Use of Infrared Imaging Techniques to Understand and Quantify

Expanded Polymer Molding Operations and Part Quality

Graham V. Walford
Walford Technologies, Inc.

Jaret J. Frafjord and Steve P. Dekanvich

BWXT Y12

ABSTRACT
The manufacture of expanded polystyrene, polypropylene and similar molded parts (automotive bumpers,
protective helmets, etc.) requires precise molding control for its vacuum, steaming and subsequent cooling
cycles. These are processes where optimal part quality demands a precise amount of steam energy be
delivered into the mold and a that precise amount be removed within a molding cycle. Accomplishing this
“energy balance” is critical in molding good quality parts. Out of balance molding cycles result in lower
molded part quality and excessive energy use. These two factors are intertwined.

Freshly molded parts exhibit moisture content and thermal gradients from the manufacturing process which
can be observed real time with a digital thermal camera. Quantification of the gradients enables molding
improvement and the identification of defect areas in the manufactured parts. Likewise, thermal imaging of
the molding equipment permits molding cycle tracking and the opportunity to correct systemic defects in the
process equipment.

Several examples are presented that show analysis of molding operations and part quality improvement. The
combined thermal analysis of the molded part and the molding machine result in significantly better part
quality and with an energy savings that can be as high as 25%.

The same camera system is utilized to quantify part gluing and laminating operations involving expanded
polymers, films and other coatings.

INTRODUCTION
The use of expanded polymers in shape and block molding has reached to most every product and
application conceivable in our daily living. Some applications may be considered mundane, such as
packaging materials and picnic supplies. Other applications, however, utilize materials with highly controlled
properties including automotive, safety, aircraft structural parts, specialty construction such as insulated
concrete form and “lost” foam for metals casting. The polymers utilized include expanded polystyrene,
polypropylene, co polymers and various blends. End use applications often require special physical
properties, well beyond the common perception often associated with low technology production needs. In
particular, quality control, cost control and the reduction of wastage is of critical interest because of the
material sources being oil derived. Further information on these uses, applications and characteristics can be
found from EPSMA (Expanded Polystyrene Molders Association) and their web site www.eps.org.

In one example application, Figure 1 shows a large expanded polystyrene (EPS) foam mold metal casting
process, where iron and steel castings are manufactured of up to 50,000 lbs final cast weight. The metal
filling through the EPS foam pattern in a sand filled steel flask is significantly influenced by the EPS properties
and is carefully engineered to maximize casting quality. For all expanded polymers and their applications, the
manufacturing concept is common. Because many users and manufacturers view these materials as
commodities, cost control is a prime and significant issue.

The processing and molding of EPS is an energy intensive process, and effective production of quality parts
requires precise control of steam energy input and energy removal in a precisely timed cycle. With the onset
of significant increases in energy costs, it is of particular importance to control the molding process both as a
cost reduction measure but primarily as a quality optimization measure. Fortunately, optimal molding
performance is accomplished with the minimization of energy usage which is discussed in this paper.

InfraMation 2008 Proceedings ITC 126 A 2008-05-14

Figure 1. Lost Foam casting process showing a) Pattern for casting, b) filling of steel flask and pattern with sand c)
Metals filling of foam pattern in sand and d completion of fill.

Because of low operating profits of many expanded polymer manufacturers and their relatively small size,
when compared with some other industries, instrumental and process control equipment developments have
been limited. Therefore it is important to find opportunities of measurement and understanding that are
prompt, require minimal installation and are low cost and flexible to accommodate the process special needs.

UNDERSTANDING THE MOLDING PROCESS

We have utilized analytic facilities of Y12 BWXT (pictured below in Figure 2) to image and understand
expanded polymer properties and behavior. This has provided a backdrop from which field measurements
can be understood and supported.

Figure 2. Images of facility and polymers at various points in the expansion process.

InfraMation 2008 Proceedings ITC 126 A 2008-05-14

Most expanded polymer parts utilized for lost foam casting are manufactured from expanded polystyrene
(EPS). For specialized applications and for iron, blends and other materials are sometimes utilized such as
polymethylmethracralate (PMMA) are also utilized. Polypropylene is also used for some shape applications.
For all these materials, the same molding concept is utilized, with minor variations. Therefore the same
technical problems and opportunities also exist in the manufacture of these materials.

Solid raw bead material (Figure 2, image 3 and 4) is utilized with dimensions typically in the region of 300μ
diameter. This material is pentane impregnated as an expansion agent and has a specific gravity in the
region of 0.70 gm/cm3. This material is pre expanded in a device called a pre expander where steam energy
is utilized to heat and soften the polymer. This steam heating and softening causes the pentane to expand
and the bead particles to expand to 1-2 mm diameter and a specific gravity, ranging 0.016 to 0.05 gm/cm3
figure 2, images 5,6,7). These pre expanded beads are then cooled and aged for 24 to 96 hours and are then
available to be utilized for molding operations.

The next process stage consists of “blowing” the pre expanded bead into a mold for final heating and
expansion into a required shape. Figure 3 shows a simple diagram of a mold and mold images filled for
molding. This is the central focus of the process of where the part is manufactured.

3: Simple diagram of a bead filled mold with

Figure 2.1
indicated steam flow

The bead starts with a void

Mold Halves
space in the region of 35%
and at the finish has a void
space approximately 0.5%
to 1.0%. This is a large
flow shift factor

In efforts to provide a complete

Vents not shown in and uniform steam profile for the
aluminum mold bead volume, steam can be applied
from each side in turn (cross
steaming) and then on each side
(autoclave mode) to provide
Bead Fill guns not shown specific surface finishes

Figure 3. Simple diagram of a bead filled mold with indicated steam flow.

In well engineered systems, one or more molds are typically held in a “receiving” frame within the steaming
system (press). The receiving frame ensures the continued mating of both mold halves, the ability to change
out mold geometries to manufacture other parts and to provide a “thermal break” with the environment
external to the press. The receiving frame is mounted so that the two mold halves can separate for ejection
of the molded parts at cycle completion. After this operation, the mold halves close together and then through
the use of “fill guns” fresh pre expanded bead is injected to re fill the molding cavity for the next molding cycle.

Polymer pre expanded beads are air filled and this has high thermal impedance to heating and cooling of the
bead mass. Therefore, after beads fill into the mold, the mold cavity as located in the press steam chest is
evacuated to remove air before any thermal processing takes place. In ideal circumstances, the initial mold
temperature is approximately 185 to 190 F, just below the glass transition temperature for the beads in the
mold. Steam is then introduced in a sequence of cross steaming and autoclaving to provide a uniform energy
distribution throughout the bead volume. Figure 4 shows a typical temperature cycle for a bead volume.

InfraMation 2008 Proceedings ITC 126 A 2008-05-14

 4: 5: Display for a molding operation and
Figure 2.3:
Figure 2.2: Typical temperature and pressure profile for the moisture profile of the molded part upon ejection
molding cycle of a press/mold system
Pressure/Foam Sensor Vacuum Cycle
Mold Onset of water cooling Onset of evaporative
Temperature cooling Foam Pressure
225 F Measurement

Temperature Mold

EPS

190 F
Time
170 F
End of cycle foam
temperature

Pressure

Figure 4. Typical temperature and pressure profile Figure 5. WTI display panel for a press/mold process
for the molding cycle of a press/hold system. and moisture profile of the molded part upon ejection.

Figure 5 shows a WTI display panel for a press/mold process showing the molding pressures and the
moisture profiles of the part upon ejection.

When steam enters the mold, some condensation occurs on the bead and more on the mold. Because of the
significantly low mass of the bead, its temperature increases rapidly with the mold lagging because of its
larger mass. As the bead heats above the glass transition point and the steam enters the bead, the presence
of pentane and residual gases causes expansion of the bead, allowed by its softening. Steam condensation
will continue as heat is transferred to the bead mass and the bead expansion will continue. This is marked by
a reduction of the void space (Figure 2, images 8 and 9) to the point where the bead is fully fused (0.5 to
1.0% void space between beads). Internally, beads (figure 2, image 7) comprise a series of cells where 98%
of the volume is gaseous and as little as 2% is solid polymer.

At this point, further steaming of the bead mass will cause degradation of the bead structure which appears
as a collapsing of the cell walls and a weakening at the bead bonds. However, before this point is reached,
the cycle is ended by the termination of the steam cycle and the introduction of cooling water applied to the
outside of the mold and inside the steam chest. Cooling water is applied for a few seconds, to bring the mold
near the polymer glass transition point and then internal bead cooling is performed through evaporative
cooling with the application of vacuum.

The application of vacuum to the mold and the molded part causes residual water and moisture in the foam
part to evaporate. In the molded part, moisture in the void spaces between beads will evaporate, causing a
rapid drop in localized temperature because of the latent heat of evaporation of water. The mold temperature
is largely insensitive to vacuum cooling. Additionally the mold thermal mass is large compared with the
molded foam part. Prompt and controlled temperature drops are essential in molding termination in order to
control the net energy delivery to the molded foam. This is complex in that void space between beads at the
commencement of molding is approximately 30% and less than 1% at process termination. An improper
molding cycle will result in observable temperature gradients in the part, entrapped moisture and a variance in
physical properties – all of which are opportunities for observation utilizing infrared imaging techniques.

EXPERIMENTAL THERMAL IMAGING OF THE MOLDING PROCESS

Direct observation of the mold or molded part at the time of molding is difficult and it is also difficult to “snap
shot” the process as the cycle is completed by the time that the mold opens and the part is ejected. However,
residual gradients can be observed in both temperature and moisture content and in the mold itself that are of
great value. Internal part profiles can be observed by periodically breaking or cutting a foam part and imaging
the newly exposed surface.

InfraMation 2008 Proceedings ITC 126 A 2008-05-14

Because of commercial sensitivity neither the manufacturers nor the parts are identified.

An Electrophysics PV320 camera was utilized where molds, molded parts and press parts could be observed
as shown in Figure 6. Figure 7 shows a typical observed image. The part is retrieved upon its ejection from
the mold and promptly rotated and imaged within thirty seconds through the use of a rotating table and
viewing table. The camera is set to image at a frame rate of four frames per second or higher while the part is
rotated. This permits a complete coverage of all part surfaces. Observation of a part can be informally
completed within a few seconds, particularly if infrared intensities are digitized on the screen so that an
operator can keep numerical track of the process. Such a simple measurement arrangement allows an
operator to sequentially view parts from a line of presses, each molding different parts. Because of the
behavior of thermal gradients in expanded polymers, (smooth and changing over periods of a few minutes)
and the differing emissivity of moisture content (sharp discontinuity and very small content causes significant
drop in emitted energy) an operator can identify the presence of problems arising from water cooling, poor
vacuum cooling and other issues associated with the molding equipment. This enables him to make process
modifications before parts exhibit significant defects. In addition, the ability to store images permits effective
record keeping for quality assurance and control purposes.

7: Thermal Images for part 1. For these molded parts, three

Figure 4.2:
molds are in the one press. Each thermal image has a different
appearance

Displayed Part 1 Part 2 from same press operation

Image

Camera

Molded Part
Being Imaged

Figure 6. Thermal camera arranged to view a shape Figure 7. Thermal images for Part 1. For these molded
molded part from a press. The image processing parts, three molds are in one press. Each thermal image
computer and analysis equipment are seen on the has a different appearance.
adjacent cart.

Figure 7 shows front and back thermal images from the part imaged in figure 6. This image shows both
temperature gradients in the part together with sharp discontinuities due to water in the part. The temperature
gradients were due to improper press set up and the water patterns were due to improper and non uniform
water cooling applied at the end of the cycle. The consequence of thermal gradients, identified in these
images by gray patches also result in gradients of the bead molding which directly translates to mechanical
property variations at those locations. The water cooling is utilized to terminate the process and non
uniformity of water distribution can likewise result in part uniformity. These defects are not visually observable
at the time of manufacture and only show a significant time later through conventional mechanical testing
optimization is required.

Figure 8 shows a sonically generated scan testing the part mechanical integrity as a function of position on
the part. Where water presence is identified, mechanical properties were also degraded. Typical moisture
contents ranged 1% to 5% by weight of the part.

InfraMation 2008 Proceedings ITC 126 A 2008-05-14

 8: Non
Sonic
Figure 4.3: Scan of Break Away
contacting Partscan
fusion Highsuperimposed
to Low Fusion upon the Thermal Image of EPS Molded Part Immediately After
image of one part from the sequence shown in figure 4.2
3 Ejection from the mold

2.5

Fusion level
1.5

Darker gray Surface Moisture

Location of Sonic Scan 0.5 Core Vent is lower
Internal Locations temperature Hotter Internal
Water
Locations Viewable
0 through Surface
3100 2600 2100 1600 1100 600 Voids
Distance

Figure 8. Non contacting fusion scan superimposed upon the image of one part from the sequence shown in Figure 4.2.

Subsequent study showed that excess water cooling was used on the mold at the cycle termination. This
saturation resulted in degradation of the vacuum cooling of the molded part with consequential part
degradation. These factors were analyzed with the thermal camera.

For some molded parts, differing density materials are injected into different parts of the mold. It is important
in these to promptly identify proper material segregation and that materials are distributed as targeted. Since
increased mass retains thermal energy for a longer period, the thermal camera was utilized to identify if
temperature gradients could be associated also with mass gradients. In a polypropylene bumper
manufacturing line, parts were molded where the body of the bumper contained 4.0 lb/ft3 material and the
bumper ends (for mounting to the car body) contained 12.0 lb/ft3 density material. Figure 9 shows a thermal
image of the part. Parts were being molded in rapid succession. Use of the imaging camera identified non
invasively that mass distribution was satisfactory but that as in the part imaged, material segregation did not
always occur properly. While alternative methods can be used for this analysis, this provided a prompt and
visual identification if process problems are occurring. Image subtraction methods are required to separate
other manufacturing issues associated with proper molding operation.

Figureshowing
Images 4.19: Part with regions
Density of
Variations
Within the differing densityPart
Freshly Molded

Low Density
Region
High Density
Region

Figure 9. Bumper Ends showing higher density ends to the molded part. This
part also shows regions where higher mass appears in un-targeted regions of the
part. Separate density scans revealed and confirmed the density variances. It is
important to separate those artifacts in the image due to thicker cross section of
shape complexity when compared with the higher density regions.

InfraMation 2008 Proceedings ITC 126 A 2008-05-14

HELMET MANUFACTURE
In a separate molding operation, protective helmets were being molded in several differing presses. In these,
molds were mounted in a large frame that when the press halves separated, the frame slid out to allow
retrieval of the freshly molded helmets. Figure 10 below shows three images of the frames with helmets at
the point of helmet ejection. These images show significant temperature gradients for the molds and the
helmets.

Combined Molding Considerations

Press Thermal Profile

Temperature
profile with one
part having fallen
Helmet
dropped
10000

9500

9000

8500

8000

7500

7000

6500

6000
Line #1
5500 Line #2
Reset Scale Auto Scale

Figure 10. Thermal Images of Three Presses at the point of helmet ejection.

Example Mass Profiles Across a Bicycle Helmet

Another part exhibiting a Another part exhibiting a (Helmet Shows Asymmetry)
thermal gradient thermal gradient
Support Stand

X-Ray Mass Profiles

Figure 11. Thermal image of a helmet removed from the press and subsequently imaged and analyzed using
X-ray profiling.

For the helmet shown in Figure 11, its thermal image was collected 60 seconds after its ejection from the
mold. In order to assess if the observed temperature gradient impacts helmet properties, an X-ray mass
profile was made of the part. The helmet was inspected in slices by scanning the cross section of the helmet
in several sections. These are also plotted in Figure 11. The higher mass profile on one side of the helmet
coincides with the thermal behavior in the press. This may imply a bead filling issue on one side that when
coupled with a differing steam distribution across the helmet provides differing fusion and density profiles.
Such non uniformity can lead to a non uniformity of the mechanical properties of the helmet.

In this case, the non uniformity of the helmet was readily observable through the use of the thermal imaging
camera. Such non uniformities can have significant impact upon the end application of the part as its
mechanical properties are correspondingly modified from its original design specification. Further work is
required to quantify these effects further.

BOARD MANUFACTURE
In board manufacture of expanded polystyrene product, boards are vertically removed from a molding system.
Their thermal images are shown in Figure 12. The two images on the left were obtained utilizing older molds
of heavier construction. The images taken on the right show parts molded with new and improved molds of
lighter construction and with further press machine optimization. These images show a change in the profiles
to be smoother and more uniform. Figure 13 shows these profiles.

InfraMation 2008 Proceedings ITC 126 A 2008-05-14

 12: Board material
Figure 4.28:
Thermal/Fusion Improved Press Profiles Figure 4.30
Map Along EPS
from press exhibiting non Thermal/Fusion Profile
uniformity vertically and along for Newer Mold
the board

Figure 12. Series of Thermal Images of Board Showing Changes in Board Manufacture With A Mold Change.

Variance along the board

for the same press
location
Old Mold New Mold
Heitz Mold
1000 Uniformity of
Variance produced
EPS

The smaller the

variance the better

D8 Uniformity
of Produced
EPS

500
Variance

Figure 13. Thermal profiles Along The Boards Before and After Mold Change. Images are Also Shown For Cut
Board Samples. These Show that Improved Venting on the New Mold Led to Better Internal Evaporative Cooling
of the Foam Parts.

Examination of the performance of the new and older molds revealed that the improved thermal profiles
described above resulted in a corresponding improvement in the material qualities along the boards.
Improved mold venting was a part of this that led to more precise control of steam injection and process
termination. This resulted in a shortening of the molding cycle from 93 seconds to 73 seconds while steam
usage was simultaneously reduced. It is important to state that the part manufacturer initiated these process
improvements and that it is fortunate that the thermal camera was available to document the improvements.

Figure 14 shows electron microscope images of foam slices cut from samples of the materials observed in
this study. The image on the left shows under fused bead, characterized with large void spaces and high gas
permeability and moisture transport. The center image represents reasonably optimum foam. The image on
the right represents over fused foam with all spaces closed up between beads. This causes internal bead
collapse with a corresponding weakening of the structure. In addition, it is difficult to control materials in this
condition in the mold so that significant non uniformities exist in the material properties. Under controlled
conditions, these observed properties could be correlated with consequential thermal evaluations.

Figure 14. Electron Microscope Images of under fused, properly fused and over fused expanded polymer.

InfraMation 2008 Proceedings ITC 126 A 2008-05-14

UNDERSTANDING THE RESULTING PRODUCT PERFORMANCE IN GLUING OPERATIONS
Expanded polymer foam materials are often subsequently cut into boards or sheets and then have paper or
other coatings laminated or glued in automated operations. The figure set below shows thermal images of a
multi-head glue spray onto expanded polystyrene. The granular image is due to the beaded structure of the
EPS and is bead fusion sensitive and surface finish sensitive. The images shown in Figure 15 are taken
through the applied paper coating. Streaks in the machine direction are due to non uniformity of the spray
and directly relate to the glue mass applied. Periodic use of the camera allows identification of glue excess or
deficiency, thereby allowing an optimization of the product quality and a minimization of glues usage on a real
time basis. Figure 16 shows the translation to glue mass applied across the sheet where higher residual heat
in the surface is proportional to the glue weight per unit area.

Figure 15. Thermal Images of Spray Gluing Operations for paper coating on EPS.

Excess Glue Applied is

Glue
Represented Above Zero Line
Defect
Glue
Defect

Figure 16. Cross Sheet Profiles of Glue Mass Derived from the Thermal Images Shown in Figure 15.

In another gluing operation, vinyl coating is applied to EPS board at a rate of 340 feet per minute. Hot melt
glue is “ink jet” applied as stripes on the EPS just before the board and the vinyl is brought together. A
thermal camera is used to image the vinyl approximately 1.0 second after the board and the vinyl are pressed
together. The images below in Figure 17 show the thermal image of the glued product moving to the right on
rollers at 60 images per second. Where glue has been successfully applied AND the board and the vinyl
have been pressed to ensure a glue bond, then heat is transferred and is observable as shown in the images
below. The line intensity is indicative of the glue mass applied and line absence can be utilized to signify an
alarm for a clogged glue nozzle. This is critical to ensure integrity of the final end product. The images below
show several instances in the process where gluing errors occur.

InfraMation 2008 Proceedings ITC 126 A 2008-05-14

 6000

5800

1 5600

5400
2 3 4
5200

5000

4800
Line #1
4600

4400
Reset Scale Auto Scale

6000 6000 6000 6000

5800 5800 5800 5800

55600

5400
6 5600

5400 7 5600

5400 8
5600

5400

5200 5200 5200

5200
5000 5000
5000
5000
4800
4800 4800 Line #1
4800 Line #1
Line #1 Line #1 4600
4600 4600
4600
4400
4400 4400 Reset Scale Auto Scale
4400 Reset Scale Auto Scale Reset Scale Auto Scale
Reset Scale Auto Scale

Figure 17. Thermal Images Showing Heat Transmitted Through the Vinyl Coating to Verify the Adherence of the Vinyl
to the EPS Backing Material.

UNDERSTANDING FOAM GAS PERMEABILITY BEHAVIOR

Molded expanded polymer foams have a beaded structure with a remaining void space between beads
approximately 0.5 to 1.0 percent of the foam volume. This provides a gas and vapor permeability property for
the product the level of which is controlled in the molding process. This is measurable by taking foam
samples and placing them in a pressured chamber where hot gas may be pressured through the foam
sample. Figure 18 shows a schematic diagram of the measurement method. Also shown are thermal
measurements for several foam samples. These images are from samples from several different molds. The
patterns are caused by a combination of steam vent locations and problems in part due to poor molding
technique. Where the patterns are uniform then it is implied that the molding process is under uniform
control. Where “blobs and blotches” are present then non uniform processing has occurred and the physical
properties of the foam part are correspondingly non uniform.

In view of this measurement, it is possible to both identify problems associated with the foam part and also
identify the corresponding problems associated with the molding system.

SUMMARY
In this paper we have discussed the characteristics of the expanded polymer molding process and how the
use of thermal imaging techniques provides a real time insight into the process molding performance. It is a
difficult process to monitor because many of the points of interest for direct measurement are not accessible.

However, when combined with the use of “off line” sampling techniques it is possible to identify that the
process line is operating properly on a cycle by cycle basis. This is of particular importance when noting that
several production shop floors contain multiple molding machines, each molding differing parts and on
differing cycle times of operation.

Of particular value is the ability of the thermal imaging techniques to detect improper molding machine
operation which result in part defects that may not be visible to operators. Thermal imaging is particularly
suited to examination of gluing operations in real time.

InfraMation 2008 Proceedings ITC 126 A 2008-05-14

 18:
Figure 7.1: Schematic Diagram Showing Measurement of Gas Permeability
of Expanded Polymer Samples

Sample
Support Plate

Pressurized
Air Delivery
System

Thermal
Camera

Heat and foam

pressurization Foam
system Sample

Figure 18. Schematic Diagram Showing the Thermal Measurement of Gas Permeability for Foam Samples. Several
Differing Images are Also Shown for Different Samples from Different Mold Types

ACKNOWLEDGEMENTS
The authors wish to thank the various manufacturers who allowed access to their plants and use of these
results. In particular we acknowledge the considerable support of Dr. Ralph Dinwiddie from the High
Temperature Materials Laboratory of the Oak Ridge National Laboratory.

ABOUT THE AUTHORS

Dr. Graham V. Walford is a radiation and nuclear physicist and for the first 15 years of his career was involved
in developing radiation and building sensors and the engineering of radiation based measurement systems.

Dr. Walford has since expanded his activities developing several non invasive measurement processes for
industrial process and control, built upon his initial systems engineering. His industrial developments have
included the use of X-ray, sonic, dielectric and resistive, infrared and thermal imaging techniques applied in
several manufacturing process operations.

Jaret J. Frafjord and Steve P. Dekanvich have many years experience in diagnostic measurements and
analysis and operate the Electron Microscope Facility together with multiple additional diagnostic activities.
They have developed and operate their laboratory as a user facility for Y12-BWXT.

InfraMation 2008 Proceedings ITC 126 A 2008-05-14

InfraMation 2008 Proceedings ITC 126 A 2008-05-14