced gel system remained stable under hypersaline conditions (24% NaCl), and temperatures ranging from 20–80 °C. Micro-CT analysis showed that this selective templating preserved an interconnected pore network with a porosity above 45% and a CT-derived permeability of approximately 1.18 D, while reducing binder consumption by 55.6% relative to bulk resin injection. Crucially, a 1:200 geometrically scaled, velocity-matched pilot model demonstrated that this gel strategy limited sediment entrainment below 0.5% and reduced fluid discharge by 45.9%. These results establish a material-efficient consolidation strategy that combines sediment stabilization with permeability preservation, providing a promising solution for safer supplementary debrining in salt-cavern CCUS and energy-storage operations. Full article

Recently, there has been a significant expansion of additive technologies, especially Fused Filament Fabrication (FFF). This article aims to upgrade a commercial 3D printer to develop viscous polymeric materials, as this option is not currently available. The FFF method is primarily used with thermoplastics and elastomers in filament form. However, materials derived from various water-soluble acrylates offer significant potential, with advantages including environmental friendliness and desirable mechanical and visual properties. The possibility of using a viscous polymer as a carrier for metal material prior to sintering is also a significant factor. The aim of the text is to present the preparation of a 3D printer suitable for printing the above materials. The main requirement was to modify the selected printer with minimal interference with HW and SW. We mainly focused on adjusting the print head. A new prototype for the printing of viscous polymeric materials was visualized. Furthermore, the individual components were designed and printed; a functional system capable of processing these materials was assembled. Full article

During fast-fill, large type IV polymer composite hydrogen storage tanks experience significant temperature gradients associated with both the compression of the gas and a Joule–Thomson effect that can compromise vessel integrity, significantly affecting overall safety. In order to remedy this concern, the current work proposes a novel active mixing approach in which the tank rotates, which leads to enhanced internal convective heat transfer and consequently minimizes temperature gradients. Transient CF simulations were performed using the Redlich–Kwong real-gas equation of state, capturing the high-pressure thermodynamic behavior of hydrogen precisely. The study, based on the 1000 s fast-refueling of a tank of 20.56 m³ internal volume, was carried out to assess the tangential speeds of rotation at 10, 30, and 50 rad/s, respectively. Results also show that thermal performance has a strongly nonlinear dependence on rotational speed. At 10 rad/s, a reasonably even temperature profile develops with a much lower energy cost. The most significant suppression of peak temperatures, and therefore the most efficient cooling, is seen at 30 rad/s. Nevertheless, when the rotation speed further elevates to 50 rad/s, abundant viscous dissipation heating results in an unwanted secondary temperature increase while partially counteracting the benefits brought about by improved mixing. On the whole, the results indicate that an ideal operating window more closely correlated with 30 rads/s is seen to provide the most beneficial compromise between temperature uniformity, maximum temperature limitation, and energy consumption for rapid refueling of large composite hydrogen storage systems. Full article

Natural waves are widely used in seismology and seismic exploration as tools for nondestructive testing of the surface layer. The study examines longitudinal and transverse vibrations of a polymer pipeline transporting petroleum products, which is modeled as a viscoelastic cylindrical shell filled with a viscous fluid. This work examines the longitudinal–transverse vibrations of a viscoelastic cylindrical shell filled with a viscous fluid, considering the viscous properties of both the fluid and the cylindrical shell during longitudinal–transverse oscillations. The differential equations governing the longitudinal–transverse vibrations of a cylindrical shell in contact with a viscous fluid are derived based on thin-shell equations satisfying the Kirchhoff–Love hypotheses, while the motion of the viscous fluid obeys the Navier–Stokes equations. The viscoelastic properties of the shell are described using the Boltzmann–Volterra hereditary integral. After applying the “freezing method” to the system of integro-differential equations, we obtain ordinary differential equations with complex coefficients, which are subsequently solved by the method of separation of variables and Godunov’s orthogonal sweep combined with Müller’s and Gauss’s methods in complex arithmetic. It is established that for small viscosity, the frequencies of both modes are close to each other in the low-frequency region, while at high frequencies, the phase velocity of the first mode tends toward the velocity of the dry shell. Full article

This article describes the technology for manufacturing a metal composite structure of a metal-cutting tool body. The main problem with using metal 3D-printing is its prohibitively high cost. The initial data for carrying out finite element calculations are presented, in particular, the calculation and justification of the selected loads on the drill body arising from metal-cutting forces. The described methodology for designing a digital model of a metal-cutting tool for the purpose of its further production using SLM 3D metal printing methods facilitates the procurement of a digital model characterized by a reduced weight and volume of material. The described design technology involves the production of a thin-walled outer shell that forms the external technological surfaces necessary for the drill body, as well as internal structural elements formed as a result of topological optimization of the product shape. Much attention in this article is paid to the description of the technology for filling internal cavities with a viscous metal polymer, formed as a result of the topological optimization of the original model. Due to this design approach, it is possible to reduce the volume of 3D metal printing by 32%, which amounts to more than USD 135 in value terms. Full article

Injection molding is a multiphase process that requires accurate simulation of the filling phase. This is a key element in predicting the complete injection molding cycle. The filling phase presents a complex set of challenges, including migrating melt fronts, multi-phase flow, non-Newtonian fluid dynamics, and intertwined heat transfer. Evolving from 1D to 2D, 2.5D, and 3D techniques, filling simulation research has adapted to capture the intricacies of injection-molded parts. However, the need for accuracy in the characterization of the rheological properties of polymers during filling is still of paramount importance. In order to systematically categorize the numerical methods used to simulate the filling phase of injection molding, this review paper provides a comprehensive summary. Particular emphasis is given to the complex interaction of multiple geometric parameters that significantly influence the dynamic evolution of the filling process. In addition, a spectrum of rheological models is thoroughly and exhaustively explored in the manuscript. These models serve as basic mathematical constructs to help describe the complex viscous behavior of polymers during the filling phase. These models cover a spectrum of complexity and include widely recognized formulations such as the Power-Law, second-order, Herschel–Bulkley, Carreau, Bird–Carreau, and Cross models. The paper presents their implementation to include the temperature-dependent influence on viscosity. In this context, the extensions of these models are explained in detail. These extensions are designed to take into account the dynamic viscosity changes caused by the different thermal conditions during the filling process. An important contribution of this study is the systematic classification of these models. This categorization encompasses both academic research and practical integration into commercial software frameworks. In addition to the theoretical importance of these models, their practical value in overcoming challenges in the field of injection molding is emphasized. By systematically outlining these models within a structured framework, this classification promotes a comprehensive understanding of their intrinsic characteristics and relevance in different scenarios. Full article

This paper presents a non-isothermal, non-Newtonian Computational Fluid Dynamics (CFD) model for the mixing of a highly viscous polymer suspension in a partially filled sigma blade mixer. The model accounts for viscous heating and the free surface of the suspension. The rheological model is found by calibration with experimental temperature measurements. Subsequently, the model is exploited to study the effect of applying heat both before and during mixing on the suspension’s mixing quality. Two mixing indexes are used to evaluate the mixing condition, namely, the Ica Manas-Zlaczower dispersive index and Kramer’s distributive index. Some fluctuations are observed in the predictions of the dispersive mixing index, which could be associated with the free surface of the suspension, thus indicating that this index might not be ideal for partially filled mixers. The Kramer index results are stable and indicate that the particles in the suspension can be well distributed. Interestingly, the results highlight that the speed at which the suspension becomes well distributed is almost independent of applying heat both before and during the process. Full article

Cells cultured in three-dimensional scaffolds express a phenotype closer to in vivo cells than cells cultured in two-dimensional containers. Natural polymers are suitable materials to make three-dimensional scaffolds to develop disease models for high-throughput drug screening owing to their excellent biocompatibility. However, natural polymer solutions have a range of viscosities, and none of the currently available liquid dispensers are capable of dispensing highly viscous polymer solutions. Here, we report the development of an automated scaffold dispensing system for rapid, reliable, and homogeneous creation of scaffolds in well-plate formats. We employ computer-controlled solenoid valves to regulate air pressure impinging upon a syringe barrel filled with scaffold solution to be dispensed. Automated dispensing of scaffold solution is achieved via a programmable software interface that coordinates solution extrusion and the movement of a dispensing head. We show that our pneumatically actuated dispensing system can evenly distribute high-viscosity, chitosan-based polymer solutions into 96- and 384-well plates to yield highly uniform three-dimensional scaffolds after lyophilization. We provide a proof-of-concept demonstration of high-throughput drug screening by culturing glioblastoma cells in scaffolds and exposing them to temozolomide. This work introduces a device that can hasten the creation of three-dimensional cell scaffolds and their application to high-throughput testing. Full article

Recently, a strong structural ordering of thermoplastic semi-crystalline polyimides near single-walled carbon nanotubes (SWCNTs) was found that can enhance their mechanical properties. In this study, a comparative analysis of the results of microsecond-scale all-atom computer simulations and experimental measurements of thermoplastic semi-crystalline polyimide R-BAPB synthesized on the basis of dianhydride R (1,3-bis-(3′,4-dicarboxyphenoxy) benzene) and diamine BAPB (4,4′-bis-(4″-aminophenoxy) biphenyl) near the SWCNTs on the rheological properties of nanocomposites was performed. We observe the viscosity increase in the SWCNT-filled R-BAPB in the melt state both in computer simulations and experiments. For the first time, it is proven by computer simulation that this viscosity change is related to the structural ordering of the R-BAPB in the vicinity of SWCNT but not to the formation of interchain linkage. Additionally, strong anisotropy of the rheological properties of the R-BAPB near the SWCNT surface was detected due to the polyimide chain orientation. The increase in the viscosity of the polymer in the viscous-flow state and an increase in the values of the mechanical characteristics (Young’s modulus and yield peak) of the SWCNT-R-BAPB nanocomposites in the glassy state are stronger in the directions along the ordering of polymer chains close to the carbon nanofiller surface. Thus, the new experimental data obtained on the R-BAPB-based nanocomposites filled with SWCNT, being extensively compared with simulation results, confirm the idea of the influence of macromolecular ordering near the carbon nanotube on the mechanical characteristics of the composite material. Full article

Extremely high mechanical performance spun bionanocomposite fibers of chitosan (CHI), and cellulose nanofibers (CNFs) were successfully achieved by gel spinning of CHI aqueous viscous formulations filled with CNFs. The microstructural characterization of the fibers by X-ray diffraction revealed the crystallization of the CHI polymer chains into anhydrous chitosan allomorph. The spinning process combining acidic–basic–neutralization–stretching–drying steps allowed obtaining CHI/CNF composite fibers of high crystallinity, with enhanced effect at incorporating the CNFs. Chitosan crystallization seems to be promoted by the presence of cellulose nanofibers, serving as nucleation sites for the growing of CHI crystals. Moreover, the preferential orientation of both CNFs and CHI crystals along the spun fiber direction was revealed in the two-dimensional X-ray diffraction patterns. By increasing the CNF amount up to the optimum concentration of 0.4 wt % in the viscous CHI/CNF collodion, Young’s modulus of the spun fibers significantly increased up to 8 GPa. Similarly, the stress at break and the yield stress drastically increased from 115 to 163 MPa, and from 67 to 119 MPa, respectively, by adding only 0.4 wt % of CNFs into a collodion solution containing 4 wt % of chitosan. The toughness of the CHI-based fibers thereby increased from 5 to 9 MJ.m⁻³. For higher CNFs contents like 0.5 wt %, the high mechanical performance of the CHI/CNF composite fibers was still observed, but with a slight worsening of the mechanical parameters, which may be related to a minor disruption of the CHI matrix hydrogel network constituting the collodion and gel fiber, as precursor state for the dry fiber formation. Finally, the rheological behavior observed for the different CHI/CNF viscous collodions and the obtained structural, thermal and mechanical properties results revealed an optimum matrix/filler compatibility and interface when adding 0.4 wt % of nanofibrillated cellulose (CNF) into 4 wt % CHI formulations, yielding functional bionanocomposite fibers of outstanding mechanical properties. Full article

Wood polymer composites are materials with pseudoplastic and viscoelastic properties. They have yield stress and exhibit slip during flow. Studies on extrusion and rheology, as well as on process modeling of these highly filled materials are limited. Extensive rheological and extrusion modeling studies on the wood polymer composite based on the polypropylene matrix were performed. Viscous and slip flow properties were determined (with Rabinowitsch, Bagley, and Mooney corrections) at broad (extrusion) range of shear rate and temperature, using a high-pressure capillary rheometer. Rheological models of Klein and power-law were used for flow modeling, and Navier model was applied for slip modeling. A novel global computer model of WPC extrusion with slip effects has been developed, and process simulations were performed to compute the extrusion parameters (throughput, power consumption, pressure, temperature, etc.), and to study the effect of the material rheological characteristics on the process flow. Simulations were validated experimentally, and were discussed with respect to both rheological and process modeling aspects. It was concluded that the location of the operating point of extrusion process, which defines the thermo-mechanical process conditions, is fundamentally dependent on the rheological materials characteristics, including slip effects. Full article

Fused filament fabrication (FFF) is a new procedure for the production of plastic parts, particularly if the parts have a complex geometry and are only needed in a limited quantity, e.g., in specific medical applications. In addition to the production of parts which are purely composed of polymers, fused filament fabrication can be successfully applied for the preparation of green bodies for sintering of metallic implant materials in medical applications. In this case, highly filled polymer–metal feedstocks, which contain a variety of polymeric components, are used. In this study, we focus on various polymer-metal feedstocks, investigate the rheological properties of these materials, and relate them to our results of FFF experiments. Small amplitudes of shear oscillations reveal that the linear range of the polymer–metal feedstocks under investigation is very small, which is caused by elastic and viscous interactions between the metallic particles. These interactions strongly influence or even dominate the flow properties of the feedstock depending on the applied shear stress. The magnitude of the complex viscosity strongly increases with decreasing angular frequency, which indicates the existence of an apparent yield stress. The viscosity increase caused by the high powder loading needed for sintering limits the maximum printing velocity and the minimum layer height. The apparent yield stress hinders the formation of smooth surfaces in the FFF process and slows down the welding of deposited layers. The influence of composition on the processing parameters (suitable temperature range) and part properties (e.g., surface roughness) is discussed on the basis of rheological data. Full article

Aimed at the molding of polymer nanostructure parts, the interface model between long- and short-chain polycarbonates (PC) and nickel mold inserts was established by the molecular dynamics method. The molecular mechanism of the replication capability of polymer nanostructure part molding was discussed by analyzing the migration and diffusion of the molecular chain, concentration profile, filling morphology evolution, interface binding energy, and filling rate of conventional injection molding (CIM) and rapid heat cycle molding (RHCM). The results show that nanostructures are filled mainly during the packing stage. A short-chain PC system has a low glass transition temperature (T_g) and viscosity, good fluidity, and a high filling rate, so the replication capability of its nanostructures is good. A long-chain PC system has a fast cooling rate in CIM, its molecular chain motion is blocked, the filling rate is low, and the interface binding energy is small, and so its nanostructures have poor replication capability. However, the high temperature at the nanostructures can be maintained for a long time in RHCM, which promotes Brownian motion in the molecular chains. Under the action of packing pressure, molecular chains can overcome entanglement barriers and viscous resistance. Thus, the polymer concentration profile and filling rate increase with increasing packing pressure, which can produce more van der Waals energy. Furthermore, the evolution process of polymer filling morphology is realized by the Brownian motion of chain segments under packing pressure; that is, the diffusion motion of the molecular chain along the direction of a tube composed of other chains around it. With the increase of temperature or pressure, the migration and diffusion of the molecular chain can be promoted; thus, the replication capability of nanostructure parts for mold cavities can be enhanced. Full article

The development of non-cellularized injectable suspensions of viscous chitosan (CHI) solutions (1.7–3.3% (w/w)), filled with cellulose nanofibers (CNF) (0.02–0.6% (w/w)) of the type nanofibrillated cellulose, was proposed for viscosupplementation of the intervertebral disc nucleus pulposus tissue. The achievement of CNF/CHI formulations which can gel in situ at the disc injection site constitutes a minimally-invasive approach to restore damaged/degenerated discs. We studied physico-chemical aspects of the sol and gel states of the CNF/CHI formulations, including the rheological behavior in relation to injectability (sol state) and fiber mechanical reinforcement (gel state). CNF-CHI interactions could be evidenced by a double flow behavior due to the relaxation of the CHI polymer chains and those interacting with the CNFs. At high shear rates resembling the injection conditions with needles commonly used in surgical treatments, both the reference CHI viscous solutions and those filled with CNFs exhibited similar rheological behavior. The neutralization of the flowing and weakly acidic CNF/CHI suspensions yielded composite hydrogels in which the nanofibers reinforced the CHI matrix. We performed evaluations in relation to the biomedical application, such as the effect of the intradiscal injection of the CNF/CHI formulation in pig and rabbit spine models on disc biomechanics. We showed that the injectable formulations became hydrogels in situ after intradiscal gelation, due to CHI neutralization occurring in contact with the body fluids. No leakage of the injectate through the injection canal was observed and the gelled formulation restored the disc height and loss of mechanical properties, which is commonly related to disc degeneration. Full article

Additive manufacturing (AM) is the fabrication of real three-dimensional objects from metals, ceramics, or plastics by adding material, usually as layers. There are several variants of AM; among them material extrusion (ME) is one of the most versatile and widely used. In MEAM, molten or viscous materials are pushed through an orifice and are selectively deposited as strands to form stacked layers and subsequently a three-dimensional object. The commonly used materials for MEAM are thermoplastic polymers and particulate composites; however, recently innovative formulations of highly-filled polymers (HP) with metals or ceramics have also been made available. MEAM with HP is an indirect process, which uses sacrificial polymeric binders to shape metallic and ceramic components. After removing the binder, the powder particles are fused together in a conventional sintering step. In this review the different types of MEAM techniques and relevant industrial approaches for the fabrication of metallic and ceramic components are described. The composition of certain HP binder systems and powders are presented; the methods of compounding and filament making HP are explained; the stages of shaping, debinding, and sintering are discussed; and finally a comparison of the parts produced via MEAM-HP with those produced via other manufacturing techniques is presented. Full article