Hybrid Geopolymers from Fly Ash and Polysiloxanes

Effect of Water-Soluble Polymers on the Rheology and Microstructure of Polymer-Modified Geopolymer Glass-Ceramics

This work explores the effects of rigid (0.1, 0.25, and 0.5 wt. %) and semi-flexible (0.5, 1.0, and 2.5 wt. %) all-aromatic polyelectrolyte reinforcements as rheological and morphological modifiers for preparing phosphate geopolymer glass-ceramic composites. Polymer-modified aluminosilicate-phosphate geopolymer resins were prepared by high-shear mixing of a metakaolin powder with 9M phosphoric acid and two all-aromatic, sulfonated polyamides. Polymer loadings between 0.5-2.5 wt. % exhibited gel-like behavior and an increase in the modulus of the geopolymer resin as a function of polymer concentration. The incorporation of a 0.5 wt. % rigid polymer resulted in a three-fold increase in viscosity relative to the control phosphate geopolymer resin. Hardening, dehydration, and crystallization of the geopolymer resins to glass-ceramics was achieved through mold casting, curing at 80 °C for 24 h, and a final heat treatment up to 260 °C. Scanning electron microscopy revealed a decrease in microstructure porosity in the range of 0.78 μm to 0.31 μm for geopolymer plaques containing loadings of 0.5 wt. % rigid polymer. Nano-porosity values of the composites were measured between 10-40 nm using nitrogen adsorption (Brunauer-Emmett-Teller method) and transmission electron microscopy. Nanoindentation studies revealed geopolymer composites with Young's modulus values of 15-24 GPa and hardness values of 1-2 GPa, suggesting an increase in modulus and hardness with polymer incorporation. Additional structural and chemical analyses were performed via thermal gravimetric analysis, Fourier transform infrared radiation, X-ray diffraction, and energy dispersive spectroscopy. This work provides a fundamental understanding of the processing, microstructure, and mechanical behavior of water-soluble, high-performance polyelectrolyte-reinforced geopolymer composites.

Geopolymer Materials for Extrusion-Based 3D-Printing: A Review

This paper examines how extrusion-based 3D-printing technology is evolving, utilising geopolymers (GPs) as sustainable inorganic aluminosilicate materials. Particularly, the current state of 3D-printing geopolymers is critically examined in this study from the perspectives of the production process, printability need, mix design, early-age material features, and sustainability, with an emphasis on the effects of various elements including the examination of the fresh and hardened properties of 3D-printed geopolymers, depending on the matrix composition, reinforcement type, curing process, and printing configuration. The differences and potential of two-part and one-part geopolymers are also analysed. The applications of advanced printable geopolymer materials and products are highlighted, along with some specific examples. The primary issues, outlooks, and paths for future efforts necessary to advance this technology are identified.

Geopolymer Materials for Bone Tissue Applications: Recent Advances and Future Perspectives

With progress in the bone tissue engineering (BTE) field, there is an important need to develop innovative biomaterials to improve the bone healing process using reproducible, affordable, and low-environmental-impact alternative synthetic strategies. This review thoroughly examines geopolymers' state-of-the-art and current applications and their future perspectives for bone tissue applications. This paper aims to analyse the potential of geopolymer materials in biomedical applications by reviewing the recent literature. Moreover, the characteristics of materials traditionally used as bioscaffolds are also compared, critically analysing the strengths and weaknesses of their use. The concerns that prevented the widespread use of alkali-activated materials as biomaterials (such as their toxicity and limited osteoconductivity) and the potentialities of geopolymers as ceramic biomaterials have also been considered. In particular, the possibility of targeting their mechanical properties and morphologies through their chemical compositions to meet specific and relevant requirements, such as biocompatibility and controlled porosity, is described. A statistical analysis of the published scientific literature is presented. Data on "geopolymers for biomedical applications" were extracted from the Scopus database. This paper focuses on possible strategies necessary to overcome the barriers that have limited their application in biomedicine. Specifically, innovative hybrid geopolymer-based formulations (alkali-activated mixtures for additive manufacturing) and their composites that optimise the porous morphology of bioscaffolds while minimising their toxicity for BTE are discussed.

Sustainable Materials Based on Geopolymer-Polyvinyl Acetate Composites for Art and Design Applications

The recent introduction of the Next Generation EU packages on the circular economy and the Italian Ecological Transition Plan has further boosted the research of effective routes to design materials with low energy and low environmental impact, in all areas of research, including art and design and cultural heritage. In this work, we describe for the first time the preparation and characterization of a new sustainable adhesive material to be used in the art and design sector, consisting of a geopolymer-based composite with polyvinyl acetate (PVAc), both considered more environmentally acceptable than the analogous inorganic or polymeric materials currently used in this sector. The key idea has been the development of organic-inorganic composites by reacting low molecular weight polymers with the geopolymer precursor to obtain a material with reduced brittleness and enhanced adhesion with common substrates. Structural, morphological, and mechanical studies pointed out the consistent microstructure of the composite materials if compared to the neat geopolymer, showing lower density (up to 15%), improved flexural strength (up to 30%), similar water absorption and a relevant toughening effect (up to 40%). Moreover, the easy pourability in complex shapes and the excellent adhesion of these materials to common substrates suggest their use as materials for restoration, rehabilitation of monuments, and decorative and architectural intervention. The organic-inorganic nature of these new materials also makes them easily recognizable from the support on which they are used, favoring, in line with the dictates of good restoration practices, their possible complete removal. For all these reasons, these new materials could represent promising candidates to overcome the limits related to the creative industry for what concerns the selection of environmentally friendly materials to meet design requirements with low environmental impacts.

Development of Geopolymer-Based Materials with Ceramic Waste for Artistic and Restoration Applications

This contribution presents the preparation and characterization of new geopolymer-based mortars obtained from recycling waste deriving from the production process and the "end-of-life" of porcelain stoneware products. Structural, morphological, and mechanical studies carried out on different kinds of mortars prepared by using several types of by-products (i.e., pressed burnt and extruded ceramic waste, raw pressed and gypsum resulting from exhausted moulds) point out that these systems can be easily cast, also in complex shapes, and show a more consistent microstructure with respect to the geopolymer paste, with a reduced amount of microcracks. Moreover, the excellent adhesion of these materials to common substrates such as pottery and earthenware, even for an elevated concentration of filler, suggests their use in the field of technical-artistic value-added applications, such as restoration, conservation, and/or rehabilitation of historic monuments, or simply as materials for building revetments. For all these reasons, the proposed materials could represent valuable candidates to try to overcome some problems experienced in the cultural heritage sector concerning the selection of environmentally friendly materials that simultaneously meet art and design technical requirements.

Geopolymers and Functionalization Strategies for the Development of Sustainable Materials in Construction Industry and Cultural Heritage Applications: A Review

In the last decades, new synthetic hybrid materials, with an inorganic and organic nature, have been developed to promote their application as protective coatings and/or structural consolidants for several substrates in the construction industry and cultural heritage field. In this context, the scientific community paid attention to geopolymers and their new hybrid functional derivatives to design and develop innovative and sustainable composites with better chemical resistance, durability and mechanical characteristics. This review offers an overview of the latest progress in geopolymer-based hybrid nanofunctional materials and their use to treat and restore cultural heritage, as well as their employment in the building and architectural engineering field. In addition, it discusses the influence of some parameters, such as the chemical and physical characteristics of the substrates, the dosage of the alkaline activator, and the curing treatment, which affect their synthesis and performance.

The Effect of Different Modifying Methods on Physical, Mechanical and Thermal Performance of Cellular Geopolymers as Thermal Insulation Materials for Building Structures

Geopolymers represent a new class of inorganic materials that have great potential for practical application due to the properties of used raw materials, as well as the peculiarities of the cementitious matrix structure formed during the geopolymerization process. Cellular geopolymer specimens were produced in this study using class F fly ash product, which is characterized by low reactivity during geopolymerization. Several standard methods, as well as microstructural studies were applied to evaluate the effect of the following factors on the physical-mechanical and thermophysical characteristics of cellular geopolymers: the use of various mineral modifying components for synthesis of geopolymer systems; high-temperature treatment; the introduction method of alkaline activator. It was observed that “ageing” an aqueous alkali solution for 24 h before mixing with fly ash and foam agent was able to provide a boost of compressive strength of cellular geopolymer specimens up to about 2.5 times, while decreasing the average density by about 28% for all experimental mixes, except for PC-modified mixes. Additionally, high-temperature treatment at 600 °C enables an enhanced strengthening effect of pore structure in cellular geopolymer matrix up to 1.5 times. This phenomenon is especially pronounced for the mixes with 24 h “aged” alkaline solution with exception for PC-modified mixes; for those, high-temperature treatment at 600 °C leads to strength decrease up to 40%. The introduction method of alkaline activator and high-temperature treatment showed a controversial effect on thermal conductivity coefficient depending on the mineral modifying component used for the synthesis of cellular geopolymers. The proposed method for calculation of total porosity of cellular structure of geopolymers as a polycomponent material demonstrated a high degree of correlation with the R2 value of at least 0.96 between the average density and the calculated total porosity. However, a low degree of correlation with R2 not exceeding 0.29 was observed for the measured nanoporosity, regardless of the introduction method of alkaline activator and high-temperature treatment.

Red Mud-Blast Furnace Slag-Based Alkali-Activated Materials

The aluminum Bayer production process is widespread all over the world. One of the waste products of the Bayer process is a basic aluminosilicate bauxite residue called red mud. The aluminosilicate nature of red mud makes it suitable as a precursor for alkali-activated materials. In this work, red mud was mixed with different percentages of blast furnace slag and then activated by sodium silicate solution at different SiO2/Na2O ratios. Obtained samples were characterized by chemical–physical analyses and compressive strength determination. Very high values of compressive strength, up to 50 MPa, even for high percentage of red mud in the raw mixture (70 wt.% of RM in powder mixture), were obtained. In particular, the higher compressive strength was measured for cubic samples containing 50 wt.% of RM, which showed a value above 70 MPa. The obtained mixtures were characterized by no or scarce environmental impact and could be used in the construction industry as an alternative to cementitious and ceramic materials.

Hemp Fiber Reinforced Red Mud/Fly Ash Geopolymer Composite Materials: Effect of Fiber Content on Mechanical Strength

Novel hemp fiber reinforced geopolymer composites were fabricated. The matrix was a new geopolymer based on a mixture of red mud and fly ash. Chopped, randomly oriented hemp fibers were used as reinforcement. The mechanical properties of the geopolymer composite, such as diametral tensile (DTS) (or Brazilian tensile) strength and compressive strength (CS), were measured. The geopolymer composites reinforced with 9 vol.% and 3 vol.% hemp fiber yielded average DTS values of 5.5 MPa and average CS values of 40 MPa. Scanning electron microscopy (SEM) studies were carried out to evaluate the microstructure and fracture surfaces of the composites. The results indicated that the addition of hemp fiber is a promising approach to improve the mechanical strength as well as to modify the failure mechanism of the geopolymer, which changed from brittle to “pseudo-ductile”.

Fibre-Reinforced Geopolymer Concretes for Sensible Heat Thermal Energy Storage: Simulations and Environmental Impact

Power plants based on solar energy are spreading to accomplish the incoming green energy transition. Besides, affordable high-temperature sensible heat thermal energy storage (SHTES) is required. In this work, the temperature distribution and thermal performance of novel solid media for SHTES are investigated by finite element method (FEM) modelling. A geopolymer, with/without fibre reinforcement, is simulated during a transient charging/discharging cycle. A life cycle assessment (LCA) analysis is also carried out to investigate the environmental impact and sustainability of the proposed materials, analysing the embodied energy, the transport, and the production process. A Multi-Criteria Decision Making (MCDM) with the Analytical Hierarchy Process (AHP) approach, taking into account thermal/environmental performance, is used to select the most suitable material. The results show that the localized reinforcement with fibres increases thermal storage performance, depending on the type of fibre, creating curvatures in the temperature profile and accelerating the charge/discharge. High-strength, high-conductivity carbon fibres performed well, and the simulation approach can be applied to any fibre arrangement/material. On the contrary, the benefit of the fibres is not straightforward according to the three different scenarios developed for the LCA and MCDM analyses, due to the high impact of the fibre production processes. More investigations are needed to balance and optimize the coupling of the fibre material and the solid medium to obtain high thermal performance and low impacts.

Hybrid Geopolymeric Foams for the Removal of Metallic Ions from Aqueous Waste Solutions

For the first time, hybrid organic–inorganic geopolymeric foams were successfully used as monolithic adsorbents for the removal of metallic ions pollutants from wastewaters. The foams were realized by the in situ foaming of a hybrid geopolymer obtained by a reaction of metakaolin and polysiloxane oligomers under strong alkaline conditions and then cured at room temperature. In this way, porous materials with densities ranging from 0.4 to 0.7 g/cm³ and showing good mechanical properties were produced. With the aim of producing self-standing monolithic adsorbents for the removal of metallic ions pollutants from wastewaters, these porous hybrid geopolymers were subjected to a washing pretreatment with ultrapure water, dried, and then used for absorption tests by dipping them into an aqueous solution with an initial concentration of 20 ppm of Pb²⁺, Cd²⁺, Cu²⁺, and Zn²⁺ ions. Preliminary results indicated that all the tested materials are effective in the adsorption of the tested metal ions and do not release the removed metal ions upon sinking in ultrapure water, even for a very long time. Interestingly, compressive strength tests performed before and after the washing treatments show that the foamed samples remain intact and maintain their physical–mechanical characteristics, suggesting that these kinds of materials are promising candidates for the production of self-standing, monolithic adsorbent substrates that can be easily collected when exhausted, which is a major advantage in comparison with the use of powdered adsorbents. Moreover, since these materials can be obtained by a simple and versatile experimental procedure, they could be easily shaped or directly foamed into precast molds to be used in packed beds as membranes.