Integrated Fabrication Processes of Novel Hybrid Materials

Integrated fabrication techniques in order to develop novel multi-functional hybrid materials for potential applications in energy conversion and sustainability were investigated. There are three major areas of investigation involved. First, we developed and demonstrated more efficient and cost effective alternative synthesis techniques to fabricate hybrid materials. Second, we designed and synthesized a new class of hybrid materials, for energy conversion, and evaluate their performance. Third, we synthesized and characterized new wear and corrosion resistant materials. Experimental approaches, including fabrication process development, materials preparation, characterization, and physical analysis were used. The study was validated to be beneficial for future design and development of hybrid material systems via more efficient and cost effective advanced fabrication techniques targeting energy conversion, wear and corrosion resistance. The first part of research focused on fabrication. Rapid solidification, thermal treatment, and spin coating techniques were studied and integrated into effective techniques for making new hybrid materials. The processing time, temperature, and environments were evaluated against microstructure. Eventually, two classes of novel hybrid materials were developed. The second part of research focused on fabrication of a new hybrid material utilizing rapid solidification, and spin coating processes. Piezoelectric poly (vinylidene fluoride) (PVDF) with magnetocaloric Gd5Si2Ge2 was developed. The PVDF – Gd5Si2Ge2 hybrid material system was found to convert magnetic energy into electrical power. The maximum electrical power output was 0.11 V that is equivalent to a power density of 14.3 mW/cm^3 Oe. An adiabatic device was built to test for pyroelectric energy conversion. This device was built in such a way that it can also be further used for waste heat recovery. The power density and the conversion efficiency were calculated. The very same system was capable of pyroelectric energy conversion using the adiabatic device. The efficiency for the energy converter was 0.43% and the maximum voltage output was 0.16 V. The third part of the research focused on fabrication of a new hybrid material utilizing rapid solidification, and thermal treatment processes. A quasicrystalline Al75Mn14Si7Fe4 with Ferro-Silico-Aluminate geopolymer phase hybrid material system was also fabricated. The role of geopolymer phase on the wear and corrosion resistance was studied. The relative amount of icosahedral (i-phase) phase was attributed to the wear resistance. The geopolymer phase was responsible for the increased corrosion resistance