Multifunctionality of Additively Manufactured Kelvin Foam for Electromagnetic Wave Absorption and Load Bearing

Rationally engineered porous structures enable lightweight broadband electromagnetic (EM) wave absorbers for countering radar signals or mitigating EM interference between multiple components. However, the scalability of such structures has been hindered by their limited mechanical properties resulting from low density. Herein, an additively manufactured Kelvin foam-based EM wave absorber (KF-EMA) is reported that exhibits multifunctionality, namely EM wave absorption and light-weighted load-bearing structures with constant relative stiffness made possible using bending-dominated lattice structures. Based on tuning design parameters, such as the backbone structures and constituent materials, the proposed KF-EMA features a multilayered 3D-printed design with geometrically optimized KF structures made of carbon black-based backbone composites. The developed KF-EMA demonstrated an absorbance greater than 90% at frequencies ranging from 5.8 to 18 GHz (average EM wave absorption rates of 95.89% and maximum of 99.1% at 15.8 GHz), while the low-density structures of the absorber (≈200 kg m-3 ) still maintained a compression index between the stiffness and relative density (n = 2) under compression. The design strategy paves the way for using metamaterials as mechanically reinforced EM wave absorbers that enable multifunctionality by optimizing unit-cell parameters through a single and low-density structure.

Optimizing and applying high-resolution, in-line laboratory phase-contrast X-ray imaging for low-density material samples

In-line, or propagation-based phase-contrast X-ray imaging (PBI) is an attractive alternative to the attenuation-based modality for low-density, soft samples showing low attenuation contrast. With the growing availability of micro- and nano-focus X-ray tubes, the method is increasingly applied in the laboratory. Here, we discuss the technique and demonstrate its advantages for selected low-density, low attenuation material samples using a lab-based micro- and nano-computed tomography systems Easytom XL Ultra, providing micron and sub-micron range resolution PBI images. We demonstrate a multi-step optimization of the lab-based PBI technique on our scanner that includes choosing the optimal detector-source hardware combination available in the setup, then optimizing the imaging geometry and finally the phase retrieval process through a parametric study. We point out and elaborate on the effect of noise correlation and texturing due to phase retrieval. We demonstrate the overall benefits of using the phase image and the phase retrieval for the selected samples such as improved image quality, increased contrast-to-noise ratio while only marginally influencing the spatial resolution. The improvement in image quality also enables further image processing steps for detailed structural analysis of the samples, which would be much more complicated if not impossible based on the transmission image.

Implementation of Circular Economy Principles in the Synthesis of Polyurethane Foams

The main strategy of the European Commission in the field of the building industry assumes a reduction of greenhouse gas emissions by up to 20% by 2020 and by up to 80% by 2050. In order to meet these conditions, it is necessary to develop not only efficient thermal insulation materials, but also more environmentally friendly ones. This paper describes an experiment in which two types of bio-polyols were obtained using transesterification of used cooking oil with triethanolamine (UCO_TEA) and diethylene glycol (UCO_DEG). The bio-polyols were next used to prepare low-density rigid polyurethane (PUR) foams. It was found that the bio-polyols increased the reactivity of the PUR systems, regardless of their chemical structures. The reactivity of the system modified with 60% of the diethylene glycol-based bio-polyol was higher than in the case of the reference system. The bio-foams exhibited apparent densities of 41-45 kg/m³, homogeneous cellular structures and advantageous values of the coefficient of thermal conductivity. It was observed that the higher functionality of bio-polyol UCO_TEA compared with UCO_DEG had a beneficial effect on the mechanical and thermal properties of the bio-foams. The most promising results were obtained in the case of the foams modified in 60% with the bio-polyol based on triethanoloamine. In conclusion, this approach, utilizing used cooking oil in the synthesis of high-value thermal insulating materials, provides a sustainable municipal waste recycling solution.

Transforming Marble Waste into High-Performance, Water-Resistant, and Thermally Insulative Hybrid Polymer Composites for Environmental Sustainability

Marble waste is generated by marble processing units in large quantities and dumped onto open land areas. This creates environmental problems by contaminating soil, water, and air with adverse health effects on all the living organisms. In this work, we report on understanding the use of calcium-rich marble waste particulates (MPs) as economic reinforcement in recyclable polypropylene (PP) to prepare sustainable composites via the injection molding method. The process was optimized to make lightweight and high-strength thermally insulated sustainable composites. Physicochemical, mineralogical, and microscopic characterization of the processed marble waste particulates were carried out in detail. Composite samples were subsequently prepared via the injection molding technique with different filler concentrations (0%, 20%, 40%, 60%, and 80%) on weight fraction at temperatures of 160, 180, and 200 °C. Detailed analysis of the mechanical and thermal properties of the fabricated composites was carried out. The composites showed a density varying from 0.96 to 1.27 g/cm³, while the water absorption capacity was very low at 0.006%-0.034%. Marble waste particulates were found to considerably increase the tensile, as well as flexural, strength of the sustainable composites, which varied from 22.06 to 30.65 MPa and 43.27 to 58.11MPa, respectively, for the molding temperature of 160 °C. The impact strength of the sustainable composites was found to surge with the increment in filler concentration, and the maximum impact strength was recorded as 1.66 kJ/m²with 20% particulates reinforcement at a molding temperature of 200 °C. The thermal conductivity of the particulates-reinforced sustainable composites was as low as 0.23 Wm^-1K^-1 at a 200 °C molding temperature with 20% and 40% filler concentrations, and the maximum thermal conductivity was 0.48 Wm^-1K^-1 at a 160 °C molding temperature with 80% filler concentration. Our findings have shown a technically feasible option for manufacturing a lightweight composite with better mechanical and thermal properties using marble waste particulates as a potential civil infrastructural material.