CAREER EPISODE 1
1.1 The episode is developed to demonstrate my understanding of material engineering and its chemical reactions by carrying out an eight-semester project named “Comprehensive Studies on Termination of Hydroxyl Polybutadiene by Modifying EPDXY Resin”. All the experimental activities were conducted in National Aerospace Laboratories from February 2005 to May 2005. During this tenure, I was studying Bachelor of Engineering Degree from SJCE College of Engineering.
1.2 Research has shown that epoxy resins are superior compared to thermosets because of their well-balanced properties at an extremely low cost. Furthermore, it can ensure better mechanical strength at maximum temperature, resistance, good flame, and fewer smoke quantities emissions with comparatively minimum toxicity during incineration, hence making it the most preferable material in the aerospace industry. But, epoxy resin is not very tough and brittle. For this purpose, many materials are introduced that can be blended with thermosets (especially with the epoxy resins) to improve this toughness without even impairing significantly thermal and mechanical properties. Such materials are liquid rubber,
1.3 I was working on the following tasks to carry out experimental work.
- Involved in carrying out background study in composite to understand toughness by resin modification.
- Performed a literature review by studying epoxy toughness with various elastomers.
- Selected the materials and explained their description.
- Conducted experimental work including preparing prepolymer and laminate and its curing.
- Determined the composite material properties including flexural, Tg (expand), and strength of HTPB by modifying Epoxy Laminates.
- Optimization of concentration of HTPB by improving fracture toughness.
- Prepares a report on experimental work by discussing its results.
CAREER EPISODE 2
2.1 The aforesaid career episode is based on the project which was an important part of my Master’s of Technology Degree in Polymer Science & Technology obtained from Sri Jayachamarajendra College of Engineering (SJCE). This research project is called “Experimental work on the Tread Based Green Compound for Radial Truck Tyres”. In this project, I was responsible to investigate the properties of the silica (non-inorganic petroleum material) by varying its amount to prepare truck radial tread compound for commercial purposes because it would help decreasethe usage of fuel and resistance of a tyre. This project was done for JK Tyre and Industries Ltd from February 2009 to May 2011.
2.2 The carbon block has been used extensively by tyre industry as a reinforcing filler, but after the emergence of using the green tyre concept, many industries have replaced carbon black with Silica due to its chemical and physical properties in reducing the tyre’s rolling resistance.
2.3During this tenure, I carried out the following required duties to achieve the milestone.
- Involved in the background history of silica to understand material properties and their chemistry.
- Understood behavior of inorganic material in the rubber compound.
- Analyzed the chemical processing of a polymer composite material.
- Used material characterization technique to select the appropriate materials.
- Prepared silica tread material by using its different proportions.
- Involved in the mixing of silica compounds using three processes, i.e. masterbatch, re-mill, and final batch.
- Involved in the induction meetings conducted in the industry and reported the progress to the radical plant manager.
CAREER EPISODE 3
3.1 For this episode, I decided to explain a casestudy that was developed to check the high viscosity of steel skim compounds to represent my understanding of material properties and their compositions. The project was named “Cure Pro Insoluble sulfur (10% oil treated)Adoption in High Viscosity Steel Skim Compound of Truck Radial Tire” conducted from February 2019 to February 2021. This project trial was done at an Indiantire company for truck radial tires during my internship tenure at Eastman Chemical. I completed this projectand it was a commercial success.
3.2 Insoluble sulfur is widely used in radial tires for vulcanization of the rubber material. The commonly used insoluble grades are OT 20 (20 % oil treated) and OT 33 (33 %oil treated). In the current project, a new grade of insoluble sulfur, Cure Pro (10 % oil treated) was introduced to the tire customer. This product has the highest thermal stability and best dispersion in the existing insoluble sulfur grades. The customer was using OT 33 grade for truck radial compounds, so this project is a comparison of Cure Pro(10 % oil treated ) against OT 33 (33 %oil treated) and ultimately replacing OT 33 with Cure pro.
3.3 I was performing the following duties in the project, i.e.
- Arrange a meeting with the tire customer and give a technical presentation on Cure Pro(10 % oil treated) insoluble sulfur.
- Working with R&D of Tire customers and collecting R&D samples for evaluation.
- SubmittingTDS(Technical datasheet), specification, and MSDS to the tire customer.
- Providing technical expertise in rubber compound missing and testing.
- Troubleshooting any issues arising from mixing and processing
- Planning and scheduling plant trials, testing, and processing.
- Made comparisons between insoluble sulfur ‘OT 33’ and ‘Cure pro and developed an experimental setup.
- Responsible for B96 mixing/processing and analyzed the results of tensile dispersion.
- Optimizing the B96 compound with cure Pro.
- Analyzed the tensile properties of the B96 Trail compound.