Ultrasonic in-line monitoring of polymer extrusion

In-line ultrasonic monitoring of polymer co-extrusion and twin-screw extrusion are presented. Co-extrusion of high density polyethylene (HDPE) and a thermoplastic elastomer based on polypropylene-EPDM (ethylene-propylene-diene monomer) has been investigated by ultrasonic sensors consisting of piezoelectric transducers and clad buffer rods. One extremity of the rod (probing end) was installed flush with the die surface so as not to disturb the material flow. The other end was air cooled in order to protect the transducer from excessive heating. This approach has been demonstrated to be quite convenient for monitoring and controlling industrial material processes: first, it can work at temperatures up to 1000 degrees C; second, the clad buffer rod probing end can be machined to the same shape as those of commercial temperature and pressure sensors commonly used in the extrusion process. Therefore, no modifications are required for the installation in the original equipment. The information obtained includes the position of the interface between polymers and the stability of the process. The same ultrasonic probe has also been installed on a barrel of a twin-screw extruder. This study was performed using polyethylene and polystyrene. It has been verified that the ultrasonic sensor can be successfully operated along the extruder screw and that the ultrasound can give access to the material properties while the polymer is being processed. This means that the technique can be exploited to monitor and control in situ, the characteristics of the polymer being transformed in operations typically performed on twin-screw extruders, such as compounding, visbreaking or reactive extrusion.