The development of acrylonitrile-butadiene-styrene (ABS) resins for use in rotational molding would provide a medium performance material, thus opening doors to new markets for the rotational molding industry. Unfortunately, ABS resins have shown serious problems during the rotational molding process, namely discoloration, bridging, and poor impact strength. It is believed that these effects are due to degradation of the carbon-carbon double bond in the butadiene, through attack by either oxygen or heat. Previous efforts have shown some success in addressing these issues. However, additional improvements are necessary to make ABS resins commercially viable to rotational molders. This study, fourth in a series of similar projects conducted though Brigham Young University, was focused on remediation of the ABS difficulties via two different approaches. First, a survey of several additives was performed with the intent of investigating four different strategies: increased protection from oxygen, decreased butadiene concentration, increased butadiene concentration, and promotion of flow. The best formulation was achieved when 15 wt % of a benzoate ester (XP-2280 available though ChemPoint) was blended into MAGNUM 342 EZ, an ABS resin (The Dow Chemical Company). This formulation showed the best balance between increased impact strength and improvement of cosmetic properties. Second, optimization of several rotational molding processing parameters was executed. These included particle size distribution of the resin, drying of the resin, internal mold atmosphere, and oven temperature. It was found that using coarse particle sizes (ground at 20-mesh rather than the industry standard of 35-mesh) increased the impact strength by about 19%. None of the other parameters proved to have a significant effect upon the system, except for the use of a nitrogen atmosphere, which lowered the impact strength. Final properties testing of this best formulation at the optimal processing conditions showed increased impact strength from 2 ft-lbs (the previous best value) to 8 ft-lbs. There was also a marginal decrease in surface hardness (95 to 78 on the Rockwell R scale) and yield tensile strength (3,900 psi to 3,300 psi). Larger differences were observed in flexural modulus (200,000 psi to 110,000 psi) and heat distortion temperature (95°C to 61°C). Therefore, these formulation and processing changes show a trade-off where stiffness and thermal stability (i.e. flexural modulus and heat distortion temperature) can be sacrificed for an increase in toughness and aesthetics, made manifest by increased impact strength, elimination of bridging, and eradication of discoloration.

De maneira geral, o mercado náutico brasileiro ainda é muito restrito, principalmente o de pequenas embarcações. Nos últimos anos, porém, devido a uma maior exposição na mídia dos bons resultados internacionais de velejadores e exploradores brasileiros, a vela tem se popularizado. Esta dissertação descreve o projeto de um veleiro de pequeno porte para esporte/lazer fabricado em polietileno linear de média densidade (PEMD) pelo método da rotomoldagem. Este método tem se difundido rapidamente no exterior para a fabricação de equipamentos náuticos de pequeno porte, como veleiros e caiaques, proporcionando redução de custos e vantagens ambientais relacionadas ao processo de construção. A embarcação projetada é voltada para uma tripulação de duas pessoas adultas (ou um adulto e duas crianças) e foi dimensionada para um fácil transporte, possibilitando carregá-la sobre o bagageiro de um automóvel. O foco deste trabalho está no projeto naval. Desta forma, foram percorridas todas as etapas pertinentes de um projeto de veleiro, desde o projeto do casco, passando pelo projeto do plano vélico, projeto dos apêndices (bolina e leme), análise estrutural do casco em elementos finitos e verificação de desempenho comparativo com um veleiro bem conhecido no ramo da vela. Destaca-se o projeto do plano vélico, no qual, de forma otimizada, se obteve um conjunto de velas (mestra e buja) de bom desempenho, sem, contudo, comprometer a estabilidade do veleiro. Uma análise econômica preliminar indicou a possibilidade de se fabricar o veleiro rotomoldado com custo reduzido, abaixo do preço de mercado de veleiros do mesmo porte disponíveis no mercado nacional. Complementarmente, verificou-se também a possibilidade de se utilizar material reciclado na construção da embarcação, o que, além de ser uma alternativa para diminuir custos, proporciona benefícios ambientais ao minimizar sobras de produção. / In a general way, the Brazilian nautical market is still very restricted, specially the one of small dinghies. In the last years, however, mainly due to a greater exposure on the media based on good international results of Brazilian sailors and explorers, sailing has being popularized. This Msc. Thesis describes the design of a small sail dinghy, for sport or leisure use, made with medium density linear polyethylene using the method of rotomolding. This method has been spreading rapidly worldwide as a process of fabrication of small nautical crafts like sailboats and kayaks, since it results in cost reductions and environmental gains related to the construction process. The designed sailboat is directed for a crew of two adults (or an adult and two children), and was dimensioned for an easy transport, even on the top of a car. This work is focused on the development of the naval design. Therefore, it goes through all the design steps of a sailboat, starting with the design of the hull, and then going through the design of the sails, appendices (rudder and dagger board), hull structural analysis by Finite Elements Method (FEM) and verification of performance of the sailboat in comparison with a well known sailing dinghy. It should be highlighted, also, the sails designing process, which, in an optimized way, generated a set of sails (main and jib) of good performance, without, however, jeopardizing the stability of the sailboat. Through a preliminary economical analysis, it was verified that it is possible to produce a rotomolded sailboat with reduced cost, even below the market prices of national sailboats of this size. As a complement, the possibility of employing recycled material in the construction of the boat has been studied. Besides being an alternative to diminish costs, it can bring environmental benefits, as it minimizes production scraps.

De maneira geral, o mercado náutico brasileiro ainda é muito restrito, principalmente o de pequenas embarcações. Nos últimos anos, porém, devido a uma maior exposição na mídia dos bons resultados internacionais de velejadores e exploradores brasileiros, a vela tem se popularizado. Esta dissertação descreve o projeto de um veleiro de pequeno porte para esporte/lazer fabricado em polietileno linear de média densidade (PEMD) pelo método da rotomoldagem. Este método tem se difundido rapidamente no exterior para a fabricação de equipamentos náuticos de pequeno porte, como veleiros e caiaques, proporcionando redução de custos e vantagens ambientais relacionadas ao processo de construção. A embarcação projetada é voltada para uma tripulação de duas pessoas adultas (ou um adulto e duas crianças) e foi dimensionada para um fácil transporte, possibilitando carregá-la sobre o bagageiro de um automóvel. O foco deste trabalho está no projeto naval. Desta forma, foram percorridas todas as etapas pertinentes de um projeto de veleiro, desde o projeto do casco, passando pelo projeto do plano vélico, projeto dos apêndices (bolina e leme), análise estrutural do casco em elementos finitos e verificação de desempenho comparativo com um veleiro bem conhecido no ramo da vela. Destaca-se o projeto do plano vélico, no qual, de forma otimizada, se obteve um conjunto de velas (mestra e buja) de bom desempenho, sem, contudo, comprometer a estabilidade do veleiro. Uma análise econômica preliminar indicou a possibilidade de se fabricar o veleiro rotomoldado com custo reduzido, abaixo do preço de mercado de veleiros do mesmo porte disponíveis no mercado nacional. Complementarmente, verificou-se também a possibilidade de se utilizar material reciclado na construção da embarcação, o que, além de ser uma alternativa para diminuir custos, proporciona benefícios ambientais ao minimizar sobras de produção. / In a general way, the Brazilian nautical market is still very restricted, specially the one of small dinghies. In the last years, however, mainly due to a greater exposure on the media based on good international results of Brazilian sailors and explorers, sailing has being popularized. This Msc. Thesis describes the design of a small sail dinghy, for sport or leisure use, made with medium density linear polyethylene using the method of rotomolding. This method has been spreading rapidly worldwide as a process of fabrication of small nautical crafts like sailboats and kayaks, since it results in cost reductions and environmental gains related to the construction process. The designed sailboat is directed for a crew of two adults (or an adult and two children), and was dimensioned for an easy transport, even on the top of a car. This work is focused on the development of the naval design. Therefore, it goes through all the design steps of a sailboat, starting with the design of the hull, and then going through the design of the sails, appendices (rudder and dagger board), hull structural analysis by Finite Elements Method (FEM) and verification of performance of the sailboat in comparison with a well known sailing dinghy. It should be highlighted, also, the sails designing process, which, in an optimized way, generated a set of sails (main and jib) of good performance, without, however, jeopardizing the stability of the sailboat. Through a preliminary economical analysis, it was verified that it is possible to produce a rotomolded sailboat with reduced cost, even below the market prices of national sailboats of this size. As a complement, the possibility of employing recycled material in the construction of the boat has been studied. Besides being an alternative to diminish costs, it can bring environmental benefits, as it minimizes production scraps.

One of the current testing method (the Dry Flow test) to qualify resin for use in production in the rotomolding process has been shown to have many flaws in both equipment and procedure. Research was done here to investigate a possible alternative that could eliminate some of these testing deficiencies. By reducing equipment and operator errors, the testing of materials becomes more valuable of an exercise. The Angular Flow test developed in this research can increase repeatability. By coming to understand the rotational molding process better, an evaluation that can give more valid information was devised.