Simulation and Injection Molding of Ring-Shaped Polymer Bonded Nickel Braze Metal Composite Preforms Based on Rheological and Thermal Analyses

Abstract

Rheological and thermal properties of LD-PE and LD-PE + 65 vol% Ni composite were examined by viscosity, pvt and thermal conductivity measurements at a wide range of shear rate, temperature and pressure. The typical shear-thinning viscosity of LD-PE polymer melt was enhanced up to four times by adding 65 vol% Ni braze metal particles. LD-PE show increasing specific volume versus temperature, decreasing with pressure and braze particle filler content. Varia- tion of specific volume of LD-PE was reduced to 5% by admixing 65 vol% rigid Ni braze metal particles. Thermal con- ductivity of LD-PE was increased up to 15 times in the composite, reduced by decreasing pressure at temperature ex- ceeding 80°C. Furthermore, thermal analysis was performed in modulated DSC to determine the specific heat capacity in wide temperature range. Viscosity and pvt-data were fitted using Cross-WLF equation and 2-domain Tait-pvt model, respectively. Simulation of LD-PE and LD-PE + 65 vol% Ni composite was performed based on rheological and ther- mal properties to define processing parameters. Simulation and injection molding of ring-shaped LD-PE + 65 vol% Ni composite braze metal preforms were performed successfully.