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High-Performance of a Thick-Walled Polyamide Composite Produced by Microcellular Injection Molding
Dariusz Sykutera1, Piotr Czyżewski1, Piotr Szewczykowski1
1Department of Manufacturing Techniques, Faculty of Mechanical Engineering, UTP University of Science and Technology, Kaliskiego 7, 85-796 Bydgoszcz, Poland.
Materials (Basel, Switzerland)
|August 7, 2021
Summary
Microcellular injection molding (MIM) of polyamide 66 with glass fiber (PA66 GF) effectively reduces defects in thick-walled parts. This lightweighting technique improves mechanical properties and reduces material waste.
Area of Science:
- Materials Science
- Polymer Engineering
- Manufacturing Processes
Background:
- Standard injection molding produces defects like sink marks and warpage in thick-walled parts.
- Microcellular injection molding (MIM) offers a solution for producing lightweight, defect-free moldings.
- Polyamide 66 (PA66) reinforced with glass fiber (GF) is a common material for demanding applications.
Purpose of the Study:
- To investigate the effectiveness of MuCell® technology for producing thick-walled PA66 GF moldings.
- To analyze the impact of molding thickness and nitrogen pressure on morphology and mechanical properties.
- To achieve lightweight, high-performance thick-walled moldings without defects.
Main Methods:
- Preparation of thick-walled PA66 GF moldings using MuCell® technology.
- Systematic variation of molding thickness (6 and 8.4 mm) and nitrogen pressure (16 and 20 MPa).
- Characterization of microcellular structure, morphology, and mechanical properties using SEM, micro CT, and FEM simulations.
Main Results:
- Successful production of microcellular PA66 GF moldings with a cell diameter of approximately 30 μm.
- Elimination of sink marks and warpage in thick-walled parts, even with a reduced holding phase time (0.3 s).
- Achieved excellent strength, favorable impact resistance, and reduced weight compared to conventional methods.
Conclusions:
- MuCell® technology is highly effective for producing defect-free, lightweight thick-walled PA66 GF moldings.
- Fiber orientation and the presence of numerous small nitrogen cells in the core and transition zones contribute to superior mechanical performance.
- This process offers significant material and energy savings for thick-walled component manufacturing.
