Search results for: fly ash composites

Authors: Razieh Shamsi, Mehdi Faezipour, Ali Abdolkhani

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In this research, the characteristics of composites prepared from waste silk fibers and recycled polycarbonate polymer (used compacted boards) at four levels of 0, 10, 20, and 30% (silk fibers) and using 2% N- 2-Aminoethyl-3-Aminopropyltrimethoxysilane was investigated as a coupling agent and melt process method. Silk fibers (carpet weaving waste) with dimensions of 8-18 mm were prepared, and recycled polymer with 9 mesh grading was ground. Production boards in 3 thicknesses, 3 mm (tensile test samples), 5 mm (bending test samples, water absorption, and thickness shrinkage), 7 mm (impact resistance test samples) ) with a specific weight of 1 gram per cubic centimeter, hot pressing time and temperature of 12 minutes and 190 degrees Celsius with a pressure of 130 bar, cold pressing time of 6 minutes with a pressure of 50 bar and using the coupling agent N- (2- Aminoethyl)-3-aminopropyltrimethoxysilane was prepared in a constant amount of 2% of the dry weight of the filler. The results showed that, in general, by adding silk fibers to the base polymer, compared to the control samples (pure recycled polycarbonate polymer) and also by increasing the amount of silk fibers, almost all the resistances increased. The amount of water absorption of the constructed composite increased with the increase in the amount of silk fibers, and the thickness absorption was equal to 0% even after 72 hours of immersion in water. The thermal resistance of the pure recycled polymer was higher than the prepared composites, and by adding silk fibers to the base polymer and also by increasing the amount of silk fibers from 10 to 30%, the thermal resistance of the composites decreased.

Keywords: wood composite, recycled polycarbonate, silk fibers, polymer

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Authors: Akanksha Singh, Mahesh Kumar, Shailesh N. Sharma

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Semiconductor quantum dots (QDs) such as CdSe, CdS, InP, etc. have gained significant interest in the recent years due to its application in various fields such as LEDs, solar cells, lasers, biological markers, etc. The interesting feature of the QDs is their tunable band gap. The size of the QDs can be easily varied by varying the synthesis parameters which change the band gap. One of the limitations with II-VI semiconductor QDs is their biological application. The use of cadmium makes them unsuitable for biological applications. III-V QD such as InP overcomes this problem as they are structurally robust because of the covalent bonds which do not allow the ions to leak. Also, InP QDs has large Bohr radii which increase the window for the quantum confinement effect. The synthesis of InP QDs is difficult and time consuming. Authors have synthesized InP using a novel, quick synthesis method which utilizes trioctylphosphine as a source of phosphorus. In this work, authors have made InP composites with P3HT(Poly(3-hexylthiophene-2,5-diyl))polymer(organic-inorganic hybrid material) and gold nanoparticles(metal-semiconductor composites). InP-P3HT shows FRET phenomenon whereas InP-Au shows charge transfer mechanism. The synthesized InP QDs has an absorption band at 397 nm and PL peak position at 491 nm. The band gap of the InP QDs is 2.46 eV as compared to the bulk band gap of InP i.e. 1.35 eV. The average size of the QDs is around 3-4 nm. In order to protect the InP core, a shell of wide band gap material i.e. ZnS is coated on the top of InP core. InP-P3HT composites were made in order to study the charge transfer/energy transfer phenomenon between them. On adding aliquots of P3HT to InP QDs solution, the P3HT PL increases which can be attributed to the dominance of Förster energy transfer between InP QDs (donor) P3HT polymer (acceptor). There is a significant spectral overlap between the PL spectra of InP QDs and absorbance spectra of P3HT. But in the case of InP-Au nanocomposites, significant charge transfer was seen from InP QDs to Au NPs. When aliquots of Au NPs were added to InP QDs, a decrease in the PL of the InP QDs was observed. This is due to the charge transfer from the InP QDs to the Au NPs. In the case of metal semiconductor composites, the enhancement and quenching of QDs depend on the size of the QD and the distance between the QD and the metal NP. These two composites have different phenomenon between donor and acceptor and hence can be utilized for two different applications. The InP-P3HT composite can be utilized for LED devices due to enhancement in the PL emission (FRET). The InP-Au can be utilized efficiently for photovoltaic application owing to the successful charge transfer between InP-Au NPs.

Keywords: charge transfer, FRET, gold nanoparticles, InP quantum dots

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Authors: Fawad Ali, Mohammad Albakri

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The increasing demand for advanced multifunctional materials has led to significant research in polymer composites, particularly polyvinylidene fluoride (PVDF) and conducting carbon black (CCB) composites. This paper explores the development and application of PVDF/CCB conducting electrodes for energy harvesting applications. PVDF is renowned for its chemical resistance, thermal stability, and mechanical strength, making it an ideal matrix for composite materials in demanding environments. When combined with CCB, known for its excellent electrical conductivity, the resulting composite electrodes not only retain the advantageous properties of PVDF but also gain enhanced electrical conductivity. This synergy makes PVDF/CCB composites suitable for energy-harvesting devices that require both durability and electrical functionality. These electrodes can be used in sensors, actuators, and flexible electronics where efficient energy conversion is critical. The study provides a comprehensive overview of PVDF/CCB conducting electrodes, from synthesis and characterization to practical applications, and discusses challenges in optimizing these materials for industrial use and future development. This research aims to contribute to the understanding of conductive polymer composites and their potential in advancing sustainable energy technologies. This paper explores the development and application of polyvinylidene fluoride (PVDF) and conducting carbon black (CCB) composite conducting electrodes for energy harvesting applications. PVDF is renowned for its piezoelectric and mechanical strength, making it an ideal matrix for composite materials in demanding environments. When combined with CCB, known for its excellent electrical conductivity, the resulting composite electrodes not only retain the advantageous properties of PVDF but also gain enhanced electrical conductivity. This synergy makes PVDF/CCB composites suitable for energy-harvesting devices that require both durability and electrical functionality. These electrodes can be used in sensors, actuators, and flexible electronics where efficient energy conversion is critical. The study provides a comprehensive overview of PVDF/CCB conducting electrodes, from synthesis and characterization to practical applications. This research aims to contribute to the understanding of conductive polymer composites and their potential in advancing sustainable energy technologies.

Keywords: additive manufacturing, polyvinylidene fluoride (PVDF), conducting polymer composite, energy harvesting, materials characterization

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Authors: Mohamed Haneef, Shanawaz Patil, Syed Zameer, Mohammed Mohsin Ali

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The emerging technologies and trends of present generation requires downsizing the unwieldy structures to light weight structures on one hand and integration of varied properties on other hand to meet the application demands. In the present investigation an attempt is made to familiarize and best possibilities of reinforcing agent in aluminum 7075 matrix with naturally occurring beryl (Be) and graphene (Gr) to develop a new hybrid composite material. A stir casting process was used to fabricate with fixed volume fraction of 6wt% weight beryl and various volume fractions of 0.5wt%, 1wt%, 1.5wt% and 2wt% of graphene. The properties such as tensile strength, hardness and dry sliding wear behavior of hybrid composites were examined. The crystallite size and morphology of the graphene and beryl particles were analyzed with X-ray diffraction (XRD) and scanning electron microscopy (SEM) respectively. It was observed that ultimate tensile strength and hardness of the hybrid composite increased with increasing reinforcement volume fraction as compared to specimen without reinforcement additions. The dry sliding wear behavior of the hybrid composites decreases as compared to Al7075 alloy without reinforcement.

Keywords: Al7075, beryl, graphene, TEM, wear

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Authors: Maizatulnisa Othman, Mohamad Bukhari, Zahurin Halim, Souad A. Muhammad, Khalisani Khalid

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Sandwich structure composites produced by epoxy core and aluminium skin were developed as potential building materials. Interface bonding between core and skin was controlled by varying kenaf content. Five different weight percentage of kenaf loading ranging from 10 wt% to 50 wt% were employed in the core manufacturing in order to study the mechanical properties of the sandwich composite. Properties of skin aluminium with epoxy were found to be affected by drying time of the adhesive. Mechanical behavior of manufactured sandwich composites in relation with properties of constituent materials was studied. It was found that 30 wt% of kenaf loading contributed to increase the flexural strength and flexural modulus up to 102 MPa and 32 Gpa, respectively. Analysis were done on the flatwise and edgewise compression test. For flatwise test, it was found that 30 wt% of fiber loading could withstand maximum force until 250 kN, with compressive strength results at 96.94 MPa. However, at edgewise compression test, the sandwich composite with same fiber loading only can withstand 31 kN of the maximum load with 62 MPa of compressive strength results.

Keywords: sandwich structure composite, epoxy, aluminium, kenaf fiber

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Authors: Veerapat Kitsawat, Muenduen Phisalaphong

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Green natural rubber (NR) composites reinforced with synthetic graphite, using alginate as thickening and dispersing agent, were developed to improve mechanical properties and electrical conductivity. The film fabrication was performed using a latex aqueous microdispersion process. The research found that up to 60 parts per hundred rubbers (phr) of graphite could be successfully integrated into the NR matrix without causing agglomeration and phase separation. Accordingly, the mechanical properties, in terms of tensile strength and Young’s modulus of the composite films, were significantly increased, while the elongation at break decreased with higher graphite loading. The reinforcement strongly improved the hydrophilicity of the composite films, resulting in a higher water absorption rate compared to the neat NR film. Moreover, the incorporation of synthetic graphite significantly improved the chemical resistance of the composite films when exposed to toluene. It is demonstrated that the electrical conductivity of the composite films was considerably enhanced with graphite loading. According to the obtained properties, the developed composites offer potential for further development as conductive substrate for electronic applications.

Keywords: alginate, composite, graphite, natural rubber

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Authors: Lee Siong Wee, Tan Kang Hai, Yang En-Hua

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This paper presents the results of an experimental study undertaken to evaluate the local bond stress-slip response of short embedment of reinforcing bars in normal concrete (NC) and high performance fiber reinforced cement composites (HPFRCC) blocks. Long embedment was investigated as well to gain insights on the distribution of strain, slip, bar stress and bond stress along the bar especially in post-yield range. A total of 12 specimens were tested, by means of pull-out of the reinforcing bars from concrete blocks. It was found that the enhancement of local bond strength can be reached up to 50% and ductility of the bond behavior was improved significantly if HPFRCC is used. Also, under a constant strain at loaded end, HPFRCC has delayed yielding of bars at other location from the loaded end. Hence, the reduction of bond stress was slower for HPFRCC in comparison with NC. Due to the same reason, the total slips at loaded end for HPFRCC was smaller than NC as expected. Test results indicated that HPFRCC has better bond slip behavior which makes it a suitable material to be employed in anchorage zone such as beam-column joints.

Keywords: bond stress, high performance fiber reinforced cement composites, slip, strain

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Authors: Rajesh Panda, Jimi Tjong, Sanjay K. Nayak, Mohini M. Sain

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The aim of this manuscript was to evaluate the effect of chemical treatment of sisal fibre on the mechanical and viscoelastic properties of bio based epoxy/fibre composites. The composite samples were manufactured through a vacuum infusion process by adding alkyl phenols from cashew nutshell liquid (CSNL). Changes in the chemical structure of the sisal fibres resulting from the treatments were analyzed by Fourier transform infrared spectroscopy (FTIR). Both alkali and silane treatments produced enhancements in the mechanical properties of sisal fibre bundles. The alkali treatment, when combined with the silane treatment, the mechanical properties of epoxy composites notably improved (13%) in comparison to untreated sisal fibre reinforced composites.This was attributed to an enhanced fibre/matrix interface. The incorporation of CSNL into the sisal/epoxy composite enhanced the fibre-matrix interfacial properties because of the addition of -OH groups to the epoxy matrix. The incorporation of sisal fibre imparts stiffness to the epoxy matrix.

Keywords: phenalkamine, sisal fiber, vacuum infusion, cashew nutshell liquid, cashew nutshell liquid (CSNL)

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Authors: Masek A., Zaborski M.

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In our studies, we propose the use of natural, pro-ecological substances such as polyphenols to protect polymers against ageing. In our studies, we plan to focus on the following compounds: polyphenols, gallic acid esters, flavonoides, carotenoids, curcumin and its derivatives, vitamin A, tocochromanoles, betalain. Phyto-compounds will be selected on the basis of available literature and our preliminary studies. So, we will select compounds with various contents of hydroxyl groups and colored substances capable of participating in color oxidation processes. The natural antioxidants which were added to ethylene-octene elastomer (polyolefin elastomer-Engage) and ethylene-nonbornene (TOPAS). Composites were then subjected to numerous ageing: weathering (climat of Floryda), UV (0,7 W/m2), thermo-oxidation ageing (1000C/10days) and thermal-shock (-600C/+1000C) as a function of the aging time. The efficiency of used anti-ageing agents was checked on the base of the changes after the degradation in deformation energy (tensile strength and elongation at the break), cross-link density, color (parameters L,a,b) and values of carbonyl index (based on the spectrum of infra red spectroscopy), OIT (induction oxygen time as performed in using differential scanning calorimeter -DSC) of the vulcanizates. Therefore polyphenols are considered to be the best stabilisers for polymeric composites against to oxidation processes.

Keywords: polymers, flavonoids, stabilization, ageing, oxidation

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Authors: Z. Miao, Y. Chu, Y. Zhang

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The unique cholesteric phase liquid crystals obtained by mixing nematic liquid crystals with chiral dopants have gained valuable applications in the display field for their selective reflection and circular dichroism properties. The periodic arrangement of the helical structure of cholesteric liquid crystals makes it possible to produce Bragg reflection of circularly polarized light irradiated perpendicularly to the liquid crystals and, therefore, to acquire semi- or fully reflective surfaces or films. If the polymer-liquid crystal composites are combined with polymeric monomers, commercialized reflective broadband films can be fabricated. In this study, the polymer-liquid crystal composites reflecting visible light region (wavelength centered at 550 nm) were studied to analyze the effects of AC electric field at different voltages and frequencies on the optical texture of the composites, as well as the effects of polymerization temperature and ultraviolet (UV) intensity on the polymerization reaction and reflection bandwidth. The optimal sample was finally obtained at 100Hz, 120V, 30℃, 1.00 mW/cm², which provides a research suggestion to solve the influencing factors of visible light reflection bandwidths.

Keywords: cholesteric liquid crystal, reflection bandwidths, negative dielectric anisotropy, planar texture

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Authors: S. Alrekabi, A. Cundy, A. Lampropoulos, I. Savina

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Due to their remarkable mechanical properties, multi-wall carbon nanotubes (MWCNTs) are considered by many researchers to be a highly promising filler and reinforcement agent for enhanced performance cementitious materials. Currently, however, achieving an effective dispersion of MWCNTs remains a major challenge in developing high performance nano-cementitious composites, since carbon nanotubes tend to form large agglomerates and bundles as a consequence of Van der Waals forces. In this study, effective dispersion of low concentrations of MWCNTs at 0.01%, 0.025%, and 0.05% by weight of cement in the composite was achieved by applying different sonication conditions in combination with the use of polycarboxylate ether as a surfactant. UV-Visible spectroscopy and Transmission electron microscopy (TEM) were used to assess the dispersion of MWCNTs in water, while the dispersion states of MWCNTs within the cement composites and their surface interactions were examined by scanning electron microscopy (SEM). A high sonication intensity applied over a short time period significantly enhanced the dispersion of MWCNTs at initial mixing stages, and 0.025% of MWCNTs wt. of cement, caused 86% and 27% improvement in tensile strength and compressive strength respectively, compared with a plain cement mortar.

Keywords: dispersion, mechanical performance, multi wall carbon nanotubes, sonication conditions

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Authors: O. I. H. Dimitry, N. A. Mansour, A. L. G. Saad

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Natural sodium montmorillonite (NaMMT), Cloisite Na⁺ and two organophilic montmorillonites (OMMTs), Cloisites 20A and 15A were used. Polycaprolactone (PCL)/MMT composites containing 1, 3, 5, and 10 wt% of Cloisite Na⁺ and PCL/OMMT nanocomposites containing 5 and 10 wt% of Cloisites 20A and 15A were prepared via solution intercalation technique to study the influence of organic modifier loading on particle dispersion of PCL/ NaMMT composites. Thermal stabilities of the obtained composites were characterized by thermal analysis using the thermogravimetric analyzer (TGA) which showed that in the presence of nitrogen flow the incorporation of 5 and 10 wt% of filler brings some decrease in PCL thermal stability in the sequence: Cloisite Na+>Cloisite 15A > Cloisite 20A, while in the presence of air flow these fillers scarcely influenced the thermoxidative stability of PCL by slightly accelerating the process. The interaction between PCL and silicate layers was studied by Fourier transform infrared (FTIR) spectroscopy which confirmed moderate interactions between nanometric silicate layers and PCL segments. The electrical conductivity (σ) which describes the ionic mobility of the systems was studied as a function of temperature and showed that σ of PCL was enhanced on increasing the modifier loading at filler content of 5 wt%, especially at higher temperatures in the sequence: Cloisite Na⁺<Cloisite 20A<Cloisite 15A, and was then decreased to some extent with a further increase to 10 wt%. The activation energy E_σ obtained from the dependency of σ on temperature using Arrhenius equation was found to be lowest for the nanocomposite containing 5 wt% of Cloisite 15A. The dispersed behavior of clay in PCL matrix was evaluated by X-ray diffraction (XRD) and scanning electron microscopy (SEM) analyses which revealed partial intercalated structures in PCL/NaMMT composites and semi-intercalated/semi-exfoliated structures in PCL/OMMT nanocomposites containing 5 wt% of Cloisite 20A or Cloisite 15A.

Keywords: electrical conductivity, montmorillonite, nanocomposite, organoclay, polycaprolactone

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Authors: A. Saccani, I. Lancellotti, E. Bursi

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Scraps deriving from the production of epoxy-carbon fibers composites have been recycled as a reinforcement to produce building materials. Short chopped fibers (5-7 mm length) have been added at low volume content (max 10%) to produce mortars. The microstructure, mechanical properties (mainly flexural strength) and dimensional stability of the derived materials have been investigated. Two different types of matrix have been used: one based on conventional Portland Cement and the other containing geopolymers formed starting from activated metakaolin and fly ashes. In the second case the materials is almost completely made of recycled ingredients. This is an attempt to produce reliable materials solving waste disposal problems. The first collected results show promising results.

Keywords: building materials, carbon fibres, fly ashes, geopolymers

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Authors: Sarabjeet Singh Sidhu, Ajay Batish, Sanjeev Kumar

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This paper reports the optimal process conditions for machining of three different types of metal matrix composites (MMCs): 65vol%SiC/A356.2; 10vol%SiC-5vol%quartz/Al and 30vol%SiC/A359 using PMEDM process. Metal removal rate (MRR), tool wear rate (TWR), surface roughness (SR) and surface integrity (SI) were evaluated after each trial and contributing process parameters were identified. The four responses were then collectively optimized using the technique for order preference by similarity to ideal solution (TOPSIS) and optimal process conditions were identified for each type of MMCS. The density of reinforced particles shields the matrix material from spark energy hence the high MRR and SR was observed with lowest reinforced particle. TWR was highest with Cu-Gr electrode due to disintegration of the weakly bonded particles in the composite electrode. Each workpiece was examined for surface integrity and ranked as per severity of surface defects observed and their rankings were used for arriving at the most optimal process settings for each workpiece.

Keywords: metal matrix composites (MMCS), metal removal rate (MRR), surface roughness (SR), surface integrity (SI), tool wear rate (TWR), technique for order preference by similarity to ideal solution (TOPSIS)

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Authors: Sónia Ribeiro, Diana Farinha, Hélia Sales, Rita Pontes, João Nunes

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The demand and commitment to sustainability in the agrifood sector introduce news opportunities for new composite materials. Composite materials are emerging as a vital entity for the sustainable development. Polylactic acid (PLA) has been recognized as a potential polymer with attractive characteristics for agrifood sector applications. PLA that can be beneficial for the development of composites, biocomposites, films, porous gels, and so on. The production of PLA from lignocellulosic biomass residues matrix is a key option towards a sustainable and circular bioeconomy and a non-competitive application with feed and food sector. The Flui and BeirInov projects presents news developments in the production of PLA composites to value the Portuguese forest ecosystem, with high amount of lignocellulosic biomass residues and available. A performance production of lactic acid from lignocellulosic biomass undergoes a process of autohydrolysis, saccharification and fermentation, originating a lactic acid fermentation medium with a 72.27g.L-1 was obtained and a final purification of 72%. The high purification PLA from multi lignocellulosic residues representing one economic expensive process, and a new materials and application for the polymers and a combination with others types of composites matrix characteristic is the drive-up for this green market.

Keywords: polylactic acid, lignocellulosic biomass, agrifood, composite materials

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Authors: Ricardo Mendoza, Jason Briceño, Juan F. Santa, Gabriel Peluffo, Mauricio Márquez, Beatriz Cardozo, Carlos Gutiérrez

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Coir natural fiber reinforced polyester composites were exposed to an accelerated environment aging in order to study the influence on the mechanical properties. Coir fibers were obtained in local plantations of the Caribbean coast of Colombia. A physical and mechanical characterization was necessary to found the best behavior between three types of coconut. Composites were fabricated by hand lay-up technique and samples were cut by water jet technique. An accelerated aging test simulates environmental climate conditions in a hygrothermal and ultraviolet chamber. Samples were exposed to the UV/moisture rich environment for 500 and 1000 hours. The tests were performed in accordance with ASTM G154. An additional water absorption test was carried out by immersing specimens in a water bath. Mechanical behaviors of the composites were tested by tensile, flexural and impact test according to ASTM standards, after aging and compared with unaged composite specimens. It was found that accelerated environment aging affects mechanical properties in comparison with unaged ones. Tensile and flexural strength were lower after aging, meantime elongation at break and flexural deflection increased. Impact strength was found that reduced after aging. Other result revealed that the percentage of moisture uptake increased with aging. This results showed that composite materials reinforced with natural fibers required an improvement adding a protective barrier to reduce water absorption and increase UV resistance.

Keywords: coir fiber, polyester composites, environmental aging, mechanical properties

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Authors: Noor Zuhaira Abd Aziz

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Rice husk and kenaf filled with calcium carbonate (CaCO3) and high density polyethylene (HDPE) composite were prepared separately using twin-screw extruder at 50rpm. Different filler loading up to 30 parts of rice husk particulate and kenaf fiber were mixed with the fixed 30% amount of CaCO3 mineral filler to produce rice husk/CaCO3/HDPE and kenaf/CaCO3/HDPE hybrid composites. In this study, the effects of natural fiber for both rice husk and kenaf in CaCO3/HDPE composite on physical and mechanical properties were investigated. The property analyses showed that water absorption increased with the presence of kenaf and rice husk fillers. Natural fibers in composite significantly influence water absorption properties due to natural characters of fibers which contain cellulose, hemicellulose and lignin structures. The result showed that 10% of additional natural fibers into hybrid composite had caused decreased flexural strength, however additional of high natural fiber (>10%) filler loading has proved to increase its flexural strength.

Keywords: Hybrid composites, Water absorption, Mechanical properties

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Authors: L. Onal

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The aim of this study is to optimize manufacturing process for thermoplastic sandwich composite structures for the pedestrian safety of automobiles subjected to collision condition. In particular, cost-effective manufacturing techniques for sandwich structures with commingled GF/PP skins and low-density foam cores are being investigated. The performance of these structures under bending load is being studied. Samples are manufactured using compression moulding technique. The relationship of this performance to processing parameters such as mould temperature, moulding time, moulding pressure and sequence of the layers during moulding is being investigated. The results of bending tests are discussed in the light of the moulding conditions and conclusions are given regarding optimum set of processing conditions using the compression moulding route

Keywords: twintex, flexural properties, automobile composites, sandwich structures

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Authors: Valerii Levshakov, Olga Fedorova

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Specific features of ship structures, made from composites, i.e. simultaneous shaping of material and structure, large sizes, complicated outlines and tapered thickness have defined leading role of technology, integrating test results from material science, designing and structural analysis. Main procedures of composite shipbuilding are contact molding, vacuum molding and winding. Now, the most demanded composite shipbuilding technology is the manufacture of structures from fiberglass and multilayer hybrid composites by means of vacuum molding. This technology enables the manufacture of products with improved strength properties (in comparison with contact molding), reduction of production duration, weight and secures better environmental conditions in production area. Mechanized winding is applied for the manufacture of parts, shaped as rotary bodies – i.e. parts of ship, oil and other pipelines, deep-submergence vehicles hulls, bottles, reservoirs and other structures. This procedure involves processing of reinforcing fiberglass, carbon and polyaramide fibers. Polyaramide fibers have tensile strength of 5000 MPa, elastic modulus value of 130 MPa and rigidity of the same can be compared with rigidity of fiberglass, however, the weight of polyaramide fiber is 30% less than weight of fiberglass. The same enables to the manufacture different structures, including that, using both – fiberglass and organic composites. Organic composites are widely used for the manufacture of parts with size and weight limitations. High price of polyaramide fiber restricts the use of organic composites. Perspective area of winding technology development is the manufacture of carbon fiber shafts and couplings for ships. JSC ‘Shipbuilding & Shiprepair Technology Center’ (JSC SSTC) developed technology of dielectric uncouplers for cryogenic lines, cooled by gaseous or liquid cryogenic agents (helium, nitrogen, etc.) for temperature range 4.2-300 K and pressure up to 30 MPa – the same is used for separating components of electro physical equipment with different electrical potentials. Dielectric uncouplers were developed, the manufactured and tested in accordance with International Thermonuclear Experimental Reactor (ITER) Technical specification. Spiral uncouplers withstand operating voltage of 30 kV, direct-flow uncoupler – 4 kV. Application of spiral channel instead of rectilinear enables increasing of breakdown potential and reduction of uncouplers sizes. 95 uncouplers were successfully the manufactured and tested. At the present time, Russian the manufacturers of ship composite structures have started absorption of technology of manufacturing the same using automated prepreg laminating; this technology enables the manufacture of structures with improved operational specifications.

Keywords: fiberglass, infusion, polymeric composites, winding

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Authors: Emre Ozaslan, Bulent Acar, Mehmet Ali Guler

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Unidirectional composites are very popular structural materials used in aerospace, marine, energy and automotive industries thanks to their superior material properties. However, the mechanical behavior of composite materials is more complicated than isotropic materials because of their anisotropic nature. Also, a stress concentration availability on the structure, like a hole, makes the problem further complicated. Therefore, enormous number of tests require to understand the mechanical behavior and strength of composites which contain stress concentration. Accurate finite element analysis and analytical models enable to understand mechanical behavior and predict the strength of composites without enormous number of tests which cost serious time and money. In this study, unidirectional Carbon/Epoxy composite specimens with central circular hole were investigated in terms of stress concentration factor and strength prediction. The composite specimens which had different specimen wide (W) to hole diameter (D) ratio were tested to investigate the effect of hole size on the stress concentration and strength. Also, specimens which had same specimen wide to hole diameter ratio, but varied sizes were tested to investigate the size effect. Finite element analysis was performed to determine stress concentration factor for all specimen configurations. For quasi-isotropic laminate, it was found that the stress concentration factor increased approximately %15 with decreasing of W/D ratio from 6 to 3. Point stress criteria (PSC), inherent flaw method and progressive failure analysis were compared in terms of predicting the strength of specimens. All methods could predict the strength of specimens with maximum %8 error. PSC was better than other methods for high values of W/D ratio, however, inherent flaw method was successful for low values of W/D. Also, it is seen that increasing by 4 times of the W/D ratio rises the failure strength of composite specimen as %62.4. For constant W/D ratio specimens, all the strength prediction methods were more successful for smaller size specimens than larger ones. Increasing the specimen width and hole diameter together by 2 times reduces the specimen failure strength as %13.2.

Keywords: failure, strength, stress concentration, unidirectional composites

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Authors: Peng Cheng, Liqing Wei, Hongyu Chen, Ruomiao Wang

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This paper discusses a light-weight reinforced thermoplastic (LWRT) composite with superior fire retardancy. This porous LWRT composite is manufactured using polyolefin, fiberglass, and fire retardant additives via a wet-lay process. However, discoloration of the LWRT can be induced by various mechanisms, which may be a concern in the building and construction industry. It is commonly understood that discoloration is strongly associated with the presence of phenolic antioxidant(s) and NO_x. The over-oxidation of phenolic antioxidant(s) is probably the root-cause of the discoloration (pinking/yellowing). Hanwha Azdel, Inc. developed a LWRT with fire-retardant property of ASTM E84-Class A specification, as well as negligible discoloration even under harsh conditions. In addition, this thermoplastic material is suitable for secondary processing (e.g. compression molding) if necessary.

Keywords: discoloration, fire-retardant, thermoplastic composites, wet-lay process

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Authors: Hisashi Imai, Kuan-Yu Chen, Katsuyoshi Kondoh, Hung-Yin Tsai, Junko Umeda

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Microstructural and electrical properties of copper-chromium alloy (Cu-Cr) dispersed with vapor-grown carbon fiber (VGCF) prepared by powder metallurgy (P/M) process have been investigated. Cu-0.7 mass% Cr pre-alloyed powder (Cu-Cr) made by water atomization process was used as raw materials, which contained solid solute Cr elements in Cu matrix. The alloy powder coated with un-bundled VGCF by using oil coating process was consolidated at 1223 K in vacuum by spark plasma sintering, and then extruded at 1073 K. The extruded Cu-Cr alloy (monolithic alloy) had 209.3 MPa YS and 80.4 IACS% conductivity. The extruded Cu-Cr with 0.1 mass% VGCF composites revealed a small decrease of YS compared to the monolithic Cu-Cr alloy. On the other hand, the composite had a higher electrical conductivity than that of the monolithic alloy. For example, Cu-Cr with 0.1 mass% VGCF composite sintered for 5 h showed 182.7 MPa YS and 89.7 IACS% conductivity. In the case of Cu-Cr with VGCFs composites, the Cr concentration was observed around VGCF by SEM-EDS analysis, where Cr23C6 compounds were detected by TEM observation. The amount of Cr solid solution in the matrix of the Cu-Cr composites alloy was about 50% compared to the monolithic Cu-Cr sintered alloy, and resulted in the remarkable increment of the electrical conductivity.

Keywords: powder metallurgy Cu-Cr alloy powder, vapor-grown carbon fiber, electrical conductivity

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Authors: Tahir Ahmad, Abubaker Khan, Muhammad Kamran, Muhammad Umer Manzoor, Muhammad Taqi Zahid Butt

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Metal Matrix Composites (MMC) is a class of weight efficient structural materials that are becoming popular in engineering applications especially in electronic, aerospace, aircraft, packaging and various other industries. This study focuses on the development of carbon fiber reinforced copper matrix composite. Keeping in view the vast applications of metal matrix composites,this specific material is produced for its unique mechanical and thermal properties i.e. high thermal conductivity and low coefficient of thermal expansion at elevated temperatures. The carbon fibers were not pretreated but coated with copper by electroless plating in order to increase the wettability of carbon fiber with the copper matrix. Casting is chosen as the manufacturing route for the C-Cu composite. Four different compositions of the composite were developed by varying the amount of carbon fibers by 0.5, 1, 1.5 and 2 wt. % of the copper. The effect of varying carbon fiber content and sizes on the mechanical properties of the C-Cu composite is studied in this work. The tensile test was performed on the tensile specimens. The yield strength decreases with increasing fiber content while the ultimate tensile strength increases with increasing fiber content. Rockwell hardness test was also performed and the result followed the increasing trend for increasing carbon fibers and the hardness numbers are 30.2, 37.2, 39.9 and 42.5 for sample 1, 2, 3 and 4 respectively. The microstructures of the specimens were also examined under the optical microscope. Wear test and SEM also done for checking characteristic of C-Cu marix composite. Through casting may be a route for the production of the C-Cu matrix composite but still powder metallurgy is better to follow as the wettability of carbon fiber with matrix, in that case, would be better.

Keywords: copper based composites, mechanical properties, wear properties, microstructure

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Authors: Santiranjan Shannigrahi, Mohit Sharma, Ivan Tan Chee Kiang, Yong Anna Marie

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Polymer-ceramics composites are gaining importance due to their high specific strength, corrosion resistance, and high mechanical properties, as well as low cost. As a result, polymer composites are suitable for various industrial applications, like automobiles, aerospace, and biomedical areas. The present work comprises the development of polymer-ceramic composite films and is tested for the harsh environment including weatherability and UV barrier property. The polymer composite films are kept in weather chamber for a fixed period of time followed by tested for their physical, mechanical and chemical properties. The composite films are fabricated using compounding followed by hot pressing. UV-visible spectroscopy results reveal that the pure polymer polyethylene (PE) films are transparent in the visible range and do not absorb UV. However, polymer ceramic composite films start absorbing UV completely even at very low filler loading amount of 5 wt.%. The changes in tensile properties of the various composite films before and after UV illuminations for 40 hrs at 60 degC are analyzed. The tensile strength of neat PE film has been observed 8% reduction, whereas the remarkable increase in tensile strength has been observed (18% improvement for 10 wt. % filled composites films). The UV exposure leads to strengthen the crosslinking among PE polymer chains in the filled composite films, which contributes towards the incremented tensile strength properties.

Keywords: polymer ceramic composite, processing, harsh environment, mechanical properties

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Authors: Antônio P. de Araújo Neto, Ruy D. A. da Silva Neto, Juliana R. de Souza, Salete K. P. de Medeiros, João T. N. de Medeiros

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The tribological test with Pin-On-Disc configuration measures friction and wear properties in dry or lubricated sliding surfaces of a variety of materials and coatings. Polymeric matrix composites loaded with mineral filler were used, 1%, 3%, 10%, 30%, and 50% mass percentage of filler, to reduce the material cost by using mineral tailings. Using a pin-on-disc tribometer to quantify coefficient of friction and wear resistance of the specimens. The parameters known to performing the test were 300 rpm rotation, normal load of 16N and duration of 33.5 minutes. The composite with 10% mineral filler performed better, considering that the wear resistance was good when compared to the other compositions and an average low coefficient of friction, in the order of μ ≤ 0.15.

Keywords: microcomposites, microparticles tailings of scheelite, PTFE, tribology

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Authors: Simon Bard, Martin Demleitner, Florian Schonl, Volker Altstadt

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For an electrically driven aircraft, whose engine is based on semiconductors, alternative materials are needed. The avoid hotspots in the materials thermally conductive polymers are necessary. Nevertheless, the mechanical properties of these materials should remain. Herein, the work of three years in a project with airbus and Siemens is presented. Different strategies have been pursued to achieve conductive fiber-reinforced composites: Metal-coated carbon fibers, pitch-based fibers and particle-loaded matrices have been investigated. In addition, a combination of copper-coated fibers and a conductive matrix has been successfully tested for its conductivity and mechanical properties. First, prepregs have been produced with a laboratory scale prepreg line, which can handle materials with maximum width of 300 mm. These materials have then been processed to fiber-reinforced laminates. For the PAN-fiber reinforced laminates, it could be shown that there is a strong dependency between fiber volume content and thermal conductivity. Laminates with 50 vol% of carbon fiber offer a conductivity of 0.6 W/mK, those with 66 vol% of fiber a thermal conductivity of 1 W/mK. With pitch-based fiber, the conductivity enhances to 1.5 W/mK for 61 vol% of fiber, compared to 0.81 W/mK with the same amount of fibers produced from PAN (+83% in conducitivity). The thermal conductivity of PAN-based composites with 50 vol% of fiber is at 0.6 W/mK, their nickel-coated counterparts with the same fiber volume content offer a conductivity of 1 W/mK, an increase of 66%.

Keywords: carbon, electric aircraft, polymer, thermal conductivity

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Authors: Ha-Guk Jeong, Jong-Beom Lee

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Cladding process is very typical technology for manufacturing composite materials by the hydrostatic extrusion. Because there is no friction between the metal and the container, it can be easily obtained in uniform flow during the deformation. The general manufacturing process for a metal-matrix composite in the solid state, mixing metal powders and ceramic powders with a suited volume ratio, prior to be compressed or extruded at the cold or hot condition in a can. Since through a plurality of unit processing steps of dispersing the materials having a large difference in their characteristics and physical mixing, the process is complicated and leads to non-uniform dispersion of ceramics. It is difficult and hard to reach a uniform ideal property in the coherence problems at the interface between the metal and the ceramic reinforcements. Metal hybrid composites, which presented in this report, are manufactured through the traditional plastic deformation processes like hydrostatic extrusion, caliber-rolling, and drawing. By the previous process, the realization of uniform macro and microstructure is surely possible. In this study, as a constituent material, aluminum, copper, and titanium have been used, according to the component ratio, excellent characteristics of each material were possible to produce a metal hybrid composite that appears to maximize. MgB₂ superconductor wire also fabricated via the same process. It will be introduced to their unique artistic and thermal characteristics.

Keywords: cladding process, metal-hybrid composites, hydrostatic extrusion, electronic/thermal characteristics

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Authors: Vijay Goud, Ramasamy Alagirusamy, Apurba Das, Dinesh Kalyanasundaram

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Thermoplastic composites render new opportunities as effective processing technology while crafting newer complications into processing. One of the notable challenges is in achieving thorough wettability that is significantly deterred by the high viscosity of the long molecular chains of the thermoplastics. As a result of high viscosity, it is very difficult to impregnate the resin into a tightly interlaced textile structure to fill the voids present in the structure. One potential solution to the above problem, is to pre-deposit resin on the fiber, prior to consolidation. The current study compares DREF spinning, powder coating and film stacking methods of predeposition of resin onto fibers. An investigation into the flexural properties of unidirectional composites (UDC) produced from blending of carbon fiber and polypropylene (PP) matrix in varying forms of fiber, powder and film are reported. Dr. Ernst Fehrer (DREF) yarns or friction spun hybrid yarns were manufactured from PP fibers and carbon tows. The DREF yarns were consolidated to yield unidirectional composites (UDCs) referred to as UDC-D. PP in the form of powder was coated on carbon tows by electrostatic spray coating. The powder-coated towpregs were consolidated to form UDC-P. For the sake of comparison, a third UDC referred as UDC-F was manufactured by the consolidation of PP films stacked between carbon tows. The experiments were designed to yield a matching fiber volume fraction of about 50 % in all the three UDCs. A comparison of mechanical properties of the three composites was studied to understand the efficiency of matrix wetting and impregnation. Approximately 19% and 68% higher flexural strength were obtained for UDC-P than UDC-D and UDC-F respectively. Similarly, 25% and 81% higher modulus were observed in UDC-P than UDC-D and UDC-F respectively. Results from micro-computed tomography, scanning electron microscopy, and short beam tests indicate better impregnation of PP matrix in UDC-P obtained through electrostatic spray coating process and thereby higher flexural strength and modulus.

Keywords: DREF spinning, film stacking, flexural strength, powder coating, thermoplastic composite

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Authors: S. Koul, Joshua Adedamola

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Currently, the global concerning fact about electromagnetic pollution (EMP) is that it not only adversely affects human health but rather projects the malfunctioning of sensitive equipment both locally and at a global level. The market offers many incumbent technologies to solve the issues, but still, a processable sustainable material solution with acceptable limits for GHG emission is still at an exploratory stage. The present work offers a sustainable material solution with a wide range of processability in terms of a polymeric resin matrix and shielding operational efficiency across the electromagnetic spectrum, covering both ionizing and non-ionizing electromagnetic radiations. The present work offers an in-situ synthesized conducting polyaniline (PANI) in the presence of the hybrid dual dopant system with tuned conductivity and high shielding efficiency between 89 to 92 decibels, depending upon the EMI frequency range. The conductive polymer synthesized in the presence of a hybrid dual dopant system via the in-situ emulsion polymerization method offers a higher surface resistance of 1.0 ohms/cm with thermal stability up to 2450C in their powder form. This conductive polymer with a hybrid dual dopant system was used as a filler material with different polymeric thermoplastic resin systems for the preparation of conductive composites. Intrinsically Conductive polymeric (ICP) composites based on hybrid dual dopant systems were prepared using melt blending, extrusion, and finally by, compression molding processing techniques. ICP composites with hybrid dual dopant systems offered good mechanical, thermal, structural, weathering, and stable surface resistivity properties over a period of time. The preliminary shielding behavior for ICP composites between frequency levels of 10 GHz to 24GHZ offered a shielding efficiency of more than 90 dB.

Keywords: ICP, dopant, EMI, shielding

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Authors: Edison E. Haro, Akindele G. Odeshi, Jerzy A. Szpunar

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Hybrid bio-composites are developed for use in protective armor through positive hybridization offered by reinforcement of high-density polyethylene (HDPE) with Kevlar short fibers and palm wood micro-fillers. The manufacturing process involved a combination of extrusion and compression molding techniques. The mechanical behavior of Kevlar fiber reinforced HDPE with and without palm wood filler additions are compared. The effect of the weight fraction of the added palm wood micro-fillers is also determined. The Young modulus was found to increase as the weight fraction of organic micro-particles increased. However, the flexural strength decreased with increasing weight fraction of added micro-fillers. The interfacial interactions between the components were investigated using scanning electron microscopy. The influence of the size, random alignment and distribution of the natural micro-particles was evaluated. Ballistic impact and dynamic shock loading tests were performed to determine the optimum proportion of Kevlar short fibers and organic micro-fillers needed to improve impact strength of the HDPE. These results indicate a positive hybridization by deposition of organic micro-fillers on the surface of short Kevlar fibers used in reinforcing the thermoplastic matrix leading to enhancement of the mechanical strength and dynamic impact behavior of these materials. Therefore, these hybrid bio-composites can be promising materials for different applications against high velocity impacts.

Keywords: hybrid bio-composites, organic nano-fillers, dynamic shocking loading, ballistic impacts, energy absorption

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