Re-agglomeration of carbon nanotubes in two-part epoxy system; influence of the concentration

Carbon nanotubes, because of their exceptional mechanical properties, are one of the potential reinforcements for polymers in near future. Before substituting these nanocomposites in commercial applications, there are many problems, like dispersion, agglomeration, cost effectiveness etc., which need to be sorted. Processing such nanocomposites for longer durations is quite frequently observed these days. Apart from the other major obstacles, re-agglomeration, because of strong van der walls forces between carbon nanotubes, is one of the latest problems that has been always underestimated and ignored. In this study, different carbon nanotubes (Single-wall nanotubes (SWNT), Double wall nanotubes (DWNT), Amino-modified double wall nanotubes (DWNT-NH2), Thin Multi wall nanotubes (MWNT) and COOH-modified thin multi wall nanotubes (MWNT-COOH)) at different concentrations (0.025, 0.05 and 0.1 %wt) in two-part epoxy system (Liquid Epoxy, Liquid hardener and Liquid epoxy-hardener mixture) were studied involving nano-particle size analyzer. After a study of 3 hours, it was observed that there is a strong dependence of re-aggregation profile on the employed homogenizing technique, i.e. high-power bath ultrasonication in this study. Apart from nanotubes/epoxy mixture, higher concentrations yielded higher aggregates profile and vice versa. Re-agglomeration, with the passage of time, in liquid epoxy was found to be least as compared to liquid hardener and liquid epoxy-hardener mixture. Hardener in liquid-epoxy mixture was the main culprit responsible for re-aggregation. Results were further verified by scanning electron microscopy, which revealed significant differences in the microstructures of the cured and fractured samples. Suggestions for altering processing parameters in order to avoid this major obstacle are discussed

Multiscale hybrid micro-nanocomposites based on carbon nanotubes and carbon fibers

Amino-modified double wall carbon nanotube (DWCNT-NH2)/carbon fiber (CF)/epoxy hybrid micro-nanocomposite laminates were prepared by a resin infusion technique. DWCNT-NH2/epoxy nanocomposites and carbon fiber/epoxy microcomposites were made for comparison. Morphological analysis of the hybrid composites was performed using field emission scanning electron microscope. A good dispersion at low loadings of carbon nanotubes (CNTs) in epoxy matrix was achieved by a bath ultrasonication method. Mechanical characterization of the hybrid micro-nanocomposites manufactured by a resin infusion process included three-point bending, mode I interlaminar toughness, dynamic mechanical analysis, and drop-weight impact testing. The addition of small amounts of CNTs (0.025, 0.05, and 0.1 wt%) to epoxy resins for the fabrication of multiscale carbon fiber composites resulted in a maximum enhancement in flexural modulus by 35%, a 5% improvement in flexural strength, a 6% improvement in absorbed impact energy, and 23% decrease in the mode I interlaminar toughness. Hybridization of carbon fiber-reinforced epoxy using CNTs resulted in a reduction in Tg and dampening characteristics, presumably as a result of the presence of micron-sized agglomerates

The production of advanced fine-grained alumina by carbon nanotube addition

Alumina and alumina+1vol.% carbon nanotube (CNT) composites were fully densified by spark plasma sintering. Post-sintering heat treatments (1300–1500 ◦C) were performed to completely oxidize CNTs and then densify the remaining 1 vol.% to produce fine-grained ceramics. The grain size and Vickers hardness of the heat-treated composites were compared with the monolithic alumina sintered without CNT addition. Compared to the initial powder particle size of alumina (D50: 356±74 nm), minimal grain growth (∼450 nm) was observed for the fully dense heat-treated composites. A 25% improvement in Vickers hardness and >10 times finer average grain size were observed for alumina produced by the heat treatment (1300 ◦C) of alumina+1vol.% CNT composite, compared to alumina sintered without CNTs

Experimental process characterisation for high-volume compression moulding of hybrid-architecture composites

Compression moulding of woven fabric prepreg and sheet moulding compound (SMC) in a single-shot process combines the superior mechanical properties of continuous fibre composites and the high design flexibility of discontinuous fibre composites. This experimental study presents insights into the moulding characteristics of prepreg and SMC and explores the interaction between these two materials during manufacturing of hybrid-architecture composites. All tests were performed under typical compression moulding conditions using a squeeze flow testing rig. The response of each material was interpreted through proposed material models applied to the data acquired from single architecture tests. Critical interaction mechanisms were identified from hybrid architecture tests, alongside some additional deformation mechanisms, such as high level of in-plane fibre tow deformation not observed in single-architecture tests. Novel experimental methods were also introduced to quantify the change in meso-scale fibre architecture in the prepreg induced by the flow of SMC. The outcomes of this study not only shed light on the essential interaction mechanisms of hybrid-architecture composites but also provide valuable insights into deformation mechanisms not apparent in isolated material studies. Ultimately, these findings will facilitate the future development of a numerical simulation model for hybrid moulding processes

Enhanced Thermal and Electrical Properties of Polystyrene-Graphene Nanofibers via Electrospinning

Polystyrene- (PS-) graphene nanoplatelets (GNP) (0.1, 1, and 10 wt.%) nanofibers were successfully produced via electrospining of dimethyformamide- (DMF-) stabilized GNP and PS solutions. Morphological analysis of the composite nanofibers confirmed uniform fiber formation and good GNP dispersion/distribution within the PS matrix. The good physical properties of GNP produced by liquid exfoliation were transferred to the PS nanofibers. GNP modified PS nanofibers showed a 6-fold increase in the thermal conductivity and an increase of 7-8 orders of magnitude in electrical conductivity of the nanofibers at 10 wt.% GNP loading

Smart and repeatable easy-repairing and self-sensing composites with enhanced mechanical performance for extended components life

Structural composites with smart functionalities of self-healing and self-sensing are of particular interest in the fields of aerospace, automotive, and renewable energy. However, most of the current self-healing methodologies either require a relatively complex design of the healing network, or sacrifice the initial mechanical or thermal performance of the carbon fibre composite system after introducing the healing agents. Herein, an extremely simple methodology based on commonly used thermoplastic interleaves has been demonstrated to achieve repeatable easy-repairing and self-sensing functionalities, alongside enhanced mechanical performance in comparison with unmodified carbon fibre/epoxy system. Moreover, due to the high glass transition temperature of the thermoplastic, the repairable composites are shown to have an unchanged storage modulus up to 80 °C, solving the previous limitation of repairable epoxy matrix systems with thermoplastics. High retention of peak load (99%) and a decent recovery of interlaminar fracture toughness (34%) was achieved. Most importantly, the mechanical properties remained greater than the unmodified system after four consecutive cycles of damage and healing. Repeatable in-situ damage sensing was achieved based on the piezoresistive method. This “new” discovery based on an “old” approach, which is fully compatible with current composite manufacturing, may overcome existing conflicts between mechanical performance and healing functions, providing a new solution to extend components’ service life towards a more sustainable development of the composite sector

Simultaneous strength and ductility enhancements of high thermal conductive Ag7.5Cu alloy by selective laser melting

High electrical and thermal conductive metals (HETCM) play a key role in smart electronics, green energy, modern communications and healthcare, however, typical HETCM (e.g., Ag, Au, Cu) usually have relatively low mechanical strength, hindering further applications. Selective laser melting (SLM) is a potentially transformative manufacturing technology that is expected to address the issue. Ag is the metal with the highest thermal conductivity, which induces microscale grain refinement, but also leads to high internal stresses by SLM. Here, we select Ag7.5Cu alloy as an example to demonstrate that multi-scale (micro/meso/macro) synergies can take advantage of high thermal conductivity and internal stresses to effectively strengthen Ag alloy. The mimicry of metal-hardened structures (e.g., large-angle boundary) is extended to the mesoscale by controlling the laser energy density and laser scanning strategy to manipulate the macroscale internal stress intensity and mesoscale internal stress direction, respectively, to form mesoscale large-angle "grains", resulting in multiple mutual perpendicular shear bands during fracture. The presented approach achieved a significant enhancement of yield strength (+ 145%) and ductility (+ 28%) without post-treatment. The results not only break the strength-ductility trade-off of conventional SLM alloys, but also demonstrate a multi-scale synergistic enhancement strategy that exploits high thermal conductivity and internal stresses

Controlling the dynamic percolation of carbon nanotube based conductive polymer composites by addition of secondary nanofillers: The effect on electrical conductivity and tuneable sensing behaviour

In this paper, the electrical properties of ternary nanocomposites based on thermoplastic polyurethane (TPU) and multi-walled carbon nanotubes (MWCNTs) are studied. In particular two nanofillers - differing in shape and electrical properties - are used in conjunction with MWCNTs: an electrically conductive CB and an insulating needle-like nanoclay, sepiolite. The ternary nanocomposites were manufactured in a number of forms (extruded pellets, filaments and compression moulded films) and their morphological and electrical properties characterised as function of time and temperature. The presence of both secondary nanofillers is found to affect the formation of a percolating network of MWCNTs in TPU, inducing a reduced percolation threshold and tuneable strain sensing ability. These ternary nanocomposites can find application as conductive and multi-functional materials for flexible electronics, sensing films and fibres in smart textiles. (c) 2012 Elsevier Ltd. All rights reserved