Non-Isothermal Crystallization Kinetics of Polyether-Ether-Ketone Nanocomposites and Analysis of the Mechanical and Electrical Conductivity Performance

High-performance polyether-ether-ketone (PEEK) is highly desirable for a plethora of engineering applications. The incorporation of conductive carbon nanotubes (CNTs) into PEEK can impart electrical conductivity to the otherwise non-conductive matrix, which can further expand the application realm for PEEK composites. However, a number of physical properties, which are central to the functionalities of the composite, are affected by the complex interplay of the crystallinity and presence of the nanofillers, such as CNTs. It is therefore of paramount importance to conduct an in-depth investigation to identify the process that optimizes the mechanical and electrical performance. In this work, PEEK/CNTs composites with different carbon nanotubes (CNTs) content ranging from 0.5 to 10.0 wt% are prepared by a parallel twin-screw extruder. The effects of CNTs content and annealing treatment on the crystallization behavior, mechanical properties and electrical conductivity of the PEEK/CNTs composites are investigated in detail. A non-isothermal crystallization kinetics test reveals a substantial loss in the composites’ crystallinity with the increased CNTs content. On the other hand, mechanical tests show that with 5.0 wt% CNTs content, the tensile strength reaches a maximum at 118.2 MPa, which amounts to a rise of 30.3% compared with the neat PEEK sample after annealing treatment. However, additional annealing treatment decreases the electrical conductivity as well as EMI shielding performance. Such a decrease is mainly attributed to the relatively small crystal size of PEEK, which excludes the conductive fillers to the boundaries and disrupts the otherwise conductive networks.

Nanomaterial reinforced composite for biomedical implants applications: a mini-review

There is heavy demand for suitable implant materials with improved mechanical and biological properties. Classically, the demand was catered by conventional materials like metals, alloys, and polymer-based materials. Recently, nanomaterial reinforced composites have played a significant role in replacing conventional materials due to their excellent properties such as biocompatibility, bioactivity, high strength to weight ratio, long life, corrosion & wear resistance, and tailor-ability. Herein, we composed a systematic focus review on the role of nanoparticles in the form of composite materials for the advancements in orthopedic implants. Several nano materials-based reinforcements have been reviewed with various matrix materials, including metals, alloys, ceramics, composites, and polymers for biomedical implant applications. Moreover, the improved biological properties, mechanical properties, and other functionalities like infection resistance, drug delivery at the target, sensing, and detection of bone diseases, and corrosion & wear resistance are elaborated. At last, a particular focus has been given to the un-resolved challenges in orthopedic implant development.

Additive Manufacturing of Polyether Ether Ketone (PEEK) for Space Applications: A Nanosat Polymeric Structure

Recent improvements in additive layer manufacturing (ALM) have provided new designs of geometrically complex structures with lighter materials and low processing costs. The use of additive manufacturing in spacecraft production is opening up many new possibilities in both design and fabrication, allowing for the reduction of the weight of the structure subsystems. In this aim, polymeric ALM structures can become a choice, in terms of lightweight and demisability, as far as good thermomechanical properties. Moreover, provided that fused-deposition modeling (FDM) is used, nanosats and other structures could be easily produced in space. However, the choice of the material is a crucial step of the process, as the final performance of the printed parts is strongly dependent on three pillars: design, material, and printing process. As a high-performance technopolymer, polyether ether ketone (PEEK) has been adopted to fabricate parts via ALM; however, the space compatibility of 3D-printed parts remains not demonstrated. This work aimed to realize a nanosat polymeric structure via FDM, including all the phases of the development process: thermomechanical design, raw material selection, printing process tuning, and manufacturing of a proof of concept of a technological model. The design phase includes the application of topology optimization to maximize mass saving and take full advantage of the ALM capability. 3D-printed parts were characterized via thermomechanical tests, outgassing tests of 3D-printed parts are reported confirming the outstanding performance of polyether ether ketone and its potential as a material for structural space application.

Preparation and Tribological Behaviors of Lubrication-Enhanced PEEK Composites

Poly-ether-ether ketone (PEEK) is a great potential thermoplastic in industry and medical treatment and health. In this work, PEEK/graphene oxide (GO) and PEEK/MoS2 composites were prepared by a novel hot isostatic pressing method. The addition of GO alters the tribological behaviors mechanism; fatigue wear mechanism is predominant to PEEK/GO composites. However, the combination of abrasive and adhesive wear mechanisms is observed for PEEK/MoS2 composites and PEEK. The reason for this is that the hardness and tensile strength of composites are increased with the appropriate addition of GO. The response time to stable friction state of PEEK/GO and PEEK/MoS2 composites is reduced in comparison with PEEK, which is conducive to shorten running-in time, reduce the energy consumption, and improve the tribological performances of composites. The addition of GO and MoS2 can effectively decrease the friction coefficient and wear rate, and the optimal content of GO and MoS2 was 0.7 wt.% and 15 wt.%, respectively. The results indicate that PEEK/GO and PEEK/MoS2 are impressive composites that possess super tribological properties.

Fused Filament Fabrication of PEEK: A Review of Process-Structure-Property Relationships

Poly (ether ether ketone) (PEEK) is a high-performance engineering thermoplastic polymer with potential for use in a variety of metal replacement applications due to its high strength to weight ratio. This combination of properties makes it an ideal material for use in the production of bespoke replacement parts for out-of-earth manufacturing purposes, in particular on the International Space Station (ISS). Additive manufacturing (AM) may be employed for the production of these parts, as it has enabled new fabrication pathways for articles with complex design considerations. However, AM of PEEK via fused filament fabrication (FFF) encounters significant challenges, mostly stemming from the semi crystalline nature of PEEK and its associated high melting temperature. This makes PEEK highly susceptible to changes in processing conditions which leads to a large reported variation in the literature on the final performance of PEEK. This has limited the adaption of FFF printing of PEEK in space applications where quality assurance and reproducibility are paramount. In recent years, several research studies have examined the effect of printing parameters on the performance of the 3D-printed PEEK parts. The aim of the current review is to provide comprehensive information in relation to the process-structure-property relationships in FFF 3D-printing of PEEK to provide a clear baseline to the research community and assesses its potential for space applications, including out-of-earth manufacturing.

Production of graphene nanoplate/polyetheretherketone composites by semi-industrial melt-compounding

Current studies on nanocomposites have focused on their multifunctional properties and their industrial production. In this work, polyetheretherketone (PEEK)/graphene nanoplate (GNP) composites were produced by a direct semi-industrial process. Different percentages of untreated GNP (1, 5, and 10 wt.%) were added to PEEK by employing melt-compounding followed by injection-moulding. Despite the semi-industrial approach used, the modulus, strength, and Poisson coefficient of the nanocomposites (1 and 5 wt.%) were not significantly affected by the addition of GNP. However, there was a slight decrease in the strength at 10 wt.% GNP. Our study also shows that the thermal conductivities of PEEK/GNP composites are up to 2.5 times higher than that of pure PEEK.

Intelligent Injection Molding on Sensing, Optimization, and Control

Injection molding is one of the most significant material processing methods for mass production of plastic products. It is widely used in various industry sectors, and its products are ubiquitous in our daily life. The settings and optimization of the injection molding process dictate the geometric precision and mechanical properties of the final products. Therefore, sensing, optimization, and control of the injection molding process have a crucial influence on product quality and have become an active research field with abundant literature. This paper defines the concept of intelligent injection molding as the integral application of these three procedures—sensing, optimization, and control. This paper reviews recent studies on methods for the detection of relevant physical variables, optimization of process parameters, and control strategies of machine variables in the molding process. Finally, conclusions are drawn to discuss future research directions and technologies, as well as algorithms worthy of being explored and developed.

The performances of modified single-walled carbon nanotubes/poly(ether ether ketone) composites prepared by solution blending and melt blending

The modified single-walled carbon nanotubes (m-SWCNTs)/poly(ether ether ketone) (PEEK) composites were prepared by solution blending and melt blending, respectively. The mechanical, dielectric, and frictional performances of the m-SWCNTs/PEEK composites obtained by different processing technic were investigated. The poly(aryl ether ketone)s with pyrene (PAEK-Pys) were synthesized through iridium-catalyzed C−H borylation followed by Suzuki coupling. PAEK-Pys were characterized using ultraviolet–visible spectroscopy, proton nuclear magnetic resonance spectroscopy, and gel permeation chromatography. The polymers were then used for surface modification of pristine SWCNTs. Finally, the m-SWCNTs were used to prepare m-SWCNTs/PEEK composites via co-blending in solution or melt. The mechanical, frictional, and dielectric performance of the m-SWCNTs/PEEK composite by solution blending were better than these in m-SWCNTs/PEEK composite by melt blending. These results suggest that the method of solution blending is more favorable for the dispersion of the SWCNTs in PEEK.

Melt-Processed Poly(Ether Ether Ketone)/Carbon Nanotubes/Montmorillonite Nanocomposites with Enhanced Mechanical and Thermomechanical Properties

The agglomeration problem of nanofillers, for instance, carbon nanotubes (CNTs) in a poly(ether ether ketone) (PEEK) matrix, is still a challenging assignment due to the intrinsic inert nature of PEEK to organic solvents. In this work, organically modified montmorillonite (MMT) was introduced as a second filler for improving the dispersion of CNTs in the PEEK matrix and enhancing the mechanical properties, as well as reducing the cost of the materials. The nanocomposites were fabricated through melt-mixing PEEK with CNTs/MMT hybrids, which were prepared in advance by mixing CNTs with MMT in water. The introduction of MMT improved the dispersion stability of CNTs, as characterized by sedimentation and zeta potential. The CNTs/MMT hybrids were maintained in PEEK nanocomposites as demonstrated by the transmission electron microscope. The mechanical and thermomechanical measurements revealed that CNTs together with MMT had a strong reinforcement effect on the PEEK matrix, especially at high temperature, although it had a negative effect on the toughness. A maximum increase of 48.1% was achieved in storage modulus of PEEK nanocomposites with 0.5 wt% CNTs and 2 wt% MMT at 240 °C, compared to that of neat PEEK. The differential scanning calorimetry results revealed that CNTs accelerated the crystallization of the PEEK matrix while a further addition of MMT played an opposite role. The nucleation activity of the fillers was also evaluated by the Dobreva method.