Dilhan M. Kalyon

Stevens Institute of Technology

Chemical Sciences and Engineering

Castle Point Station, Hoboken, New Jersey, USA

Materials filled at solid loading levels which are very close to the maximum packing fraction of the solid phase are encountered widely in various industries, including the pharmaceutical, food, ceramic, magnetic, composite, energetic, personal care, battery, and polymer industries. At such high solid loading levels the rheological characterization, continuous processing, mathematical modeling and analysis of the microstructural distributions become very challenging. In this talk the important facets of the rheology and continuous processing of highly filled suspensions, including their wall slip, mat formation, air entrainment, viscoplasticity, structure formation, and specialized simulation techniques, will be described. The talk will specifically address the twin screw extrusion process and the three dimensional Finite Element Method based source codes developed to simulate the processing of highly filled suspensions using twin screw extruders.

D.M. Kalyon is a Professor of Engineering and the Director of the Highly Filled Materials Institute at Stevens Institute of Technology in Hoboken, New Jersey. Dr. Kalyon's research has focused on the rheology, processing, simulation, microstructural analysis and tool design for the extrusion of highly filled materials since 1985. He has over 150 publications and four US patents and has presented over 250 papers at technical meetings. Some of the tools he and his colleagues have developed including adjustable-gap on-line and squeeze flow rheometers, x-ray devices for the degree of mixedness and solid particle size distributions, specialized die and screw elements for extrusion are widely used by the industry. His group has also created new technologies in mitigation of magnetic fields, disposal of chemical munitions, recycling of energetic materials, rheometry, x-ray analysis for particle size, crystallization, defect density distributions and mathematical modeling.