Influence of the Epoxy Resin Process Parameters on the Mechanical Properties of Produced Bidirectional [±45°] Carbon/Epoxy Woven Composites

Epoxy Composites with Post-Production Gray Cast-Iron Powders

Processing of cast-iron castings by machining is associated with a large amount of post-production waste in the form of cast-iron chips, which constitute up to about 5% of the weight of the entire casting. In the case of serial production, this generates large amounts of post-production waste, constituting a constantly growing scale of environmental problems. The aim of this research was to develop a simple and cheap method of utilizing post-production waste of gray cast-iron chips from the machining process for the production of small structural elements of water supply fittings. The analysis of the state of knowledge indicates that the simplest method of managing waste chips is to use them as a starting material in the process of manufacturing polymer composites. The most frequently chosen material for the matrix of polymer composites reinforced with metal powders is epoxy resin. The epoxy composite was produced by the vacuum-assisted casting method. This paper presents the results of tests of morphological, mechanical, and corrosion properties of epoxy composites filled with grey cast-iron powder with a grain size below 0.075 mm and a mass content in the composite of 65%. The composite cured at 130 °C for 90 min had the best mechanical properties. The sample cured at 130 °C for 90 min was observed to have the optimum effect, with a tensile strength of 28.35 MPa, a flexural strength of 55.4 MPa, and a compressive strength of 53.8 MPa. All tested composites were characterized by very good thermal resistance and, in comparison to gray cast iron, over 2.5 times lower weight and an over three times lower corrosion rate in the tap water environment.

Impact of the Curing Temperature on the Manufacturing Process of Multi-Nanoparticle-Reinforced Epoxy Matrix Composites

This study aims to analyze the effect of the curing temperature of nano-reinforcements during the manufacturing process on the mechanical properties of composites involving graphene (GNP), carbon nanofibers (CNFs), and a hybrid mixture of these two nanoparticles. In this context, the type of nanoparticles, their content, their type of resin, and their hybridization were considered. The results showed that both nanoparticles increased the viscosity of the resin suspension, with an increase of between 16.3% and 38.2% for GNP nanoparticles and 45.4% and 74% for CNFs depending on the type of resin. Shrinkage was also affected by the addition of nanoparticles, as the highest results were obtained with GNP nanoparticles, with a 91% increase compared with the neat resin, and the lowest results were obtained with CNFs, with a decrease of 77% compared with the neat resin. A curing temperature of 5 °C promoted the best bending and hardness performance for all composites regardless of the type of resin and reinforcement used, with improvements of up to 24.8% for GNP nanoparticles and 13.52% for CNFs compared with the neat resin at 20 °C. Hybridization led to further improvements in bending properties and hardness compared with single-reinforcement composites due to a synergistic effect. However, the effectiveness of hybridization depends on the type of resin.

Influence of a Biofiller, Polylactide, on the General Characteristics of Epoxy-Based Materials

The aim of this work was to obtain epoxy-based composite structures with good mechanical performance, high aging resistance, and an improved degradability profile. For this purpose, powdered polylactide in the amount of 5, 10, 20, 30, and 40 phr was introduced into the epoxy resin, and the composites were fabricated by a simple method, which is similar to that used on an industrial scale in the fabrication of these products. The first analysis concerned the study of the effect of PLA addition to epoxy resin-based composites on their mechanical properties. One-directional tensile tests of samples were performed for three directions (0, 90, and 45 degrees referring to the plate edges). Another aspect of this research was the assessment of the resistance of these composites to long-term exposure to solar radiation and elevated temperature. Based on the obtained results, it was observed that the samples containing 20 or 40 phr of polylactide were characterized by the lowest resistance to the solar aging process. It was therefore concluded that the optimal amount of polylactide in the epoxy resin composite should not be greater than 10 phr to maintain its mechanical behavior and high aging resistance. In the available literature, there are many examples in which scientists have proposed the use of various biofillers (e.g., lignin, starch, rice husk, coconut shell powder) in epoxy composites; however, the impact of polylactide on the general characteristics of the epoxy resin has not been described so far. Therefore, this work perfectly fills the gaps in the literature and may contribute to a more widespread use of additives of natural origin, which may constitute an excellent alternative to commonly used non-renewable compounds.

Evolution from basic to advanced structure of fulvic acid and humic acid prepared by food waste

Fulvic acid (FA) and humic acid (HA) are common polyacids in nature. However, the evolutionary process of their basic and advanced structures is still unclear. FA and HA were separated into five molecular weight components to investigate the process of evolution from small to large molecules. The primary structure analysis showed that FA were rich in CN, COOH and OH content, while HA were rich in (CH2)n, NH2 and CC. Moreover, with the molecular weight increasing, the structures could complement each other to maintain the hydrophilic or hydrophobic balance. The 2D-COS spectroscopy demonstrated that during the growth of FA, COOH, NH2 and OH firstly respond. On the other hand, during the growth of HA, NH2 and (CH2)n firstly respond. In addition, advanced structure of FA was affected by intramolecular hydrogen bonds and π - π interaction. HA was affected by hydrophobic interactions due to the abundance of hydrophobic groups, primarily (CH2)n and benzene rings. 3D conformational fitting and particle size characterization confirmed that the interaction forces determine that FA and HA become tightly and loosely molecules respectively. This study is to further explore the geochemical formation and evolution process of FA and HA molecules.

Influence of Catalytic Infrared Radiation on the Protective Properties of Industrial Epoxy Primers

The application of organic coatings is a common way of protecting metal substrates against corrosion. To dry the coating faster, catalytic infrared radiation (IR) can be applied. This paper aims to assess the differences in the physical, chemical, and corrosion properties of primer coatings dried with catalytic infrared radiation, compared to the same coatings dried under atmospheric conditions. Corrosion properties were characterized using humidity and a salt spray chamber, as well as electrochemical impedance spectroscopy (EIS), preceded by open circuit potential (OCP) measurement. Pencil hardness, cross-cut, and pull-off adhesion tests were used to compare the properties of examined primers before and after testing in the corrosion acceleration chambers. The microstructure and distribution of chemical composition were studied by scanning electron microscope (SEM) with energy-dispersive X-ray spectroscopy (EDX) together with Fourier-transform infrared spectroscopy (FTIR). Phase transitions in the coating were determined by differential scanning calorimeter (DSC). Infrared-dried primers achieved a higher curing degree. Therefore, their mechanical and corrosion properties are superior when compared to the same coatings dried under atmospheric conditions.

Sustainably sourced components to generate high-strength adhesives

Nearly all adhesives1,2 are derived from petroleum, create permanent bonds3, frustrate materials separation for recycling4,5 and prevent degradation in landfills. When trying to shift from petroleum feedstocks to a sustainable materials ecosystem, available options suffer from low performance, high cost or lack of availability at the required scales. Here we present a sustainably sourced adhesive system, made from epoxidized soy oil, malic acid and tannic acid, with performance comparable to that of current industrial products. Joints can be cured under conditions ranging from use of a hair dryer for 5 min to an oven at 180 °C for 24 h. Adhesion between metal substrates up to around 18 MPa is achieved, and, in the best cases, performance exceeds that of a classic epoxy, the strongest modern adhesive. All components are biomass derived, low cost and already available in large quantities. Manufacturing at scale can be a simple matter of mixing and heating, suggesting that this new adhesive may contribute towards the sustainable bonding of materials.

Functional Polymer Nanocomposites with Increased Anticorrosion Properties and Wear Resistance for Water Transport

Corrosive destruction and hydroabrasive wear is a serious problem in the operation of machine parts and water transport mechanisms. It is promising to develop new composite materials with improved properties to increase the reliability of transport vehicles. In this regard, the use of new polymer-based materials, which are characterized by improved anticorrosion properties and wear resistance, is promising. In this work, therefore, for the formation of multifunctional protective coatings, epoxy dian oligomer brand ED-20, polyethylene polyamine (PEPA) hardener, a mixture of nanodispersed compounds with a dispersion of 30-90 nm, fillers Agocel S-2000 and Waltrop with a dispersion of 8-12 μm, and particles of iron slag with a dispersion of 60-63 μm are used for the formation of multifunctional protective coatings. Using the method of mathematically planning the experiment, the content of additives of different physico-chemical natures in the epoxy binder is optimized to obtain fireproof coatings with improved operational characteristics. A mathematical model is developed for optimizing the content of components in the formation of protective anticorrosion and wear-resistant coatings for means of transport as a result of the complex effect of a mixture of nanodispersed compounds, iron scale, and Waltrop. Based on the mathematical planning of the experiment, new regularities of increasing the corrosion resistance and resources of the means of transport are established through the formation of four different protective coatings, which are tested for resistance to aggressive environments (technical water-CAS No. 7732-18-5, gasoline-CAS No. 64742-82-1, acetone-CAS No. 67-64-1, I-20A lubricant-CAS No. 64742-62-7, sodium solutions-CAS No. 1310-73-2, and sulfuric acid-CAS No. 7664-93-9) and hydroabrasive wear resistances. A study of the change in the permeability index in aggressive environments is additionally carried out, taking into account the rational ratio of dispersive fillers in the epoxy binder, which made it possible to create an effective barrier to the penetration of aggressive water molecules into the base. A decrease in the permeability of protective coatings by 2.0-3.3 times relative to the epoxy matrix is achieved. In addition, the wear resistance of the developed materials under the action of hydroabrasion is investigated. The relative resistance of the CM to the action of hydroabrasion was found by the method of materials and coatings testing on the gas-abrasive wear with a centrifugal accelerator. This method enables one to model the real process of the wear of mechanism parts under the hydroabrasive action. It is shown that the coefficient of the wear resistance of the developed materials is 1.3 times higher than that of the polymer matrix, which indicates the resistance of the composites to the influence of hydroabrasive environment. As a result, modified epoxy composite protective coatings with improved anticorrosion properties and wear resistance under hydroabrasive conditions are developed. It is established that the protective coating filled with particles of a mixture of nanodispersed compounds (30-90 nm), iron scale (60-63 μm), and Waltrop (8-12 μm) has the lowest permeability indicators. The permeability in natural conditions of such a coating during the time t = 300 days of the study is χ = 0.5%, which is 3.6 times less than the similar indicators of the epoxy matrix. It is substantiated that the protective coating filled with particles of a mixture of nanodispersed compounds (30-90 nm), iron scale (60-63 μm), and Agocel S-2000 (8-12 μm) is characterized by the highest indicators of wear resistance. The coefficient of wear resistance under the action of hydroabrasion of such a coating is K = 1.75, which is 1.3 times higher than the similar indicators of the original epoxy matrix.

Recycling of Wind Turbine Blades into Microfiber Using Plasma Technology

As the industry develops and energy demand increases, wind turbines are increasingly being used to generate electricity, resulting in an increasing number of obsolete turbine blades that need to be properly recycled or used as a secondary raw material in other industries. The authors of this work propose an innovative technology not yet studied in the literature, where the wind turbine blades are mechanically shredded and micrometric fibers are formed from the obtained powder using plasma technologies. As shown by SEM and EDS studies, the powder is composed of irregularly shaped microgranules and the carbon content in the obtained fiber is lower by up to seven times compared with the original powder. Meanwhile, the chromatographic studies show that no hazardous to the environment gases are formed during the fiber production. It is worth mentioning that this fiber formation technology can be one of the additional methods for recycling wind turbine blades, and the obtained fiber can be used as a secondary raw material in the production of catalysts, construction materials, etc.

Development and Characterization of Bio-Composites from the Plant Wastes of Water Hyacinth and Sugarcane Bagasse: Effect of Water Repellent and Gamma Radiation

Plant waste is a huge source of natural fibers and has great potential in the field of reinforced polymer composites to replace the environmentally harmful synthetic composites. In this study, fibers were extracted from water hyacinth (WH) petiole and sugarcane bagasse (SB) to make nonwovens by wet-laid web formation, and reinforced on the polyester (P) and epoxy (E) resins to make four types of composites namely, water hyacinth nonwoven reinforced epoxy (WH + E), water hyacinth nonwoven reinforced polyester (WH + P), sugarcane bagasse nonwoven reinforced epoxy (SB + E) and sugarcane bagasse nonwoven reinforced polyester (SB + P) composites. Water repellent (WR) on the nonwovens and gamma radiation (GR) on the composites were applied to improve the hydrophobicity and mechanical properties, such as tensile strength (TS), elongation at break and tensile modulus (TM) of the composites. The morphological structure of the fiber surfaces and tensile fractures were analyzed by SEM. FTIR spectra showed changes in functional groups before and after treatment. XRD analysis exhibited an increase in crystallinity for gamma-irradiated composites and a decrease in crystallinity for WR-treated composites compared to untreated composites. The SB composites (SB + E, SB + P) and polyester composites (WH + P, SB + P) showed higher water absorbency and lower mechanical properties than the WH composites (WH + E, WH + P) and epoxy composites (WH + E, SB + E), respectively. Hydrophobicity improved significantly by approximately 57% (average) at a concentration of 10% WR. However, TS and TM were reduced by approximately 24% at the same concentration. Thus, 5% WR is considered an optimum concentration due to the very low deterioration of TS and TM (<10%) but significant improvement in hydrophobicity (~39%) at this dose. On the other hand, GR treatment significantly improved TS, TM and hydrophobicity by 41, 32 and 25%, respectively, and decreased Eb% by 11% at a dose of 200 krd. However, mechanical properties and hydrophobicity deteriorated with further increase in dose at 300 krd. Thus, 200 krd is considered the optimum dose of GR.

Manufacturing defects of woven natural fibre thermoset composites

Thermoset polymer are components with high strength, chemical inert and thermally stable, due to its high degree of cross-linking. Natural fibre composite is providing a winning solution for extraordinary performances yet biodegradable. Woven form fibre even found better in specific energy absorption and stronger in strength. Fabricating woven thermoset composites may be done in a variety of ways. However, processing errors or manufacturing defects often occur by many factors, especially thermoset composites with natural fibre reinforcement. It is nearly impossible to achieves in detect-free when in lab scale production. Hence, it is important to study and understand the factors that causing the defects. Processing parameters, compatibility of matrix/fibre combination, yarn production and woven waiving skills may be the reasons of composite’s defects. In this chapter, several fabrication methods for woven thermoset composite were introduced. Some major defects on manufacturing the thermoset composites were highlighted. Some future perception of the woven natural fibre thermoset composite also have been discussed. This chapter set as a guidance to avoid or minimizes manufacturing defects upon thermoset composite processing.

The Use of Carbon Fibers Recovered by Pyrolysis from End-of-Life Wind Turbine Blades in Epoxy-Based Composite Panels

This work is devoted to evaluating the effectiveness of the recovery of carbon fibers from end-of-life wind turbine blades in the pyrolysis process, and the use of those fibers in the production of flat composite panels. The recovery of carbon fibers from wind turbine blades uses a pyrolysis process at 500–600 °C in a non-oxidizing atmosphere, in such a way that makes it possible to preserve the shape and dimensions of the fibers. Using recycled carbon fibers, flat CFRP sheets with epoxy resin matrix were produced by pressing. Seven different series of samples were tested, which differed in fiber length, fiber orientation, and pressure holding time. The results obtained on the recycled fibers were compared to the original carbon fibers, cut to corresponding lengths. Additionally, one of the series was reinforced with a biaxial fabric. The most favorable pressing parameters are empirically found to be pre-pressing 2 MPa (10 min), and further pressing at a pressure of 7 MPa until the resin completely cross-linked (about 120 min). A number of tests were carried out to demonstrate the usefulness of pyrolytic fibers, including tensile strength of carbon fibers, bending strength, SEM observations, FT-IR, and Raman spectroscopy. The tests carried out on the carbon fibers show that the pyrolysis process used leaves about 2% of the matrix on the surface of the fiber, and the tensile strength of the fibers drops by about 20% compared to the new carbon fibers. The research results show that the use of the recycled carbon fibers in the production of flat composite plates is reliable, and their mechanical properties do not differ significantly from plates made of corresponding original carbon fibers. Composite panels with the pyrolytic fibers (274 MPa) show up to a 35% higher flexural strength than similarly produced panels with the original new carbon fibers (203 MPa), which means that the panels can be used in the production of elements for footbridges, bridges, pipelines, or structural elements of buildings and roofing.

Influence of Epoxy Resin Curing Kinetics on the Mechanical Properties of Carbon Fiber Composites

In this study, the kinetic parameters belonging to the cross-linking process of a modified epoxy resin, Aerotuf 275-34™, were investigated. Resin curing kinetics are crucial to understanding the structure-property-processing relationship for manufacturing high-performance carbon-fiber-reinforced polymer composites (CFRPCs). The parameters were obtained using differential scanning calorimetry (DSC) measurements and the Flynn-Wall-Ozawa, Kissinger, Borchardt-Daniels, and Friedman approaches. The DSC thermograms show two exothermic peaks that were deconvoluted as two separate reactions that follow autocatalytic models. Furthermore, the mechanical properties of produced carbon fiber/Aerotuf 275-34™ laminates using thermosetting polymers such as epoxies, phenolics, and cyanate esters were evaluated as a function of the conversion degree, and a close correlation was found between the degree of curing and the ultimate tensile strength (UTS). We found that when the composite material is cured at 160 °C for 15 min, it reaches a conversion degree of 0.97 and a UTS value that accounts for 95% of the maximum value obtained at 200 °C (180 MPa). Thus, the application of such processing conditions could be enough to achieve good mechanical properties of the composite laminates. These results suggest the possibility for the development of strategies towards manufacturing high-performance materials based on the modified epoxy resin (Aerotuf 275-34™) through the curing process.

Modified Activated Carbon for Copper Ion Removal from Aqueous Solution

Because of increasing environmental awareness, it is becoming more important to remove harmful elements from water solutions. This study used activated carbon (AC) derived from waste wood-based panels as the base material, oxidized with nitric acid (OAC), and grafted with iminodiacetic acid (IDA-OAC) to improve the adsorption capacity and affinity for metals. The characterization of AC, OAC, and IDA-OAC was conducted via FTIR, SEM, N2 adsorption and desorption analysis, elemental analysis, Boehm titration, and point of zero charge (PZC). The instrument studies proved the modified increasing of the functional groups of the adsorbents. Moreover, batch and column experiments were conducted to evaluate the ability of the three adsorbents to remove copper ions from aqueous solution. In batch sorption, IDA-OAC had the highest adsorption capacity (84.51 mg/g) compared to OAC (54.74 mg/g) and AC (24.86 mg/g) at pH 5. The breakthrough point (Ct/Ci = 0.05) of copper ions for IDA-OAC occurred much later than AC in the column experiment (AC = 19 BV, IDA-OAC = 52 BV). The Langmuir isotherm and pseudo-second-model kinetics modeling could better fit with the data obtained from the batch sorption of AC, OAC, and IDA-OAC. The significant capacity and reusability of IDA-OAC displayed high applicability for water treatment.