Research On Modified ABS Composites With Aluminum Powder Filling

The parts are made by ABS/Al Powder Composites injection molding,can not only meet the requirements of mechanical properties,but also can mold the surface of plastic parts with metallic effect, it has no need for subsequent processing technology,such as polishing and spraying, and reduce production costs. Research on how to preparation of ABS/Al Powder Composites and its properties, has the vital significant to improve market competitiveness and application. Due to aluminum powder is added in composites, weld lines of parts turn to more obvious, and the apparent quality becomes poor. So it is important to find ways to improve the weld lines. Based on demands of actual production, the following aspects of ABS/Al powder composites are researched in this paper.Firstly, the preparation methods of ABS/Al Powder Composites are introduced. Extrusion particles and samples are made by extrusion and injection molding process. Compare two ways of ABS/Al powder composite preparation. The results show that ABS, aluminum powder, and aluminate coupling agent are mixed directly by mixing equipment is best way.In this way, mechanical properties of composites is better.Secondly, the effect of aluminum powder content and aluminate coupling agent content on the mechanical properties of ABS/Al powder composites are discussed. Design two sets of single factor experiments, and study ABS/Al powder composites tensile strength, bending strength and impact strength. The content of Al powder is0.5to2.5phr, and content of coupling agent is1to4phr. The impact test samples’cross-section is detected by SEM. The experiment results show that ABS/Al powder composites’tensile strength, impact strength, and bending strength are reduced gradually with content of aluminum powder increasing gradually, but tensile strength, impact strength of weld marks and v-shaped notch of impact strength are changed little. Joining coupling agent contributes to the improvement of composites’mechanical properties.When coupling agent is added excessively, mechanical properties of ABS/Al powder composites is reduced.Thirdly, the effect of Aluminum powder particle size on ABS/Al powder composites’ mechanical properties, thermal properties and rheological properties are researched. Design a set of5levels of single factor experiment, the particle size of Aluminum powder contain10μm,20μm,30μm,40μm and50μm,which influences on composites’shear viscosity, melt flow rate, specific heat, thermal conductivity, tensile strength, bending strength and other performances are studied. The results show that the larger particle size of Aluminum powder, the smaller the shear viscosity of the material and the greater the melt flow rate. With the size of aluminum powder change, the value of specific heat and thermal conductivity has a little change. With the increase of aluminum powder size, the composites’ tensile strength, bending strength and impact strength are reduced gradually, but mechanical properties of in front of three groups almost aren’t changed. Mechanics performance of composites with10μm aluminium powder is best.Fourthly, simulating process of ABS/Al powder composites molding, and effect of process parameter on the quality of the composite injection molding is researched.Three kinds of composites’ material library are established, which contain10μm,20μm or30μ size of aluminum powder. Comparing flow simulation analysis results of four groups of material, it finds that the accuracy of material library is high. Design orthogonal experitment to research on the effect of injection molding process parameters, such as injection time, mold temperature, melt temperature and packing pressure, on the quality of parts by simulation analysis. The results indicate that influence degree of four factors on the shear stress, injection pressure, volume shrinkage and shrinkage index. The better process parameters are obtained by orthogonal multi-index comprehensive analytic.Fifthly, the effect of local heating technology on weld line is researched by Moldflow. The analysis model is divided into three regions, and design nine groups of single factor experiment to simulation analysis. To compare the analysis results of weld mark. The results show that different improvements for products with different position and size of the hole by using local heating technology, weld lines have improved obviously in area1and area3, but weld mark isn’t improved in area2.