Prototype System to Study the Effect of Weld Lines on the Performance of Extruded Profiles

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1 REGULAR CONTRIBUTED ARTICLES O. S. Carneiro*, A. R. Mota, Y. Sitotaw, J. M. Nóbrega IPC/i3N Institute for Polymers and Composites, Department of Polymer Engineering, University of Minho, Guimarães, Portugal Prototype System to Study the Effect of Weld Lines on the Performance of Extruded Profiles In several thermoplastic extrusion based processes the melt flow has to be divided into independent streams that are merged before the flow channel outlet. This promotes the formation of weld lines, usually related to mechanical weak zones and aesthetic imperfections. There is a large amount of scientific publications related to weld lines formed in other processing techniques, e. g. injection molding. However, studies related to extrusion are scarce. This work presents the conception of a new prototype system that allows performing systematic studies aiming a better understanding of the effect of weld lines in extrusion. A case study illustrates the employment of the developed device to study the effect of several process parameters (e. g. spider leg location, processing temperature and flow rate) on the mechanical performance of the extruded profiles. 1 Introduction * Mail address: Olga S. Carneiro, IPC/i3N Institute for Polymers and Composites, Department of Polymer Engineering, University of Minho, Campus de Azurém, Guimarães, Portugal olgasc@dep.uminho.pt Extrusion of thermoplastic profiles is a continuous process that encompasses the following main stages: (i) plastication, taking place at the extruder where the polymer is melted, homogenised and pumped to the extrusion die; (ii) forming, where the extrusion die confers the desired cross-section shape to the melt; (iii) calibration/cooling, where the extruded profile is cooled down and, eventually, calibrated, until the polymer solidification temperature is attained, guarantying its shape downstream this stage; (iv) pulling, followed by cutting or winding. Extrusion is used to produce a wide range of products, namely pipes, profiles, sheet, blown film, wire coated cables, among others. Due to process and product requirements, different extrusion lines are used in each case. The extrusion die is always the most important component of the line that has, for each of the above type of products, a particular constructive solution. Extrusion dies employed for the production of hollow profiles, as pipes, catheters, and a series of other technical profiles, have an internal mandrel, or torpedo, required to shape the internal surface of the extruded profile. As can be seen in Fig. 1A, this torpedo is supported by spider legs that link this component to the outer part of the extrusion die, required to shape the external surface of the extruded profile. During the flow of the polymer melt through the extrusion die, the spider legs promote the flow separation into several flow fronts that re-join, or weld, downstream these obstacles. At the zone, or zones, where this welding process occurs a weld line is formed (see Fig. 1. In the case of extrusion, weld lines are continuous and extend along all the profile length, and may have a detrimental effect on the performance of the final extrudate. As shown by Huang and Prentice (1998), the performance reduction can be promoted by poor molecular entanglement, exis- Fig. 1. Extrusion die for the production of a hollow profile: typical constructive solution employing a mandrel and spider legs; formation of weld lines downstream the spider legs 254 Ó Carl Hanser Verlag, Munich Intern. Polymer Processing XXXI (2016) 2

2 tence of residual stresses at the welding zone and eventual reduction of the wall thickness. In extrusion, weld lines are also formed when flow separators are used (see Fig. 2). These are thin metallic walls inserted along the parallel zone of the die, intended to isolate the different flow paths of the melt flow. The employment of these separators should be avoided whenever possible but, as stated by Nóbrega et al. (2004), sometimes they are the only solution available to guarantee the flow balance of the die, i.e., to assure a homogeneous average melt velocity along the cross-section of the extruded profile at the die exit. In this case, the detrimental effect of these obstacles is quite strong since, to be effective for flow balancing purposes, they have to be prolonged until up just few millimetres upstream the die exit (Carneiro et al., 2003). Therefore, in this case the weld line is formed at a low pressure, which acts during a short (residence) time. Several works, e. g. Kazmer (2012), report that weld lines can also be formed in other polymer processing techniques, including blow molding and injection molding, and occur whenever an obstacle has to be circumvented by the melt stream and rejoins downstream. The study done by Chang and Faison (1999) demonstrated that the formation of weld lines creates a local mechanical weakness and may affect the product surface appearance. The reduction on the local mechanical strength in the area of the weld is magnified by the incorporation of both additives (Mielewski et al., 1998) and fibers (Jariyatammanukul et al., 2009). Wu and Liang (2005) analyzed the effect of weld lines at different scales, concluding that the performance increases with the reduction of the cross-section specimen dimension. In case of fiber reinforced materials Hashemi (2007) concluded that, when weld lines are present, an increase in the test temperature negatively affects the filler reinforcement capability. Despite its importance, the subject is rarely addressed in the technical literature, the majority of the works published being related to polymer injection molding. However, the results obtained in the injection molding studies cannot be extended to extrusion due to the huge differences in the thermo-mechanical conditions in which the weld lines are formed. In fact, in injection molding, after the mold cavity filling stage promoted with the injection pressure, a pressurization stage follows, enabling the compensation for shrinkage occurring during cooling. Differently from extrusion, this cooling process under high pressure favours smearing the weld lines negative effects and Fig. 2. Extrusion die parallel zone with flow separators avoids the reduction of thickness in these zones. Another difference relative to the extrusion process, but now having opposite consequences, is that the mold temperature is substantially lower than that of the melt, thus limiting the level of molecular diffusion that favours the welding of the distinct flow fronts. Other differences between the two techniques are the much lower viscosity of the injection molding grades and the higher melt velocities attained in injection molding, facts that have obvious impacts over the degree of molecular orientation and viscous dissipation induced by the flow. In extrusion, the most relevant work published in this field was that performed by Huang and Prentice (1998), who used a sheet extrusion die with a removable spider leg that enabled to study the influence of its geometry (using six different geometries for the removable spider leg), at a fixed location in the flow channel. However, this extrusion die did not allow changing the location of the spider leg, in order to study the effect of this important parameter on the quality of the weld lines formed. Due to the topic relevance for the extrusion process understanding and for die design purposes, the lack of available experimental based studies may, most probably, be related to the inexistence of experimental devices that facilitate performing systematic studies. Having in mind the available literature presented before, the authors of the present work designed a prototype extrusion die that allows performing systematic investigations, under controlled extrusion conditions, on the influence of the main parameters on the quality of the weld lines formed. The final goal is to get relevant information to help the design of profile extrusion dies, a subject of major industrial relevance to which the present research team has been devoted during the last fifteen years. The remaining of the paper is organized as follows. The subsequent section contains a detailed description of the novel prototype system and its employment is illustrated in Section 3. The paper ends with Section 4, where the main conclusions of the work are provided. 2 Prototype System 2.1 Description The prototype extrusion die described here has a recent patent application (Carneiro et al., 2014). Its main innovative feature is the fact that it enables to displace the spider leg along the die parallel zone flow channel, without the need of dismounting the extrusion die. Consequently, this new device facilitates the fulfilment of systematic studies, aiming to understand and quantify the impact of the most relevant process parameters on the quality of the formed weld lines. These additional insights are also expected to provide valuable guidelines for the designer of extrusion dies that incorporate flow separators or spider legs. The prototype extrusion die was designed to produce a narrow sheet, or tape, its innovative zone being the parallel one. This tape can be produced with (using a spider leg) or without (by removing the spider leg) the formation of a weld line. The weld line can be formed under different and well controlled conditions. The parallel zone of the prototype extrusion die, il- Intern. Polymer Processing XXXI (2016) 2 255

3 Fig. 3. View of the parallel zone of the prototype extrusion die: top and bottom modules; global view with the two halves mounted. The components illustrated include: top (1) and bottom (2) modules, pressure-temperature transducers (3), spider leg (4), spider leg positioning holes (5) and limiting stroke shaft (6) set is shown, mounted, in Fig. 3B, where the rectangular shape of the die exit, used to produce a tape, can be seen. Figures 4 and 5 illustrate the tool specially designed to displace the spider leg. This tool (see Fig. 4) is composed by a main structure (7) that is coupled to the die outlet surface through a screw (8) whenever there is a need to insert, displace, or remove the spider leg. The tool encompasses two stems (9) that are used to release or to capture the spider leg (see these two operational conditions in Fig. 5A and, when displaced laterally. The axial displacement of the two stems is conducted by a screw (10). The actual location of the stems head (indicating also the location of the spider leg inside the flow channel) is indicated in an engraved scale (11). This special tool is operated with the die mounted, as illustrated in Fig. 5C, enabling, therefore, to displace the spider leg, to remove it or to substi- lustrated in Fig. 3A, is composed by two halves/modules top (1) and bottom (2). The rectangular flow channel shown in this figure (parallel zone of the die) is 61 mm long, 50 mm wide and 3 mm high. Each of those modules accommodate three holes for pressure-temperature sensors (3), to monitor the flow conditions inside the die; the bottom module (2) houses also a removable/displaceable spider leg (4), 28 mm long, 7 mm wide and same thickness as the flow channel height (3 mm), that can be fixed through screws (5) and corresponding positioning holes. The shaft shown (6) is intended to limit the lower stroke of the spider leg positioning screws, as will be seen later. The Fig. 4. 3D view of the special tool designed to displace the spider leg. The components illustrated include: main structure (7), fixing screw (8), stems (9), adjusting location screw (10) and scale (11) 256 Intern. Polymer Processing XXXI (2016) 2

4 C) Fig. 5. Special tool mounted in the die: stems open; stems closed and ready to displace the spider leg; C) overview of the system when the special tool is used tute it by another one of different geometry, without demounting the extrusion die. The only condition required to perform this operation is to stop the extruder. Figure 6 depicts the constructive solution designed to lock the spider leg in the flow channel at the required axial location. Several screws (5) having flat ends are used to plug the positioning holes that are not being used, thus guarantying a smooth surface for the die flow channel, while a special screw (12), with a protruded end, together with a flat screw (5*) totally screwed, are used to position and fix the spider leg at the required location. The special screw (12) can be used in any of the existing holes and fits one of the bottom holes (13) of the spider leg. This set of screws has upper and lower stroke limits, which are defined by a recess machined in the lower die module (2) and by the shaft (6), respectively. 2.2 Potential The influence of several parameters can be studied using the prototype system developed, described in the previous section, namely:. extrusion temperature, that will define the welding temperature;. extrusion flow rate, that will determine the polymer molecular orientation, pressure at the welding zone and the residence time after welding;. geometry of the spider leg, that will determine the flow streamlines at the welding zone;. location of the spider leg, that will affect the pressure at which welding takes place and the residence time after welding;. polymer system, to study the influence of the type of polymer (amorphous versus crystalline) and the influence of using reinforcing fibres, for example. Fig. 6. Spider leg positioning system: lateral cut view. The components illustrated include: top (1) and bottom (2) modules, flat screws (5), special protruded screw (12), spider leg (4), bottom holes of the spider leg (13) and lower stroke limiting shaft (6); 3D view of lower stroke limiting shaft (6) Intern. Polymer Processing XXXI (2016) 2 257

5 In any of the above conditions, the prototype extrusion die can also be used without spider leg, enabling, therefore, to make a direct assessment of the detrimental effect promoted by the weld line. For assessment purposes, the tape produced with the prototype extrusion die can be used to perform mechanical tests as, for example, tensile, flexural and impact ones, the samples being cut from the tape as illustrated in Fig Mechanical Characterization The samples for mechanical characterization were cut from the tape produced under different conditions, as illustrated in Fig. 7. Tensile and flexural tests were performed in the following conditions:. tensile tests: for each condition, 10 samples (of rectangular shape) were tested at a cross-head speed of 25,4 mm/min 2.3 Case Study Extrusion Experiments To illustrate the potential of the prototype system described, some extrusion experiments were performed. For this sake, the prototype die was used with one general purpose polystyrene, PS, Polystyrol 158 K, from BASF, Berlin, Germany, having a MVR (200 8C/5 kg) of 3 cm 3 /10 min. The extrusion line used is illustrated in Fig. 8, being composed by a single screw extruder (25 mm screw diameter), the prototype extrusion die instrumented with pressure-temperature transducers and a set of pulling rolls. Cooling of the tape was promoted by natural convection. The remaining conditions used in the different extrusion runs performed are listed in Table 1. The reference extrusion conditions are those employed in run 2, performed at 2058C, a screw speed of 45 min 1 and the spider leg used at location L2 (see Fig. 9); runs 1 to 4 were used to assess the effect of the spider location, including the production of a tape without weld line (run 4); the influence of the extrusion temperature was assessed through runs 5 7, plus the reference one (run 2); finally, the effect of the screw speed, or flow rate, was assessed through runs 8 to 9, plus the reference one (run 2). Fig. 7. Weld line quality assessment: samples to be taken from the extruded tape for mechanical characterization Fig. 8. Extrusion set-up, in service, used to produce the PS tapes Run no. Extrusion/die temperature (8C) Screw speed (min 1 )/Melt flow rate (kg/h) Spider leg location (see Fig. 9) 1 L /5.30 L2 3 L3 4 Without spider leg /5.09 L / / /4.00 L2 9 55/6.30 Note: reference run identified in bold. Table 1. Extrusion runs performed Fig. 9. Different spider leg locations (codedistance to the die outlet) used in the extrusion runs: L1 12,0 mm close to the die outlet; L3 27,0 mm far from the die outlet; L2-19,6 mm mid distance between L1 and L3 258 Intern. Polymer Processing XXXI (2016) 2

6 and an initial distance between grips of 20 mm, in an universal tensile testing machine (model Z005; Zwick/Roell, Ulm, Germany).. flexural tests: for each condition, 10 samples (of rectangular shape) were tested, using a three point bending fixture and a cross-head speed of 25 mm/min, in an universal testing machine (model 4500, Instron, Norwood, MA, US. The specimens were deflected and the maximum load was recorded until rupture occurred in the outer surface of the test specimens. These tests were performed due to the inability of getting valid tensile results for the samples extruded without spider leg (without weld line), which always broke at the grips. 3 Results and Discussion 3.1 Effect of the Spider Leg Location To assess the effect of this variable, samples produced in extrusion runs 1 to 4 were used. Figures 10 and 11 show the results obtained in the tensile and flexural tests, respectively. As can be seen, despite of the relatively high values of the standard deviation resulting from the tensile tests (most probably due to the small size and geometry of the samples used, favouring slippage at the grips), there is a significant increase in both tensile strength and strain at break when the spider leg is displaced upstream the die flow channel (from L1 to L3). The same effect can be observed in the flexural strength, where the detrimental effect of the weld line vanishes for location L3, i.e., 27 mm upstream the die outlet, where the value of this property equals that of the sample produced without weld line. The only exception was the tensile modulus that seems to be almost insensitive to the location of the spider leg. The results have the expected trend since higher distances of the spider leg to the die outlet give rise to higher pressures at the welding zone. Additionally, the increase in the residence time after welding favours melt relaxation (mostly oriented on the flow direction, especially in the welding region downstream the spider leg, where its restrictive effect fades out) thus facilitating molecular diffusion between the two melt fronts and, therefore, some degree of entanglement between their molecules. The set of results presented here suggests that for the particular extrusion conditions used (extrusion temperature of 2058C and screw speed of 45 min 1 ) a distance of the spider leg to the die outlet of L3, 27 mm (or L/t of 9), or higher, will guarantee an adequate mechanical performance of the weld line formed. This is the type of practical information we were expecting to obtain with the prototype die, useful for die design purposes. In fact, these experiments and the corresponding re- C) Fig. 10. Results of the tensile tests performed with samples produced with a spider leg used at locations L1, L2 and L3, die temperature of 2058C and screw speed of 45 min 1 : tensile strength; strain at break; C) tensile modulus Fig. 11. Flexural strength of the samples produced with a spider leg used at locations L1, L2 and L3 and without spider leg (reference line), die temperature of 205 8C and screw speed of 45 min 1 Intern. Polymer Processing XXXI (2016) 2 259

7 sults are just the first stage of the studies that will be performed with this innovative system; the next steps will consist on the establishment of relationships between pressure/stress and local temperature at the welding zone, and residence time from this zone to the die outlet, on one hand, and mechanical performance of the extrudate, on the other hand. For this purpose, the detailed characterization of the flow field is required and will be done through numerical studies of the experimental extrusion runs. 3.2 Effect of Extrusion Temperature In this case, samples produced in the extrusion runs 2, 5, 6 and 7 were used. In order to check for an eventual effect of the flow rate, that could mask the effect of the variable under study (extrusion temperature), its magnitude was measured for all the extrusion runs. As can be seen in Table 1, variations of 2 to 4 % were obtained, when compared to the flow rate of the reference run (run 2). Therefore, in this analysis we discharged the effect of the flow rate, which will be assessed in a dedicated set of runs, where the variations imposed to the flow rate are of the order of 20% (see Table 1). The tensile results obtained for the effect of the extrusion temperature are shown in Fig. 12. For the properties measured, the effect observed is only slight, seeming to be non-monotonic. The results suggest that the weld lines have a better quality for the intermediate extrusion temperatures used (205 and 2108C). Having in mind the similarity of the results and the corresponding standard deviations, any attempt to interpret these results may be risky. However, one can speculate that melt temperature generates opposite effects since low values favour high (welding) pressures whereas high ones lead to higher molecular mobility, both positive for the weld lines quality. On the other hand low melt temperatures inhibits molecular diffusion and high ones originate lower (welding) pressures, having both a negative impact on the quality of the weld lines. The trade-off of the two conflicting effects can probably justify the trend observed. 3.3 Effect of Flow Rate The effect of flow rate, or screw speed, was assessed using the samples produced in extrusion runs 2, 8 and 9. For this variable, a sharp decrease in all the properties measured was observed for the higher flow rate, as can be seen in Fig. 13. We believe that this catastrophic behavior of the weld line is a consequence of the higher level of molecular orientation, induced by the high elongational flow developed, together with a low residence time after welding, resulting from the higher average flow velocity, both affecting negatively the degree of molecular diffusion across the weld line. The prototype system described and used in this work proved to have an enormous potential to study the quality of the weld lines formed in the extrusion process and its dependence on several parameters. The prototype system constitutes, therefore, an important tool to assist the design of extrusion dies whenever they encompass spider legs used to support torpedoes needed to shape hollow parts. The results obtained in the extrusion experiments done to illustrate the usefulness of the developed prototype system, performed with an amorphous polymer, PS, showed that the quality of the weld lines decreases with the decrease in the residence time after welding (i. e., location of the spider leg close to the die outlet and high flow rate) and depend also on the molecular mobility and orientation, both affected by the extrusion temperature. It was also observed that if the spider leg is located sufficiently upstream the die outlet (at 27 mm or L/t = 9), the detrimental effect of the weld line formed may vanish, which constitutes an important data for die design purposes. 4 Conclusions C) Fig. 12. Results of the tensile tests performed with samples produced with a spider leg used at location L2, die temperatures ranging from 200 to 2158C and screw speed of 45 min 1 : tensile strength; strain at break; C) tensile modulus 260 Intern. Polymer Processing XXXI (2016) 2

8 Future work will be carried out with other polymer systems (semicrystaline ones and glass fibre reinforced polymers) and numerical simulations of the extrusion runs will be performed to fully characterize the thermo-mechanical conditions in which the welding process takes place. References Carneiro, O. S., Nóbrega, J. M., Oliveira, P. J. and Pinho, F. T., \Flow Balancing in Extrusion Dies for Thermoplastic Profiles. Part II: Influence of the Design Strategy", Polym. Proc., 18, (2003), DOI: / Carneiro, O. S., Nóbrega, J. M. and Mota, A. R., Portuguese patent pending (2014) Chang, T. C., Faison III, E., \Optimization of Weld Line Quality in Injection Molding Using an Experimental Design Approach", The J. Inj. Moulding Tech., 3, (1999) Hashemi, S., \Thermal Effects on Weld and Unweld Tensile Properties of Injection Moulded Short Glass Fibre Reinforced ABS Composites", express Polym. Lett., 1, (2007), DOI: /expresspolymlett Huang, Y., Prentice, P., \Experimental Study and Computer Simulation of the Effect of Spider Shape on the Weld Lines in Extruded Plastic Pipes", Polym. Eng. Sci., 38, (1998), DOI: /pen Jariyatammanukul, P., Paecheroenchai, N., Pomkajohn, P. and Patcharaphun, S., \Effect of Thickness on Weld Line Strength of Injection Molded Thermoplastic Composites", Kasetsart J. (Nat. Sci.), 43, (2009) Kazmer, D. O., \Injection Mold Design Engineering", Hanser, Bad Langensalza, Germany (2012) Mielewski, D. F., Bauer, D. R., Schmitz, P. J. and van Oene, H., \Weld Line Morphology of Injection Molded Polypropylene", Polym. Eng. Sci., 38, (1998), DOI: /pen Nóbrega, J. M., Carneiro, O. S., Pinho, F. T. and Oliveira, P. J., \Flow Balancing in Extrusion Dies for Thermoplastic Profiles. Part III: Experimental Assessment", Int. Polym. Proc., 19, (2004), DOI: / Wu, C.-H., Liang, W.-J., \Effects of Geometry and Injection-Molding Parameters on Weld-Line Strength", Polym. Eng. Sci., 45, (2005), DOI: /pen Acknowledgements The authors gratefully acknowledge funding from Fundação para a Ciência e a Tecnologia (FCT) through the Project PTDC/ EME-MFE/113988/2 009, and FEDER, via FCT, through the COMPETE 2020 Programme and National Funds through FCT under the project UID/CTM/50025/2013. Paulo Teixeira is also acknowledged for his collaboration on the preparation of the paper figures. Date received: November 02, 2015 Date accepted: January 14, 2016 C) Fig. 13. Results of the tensile tests performed with samples produced with a spider leg used at location L2, die temperature of 205 8C and screw speeds of 35, 45 and 55 min 1 (or 4.0, 5.5 and 6.3 kg/h corresponding flow rates): tensile strength; strain at break; C) tensile modulus Bibliography DOI / Intern. Polymer Processing XXXI (2016) 2; page ª Carl Hanser Verlag GmbH & Co. KG ISSN X Intern. Polymer Processing XXXI (2016) 2 261

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