Real-time and in-line ultrasonic diagnostics of polymer extrusion and injection molding processes together with the high temperature ultrasonic probes used are presented. For polymer extrusion, melt quality and filler concentration and dispersion monitoring are given as the example. Clad ultrasonic rod probes consisting of a core and a cladding fabricated by a thermal spray technique are used. For injection molding diagnostics, melt flow front, averaged flow speed, filling completion and solidification monitoring are illustrated for which sprayed high temperature ultrasonic thick film transducers integrated onto the mold inserts are employed.
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