Self-assembly of faceted particles triggered by a moving ice front

Complex Composites Built through Freezing

ConspectusUsing a limited selection of ordinary components and at ambient temperature, nature has managed to produce a wide range of incredibly diverse materials with astonishingly elegant and complex architectures. Probably the most famous example is nacre, or mother-of-pearl, the inner lining of the shells of abalone and certain other mollusks. Nacre is 95% aragonite, a hard but brittle calcium carbonate mineral, that exhibits fracture toughness exceedingly greater than that of pure aragonite, when tested in the direction perpendicular to the platelets. No human-made composite outperforms its constituent materials by such a wide margin. Nature's unique ability to combine the desirable properties of components into a material that performs significantly better than the sum of its parts has sparked strong interest in bioinspired materials design.Inspired by this complex hierarchical architecture, many processing routes have been proposed to replicate one or several of these features. New processing techniques point to a number of laboratory successes that hold promise in mimicking nacre. We pioneered one of them, ice templating, in 2006. When a suspension of particles is frozen, particles are rejected by the growing ice crystals and concentrate in the space between the crystals. After the ice is freeze-dried, the resulting scaffold is a porous body that can eventually be pressed to increase the density and then be infiltrated with a second phase, providing multilayered, lamellar complex composites with a microstructure reminiscent of nacre. The composites exhibit a marked crack deflection during crack propagation, enhancing the damage resistance of the materials, offering an interesting trade-off of strength and toughness.Freezing as a path to build complex composites has turned out to be a rich line of research and development. Understanding and controlling the freezing routes and associated phenomena has become a multidisciplinary endeavor. A step forward in the complexity was achieved with the use of anisotropic particles. Ice-induced segregation and alignment of platelets can yield dense, inorganic composites (nacre-like alumina) with a complex architecture and microstructure, replicating several of the morphological features of nacre. Now, a different class of complex composites is quickly arising: engineered living materials, developed in the soft matter and biology communities. The material-agnostic nature of the freezing routes, the use of an aqueous system, the absence of organic solvents, and the low temperatures being used are all strong assets for the development of such complex composites. More complex building blocks, such as cells or bacteria, can be frozen. Understanding the fundamental mechanisms controlling the interactions between the ice crystals and the objects as well as the interactions between the soft objects themselves and their fate is essential in this context.In this Account, we highlight our efforts over the past decade to achieve the controlled synthesis of nacre-like composites and understand the associated processes and properties. We describe the unique hierarchical and chemical structure of nacre and the fabrication strategies for processing nacre-like composites. We also try to explain why natural materials work so well and see how we can implement these lessons in synthetic composites. Finally, we provide an outlook on the new trends and ongoing challenges in this field. We hope that this Account will inspire future developments in the field of ice templating and bioinspired materials.

Directionally In Situ Self-Assembled, High-Density, Macropore-Oriented, CoP-Impregnated, 3D Hierarchical Porous Carbon Sheet Nanostructure for Superior Electrocatalysis in the Hydrogen Evolution Reaction

3D ZIF-67-particles-impregnated cellulose-nanofiber nanosheets with oriented macropores are synthesized via directional-freezing-assisted in situ self-assembly, and converted to 3D CoP-nanoparticle (NP)-embedded hierarchical, but macropores-oriented, N-doped carbon nanosheets via calcination and phosphidation. The obtained nanoarchitecture delivers overpotentials at 10 and 50 mA cm^-2 and Tafel slope of 82.1 and 113.4 mV and 40.8 mV dec^-1 in 0.5 M H₂ SO₄ , and of 97.1 and 136.6 mV and 51.2 mV dec^-1 in 1 M KOH, all of which are superior to those of the most reported non-noble-metal-based hydrogen evolution reaction (HER) catalysts. This catalyst even surpasses commercial Pt/C for a much lower overpotential at high current densities, which is essential for large-scale hydrogen production. Its catalytic activity can be further optimized to become one of the best in both 0.5 M H₂ SO₄ and 1 M KOH. The outstanding catalytic activity is ascribed to the uniformly-dispersed small CoP NPs in the 3D carbon sheets and the hierarchical nanostructure with rich oriented pores. This work develops a facile, economical, and universal self-assembly strategy to fabricate uniquely nanostructured hybrids to simultaneously promote charge transfer and mass transport, and also offers an inexpensive and high-performance HER catalyst toward industry-scale water splitting.

Multiple objects interacting with a solidification front

The interaction of objects suspended in a liquid melt with an advancing solidification front is of special interest in nature and engineering sciences. The front can either engulf the object into the growing crystal or repel it. Therefore, the object-front confrontation can have a strong influence on the microstructure and mechanical or functional properties of the solidified material. The past theoretical models and experimental studies have mostly investigated the interaction of isolated, spherical, and hard objects in pure melts. However, the outcome of object-front interactions in complex (more realistic) systems, where multiple objects and solutes are present, is still poorly understood. Here we show the interaction of multiple oil droplets with an ice-water front in the absence and presence of solute effects using in situ cryo-confocal microscopy. We report on how the object size, number of objects, and bulk solute concentration influence the the object-front interaction and the front morphology, as well as the subsequent object spatial distribution. We suggest that the volume fraction of objects suspended in a liquid melt in conjunction with the amount of bulk solute concentration are two important parameters to be incorporated in the development of object-front interaction models.

Tough metal-ceramic composites with multifunctional nacre-like architecture

The brick-and-mortar architecture of biological nacre has inspired the development of synthetic composites with enhanced fracture toughness and multiple functionalities. While the use of metals as the “mortar” phase is an attractive option to maximize fracture toughness of bulk composites, non-mechanical functionalities potentially enabled by the presence of a metal in the structure remain relatively limited and unexplored. Using iron as the mortar phase, we develop and investigate nacre-like composites with high fracture toughness and stiffness combined with unique magnetic, electrical and thermal functionalities. Such metal-ceramic composites are prepared through the sol–gel deposition of iron-based coatings on alumina platelets and the magnetically-driven assembly of the pre-coated platelets into nacre-like architectures, followed by pressure-assisted densification at 1450 °C. With the help of state-of-the-art characterization techniques, we show that this processing route leads to lightweight inorganic structures that display outstanding fracture resistance, show noticeable magnetization and are amenable to fast induction heating. Materials with this set of properties might find use in transport, aerospace and robotic applications that require weight minimization combined with magnetic, electrical or thermal functionalities.

Multiscale Toughening Mechanisms in Biological Materials and Bioinspired Designs

Biological materials found in Nature such as nacre and bone are well recognized as light-weight, strong, and tough structural materials. The remarkable toughness and damage tolerance of such biological materials are conferred through hierarchical assembly of their multiscale (i.e., atomic- to macroscale) architectures and components. Herein, the toughening mechanisms of different organisms at multilength scales are identified and summarized: macromolecular deformation, chemical bond breakage, and biomineral crystal imperfections at the atomic scale; biopolymer fibril reconfiguration/deformation and biomineral nanoparticle/nanoplatelet/nanorod translation, and crack reorientation at the nanoscale; crack deflection and twisting by characteristic features such as tubules and lamellae at the microscale; and structure and morphology optimization at the macroscale. In addition, the actual loading conditions of the natural organisms are different, leading to energy dissipation occurring at different time scales. These toughening mechanisms are further illustrated by comparing the experimental results with computational modeling. Modeling methods at different length and time scales are reviewed. Examples of biomimetic designs that realize the multiscale toughening mechanisms in engineering materials are introduced. Indeed, there is still plenty of room mimicking the strong and tough biological designs at the multilength and time scale in Nature.

Interactions between Nanoparticles and Polymers in the Diffusion Boundary Layer during Freezing Colloidal Suspensions

The present work investigated diffusion interactions between nanoparticles and polymers during freezing colloidal suspensions. The size effects of nanoporous media formed by packed nanoparticles on the diffusion instability of the polymer solution were explored. It is found that small particles under low pulling speeds will obstruct the diffusion of polymers and the corresponding morphology will be banded structures. The intrinsic reason is the inhibited tube-like motion of polymer chains in the nanoporous particle layer. The increased particle size or the decreased solute size will solve the diffusion problem. On the other hand, the small pulling speed constructs an increased length of the particle layer in front of the freezing interface, which presents a longer diffusion path to impede the polymer diffusion. Instead, an increased pulling speed shortens the length of the particle layer so that it is easy for polymers to go through a short porous media. Hence, the diffusion of polymers will control the freezing morphology of the suspension and create dendrites. These results imply that a relatively larger particle size and a moderately higher pulling speed are beneficial for well-developed microstructures in the production of porous ceramics with the freeze-casting method.

Freeze-Thaw Gelation of Cellulose Nanocrystals

Gels are attractive for applications in drug delivery, tissue engineering, and 3D printing. Here, physical colloidal gels were prepared by freeze-thaw (FT) cycling of cellulose nanocrystal (CNC) suspensions. The aggregation of CNCs was driven by the physical confinement of CNCs between growing ice crystal domains. FT cycling was employed to form larger aggregates of CNCs without changing the surface chemistry or ionic strength of the suspensions. Gelation of CNC suspensions by FT cycling was demonstrated in water and other polar solvents. The mechanical and structural properties of the gels were investigated using rheometry, electron microscopy, X-ray diffraction, and dynamic light scattering. We found that the rheology could be tuned by varying the freezing time, the number of FT cycles, and concentration of CNCs in suspension.

Vertically Aligned and Interconnected SiC Nanowire Networks Leading to Significantly Enhanced Thermal Conductivity of Polymer Composites

Efficient heat removal via thermal management materials has become one of the most critical challenges in the development of modern microelectronic devices. However, previously reported polymer composites exhibit limited enhancement of thermal conductivity, even when highly loaded with thermally conductive fillers, because of the lack of efficient heat transfer pathways. Herein, we report vertically aligned and interconnected SiC nanowire (SiCNW) networks as efficient fillers for polymer composites, achieving significantly enhanced thermal conductivity. The SiCNW networks are produced by freeze-casting nanowire aqueous suspensions followed by thermal sintering to consolidate the nanowire junctions, exhibiting a hierarchical architecture in which honeycomb-like SiCNW layers are aligned. The composite obtained by infiltrating SiCNW networks with epoxy resin, at a relatively low SiCNW loading of 2.17 vol %, represents a high through-plane thermal conductivity (1.67 W m^-1 K^-1) compared to the pure matrix, which is equivalent to a significant enhancement of 406.6% per 1 vol % loading. The orderly SiCNW network which can act as a macroscopic expressway for phonon transport is believed to be the main contributor for the excellent thermal performance. This strategy provides insights for the design of high-performance composites with potential to be used in advanced thermal management materials.

Construction of 3D Skeleton for Polymer Composites Achieving a High Thermal Conductivity

Owing to the growing heat removal issue in modern electronic devices, electrically insulating polymer composites with high thermal conductivity have drawn much attention during the past decade. However, the conventional method to improve through-plane thermal conductivity of these polymer composites usually yields an undesired value (below 3.0 Wm^-1 K^-1 ). Here, construction of a 3D phonon skeleton is reported composed of stacked boron nitride (BN) platelets reinforced with reduced graphene oxide (rGO) for epoxy composites by the combination of ice-templated and infiltrating methods. At a low filler loading of 13.16 vol%, the resulting 3D BN-rGO/epoxy composites exhibit an ultrahigh through-plane thermal conductivity of 5.05 Wm^-1 K^-1 as the best thermal-conduction performance reported so far for BN sheet-based composites. Theoretical models qualitatively demonstrate that this enhancement results from the formation of phonon-matching 3D BN-rGO networks, leading to high rates of phonon transport. The strong potential application for thermal management has been demonstrated by the surface temperature variations of the composites with time during heating and cooling.

A novel h-BN–RGO hybrids for epoxy resin composites achieving enhanced high thermal conductivity and energy density

In recent decades, significant attention has been focused on developing composite materials with high thermal conductivity utilizing h-BN, which has outstanding thermal conductivity.

Interfacial undercooling in solidification of colloidal suspensions: analyses with quantitative measurements

Interfacial undercooling in the complex solidification of colloidal suspensions is of significance and remains a puzzling problem. Two types of interfacial undercooling are supposed to be involved in the freezing of colloidal suspensions, i.e., solute constitutional supercooling (SCS) caused by additives in the solvent and particulate constitutional supercooling (PCS) caused by particles. However, quantitative identification of the interfacial undercooling in the solidification of colloidal suspensions, is still absent; thus, the question of which type of undercooling is dominant in this complex system remains unanswered. Here, we quantitatively measured the static and dynamic interface undercoolings of SCS and PCS in ideal and practical colloidal systems. We show that the interfacial undercooling primarily comes from SCS caused by the additives in the solvent, while PCS is minor. This finding implies that the thermodynamic effect of particles from the PCS is not the fundamental physical mechanism for pattern formation of cellular growth and lamellar structure in the solidification of colloidal suspensions, a general case of ice-templating method. Instead, the patterns in the ice-templating method can be controlled effectively by adjusting the additives.

Ice-Templated Assembly Strategy to Construct 3D Boron Nitride Nanosheet Networks in Polymer Composites for Thermal Conductivity Improvement

Owing to the growing heat removal issue of modern electronic devices, polymer composites with high thermal conductivity have drawn much attention in the past few years. However, a traditional method to enhance the thermal conductivity of the polymers by addition of inorganic fillers usually creates composite with not only limited thermal conductivity but also other detrimental effects due to large amount of fillers required. Here, novel polymer composites are reported by first constructing 3D boron nitride nanosheets (3D-BNNS) network using ice-templated approach and then infiltrating them with epoxy matrix. The obtained polymer composites exhibit a high thermal conductivity (2.85 W m(-1) K(-1)), a low thermal expansion coefficient (24-32 ppm K(-1)), and an increased glass transition temperature (T(g)) at relatively low BNNSs loading (9.29 vol%). These results demonstrate that this approach opens a new avenue for design and preparation of polymer composites with high thermal conductivity. The polymer composites are potentially useful in advanced electronic packaging techniques, namely, thermal interface materials, underfill materials, molding compounds, and organic substrates.

Magnetically assisted slip casting of bioinspired heterogeneous composites

Natural composites are often heterogeneous to fulfil functional demands. Manufacturing analogous materials remains difficult, however, owing to the lack of adequate and easily accessible processing tools. Here, we report an additive manufacturing platform able to fabricate complex-shaped parts exhibiting bioinspired heterogeneous microstructures with locally tunable texture, composition and properties, as well as unprecedentedly high volume fractions of inorganic phase (up to 100%). The technology combines an aqueous-based slip-casting process with magnetically directed particle assembly to create programmed microstructural designs using anisotropic stiff platelets in a ceramic, metal or polymer functional matrix. Using quantitative tools to control the casting kinetics and the temporal pattern of the applied magnetic fields, we demonstrate that this approach is robust and can be exploited to design and fabricate heterogeneous composites with thus far inaccessible microstructures. Proof-of-concept examples include bulk composites with periodic patterns of microreinforcement orientation, and tooth-like bilayer parts with intricate shapes exhibiting site-specific composition and texture.

In situ observation the interface undercooling of freezing colloidal suspensions with differential visualization method

Interface undercooling is one of the most significant parameters in the solidification of colloidal suspensions. However, quantitative measurement of interface undercooling of colloidal suspensions is still a challenge. Here, a new experimental facility and gauging method are designed to directly reveal the interface undercooling on both static and dynamic cases. The interface undercooling is visualized through the discrepancy of solid/liquid interface positions between the suspensions and its solvent in a thermal gradient apparatus. The resolutions of the experimental facility and gauging method are proved to be 0.01 K. The high precision of the method comes from the principle of converting temperature measurement into distance measurement in the thermal gradient platform. Moreover, both static and dynamic interface undercoolings can be quantitatively measured.