Carbon black (CB) is used in polyethylene (PE) pipes to protect against thermal and photooxidation. However, when CB is not properly dispersed in the PE matrix during processing, white regions having little or no CB concentration, known as “windows,” appear within the CB/PE mixed black compound. In some cases, windows can drastically affect the structural integrity of both the pipe and butt fusion joint. In this work, PE pipes with varying amounts of windows were investigated for their characteristic window patterns, as well as quantifying the area fraction of windows (% windows). Tensile test on specimens with known % windows determined a critical limit above which the fracture strain rapidly degrades. Micro-tensile and micro-indentation results showed tear initiation at the window–black PE matrix boundary; however, they did not confirm the mechanism of tear initiation. In support of this work, a method of making thin shavings of a whole pipe cross section was developed, and the best viewing windows under cross-polarized monochromatic light were identified. In addition, a phased array ultrasonic test (PAUT) and microwave imaging (MWI) were directly applied to the pipe and confirmed the presence and patterns of the windows.

/pdf/visual-non-destructive-and-destructive-investigations-of-1xxwtx8g.pdf

Visual, Non-Destructive, and Destructive Investigations of Polyethylene Pipes with Inhomogeneous Carbon Black Distribution for Assessing Degradation of Structural Integrity

Abstract Composite filaments are getting increased attention in additive manufacturing (AM). More and better solutions for filament production are needed to assist researchers in discovering new materials capable of producing AM-made high-performance parts. This article presents a method for producing composite filament, including an open-source, low-cost automatic composite feeder designed to increase the accuracy and quality of the filament. The feeder includes a fibre screw designed through an iterative prototyping process to accurately control the filament's fibre percentage while reducing lumps' occurrence in a single step. An experiment evaluating the quality of filament made of Polylactic Acid (PLA) and carbon fibre (CF) tested the use of the feeder compared to manual mixing. Filament with a nominal diameter of 2.85mm with 4.5%, 7.9%, 11.2% and 14.5% CF was made. The results suggest that the composite feeder improved the filament quality. The filament diameter RMSE value was reduced from 0.08 to 0.06 and 0.15 to 0.13 for both 4.5% and 11.2%, respectively. The article concludes that the feeder design may help researchers develop and discover new materials while improving the quality of the filament.

/pdf/creating-an-open-source-low-cost-composite-feeder-design-to-3nqqpxf0.pdf

Creating an open-source, low-cost composite feeder design to improve filament quality of high-performance materials to be used in fused filament fabrication (fff)

Proposal of Performance Evaluation Method and Improvement on Butt Fusion Welding Interface of Thick-Walled Bimodal Polyethylene Pipe

The utilization of high-density polyethylene (HDPE) pipes is prevalent in water transportation due to their exceptional durability, resistance to corrosion, and ease of installation. Traditionally, butt fusion welding has been employed to connect HDPE pipes. In this study, scanning electron microscopy (SEM) was utilized to examine the microstructure of butt fusion welded joints of HDPE pipes, while the stepped isostress method (SSM) was employed to investigate their creep behavior at 100 °C in ambient air. SEM results revealed a significant presence of craze or lamellae in the base material, whereas minimal occurrences of craze or lamellae were observed in the melt zone. The results obtained from the SSM indicated that the creep life of butt fusion welded joints of HDPE pipes was not adversely affected by the welding bead, and their creep life was no less than that of the base material when ductile creep failure occurred. 

Investigation of Creep Behavior of HDPE Pipe Butt Fusion Welded Joints Using a Stepped Isostress Method

This paper describes an investigation into the effect of insufficient homogenization of pigmented resin in polyethylene (PE) pipes on the integrity of the subsequent butt fusion joints and the development of a test to quantify the amount of windows in the pipe Analysis was carried out on a number of PE pipes, made using both pre-compounded and in-line compounded resin on the same pipe extruder but using different extrusion conditions to obtain different degrees of homogenization Tensile tests using waisted tensile specimens were carried out on the butt fusion joints from these pipes It was found that the level of windows increased with decreasing degree of homogenization in PE pipes The energy to break and extension to break of the butt fusion joints reduced with increasing level of windows The higher the level of windows in pipe walls, the more the butt fusion joints tended to fracture in a brittle mode

Effect of insufficient homogenization during the extrusion of polyethylene pipes on butt fusion joint integrity

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Effect of insufficient homogenization during the extrusion of polyethylene pipes on butt fusion joint integrity