1. 3.042 Materials Project Laboratory Design Review Team No-Drip Tania Chan Michele Dufalla Jacqueline Greene

2. 3.042 Materials Project Laboratory Design Review Team No-Drip Tania Chan Michele Dufalla Jacqueline Greene

3. New Goal http://www1.istockphoto.com/file_thumbview_approve/1168596/2/istockphoto_116859 6_plastic_can_container.jpghttp://www1.istockphoto.com/file_thumbview_approve/1168596/2/istockphoto_116859 6_plastic_can_container.jpg, http://www.baproducts.com/spigot.jpg +

4. Plastic Joining Fasteners Hinges Hot Die Fusion and Hot Wire/Resistance Welding Hot Gas Welding Induction/Electromagnetic Welding Press Fits/Shrink Fits Snap Fits Spin Welding Staking/Cold Forming Threads Ultrasonic Welding Vibration Welding Lasers Adhesives Solvents **List from Joining of Plastics by Jordan Rotheiser (2 nd ed.)

5. Plastic Joining Fasteners Hinges Hot Die Fusion and Hot Wire/Resistance Welding Hot Gas Welding Induction/Electromagnetic Welding Press Fits/Shrink Fits Snap Fits Spin Welding Staking/Cold Forming Threads Ultrasonic Welding Vibration Welding Lasers Adhesives Solvents **List from Joining of Plastics by Jordan Rotheiser (2 nd ed.)

6. Hot Plate Welding (from Joining of Plastics by Jordan Rotheiser (2 nd ed.)

7. HDPE vs. LDPE Max Temp = 120°C Melt Temp = 130°C Max Temp = 80°C Melt Temp = 120°C http://www.dynalabcorp.com/technical_info_hd_polyethylene.asp http://www.dynalabcorp.com/technical_info_ld_polyethylene.asp

8. Method http://www.cooking.com/images/products/shprodde/743196.jpg, http://www.flagstaff.az.gov/images/pages/SC581/plastic%20bag.JPG

9. Extrusion http://www.flagstaff.az.gov/images/pages/SC581/plastic%20bag.JPG http://www.midi-classics.com/i/p19228.gif

10. Sample prep Plastic (HDPE, LDPE) was cut in 1x6 in strips Samples were welded together with a clothes iron, pressed together and allowed to cool at room temperature Last week tested initial control samples of varying thicknesses, as well as ability of LDPE to bond with HDPE.

11. INSTRON 90º Peel Test Free-moving stage 1/8 HDPE 1/16 LDPE 3x1 in contact area 1 in wide

12. Shear Test 1/8 HDPE 4 layers of clear LDPE film (0.0006) 3x1 in contact area

13. Results of Peel Test 1/16 in LDPE was non-uniformly bonded to the 1/8 HDPE (due to greater thickness, more difficult to melt with iron) Maximum Load: 0.020 kN Could not test LDPE film:1/8 HDPE because strength of adhesion > than the tensile strength of LDPE which is 1700psi (22kN, http://www.mcmaster.com/)

14. Results of Shear Test The bond between the LDPE film and the 1/8 HDPE was greater than the tensile strength of the 1/8 HDPE! (4400psi / 30 MPa/ 58 kN, www.mcmaster.com). We could tell because the HDPE started necking rather than breaking the adhesive bond Max load = 2.070 kN, Stress at Peak 55 MPa

16. Shear Force 1/8 HDPE: LDPE film necking

17. Continue 90 o Peel Test and Shear Test Immediate Next Steps… 1/8 HDPE Substrate -White LDPE Film -Black LDPE Film -1/16 LDPE Sheet -1/16 HDPE Sheet 1/16 HDPE Substrate -White LDPE Film -Black LDPE Film -1/16 LDPE Sheet -1/16 HDPE Sheet 1/8 LDPE Substrate -White LDPE Film -Black LDPE Film -1/16 LDPE Sheet 3 Sets of Control Samples:

18. Control Samples are Pure Polyethylene -no contaminations, impurities -effects of thickness, colors, processing temperature and material density on polyethylene adhesion Goals of the Materials Testing Materials Testing Using Post-Consumer Polyethylene -ink, dye, processing agents -nonuniform density Ultimate Goal -Establish a range of temperature, pressure, time and processing condition optimal for polyethylene welding

19. Materials Considerations: –Tube to be made from recycled polyethylene –Sealing between the flange and the containers surface Design of the Tap Basic Pop Rivet Design to Attach Pinch Tube at the Lid of Jerrycans Design Considerations: –Simple design, reduce production and materials costs

20. Continue with the idea of post-consumer polyethylene recycling –Melt plastic bags and extrude melt into tubes –Questions to be answered: Is the process plausible? How durable is the resultant products? Can the procedure be done in the field? Tube Production

21. Plastic Welding Will Be Used to Attach Tap onto Jerrycans Lids Using the welding parameters (temperature, time and processing conditions) to attach tube to containers Challenges: –Tricky interface between tube and containers, how to apply plastic welding? –Is plastic welding a water proof seal? –Can plastic welding withstand the chlorination in the water? Tap Production and Plastic Welding

22. Revised Gantt Chart