Open Access
Article
27 April 2025Steel and Aluminium Moulds: Comparative Analysis of Optimal Parameters to Inject Amorphous and Semicrystalline Polymers
The thermoplastic injection moulding process is very important in the plastics industry, as it enables automated production, supports high productivity and allows the production of plastic parts with complex geometries. It is possible to split into two large groups of polymers: amorphous and semicrystalline. Cooling rate and other injection moulding parameters have a great influence on the final properties of the plastic part. Regarding the use of aluminium as cavity material in injection moulds, new variables must be included in the analysis, since its thermal properties are significantly different from those presented by steels, which are traditionally used. In this way, the purpose of this study was to evaluate the effect of aluminium and steel cavities on different types of thermoplastics belonging to the two classes of polymers by assessing the injection parameters of a high-production part (automotive cup holder). In terms of productivity factors, moulds made of aluminium using semicrystalline polymers showed more significant reductions in cycle time compared to amorphous materials. Specifically, polypropylene exhibited a cycle time reduction between 40.6% and 52.5% when compared to steel moulds, while polyamide showed an even more substantial reduction, ranging between 56% and 63.5%. As for warpage, the amorphous materials displayed the lowest values for both types of moulds, but they also exhibited greater variations in isothermal simulations compared to semicrystalline materials. In relation to the mould materials, aluminium mould exhibited the lowest warping results and smaller variations compared to the isothermal analyses for all polymers.
Open Access
Article
28 April 2025Production and Characterization of Recovered Carbon Black (rCB) by Waste Tire Pyrolysis as a Potential Carbon Black (CB) Substitute
Recovered Carbon Black (rCB) from scrap tire pyrolysis offers a potential alternative to fossil-based virgin Carbon Black (CB) in the context of a circular economy. This study investigated the influence of pyrolysis process parameters on rCB yield and quality at laboratory and semi-industrial scales. The resulting rCBs were characterized and found to have surface and structural properties comparable to N500 and N600 series CBs, but with higher mineral and volatile contents. The quality of rCB is influenced by the feedstock composition, particularly the ratio of organic to inorganic components as well as key process parameters such as heating rate, pyrolysis temperature and residence time. Higher heating rates accelerate degradation and shift product distribution toward increased oil yield and reduced rCB formation, while higher pyrolysis temperatures lead to lower volatile content in rCB. Additionally, reactor and process design affect heat distribution, transfer efficiency, and mixing behavior, further shaping rCB properties. However, further testing is required to evaluate the actual in-rubber properties of rCBs. Therefore, additional tests are planned, incorporating rCB into butyl and nitrile rubber-based elastomer compounds, which will be addressed in a follow-up study. In addition, data from the current experiments will support a comprehensive Life Cycle Assessment (LCA) to evaluate the environmental impacts of tire pyrolysis and rCB production compared to other recycling methods, with details to follow in a future publication.
Open Access
Article
29 April 2025Application of recovered Carbon Black (rCB) by Waste Tire Pyrolysis as an Alternative Filler in Elastomer Products
The increasing global accumulation of End-of-Life (EoL) tires and the growing demand for fossil industrial Carbon Black (CB) call for sustainable alternative solutions. In this context, tire pyrolysis and the resulting recycled raw material recovered Carbon Black (rCB), are considered potential alternatives. In the study, various rCBs were incorporated into new elastomer compounds using a laboratory internal mixer and their properties were investigated. The compounds were selected based on examples of applications such as bicycle inner tubes and hydraulic membranes. By comparing the in-rubber properties of rCB-based compounds with CB reference compounds, an initial assessment of the potential use of rCB for the chosen products was derived. Compared to industrial carbon black, the use of rCB leads to a reduction in performance. Although increasing the filler content partially compensated for the mineral content in rCB and led to a slight improvement, it could not fully offset the performance loss.
