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The polymer melt temperature in the screw ante-chamber of an injection moulding machine influences a number of parameters during the polymer process and therefore the final product quality. For measurement of this temperature, a sensor must be non-invasive (because of the axial moved screw during the injection of the plasticized polymer into the mould) and withstand the high pressure (>1000 bar) and temperature (>200 °C) during the injection moulding process. It is well known that the temperature of the polymer melt in the screw ante-chamber is inhomogeneous, and for that reason the sensor system must be able to measure the temperature spatially resolved. Due to the fact that sound velocity is temperature dependent, we developed a non-invasive tomography system using the transit times of ultrasonic pulses along different sound paths for calculating the temperature distribution in a polymer melt. Simulation results and example experiments at a test measurement setup are shown. Moreover, different strategies for the ultrasonic probe design (buffer rods, generation of wide beam angle) are discussed. The results of the proposed system are important for the validation of numerical simulations, a better understanding of the plasticizing process and can be used for the input of a novel temperature control system.

Calibration-free laser-induced breakdown spectroscopy (CF-LIBS) method is employed for quantitative determination of oxide concentrations in multi-component materials. Industrial oxide materials from steel industry are laser ablated in air, and the optical plasma emission is collected by spectrometers and gated detectors. The temperature and electron number density of laser-induced plasma are determined from measured LIBS spectra. Emission lines of aluminium (Al), calcium (Ca), iron (Fe), manganese (Mn), magnesium (Mg), silicon (Si), titanium (Ti), and chromium (Cr) of low self-absorption are selected, and the concentration of oxides CaO, Al(2)O(3), MgO, SiO(2), FeO, MnO, TiO(2), and Cr(2)O(3) is calculated by CF-LIBS analysis. For all sample materials investigated, we find good match of calculated concentration values (C(CF)) with nominal concentration values (C(N)). The relative error in oxide concentration, e(r) = |C(CF) - C(N)|/C(N), decreases with increasing concentration and it is e(r) ≤ 100% for concentration C(N) ≥ 1 wt.%. The CF-LIBS results are stable against fluctuations of experimental parameters. The variation of laser pulse energy over a large range changes the error by less than 10% for major oxides (C(N) ≥ 10 wt.%). The results indicate that CF-LIBS method can be employed for fast and stable quantitative compositional analysis of multi-component materials.

Co-extrusion is a widely used processing technique for combining various polymers with different properties into a tailored multilayer product. Individual melt streams are combined in a die to form the desired shape. Under certain conditions, interfacial flow instabilities are observed; however, fundamental knowledge about their onset and about critical conditions in science and industry is scarce. Since reliable identification of interfacial co-extrusion flow instabilities is essential for successful operation, this work presents in situ measurement approaches using a novel co-extrusion demonstrator die, which is fed by two separate melt streams that form a well-controlled two-layer co-extrusion polymer melt flow. An interchangeable cover allows installation of an optical coherence tomography (OCT) sensor and of an ultrasonic (US) measurement system, where the former requires an optical window and the latter good direct coupling with the cover for assessment of the flow situation. The feasibility of both approaches was proven for a material combination that is typically found in multilayer packaging applications. Based on the measurement signals, various parameters are proposed for distinguishing reliably between stable and unstable flow conditions in both measurement systems. The approaches presented are well suited to monitoring for and systematically investigating co-extrusion flow instabilities and, thus, contribute to improving the fundamental knowledge about instability onset and critical conditions.