Numerical simulation of polypropylene foaming process assisted by carbon dioxide: Bubble growth dynamics and stability

A mathematical model was established to simulate the bubble growth process during foaming of polypropylene (PP) by carbon dioxide, taking into account of a wide range of physical and rheological properties (solubility, diffusivity, surface tension, long-chain branching, zero shear viscosity, relaxation time, strain hardening), as well as processing conditions. By employing the Considère construction the possibility of growth instability and bubble rupture at later stage of bubble growth was predicted. The simulation revealed that the improvement of foamability of polypropylene by introducing long-chain branching was due to the well-defined viscoelastic characteristics of the melt. Rheological factors that impede bubble growth are beneficial in stabilizing the bubble growth. Stability during bubble growth is further facilitated by moderate strain hardening characteristics and elastics properties of the polymers. The diffusivity and solubility characteristics also have profound impact on the bubble growth stability, while the influence of the surface tension is negligible.