A Review of Current Challenges and Case Study toward Optimizing Micro-Computed X-Ray Tomography of Carbon Fabric Composites

Development and application of a 3D image analysis strategy for focused ion beam - Scanning electron microscopy tomography of porous soft materials

In recent years, the potential of porous soft materials in various device technologies has increased in importance due to applications in fields, such as wearable electronics, medicine, and transient devices. However, understanding the 3-dimensional architecture of porous soft materials at the microscale remains a challenge. Herein, we present a method to structurally analyze soft materials using Focused Ion Beam - Scanning Electron Microscopy (FIB-SEM) tomography. Two materials, polymethyl methacrylate (PMMA) membrane and pine wood veneer were chosen as test-cases. FIB-SEM was successfully used to reconstruct the true topography of these materials in 3D. Structural and physical properties were subsequently deduced from the rendered 3D models. The methodology used segmentation, coupled with optimized thresholding, image processing, and reconstruction protocols. The 3D models generated pore size distribution, pore inter-connectivity, tortuosity, thickness, and curvature data. It was shown that FIB-SEM tomography provides both an informative and visual depiction of structure. To evaluate and validate the FIB-SEM reconstructions, porous properties were generated from the physical property analysis techniques, gas adsorption analysis using Brunauer-Emmett-Teller (BET) surface area analysis and mercury intrusion porosimetry (MIP) analysis. In general, the data obtained from the FIB-SEM reconstructions was well-matched with the physical data. RESEARCH HIGHLIGHTS: Porous specimens of both synthetic and biological nature, a poly(methyl methacrylate) membrane and a pine veneer respectively, are reconstructed via FIB-SEM tomography without resin-embedding. Different thresholding and reconstruction methods are explored whereby shadowing artifacts are present with the aid of free open-source software. Reconstruction data is compared to physical data: MIP, gas adsorption isotherms which are analyzed via BET and Barrett-Joyner-Halenda (BJH) analysis to yield a full picture of the materials.

Microscopy of Woven and Nonwoven Face Covering Materials: Implications for Particle Filtration

A suite of natural, synthetic, and mixed synthetic-natural woven fabrics, along with nonwoven filtration layers from a surgical mask and an N95 respirator, was examined using visible light microscopy, scanning electron microscopy, and micro-X-ray computed tomography (µXCT) to determine the fiber diameter distribution, fabric thickness, and the volume of solid space of the fabrics. Nonwoven materials exhibit a positively skewed distribution of fiber diameters with a mean value of ≈3 μm, whereas woven fabrics exhibit a normal distribution of diameters with mean values roughly five times larger (>15 μm). The mean thickness of the N95 filtration material is 1093 μm and is greater than that of the woven fabrics that span from 420 to 650 μm. A new procedure for measuring the thickness of flannel fabrics is proposed that accounts for raised fibers. µXCT allowed for a quantitative nondestructive approach to measure fabric porosity as well as the surface area/volume. Cotton flannel showed the largest mean isotropy of any fabric, though fiber order within the weave is poorly represented in the surface electron images. Surface fabric isotropy and surface area/volume ratios are proposed as useful microstructural quantities to consider for future particle filtration modeling efforts of woven materials.

Three-Dimensional Study of Polymer Composite Destruction in the Early Stages

The investigation of destruction processes in composite materials is a current problem for their structural application and the improvement of their functional properties. This work aimed to visualize structural changes induced in layered carbon fiber reinforced plastics (CFRP) with the help of synchrotron X-ray microtomography. This article presents the details of destructive processes in the early stages of the deformation of reinforced polymers under uniaxial stretching, investigated at the micro level. Individual structural elements of the composite-filaments, parallel fiber bundles, the nonuniformity of the polymer binder distribution, and continuity defects-were observed under an external load. We have considered the influence of the material architecture and technological defects on fracture evolution in cross-ply and quasi-isotropic fiber-reinforced plastics. The results indicate the sequence of irreversible structural changes before the destruction of the material.

Effect of Process Parameters on Void Distribution, Volume Fraction, and Sphericity within the Bead Microstructure of Large-Area Additive Manufacturing Polymer Composites

Short carbon fiber-reinforced composite materials produced by large-area additive manufacturing (LAAM) are attractive due to their lightweight, favorable mechanical properties, multifunctional applications, and low manufacturing costs. However, the physical and mechanical properties of short carbon-fiber-reinforced composites 3D printed via LAAM systems remain below expectations due in part to the void formation within the bead microstructure. This study aimed to assess void characteristics including volume fraction and sphericity within the microstructure of 13 wt% short carbon fiber acrylonitrile butadiene styrene (SCF/ABS). Our study evaluated SCF/ABS as a pellet, a single freely extruded strand, a regularly deposited single bead, and a single bead manufactured with a roller during the printing process using a high-resolution 3D micro-computed tomography (µCT) system. Micro voids were shown to exist within the microstructure of the SCF/ABS pellet and tended to become more prevalent in a single freely extruded strand which showed the highest void volume fraction among all the samples studied. Results also showed that deposition on the print bed reduced the void volume fraction and applying a roller during the printing process caused a further reduction in the void volume fraction. This study also reports the void's shape within the microstructure in terms of sphericity which indicated that SCF/ABS single freely extruded strands had the highest mean void sphericity (voids tend to be more spherical). Moreover, this study evaluated the effect of printing process parameters, including nozzle temperature, extrusion speed and nozzle height above the printing table on the void volume fraction and sphericity within the microstructure of regularly deposited single beads.

Nanofibrous scaffolds based on bacterial cellulose crosslinked with oxidized sucrose

In this work, oxidized sucrose (OS), which is a safe bio-based and non-toxic polyaldehyde, was used as a crosslinker in defibrillated bacterial cellulose (BC) sponges obtained by freeze-drying. For mimicking the proteins' crosslinking, BC was first modified with an aminosilane to partially replace the OH groups on the BC surface with more reactive amino groups. Further, the aminosilane-grafted bacterial cellulose (BCA) was crosslinked with OS in different concentrations and thermally cured. Functionalized bacterial celluloses showed a good thermal stability, comparable to that of unmodified cellulose and much improved mechanical properties. A threefold increase in the compression strength was obtained for the BCA scaffold after crosslinking and curing. This was correlated with the uniform pore structure emphasized by the micro-CT and SEM analyses. The OS-crosslinked BCA scaffolds were not cytotoxic and showed a porosity of around 80 %, which was almost 100 % open porosity. This study shows that the crosslinking of aminated BC scaffolds with OS allows the obtaining of 3D cellulose structures with good mechanical properties and high porosity, suitable for soft tissue engineering. The results recommend this new method as an innovative approach to obtaining biomaterial scaffolds that mimic the natural extracellular matrix.

Microtomographic Analysis of a Palaeolithic Wooden Point from the Ljubljanica River

A rare and valuable Palaeolithic wooden point, presumably belonging to a hunting weapon, was found in the Ljubljanica River in Slovenia in 2008. In order to prevent complete decay, the waterlogged wooden artefact had to undergo conservation treatment, which usually involves some expected deformations of structure and shape. To investigate these changes, a series of surface-based 3D models of the artefact were created before, during and after the conservation process. Unfortunately, the surface-based 3D models were not sufficient to understand the internal processes inside the wooden artefact (cracks, cavities, fractures). Since some of the surface-based 3D models were taken with a microtomographic scanner, we decided to create a volumetric 3D model from the available 2D tomographic images. In order to have complete control and greater flexibility in creating the volumetric 3D model than is the case with commercial software, we decided to implement our own algorithm. In fact, two algorithms were implemented for the construction of surface-based 3D models and for the construction of volumetric 3D models, using (1) unsegmented 2D images CT and (2) segmented 2D images CT. The results were positive in comparison with commercial software and new information was obtained about the actual state and causes of the deformation of the artefact. Such models could be a valuable aid in the selection of appropriate conservation and restoration methods and techniques in cultural heritage research.

Biomaterials Based on Carbon Nanotube Nanocomposites of Poly(styrene-b-isobutylene-b-styrene): The Effect of Nanotube Content on the Mechanical Properties, Biocompatibility and Hemocompatibility

Nanocomposites based on poly(styrene-block-isobutylene-block-styrene) (SIBS) and single-walled carbon nanotubes (CNTs) were prepared and characterized in terms of tensile strength as well as bio- and hemocompatibility. It was shown that modification of CNTs using dodecylamine (DDA), featured by a long non-polar alkane chain, provided much better dispersion of nanotubes in SIBS as compared to unmodified CNTs. As a result of such modification, the tensile strength of the nanocomposite based on SIBS with low molecular weight (Mn = 40,000 g mol-1) containing 4% of functionalized CNTs was increased up to 5.51 ± 0.50 MPa in comparison with composites with unmodified CNTs (3.81 ± 0.11 MPa). However, the addition of CNTs had no significant effect on SIBS with high molecular weight (Mn~70,000 g mol-1) with ultimate tensile stress of pure polymer of 11.62 MPa and 14.45 MPa in case of its modification with 1 wt% of CNT-DDA. Enhanced biocompatibility of nanocomposites as compared to neat SIBS has been demonstrated in experiment with EA.hy 926 cells. However, the platelet aggregation observed at high CNT concentrations can cause thrombosis. Therefore, SIBS with higher molecular weight (Mn~70,000 g mol-1) reinforced by 1-2 wt% of CNTs is the most promising material for the development of cardiovascular implants such as heart valve prostheses.

Resin-Rich Volumes (RRV) and the Performance of Fibre-Reinforced Composites: A Review

This review considers the influence of resin-rich volumes (RRV) on the static and dynamic mechanical and physical behaviour of fibre-reinforced composites. The formation, shape and size, and measurement of RRV in composites, depending upon different fabric architectures and manufacturing processes, is discussed. The majority of studies show a negative effect of RRV on the mechanical behaviour of composite materials. The main factors that cause RRV are (a) the clustering of fibres as bundles in textiles, (b) the stacking sequence, (c) the consolidation characteristics of the reinforcement, (d) the resin flow characteristics as a function of temperature, and (e) the composite manufacturing process and cure cycle. RRV are stress concentrations that lead to a disproportionate decrease in composite strength. Those who are considering moving from autoclave consolidation to out-of-autoclave (OOA) processes should be cautious of the potential effects of this change.