New Insights on Expandability of Pre-Cured Epoxy Using a Solid-State CO₂-Foaming Technique

Foaming an epoxy is challenging because the process involves the curing reaction of epoxy and hardener (from monomer to oligomer, to a gel and a final three-dimensional crosslinked network) and the loading of gas phase into the epoxy phase to develop the cellular structure. The latter process needs to be carried out at the optimum curing stage of epoxy to avoid cell coalescence and to allow expansion. The environmental concern regarding the usage of chemical blowing agent also limits the development of epoxy foams. To surmount these challenges, this study proposes a solid-state CO(2) foaming of epoxy. Firstly, the resin mixture of diglycidylether of bisphenol-A (DGEBA) epoxy and polyamide hardener is pre-cured to achieve various solid-state sheets (preEs) of specific storage moduli. Secondly, these preEs undergo CO(2) absorption using an autoclave. Thirdly, CO(2) absorbed preEs are allowed to free-foam/expand in a conventional oven at various temperatures; lastly, the epoxy foams are post-cured. PreE has a distinctive behavior once being heated; the storage modulus is reduced and then increases due to further curing. Epoxy foams in a broad range of densities could be fabricated. PreE with a storage modulus of 4 × 10(4)–1.5 × 10(5) Pa at 30 °C could be foamed to densities of 0.32–0.45 g/cm(3). The cell morphologies were revealed to be star polygon shaped, spherical and irregularly shaped. The research proved that the solid-state CO(2)-foaming technique can be used to fabricate epoxy foams with controlled density

Improving the flame-retardant property of bottle-grade PET foam made by reactive foam extrusion

Upcycling of low intrinsic viscosity (IV) poly(ethylene terephthalate) (PET) grades, such as bottle‐ or recycled grades, by a reactive foam extrusion process, provides an appropriate alternative to high pricing, high IV grades commonly used for foaming applications. However, the drawback of bottle‐grade PET foams is its flame retardant (FR) performance. In this study, pyromellitic dianhydride was used as a chain extender to foam bottle‐grade PET. The influence of different FRs, containing halogenated (HFR) and four different phosphorous‐based types, on the processability and final foam properties was investigated. HFR showed better processability to achieve proper foams with fine morphology compared to P‐based FRs, where the FR content was adjusted between 2 and 5 wt%. However, HFR exhibited lower FR performance by cone calorimeter testing compared to the P‐based FRs and the commercial reference foam Kerdyn. Nonetheless, all of the FRs can only improve the time to ignition of the neat PET foams while the other values depend on the specific type of FR. In addition, all FR foams have improved mechanical properties more than twice in comparison to the neat PET foam

A Two-Step Machine Learning Method for Predicting the Formation Energy of Ternary Compounds

Predicting the chemical stability of yet-to-be-discovered materials is an important aspect of the discovery and development of virtual materials. The conventional approach for computing the enthalpy of formation based on ab initio methods is time consuming and computationally demanding. In this regard, alternative machine learning approaches are proposed to predict the formation energies of different classes of materials with decent accuracy. In this paper, one such machine learning approach, a novel two-step method that predicts the formation energy of ternary compounds, is presented. In the first step, with a classifier, we determine the accuracy of heuristically calculated formation energies in order to increase the size of the training dataset for the second step. The second step is a regression model that predicts the formation energy of the ternary compounds. The first step leads to at least a 100% increase in the size of the dataset with respect to the data available in the Materials Project database. The results from the regression model match those from the existing state-of-the-art prediction models. In addition, we propose a slightly modified version of the Adam optimizer, namely centered Adam, and report the results from testing the centered Adam optimizer.Deutsche ForschungsgemeinschaftPeer Reviewe

Investigations on Epoxy-Carbamate Foams Modified with Different Flame Retardants for High-Performance Applications

In transport sectors such as aviation, automotive and railway, materials combining a high lightweight potential with high flame retardant properties are in demand. Polymeric foams are suitable materials as they are lightweight, but often have high flammability. This study focuses on the influence of different flame retardants on the burning behavior of Novolac based epoxy foams using Isophorone Diamine carbamate (B-IPDA) as dual functional curing and blowing agent. The flame retardant properties and possible modifications of these foams are systematically investigated. Multiple flame retardants, representing different flame retardant mechanisms, are used and the effects on the burning behavior as well as mechanical and thermal properties are evaluated. Ammonium polyphosphate (APP), used with a filler degree of 20 wt.% or higher, functions as the best performing flame retardant in this study

Tailoring Epoxy Resin Foams by Pre-Curing with Neat Amine Hardeners and Its Derived Carbamates

The use of amine-based carbamates with their dual function, acting as amine curing agents and CO2 blowing agents after their decomposition without by-products, are promising for ecofriendly epoxy foams as high-performance materials. However, controlling cell morphology requires a proper adjustment of the viscosity at the foaming step. The viscosity is altered not only by blending neat amine and its derived carbamate at a fixed pre-curing time, but also by changing the pre-curing time at a fixed blend ratio. Within this study, diglycidylether of bisphenol A (DGEBA) epoxy resin is mixed with different blend ratios of isophorone diamine (IPDA) and its derived carbamate (B-IPDA). The systems are characterized by DSC and rheology experiments to identify the pre-curing effects on the derived epoxy foams. Epoxy foams at a blend ratio of 30/70w IPDA/B-IPDA showed the best foam morphology and an optimum Tg compared to other blend ratios. Furthermore, it was found that both pre-curing times, 2 h and 3 h, for the 30/70w IPDA/B-IPDA system reveal a more homogeneous cell structure. The study proves that the blending of neat amine and carbamate is beneficial for the foaming performance of carbamate systems

Fire behavior of flame retarded sandwich structures containing PET foam cores and epoxy face sheets

Within this work, the investigation on interactions of a phosphorus‐containing flame retardant (FR) DEPAl in epoxy face sheets and five different FRs in the PET‐foam core of a sandwich laminate on the fire behavior is focused. Fourteen different combinations of resin face sheets and PET foam cores are produced by vacuum assisted resin infusion (VARI). The combustion behavior of the sandwich laminates is tested by cone calorimetry. The time to ignition is lowered when a FR resin is used while the subsequent burning behavior is mainly influenced by the PET foam core. In order to evaluate the interactions of the flame retardants in the core and face sheet, a total improvement value (TIV) was set up which compares the performance related to the specific FR combinations. The highest TIV value (76%) indicating positive interactions with DEPAl was observed with a 2‐PSMP‐PET core, the lowest value (−2%) with a DEPZn‐PET core

Electroweak corrections to hadronic event shapes and jet production in e+e- annihilation

We present a complete calculation of the electroweak O(alpha^3 alpha_s) corrections to three-jet production and related event-shape observables at electron--positron colliders. The Z-boson resonance is described within the complex-mass scheme, rendering the calculation valid both in the resonance and off-shell regions. Higher-order initial-state radiation is included in the leading-logarithmic approximation. We properly account for the corrections to the total hadronic cross section and for the experimental photon isolation criteria. To this end we implement contributions of the quark-to-photon fragmentation function both in the slicing and subtraction formalism. The effects of the electroweak corrections on various event-shape distributions and on the three-jet rate are studied. They are typically at the few-per-cent level, and remnants of the radiative return are found even after inclusion of appropriate cuts.Comment: 47 pages, 20 figure