There is a consensus in the rotational molding and related industries that crosslinkable polyethylene (XLPE) is the choice material for gasoline-type reservoirs. Field failure of XLPE-based reservoirs is not common, and to resolve one such situation involving hydraulic fluid tanks, students of Pittsburg State University's plastics engineering technology program are utilizing the concepts of "six sigma," (DMAIC), define, measure, analyze, improve and control. In collaboration with the reservoir producing and user companies, the problem situation was defined; film products from the hydraulic fluid-XLPE tank interface clog up the fuel filter system and subsequently result in damaged pumps. Preliminary DSC (differential scanning calorimetry) measurements indicate similar thermal transition profiles for both film and tank materials, suggesting that the film is a plasticization rather than reaction product. Additional analysis of DSC, torque rheometry, rotational molding and solvent test data yield insightful information and the optimum processing parameters for improving and controlling XLPE hydraulic reservoir production.
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