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The capabilities of Stevens Institute of
Technology in the areas of rheology, structure
formation, mathematical modeling of
continuous processing of energetics
Dilhan M. Kalyon, HfMI
Stevens Institute of Technology
201 216 8225 [email protected]
Dilhan M. Kalyon
October 13, 2015,
Lubbock, TX
1
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Highly Filled Materials
Institute at Stevens
• Founded in 1989 at Stevens Institute of Technology
capitalizing on the strong funding history in the area of
processing of energetic materials
• HfMI focuses on the manufacturing of materials which
are loaded with solids at concentrations which approach
the maximum packing fraction of the solid phase. Such
materials are difficult to characterize, process, simulate.
Especially with energetics there is little room for
experimentation.
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Fiske , Kalyon, Powder Technology, 81, 57-64 (1994).
Bimodal size distribution:
Diameter Ratio= 20
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CONTINUOUS PROCESSING
HIGHLY CONCENTRATED SUSPENSIONS
SOLID PHASE approaching maximum loading level
+
CERAMICS
AEROSPACE
BLOW
MOLDED
COMPOSITES
PHARMACEUTICAL
&
TISSUE
ENGINEERING
SCAFFOLDS
BATTERIES
MAGNETIC
RECORDING
MEDIA
DETERGENTS
AND SOAPS
EXPLOSIVES AND
ROCKET FUELS
NANOCOMPOSITES
& COMPOSITES
EMF/EMI
SHIELDING
FILLED RUBBER
AND ELASTOMERS
POLYMERIC COMPOUNDS
AND MASTERBATCHES
FOOD
PRODUCTS ELECTRONIC
PACKAGING
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Highly Filled Materials Institute (1989- ):
From particles to products with specialization in
Highly filled suspensions
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Continuous Processing Lab
of HfMI: Twin Screw
Extruder Facility and the
Slit Die Rheometer
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CORE STRENGTHS
• Ability to characterize accurately the rheological behavior of highly filled materials
• Ability to simulate the processing of highly filled materials
• Ability to characterize microstructural distributions quantitatively
• Ability to design and manufacture tools for processing of highly filled materials: dies, processors, control systems.
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Specialized Tools
• Custom designed rheometers with remote loading
and data acquisition capabilities
• Custom designed processing equipment with
remote access for data acquisition and control
• Source codes (FEM, FD) with ability to run using
the internet
• Structural analysis tools for degree of mixedness,
particle size analysis and coating thickness
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Challenge: To determine how to process-
processing-structure development and ultimate properties
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Counter-rotating tangential twin screws.
Co-rotating fully intermeshing twin screws.
Counter-rotating fully
intermeshing twin screws.
•M. Malik and D. Kalyon, “Three-dimensional Finite Element
Simulation of Processing of Generalized Newtonian Fluids in
Counter-rotating and Tangential Twin Screw Extruder ”,
Int. Polym. Processing, 20, 398- 409 (2005).
•D. M. Kalyon and M. Malik,
“An integrated approach for numerical analysis of coupled
flow and heat transfer in co-rotating twin screw extruders”,
International Polymer Processing, 22, 293-302 (2007)
•M. Malik, D. M. Kalyon, and J. C. Golba Jr., “Simulation of
co-rotating twin screw extrusion process subject to
pressure-dependent wall slip at barrel and screw surfaces”,
International Polymer Processing, 29, 1, 51-62 (2014).
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Many types of flighted-screws
and kneading disks: right or left
handed, different stagger angles
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16x1/2”
90°
Neutral
Mixing
Paddles
10” Feed
Screw
3” 90°
Helical
Screw
Orifice
Plug
3.5”
Camel
back
Discharge
Each screw configuration is a different processor- how does one
select the screw barrel configuration- given a task
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Specialized technologies
• Rheology
• Structure analysis using WXD
• Mathematical modeling using 3-D FEM
• Experimental validation methods
• Custom design and manufacture
– Rheometers
– Dies
– Extruders
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Demonstration of Apparent Wall Slip
60% vol. solids
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Demonstration of Viscoplasticity for
Gels:
Yield stress
S. Aktas, D. M. Kalyon, B. M. Marín-Santibáñez and J.Pérez-González, “Shear viscosity and wall slip behavior of a viscoplastic hydrogel”,
J. Rheology, 58, 2, 513-535 (2014).
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With wall slip rheology data become dependent on the
surface/volume ratio: Flow curves at constant capillary length/radius (L/R)
D. Kalyon, “Apparent Slip and Viscoplasticity of Concentrated Suspensions”,
J. Rheology, 49, 3, 621-640 (2005).
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Wall slip velocity versus shear stress behavior is characterized
and used as the boundary condition in mathematical modeling
B. Aral and D. M. Kalyon, "Effects of Temperature and Surface Roughness on Time-Dependent Development of Wall Slip in
Torsional Flow of Concentrated Suspensions," J. Rheol., 38 (4), 957-972 (1994).
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t × (u - usolid) = bnt : TUnit tangent vector
Unit normal vector
Total stress tensor
Boundary condition in simulation: wall slip
A. Lawal and D. M. Kalyon, "Non-isothermal Model of Single Screw Extrusion of Generalized
Newtonian Fluids," Numerical Heat Transfer, 26 (1), 103-121 (1994).
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Filling station
a) Off-line adjustable gap slit die
b) On-line
adjustable gap slit
die
c) Squeeze flow
rheometer-
Specialized rheometers which allow the determination of wall slip
velocity as well as shear viscosity
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Pressure versus distance
ADJUSTABLE GAP
RECTANGULAR SLIT DIE
Off-line
On-line,
twin screw
extruder
Kalyon, Gevgilili, Kowalczyk, Prickett and Murphy, “Use of adjustable-gap on-line
and off-line slit rheometers for the characterization of the wall slip and shear viscosity behavior of
energetic formulations”, Journal of Energetic Materials, 24, 175-193 (2006).
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F
h
R SAMPLE
Squeeze flow rheometer
•Simple to operate
•Data analysis instantaneous
•Ideal for complex fluids
•Replaces the “finger” rheometer
squeeze
flow
D. Kalyon, H. Tang and B. Karuv, Journal of Energetic Materials, 24, 195-202 (2006).
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Adjustable Gap On-line Rheometer Squeeze Flow Rheometer
- Currently used for live energetics @
NSWC / IH
- Built for characterization of gun
propellants @ Alliant TechSystems /
Radford, VA
NOVEL RHEOMETERS DEVELOPED, DESIGNED AND BUILT
BY SIT
HFMI/SIT DEC.’98
•D. Kalyon, H. Gevgilili, J. Kowalczyk, S. Prickett and C. Murphy, “Use of adjustable-gap on-line and off-line slit rheometers for the
characterization of the wall slip and shear viscosity behavior of energetic formulations”, Journal of Energetic Materials, 24, 175-193 (2006).
•D. Kalyon, H. Tang and B. Karuv, “Squeeze flow rheometry for rheological characterization of energetic formulations”, Journal of Energetic
Materials, 24, 195-202 (2006).
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New-generation of squeeze flow rheometer built for IBM
and Bergquist
D. Kalyon, Journal of Energetic Materials, 24, 213 (2006).
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Inverse problem solution in compressive squeeze flow:
viscoplastic with wall slip
Kalyon and Tang, Journal of Non-Newtonian Fluid Mechanics, 143, 133 (2007).
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z
u
r
ru
r
zr
10
)1
(0zrr
r
rr
p rzrr
)1
(0zr
r
rz
p zzrz
Lawal and Kalyon, Int. Polym. Proc., 15, 63 (2000).
Analysis of the squeeze flow data for parameters of shear viscosity and
wall slip using 2-D FEM:
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Mathematical modeling
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Challenge: To determine how to process-
processing-structure development and ultimate properties
Kalyon and Malik, International Polymer Processing, 22, 293-302 (2007)
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Kalyon, Lawal, Yazici, Yaras and Railkar, "Mathematical Modeling and Experimental Studies
of Twin Screw Extrusion of Filled Polymers", Polym. Eng. Sci., 39, 6, 1139-1151 (1999).
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30
0
0.2
0.4
0.6
-0.3 -0.2 -0.1 0 0.1
Distance along extruder axis, z (m)
Bu
lk p
ress
ure
, P
(M
Pa)
Reversing
Screws
Forwarding
Screws Neutral
Kneading Discs
90o N
50 Kg/h
40
30 20
9
Kalyon and Malik, International Polymer Processing, 22, 293-302 (2007)
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0.2
0
0.2
0.4
0.6
0.8
1
-0.2 -0.1 0 0.1
Distance along extruder axis, z (m)
Bu
lk p
ress
ure
, P
(M
Pa)
100 Kg/h
80
60
40
Forwarding
Fully-flighted Screws
Rectangular slit die
Kalyon and Malik, International Polymer Processing, 22, 293-302 (2007)
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Experimental validation
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HfMI Experiments, Hebedove,
50 mm Twin- extruder, 10 Rpm, Ti 22 C
0.00
100.00
200.00
300.00
400.00
500.00
600.00
700.00
800.00
900.00
1000.00
0 5 10 15 20 25 30 35 40 45 50
Distance, cm
Pre
ss
ure
, P
si
Experiment Die
Experiment Screw
FEM Die
FEM SCREW
sc1d2d3d.die
Die exit
Die Screw
G3
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Thermal imaging camera: extrusion
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Temperature distribution: experimental
versus simulation
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Extrudate with 76.5%
solids prior to axial
migration of binder
Filtration of the
binder phase
Unstable flow
U. Yilmazer , C. Gogos and D. M. Kalyon, "Mat Formation and Unstable Flows of Highly Filled Suspensions in
Capillaries and Continuous Processors," Polymer Composites, 10 (4), 242-248(1989).
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Yaras, Kalyon, Yilmazer, "Flow Instabilities
in Capillary Flow of Concentrated Suspensions,
" Rheologica Acta, 33, 48-59 (1994).
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Concentration Distribution
in Poiseuille Flow
2 a
R
r
0.40
0.45
0.50
0.55
0.60
0.65
0.70
0.00 0.20 0.40 0.60 0.80 1.00
r/R
a/R=0.005
a/R=0.05
o= 0.50
L/D = 100
M. Allende, D. Fair, D. M. Kalyon, D. Chiu and S. Moy,
“Development of particle concentration distributions and burn rate gradients upon shear-induced particle migration during processing
of energetic suspensions”, Journal of Energetic Materials, 25, 49- 67 (2007).
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Mixing-
degree of
mixedness
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Ability to mathematically model
the processing/mixing process
A. Lawal and D. M. Kalyon, Polym. Eng. Sci., 35, 1325-1338 (1995).
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Analysis of Kneading Disks staggered at 30 forward
t=0 1 period
5 periods
20 periods
A. Lawal and D. M. Kalyon, "Mechanisms of Mixing in Single and Co-rotating Twin Screw Extruders,“
Polym. Eng. Sci., 35 (17) 1325-1338 (1995).
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Aluminum Scan Sulfur scan
SEM and EDX
for mixing
analysis
Yazici and Kalyon, Rubber Chem. and Tech., 66 (4), 527-537 (1993).
Yazici and Kalyon, Rubber Chem. and Tech., 66 (4), 527-537 (1993).
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To quantitatively characterize the degree of
mixedness of the ingredients
Fig. 2 X-RAY DIFFRACTION PATTERN OF A MIXTURE AND ITS
DECONVOLUTION TO ITS COMPONENTS
5 10 15 20 25 30 35 40
2Q Braggs' Angle
Re
lati
ve
In
ten
sit
ymixture
diffraction pattern
of the mixture
binder
ingredient 1
ingredient 2
additive
Yazici and Kalyon, Rubber Chem. and Tech., 66 (4), 527-537 (1993).
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Effects of mixing time on distribution of particle concentration in the mixture
Erol and Kalyon, International Polymer Processing, 20, 228-237 (2005).
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R. Yazici and D. M. Kalyon, "Quantitative Characterization of Degree of Mixedness of LOVA Grains," Journal of Energetic Materials,
14 (1), 57-73(1996).
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TSE Extrudate
HyTe+DOA Gr Fe2O3 ZrC AP
MEAN 0.123 0.003 0.020 0.005 0.849
STDEV 0.028 0.002 0.007 0.002 0.037
COEF.VAR 0.23 0.46 0.35 0.39 0.04
MIX.INDX. 0.91 0.97 0.95 0.97 0.90
Degree of mixing parameters of the twin screw extruded
grains (SIT/ARDEC study).
AP variation at 10 sq.mm
0.75
0.80
0.85
0.90
0.95
We
igh
t fr
ac
tio
n
Fe2O3 Variation at 10 sq.mm
0.005
0.010
0.015
0.020
0.025
We
igh
t fr
ac
tio
n
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sN
c ci
i
N2
2
1
1
1
( )
S is the standard deviation, Ci is the concentration,
C is the average, N is the number of specimens
s c c0
2 1 Variance for the completely segregated sample
Mixing Index, MI = 1 – s/so
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1.E+05
1.E+07
1.E+09
1.E+11
1.E+13
1.E+15
1.E+17
0.96 0.97 0.98 0.99 1.00
Mixing Index, (1-S/So)
Volume resistivity versus the mixing index
1013
1011
109
107
1017
1015
Vo
lum
e R
esis
tivit
y, o
hm
-cm
Erol and Kalyon, International Polymer Processing, 20, 228-237 (2005).
Conductive particles in insulating binder
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10
100
1000
0.01 0.1 1 10 100Shear Rate, 1/s
Mixing index=0.878
Mixing index=0.91
Mixing Index=0.957
Sh
ear
Str
ess,
kP
a
Comparison of flow curves for the suspension specimens
with different mixing indices and extruded through a capillary die
Kalyon et al. Rheologica Acta, 45, 641-658 (2006).
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Comparison of slip velocity vs wall shear stress data for the
suspension specimens batch mixed for different durations
0.01
0.1
1
10 100 1000
Wall Shear Stress, kPa
Mixing index=0.88
Mixing index=0.91
Mixing index=0.96
Sli
p V
eloci
ty, U
s, m
m/s
Kalyon et al. Rheologica Acta, 45, 641-658 (2006).
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STATISTICS OF MIXING DISTRIBUTIONS IN FILLED ELASTOMERS PROCESSED BY TWIN SCREW EXTRUSION
26 mm
60 mm
Annular extrudate cross section
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STATISTICS OF MIXING DISTRIBUTIONS IN FILLED ELASTOMERS PROCESSED BY TWIN SCREW EXTRUSION
Mixing distribution of ammonium peroxide (AP) in filled elastomer
extrudate as a function of radial location on the annular cross section.
0.70
0.72
0.74
0.76
0.78
0.80
0.82
0.84
0.86
0.88
0.90
13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Radial Location, mm
AP
We
igh
t P
erc
en
t
INNER WALL OUTER WALL
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Capabilities with
industrial impact:
•Dies
•New rheometers
•New extruders- Universal and the mini
•New screw elements
•New technologies based on extrusion
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Continuous processing platforms: Universal and the Mini
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Universal twin screw extruder
Extrusion Facility to probe all types of extruders
Single Screw
Twin Screw
Shear Roll Mill
Co-rotating Counter-rotating
Fully-Intermeshing Tangential
Remote running using the internet and
wireless
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Universal extrusion system for energetic materials processing
J. E. Kowalczyk, M. Malik, D. M. Kalyon, H. Gevgilili, D. F. Fair, M. Mezger and M. Fair,
“Safety in Design and Manufacturing of Extruders used for the Continuous Processing of Energetic Formulations”,
Journal of Energetics Materials, 25, 247-271 (2007).
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The smallest twin screw extruder in the World: 7.5 mm
62. S. Ozkan, H. Gevgilili, D.M. Kalyon, J. Kowalczyk, and Mark Mezger, “Twin screw extrusion of nano-alumina
63. based simulants of energetic formulations involving gel based binders”, Journal of Energetics Materials, 25, 3, 173-201 (2007).
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59 Complex Screw Configuration
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Brabender SR12-05 Feeder with the mini-TSE
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HfMI Highly Filled Materials Institute
Specialized capabilities in particle formation, rheology, processing, simulation, structural analysis.
Sources of funding used in 2005: ONR, ARDEC, P&G, MPR, IBM (750K for 7 staff and 8 students)
Processing of nanoparticles
for energetic applications
Processing of nanoparticles:
Examples
500 nm
In situ synthesis of
hydroxyapatite
for tissue engineering
200 nm 100 nm
Intercalation and exfoliation
of clay tactoids into nanoclays
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Polycaprolactonepolymer
Carbon nanotubeswith Pt, Ag, Co, and Pd nanoparticles
Pd
Co
Ag
Pt
Mixing of nanotubesand polymer
Twin-screw extruder
a
1
Voltage supply
PtAg
CoPd
b
c
d
e
f
Production of a nanobursa mesh material with a newly-developed hybrid process of twin-screw extrusion and
electrospinning: (a) Feeding of the polymer and metal-functionalized CNTs, (b) Continuous mixing of the polymer with
CNTs, (c) Electrospinning via a spinneret with multiple nozzles, (d) Encapsulation of the nanotubes into polymer
nanofibres, (e) Graded nanobursa mesh with consecutive layers of CNTs functionalized with Pd, Co, Ag, and Pt
nanoparticles.
S. Senturk-Ozer, T. Chen, N. Degirmenbasi, H. Gevgilili, S. G. Podkolzin, D. M. Kalyon, “Nanobursa mesh: Graded electrospun
nanofiber mesh with metal nanoparticles on carbon nanotubes”, Nanoscale, 6, 8527-8530 (2014).
A recent example of development of a novel processing method
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Ramifications of capabilities on additive manufacturing
•Rheology, viscoplasticity, viscoelasticity, wall slip
•Microstructure formation
•Modeling - time dependence- functional grading
•Capabilities in hardware design and fabrication
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Government Sponsors
• BMDO/IST
• DARPA
• DURIP
• ONR
• NAWC
• NSF
• NSWC
• SDI
• SERDP
• US Army RO
• US Army PBMA
• US Army
TACOM/TARDEC
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Thanks for listening