Ultrafast Remote Healing of Magneto-Responsive Thermoplastic Elastomer-Based Nanocomposites

Induction Heating of Laminated Composite Structures with Magnetically Responsive Nanocomposite Interlayers for Debonding-on-Demand Applications

In the present study, the feasibility to achieve localized induction heating and debonding of multi-material composite structures is assessed in testing coupons prepared by Automated Fiber Placement (AFP) and extrusion-based additive manufacturing (AM) technologies. Nano-compounds of Polyether-ketone-ketone (PEKK) with iron oxide nanoparticles acting as electromagnetic susceptors have been processed in a parallel co-rotating twin-screw extruder to produce filament feedstock for extrusion-based AM. The integration of nanocomposite interlayers as discrete debonding zones (DZ) by AFP-AM manufacturing has been investigated for two types of sandwich-structured laminate composites, i.e., laminate-DZ-laminate panels (Type I) and laminate-DZ-AM gyroid structures (Type II). Specimens were exposed to an alternating magnetic field generated by a radio frequency generator and a flat spiral copper induction coil, and induction heating parameters (frequency, power, heating time, sample standoff distance from coil) have been investigated in correlation with real-time thermal imaging to define the debonding process window without compromising laminate quality. For the optimized process parameters, i.e., 2-3 kW generator power and 20-25 mm standoff distance, corresponding to magnetic field intensities in the range of 3-5 kA m-1, specimens were effectively heated above PEKK melting temperature, exhibiting high heating rates within the range of 5.3-9.4 °C/s (Type I) and 8.0-17.5 °C/s (Type II). The results demonstrated that localized induction heating successfully facilitated debonding, leading to full unzipping of the debonding zones in both laminate structures. Further insight on PEKK nanocomposites debonding performance was provided by thermal, morphological characterization and non-destructive inspection via X-ray micro-computed tomography at different processing stages. The developed framework aims to contribute to the development of rapid, on-demand joining, repair and disassembly technologies for thermoplastic composites, towards more efficient maintenance, repair and overhaul operations in the aviation sector and beyond.

Fabrication and Applications of Magnetic Polymer Composites for Soft Robotics

The emergence of magnetic polymer composites has had a transformative impact on the field of soft robotics. This overview will examine the various methods by which innovative materials can be synthesized and utilized. The advancement of soft robotic systems has been significantly enhanced by the utilization of magnetic polymer composites, which amalgamate the pliability of polymers with the reactivity of magnetic materials. This study extensively examines the production methodologies involved in dispersing magnetic particles within polymer matrices and controlling their spatial distribution. The objective is to gain insights into the strategies required to attain the desired mechanical and magnetic properties. Additionally, this study delves into the potential applications of these composites in the field of soft robotics, encompassing various devices such as soft actuators, grippers, and wearable gadgets. The study emphasizes the transformative capabilities of magnetic polymer composites, which offer a novel framework for the advancement of biocompatible, versatile soft robotic systems that utilize magnetic actuation.

Fate of Magnetic Nanoparticles during Stimulated Healing of Thermoplastic Elastomers

We have investigated the heating mechanism in industrially relevant, multi-block copolymers filled with Fe nanoparticles and subjected to an oscillatory magnetic field that enables polymer healing in a contactless manner. While this procedure aims to extend the lifetime of a wide range of thermoplastic polymers, repeated or prolonged stimulus healing is likely to modify their structure, mechanics, and ability to heat, which must therefore be characterized in depth. In particular, our work sheds light on the physical origin of the secondary heating mechanism detected in soft systems subjected to magnetic hyperthermia and triggered by copolymer chain dissociation. In spite of earlier observations, the origin of this additional heating remained unclear. By using both static and dynamic X-ray scattering methods (small-angle X-ray scattering and X-ray photon correlation spectroscopy, respectively), we demonstrate that beyond magnetic hysteresis losses, the enormous drop of viscosity at the polymer melting temperature enables motion of nanoparticles that generates additional heat through friction. Additionally, we show that applying induction heating for a few minutes is found to magnetize the nanoparticles, which causes them to align in dipolar chains and leads to nonmonotonic translational dynamics. By extrapolating these observations to rotational dynamics and the corresponding amount of heat generated through friction, we not only clarify the origin of the secondary heating mechanism but also rationalize the presence of a possible temperature maximum observed during induction heating.

Magnetic Nanoparticles Improve Flow Rate and Enable Self-Healing in Covalent Adaptable Networks

Covalent adaptable networks (CANs) combine the mechanical and chemical stability of thermosets with the reprocessability of thermoplastics through the incorporation of stimuli-responsive dynamic crosslinks. To allow for processing through induction heating, we have created associative CANs that include fillers in the polymer matrix for efficient heat transfer. While the inclusion of inorganic fillers often decreases flow rate in CANs and complicates reprocessing of the material, the presence of Fe₃O₄ nanoparticles had no detrimental effect on flow behavior in a vinylogous urethane vitrimer, an observation we attribute to the catalytic nature of nanoparticles on the dynamic exchange chemistry. We employed two methods of nanoparticle incorporation: blending bare nanoparticles and crosslinking chemically modified nanoparticles. The vitrimers with covalently crosslinked nanoparticles exhibited a decreased relaxation time compared to those with blended nanoparticles. The magnetic character of the Fe₃O₄ nanoparticles enabled self-healing of the vitrimer composite materials upon exposure to an alternating electromagnetic field during induction heating.