Graphene’s incorporation into polymers has enabled the development of advanced polymer/graphene nanocomposites with superior properties. This study focuses on the use of a microcellular foamed polystyrene (PS)/graphene (GP) nanocomposite (3 wt%) for nickel (II) ion removal from aqueous solutions. Adsorption behavior was evaluated through FTIR, TEM, SEM, TGA, and XRD analyses. Key factors, including initial ion concentration, pH, temperature, and sorbent dosage, were examined. Results showed optimal nickel removal at specific pH levels with removal efficiency decreasing from 91 to 80% as Ni (II) concentrations increased from 10 to 100 mg/L. The adsorption capacity improved from 11 to 130 mg/g. Equilibrium data aligned with Langmuir and Freundlich isotherm models, while adsorption kinetics followed a second-order kinetic model. These findings highlight the potential of PS/GP nanocomposites for nickel ion removal, offering a promising solution for small-scale industrial applications.

The injection molding process is one of the most widely used methods for polymer processing in mass production. Three critical factors in this process include the type of polymer, injection molding machines, and processing molds. Polypropylene (PP) is a widely used semi-crystalline polymer due to its favorable flow characteristics, including a high melt flow index and the absence of a need for a mold temperature controller. Additionally, PP exhibits good elongation and toughness, making it suitable for applications such as box hinges. However, its tensile strength is a limitation; thus, glass fiber is added to enhance this property. It is important to note that the incorporation of glass fiber increases the viscosity of PP. Multi-cavity molds are commonly employed to achieve cost-effective and efficient mass production. The filling challenges associated with geometrically balanced layouts are well documented in the literature. These issues arise due to the varying shear rates of the melt in the runner. High shear rate melts lead to high melt temperatures, which decrease melt viscosity and facilitate easier flow. Consequently, this results in an imbalanced filling phenomenon. This study examines the impact of runner size, gate size, polymer viscosity, and molding process on the filling imbalanced problem in multi-cavity injection molds. Tensile bar injection molding was performed using conventional injection molding (CIM) and microcellular injection molding (MIM) techniques. The tensile properties of the imbalanced multi-cavity molds were analyzed. Flow length within the cavity served as an indicator of the filling imbalance. Additionally, computer simulations were conducted to assess the shear rate’s effect on the runner’s melt temperature. The results indicated that small runner and gate sizes exacerbate the filling imbalance. Conversely, glass fiber-filled polymer composites also contribute to increased filling imbalance. However, foamed polymers can mitigate the filling imbalance phenomenon.

Fiber-reinforced composites (FRPs) are characterized by their lightweight nature and superior mechanical characteristics, rendering them extensively utilized across various sectors such as aerospace and automotive industries. Nevertheless, the precise mechanisms governing the interaction between the fibers present in FRPs and the polymer melt during industrial processing, particularly the manipulation of the flow–fiber coupling effect, remain incompletely elucidated. Hence, this study introduces a geometrically symmetrical 1 × 4 multi-cavity mold system, where each cavity conforms to the ASTM D638 Type V standard specimen. The research utilizes theoretical simulation analysis and experimental validation to investigate the influence of runner and overflow design on the flow–fiber coupling effect. The findings indicate that the polymer melt, directed by a geometrically symmetrical runner, results in consistent fiber orientation within each mold cavity. Furthermore, in the context of simulation analysis, the inclusion of the flow–fiber coupling effect within the system results in elevated sprue pressure levels and an expanded core layer region in comparison to systems lacking this coupling effect. This observation aligns well with the existing literature on the subject. Moreover, analysis of fiber orientation in different flow field areas reveals that the addition of an overflow area alters the flow field, leading to a significant delay in the flow–fiber coupling effect. To demonstrate the impact of overflow area design on the flow–fiber effect, the integration of fiber orientation distribution analysis highlights a transformation in fiber arrangement from the flow direction to cross-flow and thickness directions near the end-of-fill region in the injected part. Additionally, examination of the geometric dimensions of the injected part reveals asymmetrical geometric shrinkage between upstream and downstream areas in the end-of-fill region, consistent with microscopic fiber orientation changes influenced by the delayed flow–fiber coupling effect guided by the overflow area. In brief, the introduction of the overflow area extends the duration in which the polymer melt exerts control in the flow direction, consequently prolonging the period in which the fiber orientation governs in the flow direction (A₁₁). This leads to the impact of fiber orientation on the flow of the polymer melt, with the flow reciprocally affecting the fibers. Subsequently, the interaction between these two elements persists until a state of equilibrium is achieved, known as the flow–fiber coupling effect, which is delayed.

Microcellular injection-molded oyster shell nano-powder (OSP) with polypropylene (PP) is a potential adsorbent material that can reduce toxic metal ion contamination in groundwater. This study aims to investigate the PP/OSP composite material properties and determine the toxic metal ion adsorption properties of polypropylene/oyster shell nano-powder (PP/OSP) in an aqueous medium. This research focused on lead Pb(II) ion using different parameters such as contact time, pH value, and initial concentrations to optimize the conditions for heavy metal remediation. Characterization techniques such as XRD, SEM, FTIR, and TGA were used to analyze the surface morphology, functional groups, and thermal stability, respectively. The adsorption isotherms were conducted, and the behavior was consistent with the Langmuir and Temkin isotherms. A pseudo-first-order kinetic model was preferred, with a maximum adsorption capacity for lead removal obtained at 13,89 mg/g.

Microcellular injection-molded polypropylene/oyster shell nano-powder (PP/OSP) composites show potential as adsorbent materials for reducing toxic metal ion contamination in groundwater. This study investigates the material properties of PP/OSP composites and evaluates their Pb(II) adsorption performance in aqueous media. The effects of key operational parameters, including contact time, pH, and initial Pb(II) concentration, were examined to determine the optimal conditions for heavy metal remediation. The composites were characterized using XRD, SEM, FTIR, and TGA to assess their crystalline structure, surface morphology, functional groups, and thermal stability, respectively. Adsorption isotherm analysis indicated that the Pb(II) uptake behavior followed both the Freundlich and Temkin models. Kinetic studies showed that the adsorption process was best described by the pseudo-first-order model. The maximum adsorption capacity for Pb(II) removal was determined to be 13.89 mg/g.

The study focuses on the asymmetric shrinkage typically occurring between the upstream and downstream regions of FRP injection-molded products, a challenge that is particularly difficult to manage and improve. Specifically, two sets of four-cavity systems in one mold were utilized as the experimental platform. One set used a balanced runner (BR) system, and the other used a non-balanced runner (NBR) system. Each cavity in the four-cavity systems contained an ASTM D638 standard specimen with dimensions of 63.5 mm × 9.53 mm × 3.5 mm. Both CAE simulation and experimental methods were applied. The results show that the filling patterns from the simulation analysis closely matched those from the experimental study for both BR and NBR systems. Furthermore, by comparing the geometric shrinkage of the injected parts, significant differences were observed in the dimensional deformation in three directions (x, y, and z) between the NBR and BR systems. Specifically, at the end of the filling region (EFR), there was no noticeable difference in shrinkage along the flow direction, but the shrinkage in the cross-flow and thickness directions was reduced in the NBR system. Additionally, for the same cavity (1C) in both BR and NBR systems, the melt-rotation effect significantly reduced shrinkage in both the cross-flow and thickness directions. These findings strongly suggest that melt rotation can effectively modify the dimensional shrinkage of injection-molded parts. Moreover, fiber orientation analyses of the 1C cavity were also performed using CAE simulation for both BR and NBR systems. The results show that in the NBR system, the melt-rotation effect substantially alters the fiber orientation. Specifically, the fiber orientation tensors in the cross-flow (A₂₂) direction exhibit a decreasing trend. It can be speculated that the melt rotation alters the flow field, which subsequently changes the fiber orientation by reducing the flow-fiber coupling effect, thereby reducing the upstream-to-downstream asymmetry in the cross-flow direction. Through in-depth analysis, it is demonstrated that the correlation between the macroscopic geometric shrinkage and the microscopic fiber orientation changes is highly consistent. Specifically, in the EFR, ΔA₂₂ decreased by 0.0376, improving upstream/downstream shrinkage asymmetry in the cross-flow direction (Ly). Future work will investigate alternative melt-rotation designs and the optimization of model-internal parameters in FOD prediction.