Simulation and Injection Molding of Ring-Shaped Polymer Bonded Nickel Braze Metal Composite Preforms Based on Rheological and Thermal Analyses

Rheological and thermal properties of LD-PE and LD-PE + 65 vol% Ni composite were examined by viscosity, pvt and thermal conductivity measurements at a wide range of shear rate, temperature and pressure. The typical shear-thinning viscosity of LD-PE polymer melt was enhanced up to four times by adding 65 vol% Ni braze metal particles. LD-PE show increasing specific volume versus temperature, decreasing with pressure and braze particle filler content. Variation of specific volume of LD-PE was reduced to 5% by admixing 65 vol% rigid Ni braze metal particles. Thermal conductivity of LD-PE was increased up to 15 times in the composite, reduced by decreasing pressure at temperature exceeding 80 ̊C. Furthermore, thermal analysis was performed in modulated DSC to determine the specific heat capacity in wide temperature range. Viscosity and pvt-data were fitted using Cross-WLF equation and 2-domain Tait-pvt model, respectively. Simulation of LD-PE and LD-PE + 65 vol% Ni composite was performed based on rheological and thermal properties to define processing parameters. Simulation and injection molding of ring-shaped LD-PE + 65 vol% Ni composite braze metal preforms were performed successfully.