Properties of 3D-Printed Polymer Fiber-Reinforced Mortars: A Review

A Review of Sisal Fiber-Reinforced Geopolymers: Preparation, Microstructure, and Mechanical Properties

The early strength of geopolymers (GPs) and their composites is higher, and the hardening speed is faster than that of ordinary cementitious materials. Due to their wide source of raw materials, low energy consumption in the production process, and lower emissions of pollutants, they are considered to have the most potential to replace ordinary Portland cement. However, similar to other inorganic materials, the GPs themselves have weak flexural and tensile strength and are sensitive to micro-cracks. Improving the toughness of GP materials can be achieved by adding an appropriate amount of fiber materials into the matrix. The use of discrete staple fibers shows great potential in improving the toughness of GPs. Sisal is a natural fiber that is reproducible and easy to obtain. Due to its good mechanical properties, low cost, and low carbon energy usage, sisal fiber (SF) is a GP composite reinforcement with potential development. In this paper, the research progress on the effect of SF on the properties of GP composites in recent decades is reviewed. It mainly includes the chemical composition and physical properties of SFs, the preparation technology of sisal-reinforced geopolymers (SFRGs), the microstructure analysis of the interface of SFs and the GP matrix, and the macroscopic mechanical properties of SFRGs. The properties of SFs make them have good bonding properties with the GP matrix. The addition of SFs can improve the flexural strength and tensile strength of GP composites, and SFRGs have good engineering application prospects.

Unlocking the future of precision manufacturing: A comprehensive exploration of 3D printing with fiber-reinforced composites in aerospace, automotive, medical, and consumer industries

Rapid advancements in the field of 3D printing in the last several decades have made it possible to produce complex and unique parts with remarkable precision and accuracy. Investigating the use of 3D printing to create various high-performance materials is a relatively new field that is expanding exponentially worldwide. Automobile, biomedical, construction, aerospace, electronics, and metal and alloy industries are among the most prolific users of 3D printing technology. Modern 3D printing technologies, such as polymer matrices that use fiber-reinforced composites (FRCs) to enhance the mechanical qualities of printed components greatly, have been useful to several industries. High stiffness and tensile strength lightweight components are developed from these materials. Fiber-reinforced composites have a wide range of applications, such as military vehicles, fighter aircraft, underwater structures, shelters, and warfare equipment. Fabricating FRCs using fused deposition modeling (FDM) is also advantageous over other 3D printing methods due to its low cost and ease of operation. The impact of different continuous fiber and matrix polymer selections on FRC performance is covered in this review paper. We will also evaluate the important parameters influencing FRC characteristics and review the most recent equipment and methods for fabricating FRCs. Furthermore, the challenges associated with 3D printing fiber-reinforced composites are covered. The constraints of present technology have also been used to identify future research areas.

The Effect of Zinc Oxide on DLP Hybrid Composite Manufacturability and Mechanical-Chemical Resistance

The widespread use of epoxy resin (ER) in industry, owing to its excellent properties, aligns with the global shift toward greener resources and energy-efficient solutions, where utilizing metal oxides in 3D printed polymer parts can offer extended functionalities across various industries. ZnO concentrations in polyurethane acrylate composites impacted adhesion and thickness of DLP samples, with 1 wt.% achieving a thickness of 3.99 ± 0.16 mm, closest to the target thickness of 4 mm, while 0.5 wt.% ZnO samples exhibited the lowest deviation in average thickness (±0.03 mm). Tensile stress in digital light processed (DLP) composites with ZnO remained consistent, ranging from 23.29 MPa (1 wt.%) to 25.93 MPa (0.5 wt.%), with an increase in ZnO concentration causing a reduction in tensile stress to 24.04 MPa and a decrease in the elastic modulus to 2001 MPa at 2 wt.% ZnO. The produced DLP samples, with their good corrosion resistance in alkaline environments, are well-suited for applications as protective coatings on tank walls. Customized DLP techniques can enable their effective use as structural or functional elements, such as in Portland cement concrete walls, floors and ceilings for enhanced durability and performance.

Effect of Wet-Dry Cycling on Properties of Natural-Cellulose-Fiber-Reinforced Geopolymers: A Short Review

To study the long-term properties of cement-based and geopolymer materials exposed to outdoor environments, wet-dry cycles are usually used to accelerate their aging. The wet-dry cycling can simulate the effects of environmental factors on the long-term properties of the composites under natural conditions. Nowadays, the long-term properties of geopolymer materials are studied increasingly deeply. Unlike cement-based materials, geopolymers have better long-term properties due to their high early strength, fast hardening rate, and wide range of raw material sources. At the same time, natural cellulose fibers (NCFs) have the characteristics of abundant raw materials, low price, low carbon, and environmental protection. The use of NCFs as reinforcements of geopolymer matrix materials meets the requirements of sustainable development. In this paper, the types and properties of NCFs commonly used for geopolymer reinforcement and the polymerization mechanism of geopolymer matrix materials are summarized. By analyzing the properties of natural-cellulose-fiber-reinforced geopolymers (NCFRGs) under non-wet-dry cycles and NCFRGs under wet-dry cycles, the factors affecting the long-term properties of NCFRGs under wet-dry cycles are identified. Meanwhile, the degradation mechanism and mechanical properties of NCFRG composites after wet-dry cycles are analyzed. In addition, the relationship between the properties of composites and the change of microstructure of fiber degradation is further analyzed according to the results of microscopic analysis. Finally, the effects of wet-dry cycles on the properties of fibers and geopolymers are obtained.

Effect of Plant Fiber on Early Properties of Geopolymer

Geopolymer (GP) is environmentally friendly, has good mechanical properties and long-term workability, and has broad application prospects. However, due to the poor tensile strength and toughness of GPs, they are sensitive to microcracks, which limits their application in engineering. Fiber can be added to GPs to limit the growth of cracks and enhance the toughness of the GP. Plant fiber (PF) is cheap, easy to obtain, and abundant in source, which can be added to GP to improve the properties of composites. This paper reviews recent studies on the early properties of plant fiber-reinforced geopolymers (PFRGs). In this manuscript, the properties of PFs commonly used for GP reinforcements are summarized. The early properties of PFRGs were reviewed, including the rheological properties of fresh GPs, the early strength of PFRGs, and the early shrinkage and deformation properties of PFRGs. At the same time, the action mechanism and influencing factors of PFRGs are also introduced. Based on the comprehensive analysis of the early properties of PFRGs, the adverse effects of PFs on the early properties of GPs and the solutions were summarized.

Alkaline Degradation of Plant Fiber Reinforcements in Geopolymer: A Review

Plant fibers (PFs), such as hemp, Coir, and straw, are abundant in resources, low in price, light weight, biodegradable, have good adhesion to the matrix, and have a broad prospect as reinforcements. However, the degradation of PFs in the alkaline matrix is one of the main factors that affects the durability of these composites. PFs have good compatibility with cement and the geopolymer matrix. They can induce gel growth of cement-based materials and have a good toughening effect. The water absorption of the hollow structure of the PF can accelerate the degradation of the fiber on the one hand and serve as the inner curing fiber for the continuous hydration of the base material on the other. PF is easily deteriorated in the alkaline matrix, which has a negative effect on composites. The classification and properties of PFs, the bonding mechanism of the interface between PF reinforcements and the matrix, the water absorption of PF, and its compatibility with the matrix were summarized. The degradation of PFs in the alkaline matrix and solution, drying and wetting cycle conditions, and high-temperature conditions were reviewed. Finally, some paths to improve the alkaline degradation of PF reinforcement in the alkaline matrix were proposed.

Properties of 3D Printing Fiber-Reinforced Geopolymers Based on Interlayer Bonding and Anisotropy

The engineering applications and related researches of 3D printing fiber-reinforced geopolymers are becoming more and more extensive. However, compared with traditional mould-casted cement-based materials, the properties of 3D-printed fiber-reinforced geopolymers are significantly different, and their interlayer bonding and anisotropy effects are less studied, so in-depth analysis and summary are needed. Similar to common cement-based materials, the reinforcement fibers for geopolymers include not only traditional fibers, such as steel fibers and carbon fibers, but also synthetic polymer fibers and natural polymer fibers. These fibers have unique properties, most of which have good mechanical properties and bonding properties with geopolymers, as well as excellent crack resistance and enhancement. This paper summarizes and analyzes the effects of traditional fibers, polymer fibers, plant fibers and other reinforcement fibers on the properties of 3D-printed fiber-reinforced geopolymers, especially on the interlayer bonding and anisotropy. The influence of the flow and thixotropic properties of fiber-reinforced fresh geopolymer on the weak bond and anisotropy between layers is summarized and analyzed. At the same time, the influence of fibers on the compressive strength, flexural strength and interlayer binding strength of the hardened geopolymers is investigated. The effect of fibers on the anisotropy of 3D-printed geopolymers and the methods to improve the interlayer binding degree are summarized. The limitations of 3D printing fiber-reinforced geopolymers are pointed out and some suggestions for improvement are put forward. Finally, the research on 3D printing fiber-reinforced geopolymers is summarized. This paper provides a reference for further improving the interlayer bonding strength of 3D-printed fiber-reinforced geopolymers. At the same time, the anisotropy properties of 3D-printed fiber-reinforced geopolymers are used to provide a basis for engineering applications.

The Mechanical Properties of Plant Fiber-Reinforced Geopolymers: A Review

Both geopolymer and plant fiber (PF) meet the requirements of sustainable development. Geopolymers have the advantages of simple preparation process, conservation and environmental protection, high early strength, wide source of raw materials, and low cost. They have broad application prospects and are considered as the most potential cementitious materials to replace cement. However, due to the ceramic-like shape and brittleness of geopolymers, their flexural strength and tensile strength are poor, and they are sensitive to microcracks. In order to solve the brittleness problem of geopolymers, the toughness of composites can be improved by adding fibers. Adding fibers to geopolymers can limit the growth of cracks and enhance the ductility, toughness and tensile strength of geopolymers. PF is a good natural polymer material, with the advantages of low density, high aspect ratio. It is not only cheap, easy to obtain, abundant sources, but also can be repeatedly processed and biodegradable. PF has high strength and low hardness, which can improve the toughness of composites. Nowadays, the research and engineering application of plant fiber-reinforced geopolymers (PFRGs) are more and more extensive. In this paper, the recent studies on mechanical properties of PFRGs were reviewed. The characteristics of plant fibers and the composition, structure and properties of geopolymers were reviewed. The compatibility of geopolymer material and plant fiber and the degradation of fiber in the substrate were analyzed. From the perspective of the effect of plant fibers on the compression, tensile and bending properties of geopolymer, the reinforcing mechanism of plant fibers on geopolymer was analyzed. Meanwhile, the effect of PF pretreatment on the mechanical properties of the PFRGs was analyzed. Through the comprehensive analysis of PFFRGs, the limitations and recommendations of PFFRG are put forward.

Properties of Fiber-Reinforced One-Part Geopolymers: A Review

Geopolymers have the advantages of low carbon, being environmentally friendly and low price, which matches the development direction of building materials. Common geopolymer materials are also known as two-part geopolymers (TPGs). TPGs are usually prepared from two main substances, which are formed by polymerization of a silicoaluminate precursor and an alkaline activator solution. The TPG has many limitations in engineering application because of its preparation on the construction site, and the use of solid alkaline activator in one-part geopolymers (OPGs) overcomes this shortcoming. However, the brittleness of OPGs such as ceramics also hinders its popularization and application. The properties of the new OPG can be improved effectively by toughening and strengthening it with fibers. This review discusses the current studies of fiber-reinforced one-part geopolymers (FOPGs) in terms of raw precursors, activators, fibers, physical properties and curing mechanisms. In this paper, the effects of the commonly used reinforcement fibers, including polyvinyl alcohol (PVA) fiber, polypropylene (PP) fiber, polyethylene (PE) fiber, basalt fiber and other composite fibers, on the fresh-mixing properties and mechanical properties of the OPGs are summarized. The performance and toughening mechanism of FOPGs are summarized, and the workability, macroscopic mechanical properties and durability of FOPGs are investigated. Finally, the development and engineering application prospect of FOPGs are prospected.

Mechanical Properties of Hybrid PVA-Natural Curaua Fiber Composites

This work presents the experimental study of hybrid cement-based composites with polyvinyl alcohol fiber (PVA) and alkali-treated, short, natural curaua fiber. The objective of this research is to develop composites reinforced with PVA and curaua fiber to present strain-hardening behavior with average crack width control. To achieve this objective, three groups of composites were investigated. The first group had only PVA fiber in volumes of 0.5, 1, and 2%. The composite with 2% PVA fiber was the only one with strain-hardening and crack width control. The second group had 0.5% PVA fiber and volume fractions of 2, 2.5, and 3% curaua fiber, and presented only deflection-hardening behavior. The third group had 1% PVA and volumes of 1, 1.5, and 2% curaua fiber, and presented strain-hardening behavior. Based on the results, the hybrid combination of 1% PVA and 1.5% curaua was the optimal mixture as it presented strain-hardening behavior and crack width control, with a lower volume of synthetic PVA fiber. Additionally, compressive strength and mix workability were calculated for the investigated composites for comparison.