Mechanical properties and failure behavior of unidirectional porous ceramics

Environmental Friendly Fabrication of Porous Cement Membranes via Reusable Camphene-Based Freeze-Casting Method

Inorganic membranes have been developed rapidly in recent years because of excellent anti-fouling performance, high mechanical strength and outstanding resistances to acid and alkali. However, the high production cost still restricts its large-scale industrial application. In this work, an environmental friendly unidirectional freezing method via introducing camphene as a reusable template was adapted to prepare porous cement membranes (PCMs). The naturally formed and highly aligned porous structures of PCMs could be divided into three parts: a dense layer, a transition layer and a supporting layer. With the solid content rising from 40 wt.% to 60 wt.%, the pore size of the PCMs decreased from 3.34 nm to 3.62 nm, the bovine serum albumin (BSA) rejection increased from 81.3% to 93.5% and water flux decreased from 346.8 L·m^-2·h^-1 to 167.3 L·m^-2·h^-1 (0.2 MPa). Significantly, the performance of PCMs was maintained; even the camphene was reused 20 times. Additionally, the recovery rate of camphene could be reached up to 97.16%. Therefore, this method is cost effective and environmental friendly, which endowed the PCMs great potential in water treatment.

Ordered stereom structure in sea urchin tubercles: High capability for energy dissipation

Tubercles in sea urchin shells serve as a base on the test plates connecting the spine; these undergo compressive or impact stress from the spines. As the volume fraction of the ordered stereom structure in a tubercle increases, the compressive load-displacement curves are gradually characterized by the typical behavior of ceramic foams. Although this ordered stereom structure only exhibits an average porosity of 50.6%, it also exhibits high fracture resistance and energy dissipation capacity. Such remarkable behavior of the ordered stereom structure is attributed to its unique hierarchical microstructure. Specifically, at the macroscale, the stereom structure is periodic. It has uniformly distributed pores that are typically round, which can effectively reduce the stress concentration around the pores, and the ordered arrangement of the trabeculae along the axial direction of the tubercle bears the most compressive stress. The trabeculae present a bottleneck shape with a specific dimension, ensuring the best fracture resistance with a relatively higher porosity. Furthermore, crack deflection in the trabeculae changes the local fracture mode of the mineral, thereby increasing the crack surface area. STATEMENT OF SIGNIFICANCE: The connecting bases of the spines in sea urchin shell, known as tubercle, effectively undergo the compressive stress or impact stress from the spines. An ordered stereom structure is found in the tubercle, and it shows an excellent fracture resistance and energy dissipation capacity. Such a fantastic behavior of the ordered stereom structure mainly takes advantage of its unique hierarchical microstructure. The stereom structure presents a periodic structure on macroscale, the trabeculae show a bottleneck shape with a specific dimension to guarantee the best fracture resistance with a relatively higher porosity, and the soft fillers among CaCO₃ nanoparticles in a trabecula cause consecutive crack deflections.

Dual-Scale Porosity Alumina Structures Using Ceramic/Camphene Suspensions Containing Polymer Microspheres

This study demonstrates the utility of thermo-regulated phase separable alumina/camphene suspensions containing poly(methyl methacrylate) (PMMA) microspheres as porogens for the production of multi-scale porosity structures. The homogeneous suspension prepared at 60 °C could undergo phase separation during freezing at room temperature. This process resulted in the 3D networks of camphene crystals and alumina walls containing PMMA microspheres. As a consequence, relatively large dendritic pores with several tens of microns size could be created as the replica of frozen camphene crystals. In addition, after the removal of PMMA microspheres via heat-treatment, micron-sized small spherical pores could be generated in alumina walls. As the PMMA content with respect to the alumina content increased from 0 vol% to 40 vol%, while the camphene content in the suspensions was kept constant (70 vol%), the overall porosity increased from 45.7 ± 0.5 vol% to 71.4 ± 0.5 vol%. This increase in porosity is attributed to an increase in the fraction of spherical pores in the alumina walls. Thus, compressive strength decreased from 153 ± 18.3 MPa to 33 ± 7.2 MPa. In addition, multi-scale porosity alumina objects with a honeycomb structure comprising periodic hexagonal macrochannels surrounded by dual-scale porosity walls were constructed using a 3D plotting technique.

Mechanical and optimization studies of polypropylene hybrid biocomposites

Towards developing a polymeric matrix characterized by high strength to cost ratio, polypropylene (PP) was hybridized with low-cost particulate snail shell (PSS) and kenaf fiber (KF) via compression moulding at 180 °C and 0.2 MPa. The developed composites were grouped into three and labeled as mix 2, 4, and 10. Each group entailed the blend of 5, 10, 20, and 30 wt% KF with 2, 4, 10 wt% PSS respectively. From the results, it is observed that the hardness value was enhanced by the blend of 5 to 30 wt% KF and 2, 4, and 10 wt% PSS. However, 2 wt% PSS mix with 5 to 30 wt% KF resulted in progressive improvement in impact, compressive, flexural, and tensile strengths values. The 4 wt% PSS yielded consecutive increase in impact, compressive and flexural strength when combined with 5 and 10 wt% KF. However, it was observed that subsequent addition of 20 and 30 wt% KF led to a marginal reduction in the strength values. The tensile strength attained optimum value when 4 wt% PSS was commixed with 30 wt% KF. Conversely, the combinations of 10 wt% PSS with 5, 10, 20, and 30 wt% KF had no significant improvement to the mechanical properties of PSS/KF-bio-PP composite (except for hardness) siring strength decrease. Taguchi optimization revealed that the collage of 4 wt% PSS and 10 wt% KF presented optimum mix for hybrid bio-PP composite.

Bioactive Cellulose Acetate Electrospun Mats as Scaffolds for Bone Tissue Regeneration

In the last decades, cell-based approaches for bone tissue engineering (BTE) have relied on using models that cannot replicate the complexity of the bone microenvironment. There is an ongoing amount of research on scaffold development responding to the need for feasible materials that can mimic the bone extracellular matrix (ECM) and aid bone tissue regeneration (BTR). In this work, a porous cellulose acetate (CA) fiber mat was developed using the electrospinning technique and the mats were chemically modified to bioactivate their surface and promote osteoconduction and osteoinduction. The mats were characterized using FTIR and SEM/EDS to validate the chemical modifications and assess their structural integrity. By coupling adhesive peptides KRSR, RGD, and growth factor BMP-2, the fiber mats were bioactivated, and their induced biological responses were evaluated by employing immunocytochemical (ICC) techniques to study the adhesion, proliferation, and differentiation of premature osteoblast cells (hFOB 1.19). The biological assessment revealed that at short culturing periods of 48 hours and 7 days, the presence of the peptides was significant for proliferation and adhesion, whereas at longer culture times of 14 days, it had no significant effect on differentiation and maturation of the osteogenic progenitor cells. Based on the obtained results, it is thus concluded that the CA porous fiber mats provide a promising surface morphology that is both biocompatible and can be rendered bioactive upon the addition of osteogenic peptides to favor osteoconduction leading to new tissue formation.

Fabrication of porous TiO2 foams by powder metallurgy technique and study of bulk crushing strength for biomedical application

Despite the importance of porous titanium oxide (PA-TiO2) in diverse functional applications, very little information is available on the compatible mechanical properties for potential biomedical applications. In this study, PA-TiO2 foam was synthesized using space-holding powder metallurgy and sintering methods to produce interconnected opened-cell structure with surface morphology of mountain-like features associated with the extensive rift valley system. Three different types of PA-TiO2 foams with porosities of 35-52% and mean pore diameter of 190-210 μm were fabricated for evaluating the effect of porosity on mechanical properties of bulk PA-TiO2. The modulus of elasticity of PA-TiO2 foams exhibited in the range of 45-262 MPa which was within the range of modulus of elasticity of human cancellous bone. Cytotoxicity test is performed in vitro analysis to observe the effect of cell toxicity to produce osteointegration when used as implantable materials. There was no cytotoxicity effect found and remarkable cell growth was observed for human cancerous (HeLa) cell line. However, there was no cytotoxicity effect found and cell growth was not observed for Vero cell line. This study suggested that PA-TiO2 facilitates cell growth without spreading toxicity and has mechanical properties of cancellous bone. Hence, it has potential application as implant and medical devices in biomedical applications.

3DICE coding matrix multidirectional macro-architecture modulates cell organization, shape, and co-cultures endothelization network

Natural extracellular matrix governs cells providing biomechanical and biofunctional outstanding properties, despite being porous and mostly made of soft materials. Among organs, specific tissues present specialized macro-architectures. For instance, hepatic lobules present radial organization, while vascular sinusoids are branched from vertical veins, providing specific biofunctional features. Therefore, it is imperative to mimic such structures while modeling tissues. So far, there is limited capability of coupling oriented macro-structures with interconnected micro-channels in programmable long-range vertical and radial sequential orientations. Herein, a three-directional ice crystal elongation (3DICE) system is presented to code geometries in cryogels. Using 3DICE, guided ice crystals growth templates vertical and radial pores through bulky cryogels. Translucent isotropic and anisotropic architectures of radial or vertical pores are fabricated with tunable mechanical response. Furthermore, 3D combinations of vertical and radial pore orientations are coded at the centimeter scale. Cell morphological response to macro-architectures is demonstrated. The formation of endothelial segments, CYP450 activity, and osteopontin expression, as liver fibrosis biomarkers, present direct response and specific cellular organization within radial, linear, and random architectures. These results unlock the potential of ice-templating demonstrating the relevance of macro-architectures to model tissues, and broad possibilities for drug testing, tissue engineering, and regenerative medicine.

Electrospun PCL Patches with Controlled Fiber Morphology and Mechanical Performance for Skin Moisturization via Long-Term Release of Hemp Oil for Atopic Dermatitis

Atopic dermatitis (AD) is a chronic, inflammatory skin condition, caused by wide genetic, environmental, or immunologic factors. AD is very common in children but can occur at any age. The lack of long-term treatments forces the development of new strategies for skin regeneration. Polycaprolactone (PCL) is a well-developed, tissue-compatible biomaterial showing also good mechanical properties. In our study, we designed the electrospun PCL patches with controlled architecture and topography for long-term release in time. Hemp oil shows anti-inflammatory and antibacterial properties, increasing also the skin moisture without clogging the pores. It can be used as an alternative cure for patients that do not respond to traditional treatments. In the study, we tested the mechanical properties of PCL fibers, and the hemp oil spreading together with the release in time measured on skin model and human skin. The PCL membranes are suitable material as patches or bandages, characterized by good mechanical properties and high permeability. Importantly, PCL patches showed release of hemp oil up to 55% within 6 h, increasing also the skin moisture up to 25%. Our results confirmed that electrospun PCL patches are great material as oil carriers indicating a high potential to be used as skin patches for AD skin treatment.

A new silicon oxycarbide based gas diffusion layer for zinc-air batteries

Rational material designs play a vital role in the gas diffusion layer (GDL) by increasing the oxygen diffusion rate and, consequently, facilitating a longer cycle life for metal-air batteries. In this work, a new porous conductive ceramic membrane has been developed as a cathodic GDL for zinc-air battery (ZAB). The bilayered structure with a thickness of 390 μm and an open porosity of 55% is derived from a preceramic precursor with the help of the freeze tape casting technique. The hydrophobic behaviour of the GDL is proved by the water contact angle of 137.5° after the coating of polytetrafluoroethylene (PTFE). The electrical conductivity of 5.59 * 10^-3 S/cm is reached using graphite and MWCNT as filler materials. Tested in a ZAB system, the as-prepared GDL coated with commercial Pt-Ru/C catalyst shows an excellent cycle life over 200 cycles and complete discharge over 48 h by consuming oxygen from the atmosphere, which is comparable to commercial electrodes. The as-prepared electrode exhibits excellent ZAB performance due to the symmetric sponge-like structure, which facilitates the oxygen exchange rate and offers a short path for the oxygen ion/-electron kinetics. Thus, this work highlights the importance of a simple manufacturing process that significantly influences advanced ZAB enhancement.

Performance evaluation of bilayer oxidized regenerated cellulose/poly ε-caprolactone knitted fabric-reinforced composites for dural substitution

Ideally, alloplastic dural substitute should have functional properties resembling human dura mater and retain a watertight closure to prevent cerebrospinal leakage. Therefore, functional properties for successful dural closure application of newly developed bilayer oxidized regenerated cellulose knitted fabric/poly ε-caprolactone knitted fabric-reinforced composites were studied and compared with human cadaveric dura mater and three commercial dural substitutes including two collagen matrices and one synthetic poly-L-lactide patch. It was found that oxidized regenerated cellulose knitted fabric/poly ε-caprolactone knitted fabric-reinforced composites uniquely contained a bilayer structure consisting of micropores distributed within the relatively dense microstructure. Density, tensile properties and stitch tear strength of oxidized regenerated cellulose knitted fabric/poly ε-caprolactone knitted fabric-reinforced composites were found to be closed to human cadaveric dura mater than those of dense-type and porous-type dural substitutes. Water tightness performance in both sutured and non-sutured forms of oxidized regenerated cellulose knitted fabric/poly ε-caprolactone knitted fabric-reinforced composites was slightly inferior to human cadaveric dura mater, but still better than those of commercial dural substitutes. This study revealed that oxidized regenerated cellulose knitted fabric/poly ε-caprolactone knitted fabric-reinforced composite showed better functional properties than typical dural substitutes and was found to be a good candidate for being employed as a dural substitute. The role and relationship of both microstructure and the type of materials on the functional properties and water tightness of the dural substitutes were also elucidated.

Fabrication and Characterization of Ice Templated Membrane Supports from Portland Cement

Porous ceramic membranes for aqueous microfiltration and ultrafiltration processes suffer from the high-costs of material and processing. The latter is mainly due to the high-temperature sintering step. In this work, cement-based membrane supports from ultrafine Portland cement are studied as a low-cost alternative to traditional oxidic ceramic supports. An environmentally friendly freeze-casting fabrication route is applied for the fabrication of porous membrane supports. Cement membrane supports are becoming mechanically stabile after hydration reaction of cement with water, which does not require any high-temperature sintering step as in a conventional ceramic membrane fabrication process. This fabrication route, which is sintering-free, decreases the cost and environmental impact of the membrane fabrication process by eliminating extra energy consumption step during sintering. The Archimedes method, scanning electron microscopy (SEM), micro-computed tomographic (µCT), and mercury porosimetry characterize the membrane supports in respect to open porosity, pore size distribution, morphology, and connectivity. The flexural strength of the 3 mm thick membranes is in the range from 1 to 6 MPa, as obtained by the ring-on-ring tests. The obtained membrane supports possess porosity in the range between 48 and 73% depending on fabrication conditions (cooling rate and the solid content, as determined by Archimedes method enabling water flux in the range between 79 and 180 L/(h·m²) at 0.5 bar transmembrane pressure difference and 3 mm membrane thickness.

Gamma-irradiation-induced micro-structural variations in flame-retardant polyurethane foam using synchrotron X-ray micro-tomography

Flame-retardant polyurethane foams are potential packing materials for the transport casks of highly active nuclear materials for shock absorption and insulation purposes. Exposure of high doses of gamma radiation causes cross-linking and chain sectioning of macromolecules in this polymer foam, which leads to reorganization of their cellular microstructure and thereby variations in physico-mechanical properties. In this study, in-house-developed flame-retardant rigid polyurethane foam samples were exposed to gamma irradiation doses in the 0-20 kGy range and synchrotron radiation X-ray micro-computed tomography (SR-µCT) imaging was employed for the analysis of radiation-induced morphological variations in their cellular microstructure. Qualitative and quantitative analysis of SR-µCT images has revealed significant variations in the average cell size, shape, wall thickness, orientations and spatial anisotropy of the cellular microstructure in polyurethane foam.

Spring Based Connection of External Wires to a Thin Film Temperature Sensor Integrated Inside a Solid Oxide Fuel Cell

Thermal management of SOFCs (solid oxide fuel cell) is important for helping to minimise high temperature-related performance losses and maximising cell/stack lifetime. Thin film sensor technology is proposed as an excellent candidate to measure the cell temperature during operation due to its negligible mass, minimal disturbance to normal operation and higher temporal and spatial resolutions. However, the effective application of such sensors in SOFC systems is a challenging endeavour and predicated on incorporating the external wire attachments to complete the electrical circuit. This is because of the high sensitivity of SOFC materials to any interference to operation, limited available space and harsh operating conditions. In this paper, a new concept of packaging external wire attachments to the thin film sensor is described to enable the integration of the sensor in the SOFC system. Temperature measurements have been monitored under OCV and operating condition with the thin film sensor directly from SOFC cathode surface via proposed spring-based wire connection, from room temperature to SOFC operating temperature. The impact of the parameters including contact resistance (Rc) between sensor pads and attached wire on monitored temperature has also been analysed with the contribution of conductive paste. High temporal and spatial resolutions have been obtained with the implemented sensor.

Strength, elasticity and the limits of energy dissipation in two related sea urchin spines with biomimetic potential

The calcitic spines of the sea urchins Heterocentrotus mamillatus and H. trigonarius are promising role models for lightweight applications, bone tissue scaffolds and energy dissipating processes due to their highly porous and organized structure. Therefore, mechanical properties including Young's Modulus, strength, failure behaviour and energy dissipation efficiency have been investigated in depth with uniaxial compression experiments, 3-point bending tests and resonance frequency damping analysis. It was found that despite a very similar structure, H. trigonarius has a significantly lower porosity than H. mamillatus leading to a higher strength and Young's Moduli, but limited ability to dissipate energy. In order to show reliable energy dissipation during failure in uniaxial compression, a transition porosity of 0.55-0.6 needs to be exceeded. The most effective structure for this purpose is a homogeneous, foam-like structure confined by a thin and dense shell that increases initial strength and was found in numerous spines of H. mamillatus. Sharp porosity changes induced by dense growth layers or prominent wedges of the spines' radiating building principle act as structural weaknesses, along which large flakes can be spalled, reducing the energy dissipation efficiency considerably. The high strength and Young's Modulus at the biologically necessary high porosity levels of the spines is useful for Heterocentrotus and their construction therefore remains to be a good example of biomimetics. However, the energy dissipative failure behaviour may be regarded as a mere side effect of the structure.

Mechanical Analysis of Ceramic/Polymer Composite with Mesh-Type Lightweight Design Using Binder-Jet 3D Printing

3D printing technology has recently been highlighted as an innovative manufacturing process. Among various 3D printing methods, binder jetting (BJ) 3D printing is particularly known as technology used to produce the complex sand mold quickly for a casting process. However, high manufacturing costs, due to its expensive materials, need to be lowered for more industrial applications of 3D printing. In this study, we investigated mechanical properties of sand molds with a lightweight structure for low material consumption and short process time. Our stress analysis using a computational approach, revealed a structural weak point in the mesh-type lightweight design applied to the 3D-printed ceramic/polymer composite.

Ultralight Conductive Silver Nanowire Aerogels

Low-density metal foams have many potential applications in electronics, energy storage, catalytic supports, fuel cells, sensors, and medical devices. Here, we report a new method for fabricating ultralight, conductive silver aerogel monoliths with predictable densities using silver nanowires. Silver nanowire building blocks were prepared by polyol synthesis and purified by selective precipitation. Silver aerogels were produced by freeze-casting nanowire aqueous suspensions followed by thermal sintering to weld the nanowire junctions. As-prepared silver aerogels have unique anisotropic microporous structures, with density precisely controlled by the nanowire concentration, down to 4.8 mg/cm³ and an electrical conductivity up to 51 000 S/m. Mechanical studies show that silver nanowire aerogels exhibit "elastic stiffening" behavior with a Young's modulus up to 16 800 Pa.

Straightforward Processing Route for the Fabrication of Robust Hierarchical Zeolite Structures

Strong hierarchical porous zeolite structures are prepared by a sol-gel method using freeze gelation. Instead of conventional binders in powder form, such as bentonite or kaolin, it has been proven that using a freeze gelation method based on a colloidal silica sol is a more straightforward and easier-to-use-approach in fabricating highly mechanically stable zeolite monoliths. The resulting zeolite slurries possess superior rheological properties (not being pseudoplastic) and show low viscosities. This low viscosity of the slurry enables an increase in the solid content without compromising the extraordinary good flow behavior for casting applications. Additionally, in comparison to conventional powdery binders, zeolite samples prepared by using a colloidal silica sol exhibit a significantly higher mechanical strength. This mechanical strength can be further improved by either increasing the zeolite content or increasing the silica to zeolite ratio. Increasing the zeolite content leads to an increased volumetric adsorption capacity for CO₂ as the test gas, resulting from the increased amount of zeolite particles per unit volume. In addition, a higher solid content of the zeolite monoliths leads to higher compression strengths, while showing the same elastic deformation and brittle failure characteristics. In turn, increasing the silica to zeolite ratio does not affect the volumetric adsorption capacity for CO₂. Nevertheless, higher silica contents lead to a significant increase in the elastic deformation and absorbed work until failure. Therefore, the proposed processing route based on freeze gelation presents an easy and unique tool to tune the mechanical and gas adsorptive properties of hierarchically structured zeolite monoliths, according to the application requirements.

Gradient-Hierarchic-Aligned Porosity SiOC Ceramics

This work describes a simple technique to produce porous ceramics with aligned porosity having very high permeability and specific surface area. SiOC-based compositions were processed from blends of three types of preceramic polymer and a catalyst, followed by curing and pyrolysis. The heating applied from the bottom of molds promoted the nucleation, expansion and rising of gas bubbles, and the creation of a ceramic matrix with axially oriented channels interconnected by small round pores. The samples were analyzed by SEM, tomography, BET, water immersion porosimetry and permeation to gas flow. The resulting bodies presented levels of open porosity (69.9-83.4%), average channel diameter (0.59-1.25 mm) and permeability (0.56-3.83 × 10-9 m2) comparable to those of ceramic foams and honeycomb monoliths, but with specific surface area (4.8-121.9 m2/g) typical adsorbents, enabling these lotus-type ceramics to be advantageously used as catalytic supports and adsorption components in several environmental control applications.

Gas permeability of ice-templated, unidirectional porous ceramics

We investigate the gas flow behavior of unidirectional porous ceramics processed by ice-templating. The pore volume ranged between 54% and 72% and pore size between 2.9 [Formula: see text]m and 19.1 [Formula: see text]m. The maximum permeability ([Formula: see text] [Formula: see text] m[Formula: see text]) was measured in samples with the highest total pore volume (72%) and pore size (19.1 [Formula: see text]m). However, we demonstrate that it is possible to achieve a similar permeability ([Formula: see text] [Formula: see text] m[Formula: see text]) at 54% pore volume by modification of the pore shape. These results were compared with those reported and measured for isotropic porous materials processed by conventional techniques. In unidirectional porous materials tortuosity ([Formula: see text]) is mainly controlled by pore size, unlike in isotropic porous structures where [Formula: see text] is linked to pore volume. Furthermore, we assessed the applicability of Ergun and capillary model in the prediction of permeability and we found that the capillary model accurately describes the gas flow behavior of unidirectional porous materials. Finally, we combined the permeability data obtained here with strength data for these materials to establish links between strength and permeability of ice-templated materials.