Improving the fracture toughness and the strength of epoxy using nanomaterials--a review of the current status

Fracture Toughness, Radiation Hardness, and Processibility of Polymers for Superconducting Magnets

High fracture toughness at cryogenic temperature and radiation hardness can be conflicting requirements for the resins for the impregnation of superconducting magnet coils. The fracture toughness of different epoxy-resin systems at room temperature (RT) and at 77 K was measured, and their toughness was compared with that determined for a polyurethane, polycarbonate (PC) and poly(methyl methacrylate) (PMMA). Among the epoxy resins tested in this study, the MY750 system has the highest 77 K fracture toughness of KIC = 4.6 MPa√m, which is comparable to the KIC of PMMA, which also exhibits linear elastic behaviour and unstable crack propagation. The polyurethane system tested has a much higher 77 K toughness than the epoxy resins, approaching the toughness of PC, which is known as one of the toughest polymer materials. CTD101K is the least performing in terms of fracture toughness. Despite this, it is used for the impregnation of large Nb3Sn coils for its good processing capabilities and relatively high radiation resistance. In this study, the fracture toughness of CTD101K was improved by adding the polyglycol flexibiliser Araldite DY040 as a fourth component. The different epoxy-resin systems were exposed to proton and gamma doses up to 38 MGy, and it was found that adding the DY040 flexibiliser to the CTD101K system did not significantly change the irradiation-induced ageing behaviour. The viscosity evolution of the uncured resin mix is not significantly changed when adding the DY040 flexibiliser, and at the processing temperature of 60 °C, the viscosity remains below 200 cP for more than 24 h. Therefore, the new resin referred to as POLAB Mix is now used for the impregnation of superconducting magnet coils.

Nanocellulose Grades with Different Morphologies and Surface Modification as Additives for Waterborne Epoxy Coatings

While adding different micro- and nanocellulose types into epoxy coating formulations with waterborne phenalkamine crosslinker, effects on processing conditions and coating performance were systematically investigated. The variations in viscosity, thermal and thermomechanical properties, mechanical behavior, abrasive wear, water contact angles, and coating morphologies were evaluated. The selected additives include microcrystalline cellulose (MCC) at 1 to 10 wt.% and cellulose nanocrystals (CNC), cellulose nanofibers (CNF), cellulose microfibers (CMF), and hydrophobically modified cellulose microfibers (mCMF) at 0.1 to 1.5 wt.%. The viscosity profiles are determined by the inherent additive characteristics with strong shear thinning effects for epoxy/CNF, while the epoxy/mCMF provides lower viscosity and better matrix compatibility owing to the lubrication of encapsulated wax. The crosslinking of epoxy/CNF is favored and postponed for epoxy/(CNC, CMF, mCMF), as the stronger interactions between epoxy and CNF are confirmed by an increase in the glass transition temperature and reduction in the dampening factor. The mechanical properties indicate the highest hardness and impact strength for epoxy/CNF resulting in the lowest abrasion wear rates, but ductility enhances and wear rates mostly reduce for epoxy/mCMF together with hydrophobic protection. In addition, the mechanical reinforcement owing to the specific organization of a nanocellulose network at percolation threshold concentrations of 0.75 wt.% is confirmed by microscopic analysis: the latter results in a 2.6 °C (CNF) or 1.6 °C (CNC) increase in the glass transition temperature, 50% (CNF) or 20% (CNC) increase in the E modulus, 37% (CNF) or 32% (CNC) increase in hardness, and 58% (CNF) or 33% (CNC) lower abrasive wear compared to neat epoxy, while higher concentrations up to 1.5 wt.% mCMF can be added. This research significantly demonstrates that nanocellulose is directly compatible with a waterborne phenalkamine crosslinker and actively contributes to the crosslinking of waterborne epoxy coatings, changing the intrinsic glass transition temperatures and hardness properties, to which mechanical coating performance directly relates.

Mechanical Properties of a Honeycomb Structure Dispersed with 3D-Printed Fe3O4 Nanomaterials

The honeycomb structure demonstrates exceptional stability, efficient mechanical performance, outstanding load-bearing capacity, and energy-saving and lightweight properties, rendering it extensively employed in various fields such as industrial manufacturing, radiation protection building, aerospace engineering, and wave-absorbing stealth materials. Bionic design can enhance the performance of structures, making bionic honeycomb design valuable in engineering. This study employs a bionic optimization design based on the original honeycomb size to investigate the impact of a new composite honeycomb core structure on mechanical properties. Orthogonal experiments are conducted to explore the effect of honeycomb size on mechanical properties and determine the optimal size. Combining numerical simulation and 3D printing experiments, we examine the mechanical properties of both nano-Fe3O4 particle-distributed honeycomb structure and common structures, analyzing mechanisms behind their tensile and compressive properties.

Amino-Modified Graphene Oxide from Kish Graphite for Enhancing Corrosion Resistance of Waterborne Epoxy Coatings

Waterborne epoxy (WEP) coatings with enhanced corrosion resistance were prepared using graphene oxide (GO) that was obtained from kish graphite, and amino-functionalized graphene oxide (AGO) was modified by 2-aminomalonamide. The structural characteristics of the GO and AGO were analyzed using X-ray diffraction (XRD), Raman spectroscopy, Fourier transform infrared spectroscopy (FT-IR), scanning electron microscopy (SEM), and transmission electron microscopy (TEM). And the anti-corrosive performance of waterborne epoxy-cased composite coatings with different addition amounts of AGO was investigated using electrochemical measurements, pull-off adhesion tests, and salt spray tests. The results indicate that AGO15/WEP with 0.15 wt.% of AGO has the best anti-corrosive performance, and the lowest frequency impedance modulus increased from 1.03 × 108 to 1.63 × 1010 ohm·cm-2 compared to that of WEP. Furthermore, AGO15/WEP also demonstrates the minimal corrosion products or bubbles in the salt spray test for 200 h, affirming its exceptional long-term corrosion protection capability.

Ultrastrong and High-Tough Thermoset Epoxy Resins from Hyperbranched Topological Structure and Subnanoscaled Free Volume

The strength and toughness of thermoset epoxy resins are generally mutually exclusive, as are the high performance and rapid recyclability. Experimentally determined mechanical strength values are usually much lower than their theoretical values. The preparation of thermoset epoxy resins with high modulus, high toughness, ultrastrong strength, and highly efficient recyclability is still a challenge. Here, novel hyperbranched epoxy resins (Bn, n = 6, 12, 24) with imide structures by a thiol-ene click reaction. Bn shows an excellent comprehensive function in simultaneously improving the strength, modulus, toughness, low-temperature resistance, and degradability of diglycidyl ether of bisphenol-A (DGEBA). All the mechanical properties first increase and then decrease with minimization of the free volume properties. The improvement is attributable to uniform molecular holes or free volume by a molecular mixture of linear and hyperbranched topological structures. The precise measurement and controllability of the molecular free volume properties of epoxy resins is first discovered, as well as the imide structure degradation of crosslinked epoxy resins. The two conflicts are successfully resolved between strength and toughness and between high performance during service and high efficiency during degradation. These findings provide a route for designing ultrastrong, tough, and recyclable thermoset epoxy resins.

Cavitation pit evolution process of epoxy and polyurea coatings on mortar substrates

This study focuses on unraveling the failure mechanisms of three distinct polymer-coating structures applied to mortar substrates: an epoxy coating (MEP1), an epoxy coating with an intermediate epoxy mortar layer (MEP2), and a polyurea coating with an intermediate epoxy mortar layer (MPU). Ultrasonic cavitation experiments are conducted to investigate the initial stages of cavitation erosion. The damaged surfaces of these three coating structures are meticulously investigated and characterized. An in-depth analysis is performed on the distribution characteristics of cavitation pits and the evolutionary patterns of these pits. The results indicate that the introduction of epoxy mortar as an intermediate layer significantly enhances the material's cavitation resistance by improving its energy absorption capacity. This enhancement delays the formation of cavitation pits on the coating surface. Additionally, the superior adhesive properties of the intermediate epoxy mortar with the mortar substrate prevent direct cavitation erosion from forming on the substrate, even when brittleness failure occurs and coating erosion is observed on the surface epoxy polymer. The polyurea coatings demonstrate exceptional elastic-plastic deformation capabilities. When combined with the intermediate epoxy mortar layer, MPU can withstand prolonged and repetitive cavitation impacts, resulting in minimal coating erosion.

Interpenetrated and Bridged Nanocylinders from Self-Assembled Star Block Copolymers

The design of functional polymeric materials with tunable response requires a synergetic use of macromolecular architecture and interactions. Here, we combine experiments with computer simulations to demonstrate how physical properties of gels can be tailored at the molecular level, using star block copolymers with alternating block sequences as a paradigm. Telechelic star polymers containing attractive outer blocks self-assemble into soft patchy nanoparticles, whereas their mirror-image inverted architecture with inner attractive blocks yields micelles. In concentrated solutions, bridged and interpenetrated hexagonally packed nanocylinders are formed, respectively, with distinct structural and rheological properties. The phase diagrams exhibit a peculiar re-entrance where the hexagonal phase melts upon both heating and cooling because of solvent-block and block-block interactions. The bridged nanostructure is characterized by similar deformability, extended structural coherence, enhanced elasticity, and yield stress compared to micelles or typical colloidal gels, which make them promising and versatile materials for diverse applications.

Damage-Tolerant Wood Layers for Corrosion Protection of Metal Structures

Mechanically strong and damage-tolerant corrosion protection layers are of great technological importance. However, corrosion protection layers with high modulus (>1.5 GPa) and tensile strength (>100 MPa) are rare. Here, we report that a 130 μm thick densified wood veneer with a Young's modulus of 34.49 GPa and tensile strength of 693 MPa exhibits both low diffusivity for metal ions and the ability of self-recovery from mechanical damage. Densified wood veneer is employed as an intermediate layer to render a mechanically strong corrosion protection structure, referred to as "wood corrosion protection structure", or WCPS. The corrosion rate of low-carbon steel protected by WCPS is reduced by 2 orders of magnitude than state-of-the-art corrosion protection layers during a salt spray test. The introduction of engineered wood veneer as a thin and mechanically strong material points to new directions of sustainable corrosion protection design.

An elastomer with ultrahigh strain-induced crystallization

Strain-induced crystallization (SIC) prevalently strengthens, toughens, and enables an elastocaloric effect in elastomers. However, the crystallinity induced by mechanical stretching in common elastomers (e.g., natural rubber) is typically below 20%, and the stretchability plateaus due to trapped entanglements. We report a class of elastomers formed by end-linking and then deswelling star polymers with low defects and no trapped entanglements, which achieve strain-induced crystallinity of up to 50%. The deswollen end-linked star elastomer (DELSE) reaches an ultrahigh stretchability of 12.4 to 33.3, scaling beyond the saturated limit of common elastomers. The DELSE also exhibits a high fracture energy of 4.2 to 4.5 kJ m-2 while maintaining low hysteresis. The heightened SIC and stretchability synergistically promote a high elastocaloric effect with an adiabatic temperature change of 9.3°C.

A Comparison Study on Toughening Vinyl Ester Resins Using Different Nanocarbon Materials

This study aims to comprehensively compare and evaluate the toughening effects of different nanocarbon materials on vinyl ester resins. Four typical nanocarbon materials, including graphene, graphene oxide (GO), single-walled carbon nanotubes (SWCNTs), and multi-walled carbon nanotubes (MWCNTs), were used as reinforcing fillers for vinyl ester resins. These four nanocarbon materials were dispersed in the vinyl ester resin matrix by the combination of high-speed stirring and probe sonication, and their dispersion states were observed with optical microscopy. The effects of incorporating different nanocarbon materials on the viscosities, thermal properties, tensile properties, and fracture toughness of the resulting modified vinyl ester resins were systematically investigated. The results indicate that the four nanocarbon materials show enhanced toughening effects on the vinyl ester resin in the sequence of SWCNTs, GO, MWCNTs, and graphene. Compared with the control resin, the modified vinyl ester resin containing 0.2 wt% graphene shows 45% and 54% enhancements in the critical stress intensity factor (KIC) and critical strain energy release rate (GIC), respectively. The incorporation of the four nanocarbon materials has almost no effect on the glass transition temperatures of the resulting modified vinyl ester resins. This study provides valuable insights into the selection of nanocarbon additives for enhancing the toughness of vinyl ester resins.

Fabrication of a Co-Mo-Based Metal-Organic Framework for Growth of Double-Walled Carbon Nanotubes

Double-walled carbon nanotubes (DWCNTs) make up a unique class of carbon nanotubes (CNTs) that are particularly intriguing for scientific research and are promising candidates for technological applications. A more precise level of control and greater yields can be achieved via catalytic chemical vapor deposition (CCVD), which involves the breakdown of a carbonaceous gas over nanoparticles. The addition of molybdenum to the system can increase the selectivity with regard to the number of walls that exist in the obtained CNTs. As reported herein, we have designed and synthesized a novel Co-Mo-MOF, [Co(3-bpta)1.5(MoO4)]·H2O (where 3-bpta = N,N'-bis(3-pyridyl)terephthalamide), and employed the Co-Mo-MOF as a bimetallic catalyst precursor for the CCVD approach to prepare high-quality DWCNTs. The Co-Mo-MOF was employed after being calcined in N2 and H2 at 1100 °C and decomposing into CoO, CoMoO4, and MoO3. Existing CoMoO4 is unaltered after reduction in H2 at 1100 °C, while CoO and MoO3 are converted into Co0 and MoO2, and more CoMoO4 is created at the expense of Co0 and MoO2 without clearly defining agglomeration. Finally, the interaction between metallic Co particles and C2H4 is what initiates the formation of DWCNTs. In-depth discussion is provided in this paper regarding the mechanism underlying the high selectivity and activity of Co-Mo catalysts in regulating the development and structure of DWCNTs. The DWCNTs also offer excellence performance when they are used as water purification agents and as selective sorbents. This work opens a feasible way to use MOFs as a way to produce MWCNTs, thus blazing a new trail in the field of MOF-derived carbon-based materials.

Surface-Modified Electrospun Glass Nanofibers from Silane Treatment and Their Use for High-Performance Epoxy-Based Nanocomposite Materials

As a new and promising reinforcing filler, electrospun glass nanofibers (EGNFs) have attracted attention in the field of polymer composite materials. However, the reinforcing effectiveness of surface-modified EGNFs using different silane coupling agents in epoxy resin is still not quite clear. In this research, a series of silane coupling agents with increasing chain lengths in the order of methyl trimethoxysilane (MTMS), (3-aminopropyl) triethoxysilane (APTES), (3-glycidyloxypropyl) trimethoxysilane (GPTMS), and dual silane coupling agent APTES-GPTMS were employed to carry out surface treatment on the EGNFs. The pristine and silane functionalized EGNFs were then incorporated into epoxy resin as reinforcing fillers at low loading levels, i.e., 0.25 wt.%, 0.5 wt.%, and 1 wt.%, and the mechanical properties of the resultant epoxy nanocomposites, including strength, stiffness, ductility, and toughness, were evaluated. A commercial product of glass nanoparticles (GNPs) was used as a control to compare the reinforcing effectiveness of the EGNFs and the GNPs. This study revealed that the EGNFs could provide significant reinforcing and toughening effects at ultra-low loading (0.25 wt.%) in epoxy nanocomposite materials. Furthermore, surface modification of the EGNFs with silane coupling agents with long chain lengths, e.g., by using dual silane coupling agents, APTES-GPTMS, could enhance the interfacial bonding between the EGNFs and the epoxy matrix and further increase the mechanical performance of the EGNF-reinforced epoxy nanocomposite materials. Through this research, we realized epoxy nanocomposite materials with much-improved mechanical properties, i.e., 37%, 24%, 18%, 57% improvement in strength, stiffness, ductility, and toughness, respectively, with respect to those of the cured neat epoxy material with an ultra-low loading (0.25 wt.%) of APTES-GPTMS-EGNFs. Our research paves the road for developing lighter and stronger epoxy nanocomposite materials with EGNFs.

Bioinspired Design Rules from Highly Mineralized Natural Composites for Two-Dimensional Composite Design

Discoveries of two-dimensional (2D) materials, exemplified by the recent entry of MXene, have ushered in a new era of multifunctional materials for applications from electronics to biomedical sensors due to their superior combination of mechanical, chemical, and electrical properties. MXene, for example, can be designed for specialized applications using a plethora of element combinations and surface termination layers, making them attractive for highly optimized multifunctional composites. Although multiple critical engineering applications demand that such composites balance specialized functions with mechanical demands, the current knowledge of the mechanical performance and optimized traits necessary for such composite design is severely limited. In response to this pressing need, this paper critically reviews structure-function connections for highly mineralized 2D natural composites, such as nacre and exoskeletal of windowpane oysters, to extract fundamental bioinspired design principles that provide pathways for multifunctional 2D-based engineered systems. This paper highlights key bioinspired design features, including controlling flake geometry, enhancing interface interlocks, and utilizing polymer interphases, to address the limitations of the current design. Challenges in processing, such as flake size control and incorporating interlocking mechanisms of tablet stitching and nanotube forest, are discussed along with alternative potential solutions, such as roughened interfaces and surface waviness. Finally, this paper discusses future perspectives and opportunities, including bridging the gap between theory and practice with multiscale modeling and machine learning design approaches. Overall, this review underscores the potential of bioinspired design for engineered 2D composites while acknowledging the complexities involved and providing valuable insights for researchers and engineers in this rapidly evolving field.

Improved Interlaminar Properties of Glass Fiber/Epoxy Laminates by the Synergic Modification of Soft and Rigid Particles

Poor interlaminar fracture toughness has been a major issue in glass fiber-reinforced epoxy resin (GF/EP) laminate composites. In this paper, soft carboxy-terminated nitrile (CTBN) rubber particles and rigid nano-SiO2 are used to toughen the epoxy resin (EP) matrix to improve the interlayer properties of GF/EP laminate composites. The effects of adding two toughening agents on the mechanical and interlayer properties of GF/EP laminates were studied. The results showed that adding the two kinds of particles improved the mechanical properties of the epoxy matrix. When the additional amount of flexible CTBN rubber particles was 8 wt%, and the rigid nano-SiO2 was 0.5 wt%, the fracture toughness of the matrix resin was increased by 215.8%, and the tensile strength was only decreased by 2.3% compared with the pure epoxy resin. On this basis, the effects of two kinds of particles on the interlayer properties of GF/EP composites were studied. Compared with the unmodified GF/EP laminates, the interlayer shear strength and mode I interlayer fracture toughness is significantly improved by a toughening agent, and the energy release rate GIC of interlayer shear strength and interlayer fracture toughness is increased by 109.2%, and 86.8%, respectively. The flexible CTBN rubber particles and rigid nano-SiO2 improve the interfacial adhesion between GF and EP. The cavitation of the two particles and the plastic deformation of the matrix is the toughening mechanism of the interlayer properties of the composite. Such excellent interlaminar mechanical properties make it possible for GF/EP laminates to be widely used as engineering materials in various industries (e.g., aerospace, hydrogen energy, marine).

Examining the Quasi-Static Uniaxial Compressive Behaviour of Commercial High-Performance Epoxy Matrices

Four commercial high-performance aerospace aromatic epoxy matrices, CYCOM®890, CYCOM®977-2, PR520, and PRISM EP2400, were cured to a standardised 2 h, 180 °C cure cycle and evaluated in quasi-static uniaxial compression, as well as by dynamic scanning calorimetry (DSC) and thermogravimetric analysis (TGA). The thermoplastic toughened CYCOM®977-2 formulation displayed an overall increase in true axial stress values across the entire stress-strain curve relative to the baseline CYCOM®890 sample. The particle-toughened PR520 sample exhibited an overall decrease in true axial stress values past the yield point of the material. The PRISM EP2400 resin, with combined toughening agents, led to true axial stress values across the entire plastic region of the stress-strain curve, which were in line with the stress values observed with the CYCOM®890 material. Interestingly, for all formulations, the dilation angles (associated with the volume change during plastic deformation), recorded at 0.3 plastic strain, were close to 0°, with the variations reflecting the polymer structure. Compression data collected for this series of commercial epoxy resins are in broad agreement with a selection of model epoxy resins based on di- and tetra-functional monomers, cured with polyamines or dicarboxylic anhydrides. However, the fully formulated resins demonstrate a significantly higher compressive modulus than the model resins, albeit at the expense of yield stress.

Insights into Mechanical Dynamics of Nanoscale Interfaces in Epoxy Composites Using Nanorheology Atomic Force Microscopy

Interfacial polymer layers with nanoscale size play critical roles in dissipating the strain energy around cracks and defects in structural nanocomposites, thereby enhancing the material's fracture toughness. However, understanding how the intrinsic mechanical dynamics of the interfacial layer determine the toughening and reinforcement mechanisms in various polymer nanocomposites remains a major challenge. Here, by means of a recently developed nanorheology atomic force microscopy method, also known as nanoscale dynamic mechanical analysis (nDMA), we report direct mapping of dynamic mechanical responses at the interface of a model epoxy nanocomposite under the transition from a glassy to a rubbery state. We demonstrate a significant deviation in the dynamic moduli of the interface from matrix behavior. Interestingly, the sign of the deviation is observed to be reversed when the polymer changes from a glassy to a rubbery state, which provides an excellent explanation for the difference in the modulus reinforcement between glassy and rubbery epoxy nanocomposites. More importantly, nDMA loss tangent images unambiguously show an enhanced viscoelastic response at the interface compared to the bulk matrix in the glassy state. This observation can therefore provide important insights into the nanoscale toughening mechanism that occurs in epoxy nanocomposites due to viscoelastic energy dissipation at the interface.

Understanding the Effect of Grain Boundaries on the Mechanical Properties of Epoxy/Graphene Composites

This work presents a molecular dynamics (MD) simulation study on the effect of grain boundaries (GBs) on the mechanical properties of epoxy/graphene composites. Ten types of GB models were constructed and comparisons were made for epoxy/graphene composites containing graphene with GBs. The results showed that the tensile and compressive behaviors, the glass transition temperature (Tg), and the configurations of epoxy/graphene composites were significantly affected by GBs. The tensile yield strength of epoxy/graphene composites could be either enhanced or weakened by GBs under a tensile load parallel to the graphene sheet. The underlying mechanisms may be attributed to multi-factor coupling, including the tensile strength of the reinforcements, the interfacial interaction energy, and the inflection degree of reinforcements. A balance exists among these effect factors, resulting in the diversity in the tensile yield strength of epoxy/graphene composites. The compressive yield strength for epoxy/graphene composites is higher than their counterpart in tension. The tensile/compressive yield strength for the same configuration presents diversity in different directions. Both an excellent interfacial interaction and the appropriate inflection degree of wrinkles for GB configurations restrict the translational and rotational movements of epoxy chains during volume expansion, which eventually improves the overall Tg. Understanding the reinforcing mechanism for graphene with GBs from the atomistic level provides new physical insights to material design for epoxy-based composites containing defective reinforcements.

Highly Toughened Nanostructured Self-Assembled Epoxy-Based Material—Correlation Study between Nanostructured Morphology and Fracture Toughness—Impact Characteristics

We present an efficient and effective method for preparing a novel self-assembled nanostructured material with high toughness and impact strength from a blend of di-glycidyl ether of bisphenol-A (DGEBA) and epoxidized poly(styrene-block-butadiene-block-styrene) (eSBS55) tri-block copolymer. The field emission scanning electron microscopy and transmission electron microscope results show the nanostructured morphological characteristics of the blends. This study achieved the highest fracture toughness, with a fracture toughness in the form of critical stress intensity factors (KIC) value of 2.54 MPa m1/2, in epoxy/block copolymer blends compared to previous works in the field. The impact strength also increased by 116% compared to neat epoxy. This is a major advancement in epoxy toughening due to the use of a single secondary phase. The resulting highly tough and impact-resistant material is a promising candidate for coating applications in industries such as flooring, building, aerospace, and automobiles.

Mechanism of Morphology Development in HDGEBA/PAMS Hybrid Thermosets: Monte Carlo Simulation and LSCM Study

Reactive combinations of aliphatic epoxy resins and functional polysiloxanes form a class of hybrid thermosetting materials with properties that may come from both the organic and the inorganic phases. The two typically immiscible phases form a suspension whose morphology, composition, and thermal properties vary with curing time. The aim of this research was to elucidate the mechanism by which morphology changed with time and to simulate it through Metropolis-Monte Carlo. The selected system was hydrogenated epoxy (HDGEBA) and a synthetic polyaminosiloxane (PAMS). It was studied by DSC, FTnIR, gel point, viscometry, and in-situ laser scanning confocal microscopy. A mechanism for morphology generation was proposed and simulated, exploring a wide range of values of the "a priori" relevant variables. The essential features were captured by simulations with a reasonable agreement with experimental data. However, the complete process was more complex than the geometrical approach of the simulation. The main deviations that were found and qualitatively explained are: (i) the induction period on the rate of coalescence, and (ii) PAMS-rich domain average size increases faster than predictions.

Structure and Properties of Epoxy Polysulfone Systems Modified with an Active Diluent

An epoxy resin modified with polysulfone (PSU) and active diluent furfuryl glycidyl ether (FGE) was studied. Triethanolaminotitanate (TEAT) and iso-methyltetrahydrophthalic anhydride (iso-MTHPA) were used as curing agents. It is shown that during the curing of initially homogeneous mixtures, heterogeneous structures are formed. The type of these structures depends on the concentration of active diluent and the type of hardener. The physico-mechanical properties of the hybrid matrices are determined by the structure formed. The maximum resistance to a growing crack is provided by structures with a thermoplastic-enriched matrix-interpenetrating structures. The main mechanism for increasing the energy of crack propagation is associated with the implementation of microplasticity of extended phases enriched in polysulfone and their involvement in the fracture process.

Effect of the Mixing Technique of Graphene Nanoplatelets and Graphene Nanofibers on Fracture Toughness of Epoxy Based Nanocomposites and Composites

In this work, the effect of different mixing techniques on thermal and mechanical properties of graphene nanoplatelets (GNPs) and graphene nanofibers (GANFs) loaded epoxy nanocomposites was investigated. Three dispersion methods were employed: a high shear rate (HSR), ultrasonication (US) and the fluidized bed method (FBM). The optical microscopy has revealed that the most suitable dispersion, in terms of homogeneity and cluster size, is achieved by implementing the US and FBM techniques, leading to nanocomposites with the largest increase of glass transition temperature, as supported by the DMA analysis data. The fracture toughness results show a general increase of both the critical stress intensity factor (K_IC) and the critical strain energy release rate (G_IC), likely due to the homogeneity and the low scale dispersion of the carbonaceous nanostructures. Based on the nanocomposite fracture toughness improvements and also assuming a potential large scale up production of the nanocomposite matrix, a single mixing technique, namely the FBM, was employed to manufacture the carbon fiber reinforced composite (CFRC). This method has resulted in being less time-consuming and is potentially most suitable for the high volume industrial production. The CFRCs were characterized in terms of tensile, flexural and interlaminar fracture toughness properties and the results were analyzed and discussed.

Construction of Photoinitiator Functionalized Spherical Nanoparticles Enabling Favorable Photoinitiating Activity and Migration Resistance for 3D Printing

A straight-forward method was exploited to construct a multifunctional hybrid photoinitiator by supporting 2-hydroxy-2-methylpropiophenone (HMPP) onto a nano-silica surface through a chemical reaction between silica and HMPP by using (3-isocyanatopropyl)-triethoxysilane (IPTS) as a bridge, and this was noted as silica-s-HMPP. The novel hybrid-photoinitiator can not only initiate the photopolymerization but also prominently improve the dispersion of nanoparticles in the polyurethane acrylate matrix and enhance the filler-elastomer interfacial interaction, which results in excellent mechanical properties of UV-cured nanocomposites. Furthermore, the amount of extractable residual photoinitiators in the UV-cured system of silica-s-HPMM shows a significant decrease compared with the original HPMM system. Since endowing the silica nanoparticle with photo-initiated performance and fairly lower mobility, it may lead to a reduction in environmental contamination compared to traditional photoinitators. In addition, the hybrid-photoinitiator gives rise to an accurate resolution object with a complex construction and favorable surface morphology, indicating that multifunctional nanosilica particles can be applied in stereolithographic 3D printing.

Evaluation of augmented thermal, thermo-mechanical, mechanical properties of nano alumina reinforced TGDDM epoxy nanocomposites

N,N′-Tetraglycidyldiaminodiphenyl methane (TGDDM) was reinforced with various weight fractions (0.5, 1, and 1.5 wt%) of amine functionalized nano alumina (F-Al) were cured with diaminodiphenyl-methane (DDM). FT-IR analysis revealed that formation of functionalized nano alumina (F-Al) structure, was brought about via coupling agent APTES. Furthermore, the morphology of TGDDM epoxy nanocomposites was studied using X-ray Diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM), microscopic analysis and an atomic force microscope (AFM). We found a bonding relationship between TGDDM epoxy and F-Al in TGDDM/F-Al nanocomposites It was interesting to note that the values of tensile, flexural and impact strength of 1 wt% F-Al reinforced TGDDM epoxy nanocomposites were found to be 141.5, 192.5 MPa, and 92.4 J/m2, respectively., which resulted in a substantial improvement in the dynamic mechanical analysis (DMA) to 4.3 and 5.5 for 0.5 and 1 wt% F-Al reinforced TGDDM epoxy nanocomposites and the glass transition temperature (Tg) increased from 210°C to 225°C as the F-Al content increased. The initial degradation temperature (IDT) of 0.5, 1, and 1.5 wt% F-Al reinforced TGDDM epoxy nanocomposites were significantly enriched to 328°C, 345°C, and 335°C respectively from 290°C of neat (TGDDM) epoxy matrix. Likewise, the char yield for the neat (TGDDM) epoxy matrix was 13% and that for 0.5, 1, and 1.5 wt% F-Al reinforced TGDDM epoxy nanocomposites were 17%, 25%, and 20% respectively. It is feasible to state unequivocally that considerable F-Al diffusion within the TGDDM epoxy can only occur at low weight percentages. The results clearly showed that F-Al reinforced TGDDM epoxy nanocomposites may be investigated for advanced high performance industrial engineering applications.

Polymer-mediated self-assembly, dispersion, and phase separation of Janus nanorods

The challenge of stabilizing polymer nanocomposites lies in the fact that nanoparticles tend to phase separate from the polymer melt due to an entropic 'depletion attraction' between nanoparticles. Additionally, composites of polymer and nanorods show a decrease in miscibility with increasing nanorod aspect ratio [U. K. Sankar and M. Tripathy, Macromolecules, 2015, 48, 432-442; U. Erigi, U. Dhumal and M. Tripathy, J. Chem. Phys., 2021, 154, 124903]. In this work, we have studied the structure and phase behaviour of polymer-Janus nanorod mixtures using Polymer Reference Interaction Site Model (PRISM) theory and molecular dynamics simulations. The composite system of polymer and Janus nanorods of two different thicknesses, at various Janus nanorod densities, and for different interaction strengths between polymer and attractive sites of Janus nanorods (ε_pa), is investigated for their miscibility and self-assembly. At low Janus nanorod density, PRISM theory predicts transitions from the entropic depletion-driven contact aggregation of Janus nanorods to a well-dispersed phase to the bridging-driven phase separation of Janus nanorods, with increasing ε_pa. This behaviour is similar to earlier predictions for homogeneous nanorods. However, molecular dynamics simulations do not confirm the bridging-driven phase separation at high ε_pa predicted by PRISM theory. We find that both PRISM theory and molecular dynamics simulations are in agreement in the intermediate and high Janus nanorod density regimes. PRISM theory predicts, and simulations confirm, that at high Janus nanorod densities, the system undergoes a transition from depletion-driven macrophase separation to dispersion to chemical anisotropy-driven self-assembly with increasing ε_pa. The self-assembly at high ε_pa is mediated by the polymer. At intermediate Janus nanorod densities, the usual transition from an entropic depletion-driven macrophase separation to dispersion is predicted at low ε_pa. At high ε_pa, both PRISM theory and molecular dynamics simulations show transition to a state that is simultaneously macrophase separated and microphase separated (self-assembled).

Unraveling Nanoscale Elastic and Adhesive Properties at the Nanoparticle/Epoxy Interface Using Bimodal Atomic Force Microscopy

The addition of a small fraction of solid nanoparticles to thermosetting polymers can substantially improve their fracture toughness, while maintaining various intrinsic thermomechanical properties. The underlying mechanism is largely related to the debonding process and subsequent formation of nanovoids at a nanoscale nanoparticle/epoxy interface, which is thought to be associated with a change in the structural and mechanical properties of the formed epoxy network at the interface compared with the matrix region. However, a direct characterization of the local physical properties at this nanoscale interface remains significantly challenging. Here, we employ a recently developed bimodal atomic force microscopy technique for the direct mapping of nanoscale elastic and adhesive responses of an amine-cured epoxy resin filled with ∼50 nm diameter silica nanoparticles. The obtained elastic modulus and dissipated energy maps with high spatial resolution evidence the existence of a ∼20-nm-thick interfacial epoxy layer surrounding the nanoparticles, which exhibits a reduced modulus and weaker adhesive response in comparison with the matrix properties. While the presence of such a soft and weak-adhesive interfacial layer is found not to affect the architecture of structural heterogeneities in the epoxy matrix, it conceivably supports the toughening mechanism related to the debonding and plastic nanovoid growth at the silica/epoxy interface. The incorporation of this soft interfacial layer into the Halpin-Tsai model also provides a good explanation for the effect of the silica fraction on the tensile modulus of cured epoxy nanocomposites.

Kinetics of the interfacial curing reaction for an epoxy-amine mixture

A better understanding of the chemical reaction between epoxy and amine compounds at a solid interface is crucial for the design and fabrication of materials with appropriate adhesive strength. Here, we examined the curing reaction kinetics of epoxy phenol novolac and 4,4'-diaminodiphenyl sulfone at the outermost interface using sum-frequency generation spectroscopy, and X-ray and neutron reflectivity in conjunction with a full atomistic molecular dynamics simulation. The reaction rate constant was much larger at the quartz interface than in the bulk. While the apparent activation energy at the quartz interface obtained from an Arrhenius plot was almost identical to the bulk value, the frequency factor at the quartz interface was greater than that in the bulk. These results could be explained in terms of the densification and orientation of reactants at the interface, facilitating the encounter of the reactants present.

A nanoconcrete welding strategy for constructing high-performance wound dressing

Engineering biomaterials to meet specific biomedical applications raises high requirements of mechanical performances, and simultaneous strengthening and toughening of polymer are frequently necessary but very challenging in many cases. In this work, we propose a new concept of nanoconcrete welding polymer chains, where mesoporous CaCO₃ (mCaCO₃) nanoconcretes which are composed of amorphous and nanocrystalline phases are developed to powerfully weld polymer chains through siphoning-induced occlusion, hydration-driven crystallization and dehydration-driven compression of nanoconcretes. The mCaCO₃ nanoconcrete welding technology is verified to be able to remarkably augment strength, toughness and anti-fatigue performances of a model polymer poly(3-hydroxybutyrate-co-3-hydroxyvalerate)-based porous membrane. Mechanistically, we have revealed polymer-occluded nanocrystal structure and welding-derived microstress which is much stronger than interfacial Van der Waals force, thus efficiently preventing the generation of microcracks and repairing initial microcracks by microcracks-induced hydration, crystallization and polymer welding of mCaCO₃ nanoconcretes. Constructed porous membrane is used as wound dressing, exhibiting a special nanoplates-constructed surface topography as well as a porous structure with plentiful oriented, aligned and opened pore channels, improved hydrophilicity, water vapor permeability, anti-bacterial and cell adherence, in support of wound healing and skin structural/functional repairing. The proposed nanoconcrete-welding-polymer strategy breaks a new pathway for improving the mechanical performances of polymers.

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An innovative nanoconcrete welding technology is developed for improving the mechanical performances of composite.

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A new kind of mesoporous CaCO₃ nanoconcretes is synthesized by an ion etching method.

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High-performance artificial skin is constructed based on a porous CaCO₃-PHBV membrane.

Effect of MWNT Functionalization with Tunable-Length Block Copolymers on Dispersity of MWNTs and Mechanical Properties of Epoxy/MWNT Composites

The dispersion level of carbon nanotubes (CNTs) and interface design are two of the most crucial roles in developing the superior mechanical performance of polymer/CNT nanocomposites. In this work, a series of azide-terminated poly(glycidyl methacrylate)-block-poly(hexyl methacrylate) (PGMA-b-PHMA) copolymers with different PHMA chain lengths and similar PGMA chain lengths were grafted on the surface of multiwall carbon nanotubes (MWNTs). PHMA length changes significantly impact the grafting density and solubility in organic solvents of as-prepared block copolymer functionalized MWNTs(bc@fMWNTs). Then, the bc@fMWNTs were introduced to epoxy, and the resulted epoxy/bc@fMWNT composites show better mechanical properties than neat epoxy and epoxy/p-MWNT composites. The results suggest that longer PHMA chains cause the two competitive and opposing effects on the dispersion state and soft interface. On the one hand, the longer PHMA chains on the surface of MWNTs would afford higher deformation for the matrix and enhanced mobility for MWNTs because of the soft and flexible nature of PHMA, enhancing the energy dissipation during strain. On the other hand, as the length of PHMA extends, the dispersion level of bc@fMWNTs in epoxy declines, which is harmful to the composite’s mechanical properties. Hence, epoxy/bc@fMWNTs composites with relatively short PHMA chains show the best tensile and fracture properties.

Effect of reduction time of functionalized graphene oxide on the morphology and properties of epoxy composite foams

In this study, N-aminoethylpiperazine (AEP)-functionalized and reduced graphene oxide (RGO) with different structures and properties was prepared by simply tuning the reduction time and then its effect on the rheological, curing and foaming behavior of epoxy resin was carefully investigated using the environment-friendly carbamate as a chemical foaming agent. As the reduction time of RGO increased, the reduction degree of RGO first increased and then levelled off but the grafted AEP was little affected by the reduction time. The addition of RGO undergoing long reduction time improved the viscoelasticity of epoxy/reduced graphene oxide (EP/RGO) composites but weakened the interfacial compatibility of RGO and EP. With increasing the reduction time of RGO, the cell size of EP/RGO composite foams decreased and the cell density increased. However, as compared with pure EP foam, the composite foams containing RGO with lower reduction degree had a larger cell size and a lower density. These results were attributed to the complicated effect of RGO, which not only acted as the heterogeneous nucleating and foaming agent but also affected the viscoelasticity of composites. In addition, as the reduction time of RGO increased, the initial thermal decomposition temperature, storage modulus at room temperature, electrical conductivity, thermal conductivity, and compressive properties of EP/RGO composite foams increased while the glass transition temperature remained unchanged. These results were related not only to the intrinsic properties and dispersion of RGO, but also to the density and cell morphology of the composite foams.

Electromagnetic field controlled domain wall displacement for induced strain tailoring in BaTiO3-epoxy nanocomposite

Failure in an epoxy polymer composite material is prone to initiate by the coalescence of microcracks in its polymer matrix. As such, matrix toughening via addition of a second phase as rigid or/and rubber nano/micro-particles is one of the most popular approaches to improve the fracture toughness across multiple scales in a polymer composite, which dissipates fracture energy via deformation mechanisms and microcracks arrest. Few studies have focused on tailorable and variable toughening, so-called ‘active toughening’, mainly suggesting thermally induced strains which offer slow and irreversible toughening due to polymer’s poor thermal conductivity. The research presented in the current article has developed an instantaneous, reversible extrinsic strain field via remote electromagnetic radiation. Quantification of the extrinsic strain evolving in the composite with the microwave energy has been conducted using in-situ real-time fibre optic sensing. A theoretical constitutive equation correlating the exposure energy to micro-strains has been developed, with its solution validating the experimental data and describing their underlying physics. The research has utilised functionalised dielectric ferroelectric nanomaterials, barium titanate (BaTiO₃), as a second phase dispersed in an epoxy matrix, able to introduce microscopic electro-strains to their surrounding rigid epoxy subjected to an external electric field (microwaves, herein), as result of their domain walls dipole displacements. Epoxy Araldite LY1564, a diglycidyl ether of bisphenol A associated with the curing agent Aradur 3487 were embedded with the BaTiO₃ nanoparticles. The silane coupling agent for the nanoparticles’ surface functionalisation was 3-glycidoxypropyl trimethoxysilane (3-GPS). Hydrogen peroxide (H₂O₂, 30%) and acetic acid (C₂H₄O₂, 99.9%) used as functionalisation aids, and the ethanol (C₂H₆O, 99.9%) used for BaTiO₃ dispersion. Firstly, the crystal microstructure of the functionalised nanoparticles and the thermal and dielectric properties of the achieved epoxy composite materials have been characterised. It has been observed that the addition of the dielectric nanoparticles has a slight impact on the curing extent of the epoxy. Secondly, the surface-bonded fibre Bragg grating (FBG) sensors have been employed to investigate the real-time variation of strain and temperature in the epoxy composites exposed to microwaves at 2.45 GHz and at different exposure energy. The strains developed due to the in-situ exposure at composite, adhesive and their holding fixture material were evaluated using the FBG. The domain wall induced extrinsic strains were distinguished from the thermally induced strains, and found that the increasing exposure energy has an instantaneously increasing effect on the development of such strains. Post-exposure Raman spectra showed no residual field in the composite indicating no remnant strain field examined under microwave powers < 1000 W, thus suggesting a reversible strain introduction mechanism, i.e. the composite retaining its nominal properties post exposure. The dielectric composite development and quantifications presented in this article proposes a novel active toughening technology for high-performance composite applications in numerous sectors.

Glass Fiber-Epoxy Composites with Boron Nitride Nanotubes for Enhancing Interlaminar Properties in Structures

Hybrid composite materials are a class of materials where more than one type of reinforcement is integrated into a matrix to achieve superior properties. This typically involves nanoparticle fillers employed within traditional advanced composites with fiber reinforcements such as carbon or glass. The current study builds on previous investigations of boron nitride nanotube (BNNT) hybrid composites, specifically glass fiber (GF)-epoxy/BNNT composite laminates. GF is an effective and affordable primary reinforcement fiber in many applications, and boron nitride nanotubes (BNNTs) exhibit impressive mechanical properties comparable to carbon nanotubes (CNTs) with distinct functional properties, such as electrical insulation, which is desirable in manufacturing insulating composites when combined with GF. GF-epoxy/BNNT composite laminates, incorporating BNNT materials with different loadings (1 and 2 wt %) and purity, were manufactured using a hand layup technique and prepared for three-point bending, modified Charpy, dynamic mechanical analysis (DMA), and fracture toughness (mode I and mode II) measurements. A comprehensive microscopy study was also performed using scanning electron microscopy (SEM) showing prominent failure mechanism, nanotube dispersion, and their mode of reinforcement in different loading scenarios. Enhanced properties, including a 43% increase in mode II fracture toughness, were observed in hybrid composites with 1 wt % BNNT compared to the GF composites with neat epoxy, and the reinforcement mechanisms were discussed.

A Review of Nanocarbon-Based Solutions for the Structural Health Monitoring of Composite Parts Used in Renewable Energies

The growing demands for electrical energy, especially renewable, is boosting the development of wind turbines equipped with longer composite blades. To reduce the maintenance cost of such huge composite parts, the structural health monitoring (SHM) is an approach to anticipate and/or follow the structural behaviour along time. Apart from the development of traditional non-destructive testing methods, in order to reduce the use of intrusive instrumentation there is a growing interest for the development of “self-sensing materials”. An interesting route to achieve this, can be to introduce carbon nanofillers such as nanotubes (CNT) in the composite structures, which enables to create systems that are sensitive to both strain and damage. This review aims at updating the state of the art of this topic so far. A first overview of the existing SHM techniques for thermoset based wind turbine blades composites is presented. Then, the use of self-sensing materials for strain and damage sensing is presented. Different strategies are overviewed and discussed, from the design of conductive composites such as carbon fibres reinforced polymers, to the elaboration of conductive nano-reinforced polymer composites. The origins of sensing mechanisms along with the percolation theory applied to nanofillers dispersed in polymer matrices are also detailed.

Preparation and research of epoxy modified by carboxyl-terminated polybutylene adipate at room temperature

In this study, carboxyl-terminated polybutylene adipate (CTPBA) was used to modify epoxy resin, and the modified epoxy resin was cured by a room temperature rapid curing agent (T-31). The effects of CTPBA modification on bonding properties and mechanical properties of epoxy resin adhesive at room temperature were carefully studied. Epoxy-terminated prepolymer was synthesized by pre-polymerization and its structure was characterized. Compared with the addition method of direct blending, the bonding properties and mechanical properties of pre-polymerized epoxy resin adhesive were significantly better. Compared with unmodified epoxy resin, CTPBA modification significantly improved the bonding strength. Furthermore, with the increase of CTPBA content, the shear strength of the material increased first and then decreased, and reached the maximum when the addition amount was 40 phr. This shows that the tensile strength of the material decreased with the increase of CTPBA content, and the elongation at break increased with the increase of CTPBA content. Dynamic mechanical analyzer (DMA) test results showed that the addition of CTPBA reduced the glass transition temperature, but broadened the damping temperature range. TG analysis showed that the thermal stability of the modified epoxy resin was good, and compared with pure epoxy resin, the initial temperature of thermal weight loss and the maximum thermal decomposition rate decreased, but the overall thermal stability was not significantly different. In summary, CTPBA modification of epoxy resin is expected to improve the comprehensive mechanical properties at room temperature.

In this study, carboxyl-terminated poly(butylene adipate) (CTPBA) was synthesized, which was terminated with epoxy and used as a toughening agent to modify the epoxy resin, and the modified epoxy resin was cured at room temperature.