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Optimization of Composite Formulation Using Recycled Polyethylene for Rotational Molding.

Vitaliy Tyukanko1, Roman Tarunin1, Alexandr Demyanenko1

  • 1Department of Chemistry and Chemical Technology, M. Kozybayev North Kazakhstan University, Petropavlovsk 150000, Kazakhstan.

Polymers
|December 31, 2025
PubMed
Summary

Optimizing recycled polyethylene (rPE) content, pigment (Cp) content, and peak internal air temperature (PIAT) in rotational molding composites is crucial. The study found optimal conditions (30% rPE, 0.5% Cp, 195°C PIAT) for enhanced performance and extended product life.

Keywords:
ESCRhigher harmonicsinternal stresses in plasticspolyethylene recyclingrPErotational moldingrotomoldingultrasound in plastics

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Area of Science:

  • Materials Science
  • Polymer Engineering
  • Manufacturing Processes

Background:

  • Rotational molding is a versatile manufacturing process for polymer composites.
  • Optimizing material composition and processing parameters is key to achieving desired product properties.
  • Recycled polyethylene (rPE) and pigments (Cp) are common additives, but their effects require careful study.

Purpose of the Study:

  • To optimize key factors in rotational molding composites: recycled polyethylene (rPE) content, pigment (Cp) content, and peak internal air temperature (PIAT).
  • To investigate the influence of these factors on mechanical properties, surface characteristics, thermal stability, and environmental stress cracking resistance (ESCR).
  • To establish correlations between ultrasonic signals and internal stress for performance prediction.

Main Methods:

  • Systematic variation of rPE content (0-50%), Cp content (0-2%), and PIAT (170-230°C).
  • Characterization of composite properties including elastic modulus (E), impact strength (MFEsp), contact angle (θ), IR spectroscopy, DTA-TG analysis, and ESCR.
  • Ultrasonic testing to measure the amplitude of the third harmonic (β) as an indicator of internal stress.

Main Results:

  • Increased rPE and Cp slightly enhanced surface hydrophilicity.
  • PIAT significantly impacted all studied composite characteristics.
  • A strong correlation was observed between β, ESCR, MFEsp, and E, validating β as a quantitative indicator of internal stress.
  • Optimal conditions identified as 30% rPE, 0.5% Cp, and 195°C PIAT for minimal internal stress and superior performance.

Conclusions:

  • The study successfully optimized rotational molding parameters for rPE/pigment composites.
  • Developed nomograms enable prediction and selection of rPE and Cp content based on PIAT and desired mechanical properties (MFEsp, β).
  • The findings provide a pathway to enhance the performance and service life of rotomolded products through controlled composition and processing.