Mechanical,Thermal, and Fire Properties of Composite Materials Based on Gypsum and PCM

One of the solutions for overheating the interior in the summer without increasing energy consumption is the integration of phase change material (PCM) into interior plasters. However, adding PCM to plasters deteriorates their properties and thus their usability. The aim of this paper is to determine how the microencapsulated PCM affects the mechanical, thermal, and fire properties of plasters and how much PCM can be added to the plaster. Two sets of samples were prepared: in set S, part of the aggregate was replaced by PCM; and in set R, only PCM was added. The bulk density, flexural strength, compressive strength, tensile strength perpendicular to the surface, thermal conductivity coefficient, specific heat capacity, melting, and solidification temperatures and enthalpy were measured. A single-flame source fire test and a gross heat of combustion fire test were performed to determine the reaction to the fire class. The results show that with an increasing proportion of PCM, the strength of the samples of set R decreased more significantly than it did with the samples of set S. It was found that only up to about 10% PCM could be added to set R, while up to 30% PCM could be added to set S.     

Mechanical Behavior of Plaster Composites Based on Rubber Particles from End-of-Life Tires Reinforced with Carbon Fibers

The principal objective of this research project is the disposal of end-of-life tire rubber waste and its incorporation in gypsum composites. As a continuation of previous projects, which established a reduction in the mechanical properties of the resulting products, the behavior of these composites is analyzed with the incorporation of carbon fibers. The density, Shore C hardness, flexural strength, compressive strength, dynamic modulus of elasticity, strength–strain curves, toughness and resistance values and microstructure of the material are studied and compared. The results obtained show a significant increase in the mechanical tensile strength of all of the samples containing fibers. The moduli of elasticity results show a decrease in rigidity and increase in toughness and resistance of the material produced by incorporating the fibers. An optimum dosage of a water/gypsum ratio of 0.6 and incorporation of 1.5% carbon fibers is proposed. This lightweight material, which offers a high mechanical performance, features characteristics which are suitable for large prefabricated building elements in the form of panels or boards.     

Basalt Fiber-Based Flame Retardant Epoxy Composites: Preparation,Thermal Properties,and Flame Retardancy

We aimed to study the impact of surface modification of basalt fiber (BF) on the mechanical properties of basalt fiber-based epoxy composites. Four different types of pretreatment approaches to BF were used; then a silane coupling agent (KH550) was applied to further modify the pretreated BF, prior to the preparation of epoxy resin (EP)/BF composites. The combination of acetone (pre-treatment) and KH550 (formal surface treatment) for basalt fiber (BT-AT) imparted the EP/BF composite with the best performance in both tensile and impact strengths. Subsequently, such modified BF was introduced into the flame-retardant epoxy composites (EP/AP750) to prepare basalt fiber reinforced flame-retardant epoxy composite (EP/AP750/BF-AT). The fire behaviors of the composites were evaluated by vertical burning test (UL-94), limiting oxygen index (LOI) test and cone calorimetry. In comparison to the flame-retardant properties of EP/AP750, the incorporation of BF-AT slightly reduced LOI value from 26.3% to 25.1%, maintained the good performance in vertical burning test, but increased the peak of the heat release rate. Besides, the thermal properties and mechanical properties of the composites were investigated by thermogravimetric analysis (TGA), universal tensile test, impact test and dynamic mechanical analysis (DMA).     

Effect of the Topology of Carbon-Based Nanofillers on the Filler Networks and Gas Barrier Properties of Rubber Composites

The topology of nanofillers is one of the key factors affecting the gas barrier properties of rubber composites. In this research, three types of carbon-based nanofillers, including spherical carbon black (CB), fibrous carbon nanotubes (CNTs), and layered graphene (GE) were chosen to investigate the effect of the topological structures of nanofillers on the gas barrier properties of styrene-butadiene rubber (SBR) composites. Results showed that the structure and strength of the filler networks in SBR composites were closely associated with the topology of nanofillers. When filled with 35 phr CB, 8 phr CNTs, and 4 phr GE, the SBR composites had the same strength of the filler network, while the improvement in gas barrier properties were 39.2%, 12.7%, and 41.2%, respectively, compared with pure SBR composites. Among the three nanofillers, GE exhibited the most excellent enhancement with the smallest filler content, demonstrating the superiority of two-dimensional GE in improving the barrier properties of rubber composites.     

Phase Evaluation,Mechanical Properties and Thermal Behavior of Hot-Pressed LC-YSZ Composites for TBC Applications

In this work, La₂Ce₂O₇-yttria-stabilized zirconia (LC-YSZ) composites with different weight fractions of YSZ (40–70 wt.%) were prepared by hot pressing at 1400 °C and investigated as a material for thermal barrier-coating (TBC) applications. For this purpose, the effect of YSZ addition on the phase composition, microstructure, mechanical performance and thermal behavior was studied. X-ray diffraction analysis showed that the LC-YSZ composites were mainly composed of a cubic ZrO₂ and La₂O₃-CeO₂-ZrO₂ solid solution with a pyrochlore structure, indicating that the reaction between LC and YSZ took place during hot pressing. Scanning electron microscopy revealed the high microstructural stability of the prepared composites, as the pore formation was significantly controlled and a high relative density (>97%) was obtained. The microstructure of LC-YSZ bulk samples was relatively fine-grained, with an average grain size below or very close to 1 µm. YSZ doping improved the Vickers hardness of the LC-YSZ composites; the highest hardness, with value of 12 ± 0.62 GPa, was achieved for the composite containing 70 wt.% of YSZ. The fracture toughness of LC-YSZ composites was in the range from 2.13 to 2.5 MPa·m^1/2. No statistically significant difference in heat capacity or thermal conductivity was found between the composites with different content of YSZ. The results showed that LC-YSZ composites have relatively low thermal conductivities from room temperature (1.5–1.8 W·m⁻¹·K⁻¹) up to 1000 °C (2.5–3.0 W·m⁻¹·K⁻¹). This indicates that the prepared LC-YSZ composite materials are promising candidates for TBC applications.     

Infill Density Influence on Mechanical and Thermal Properties of Short Carbon Fiber-Reinforced Polyamide Composites Manufactured by FFF Process

In three-dimensional (3D) printing, one of the main parameters influencing the properties of 3D-printed materials is the infill density (ID). This paper presents the influence of ID on the microstructure, mechanical, and thermal properties of carbon fiber-reinforced composites, commercially available, manufactured by the Fused Filament Fabrication (FFF) process. The samples were manufactured using FFF by varying the infill density (25%, 50%, 75%, and 100%) and were subjected to tensile tests, three-point bending, and thermal analyses by Differential Scanning Calorimetry (DSC) and Thermogravimetric Analysis (TGA). It was shown that the samples with 100% ID had the highest values of both tensile, 90.8 MPa, and flexural strengths, 114 MPa, while those with 25% ID had the lowest values of 56.4 MPa and 62.2 MPa, respectively. For samples with infill densities of 25% and 50%, the differences between the maximum tensile and flexural strengths were small; therefore, if the operating conditions of the components allow, a 25% infill density could be used instead of 50%. After DSC analysis, it was found that the variation in the ID percentage determined the change in the glass transition temperature from 49.6 °C, for the samples with 25% ID, to 32.9 °C, for those with 100% ID. TGA results showed that the samples with IDs of 75% and 100% recorded lower temperatures of onset degradation (approximately 344.75 °C) than those with infill densities of 25% and 50% (348.5 °C, and 349.6 °C, respectively).     

Effect of Basalt Powder Surface Treatments on Mechanical and Processing Properties of Polylactide-Based Composites

Legislative restrictions and the needs of consumers have created a demand for sustainable materials. Polylactide (PLA) is a biodegradable polyester with advantageous mechanical properties, however, due to its low crystallization rate, it also has low thermomechanical stability. Its range of application temperatures can be widened using nucleating agents and fillers including basalt powder (BP), a waste product from the mining industry. This study analyzed the possibility of enhancing the properties of a PLA-BP composite by chemically treating the filler. Basalt powder was subjected to silanization with 3-aminopropyltriethoxysilane or γ-glycidoxypropyltrimethoxysilane and mixed with PLA at 5–20 wt%. The nucleating effect of a potassium salt of 3,5-bis(methoxycarbonyl) (LAK-301) in the silanized composite was also evaluated. The properties of the materials with silanized BP were compared with the unmodified basalt powder. The miscibility of the filler and the polymer was assessed by oscillatory rheometry. The structure of the composites was studied using scanning electron microscopy and their thermomechanical properties were analyzed using dynamic mechanical thermal analysis. Mechanical properties such as tensile strength, hardness and impact strength, and heat deflection temperature of the materials were also determined. It was concluded that BP-filled nucleated PLA composites presented satisfactory thermomechanical stability without silanization, but chemical treatment could improve the matrix–filler interactions.     

Effect of Nanofiller on the Mechanical Properties of Carbon Fiber/Epoxy Composites under Different Aging Conditions

In this study, carbon fiber-reinforced epoxy composites (CFRPs) containing multi-walled carbon nanotube (MWCNT) and halloysite nanoclay were fabricated. The effects of these nanofillers (MWCNT and nanoclay) on the tensile and flexural properties of the CFRPs under different aging conditions were studied. These aging conditions included water soaking, acid soaking, alkali soaking, and thermal shock cycling. The experimental results showed that, after accelerated aging, the mechanical performance of the CFRPs decreased. The performance degradation in the soaking environment depends on the immersion temperature and immersion medium. High-temperature accelerated the aging behavior of the CFRPs, resulting in low strength and modulus. The CFRPs were more vulnerable to acid soaking and alkali soaking than water soaking. The MWCNT and halloysite nanoclay are beneficial to improve the immersion aging resistance of the CFRPs, and the additions of nanofillers delayed the performance degradation under immersion aging conditions. However, nanofillers hardly improve the aging resistance of the CFRPs under thermal shock cycling condition. The fracture morphologies were observed by scanning electron microscopy (SEM) to reflect the failure modes of the CFRPs under various aging conditions. Differential scanning calorimeter (DSC) and fourier transform infrared (FTIR) spectroscopy tests were used to estimate the changes in the chemical structures and properties of epoxy resin and its composites under different conditions.     

High Density Polyethylene Composites Reinforced with Hybrid Inorganic Fillers: Morphology,Mechanical and Thermal Expansion Performance

The effect of individual and combined talc and glass fibers (GFs) on mechanical and thermal expansion performance of the filled high density polyethylene (HDPE) composites was studied. Several published models were adapted to fit the measured tensile modulus and strength of various composite systems. It was shown that the use of silane-modified GFs had a much larger effect in improving mechanical properties and in reducing linear coefficient of thermal expansion (LCTE) values of filled composites, compared with the use of un-modified talc particles due to enhanced bonding to the matrix, larger aspect ratio, and fiber alignment for GFs. Mechanical properties and LCTE values of composites with combined talc and GF fillers varied with talc and GF ratio at a given total filler loading level. The use of a larger portion of GFs in the mix can lead to better composite performance, while the use of talc can help lower the composite costs and increase its recyclability. The use of 30 wt % combined filler seems necessary to control LCTE values of filled HDPE in the data value range generally reported for commercial wood plastic composites. Tensile modulus for talc-filled composite can be predicted with rule of mixture, while a PPA-based model can be used to predict the modulus and strength of GF-filled composites.     

Mechanical Properties of Hybrid Fiber Reinforced Rubber Concrete

Orthogonal experiments were designed for hybrid fiber rubber concrete (HFRC). The mechanical properties of HFRC were tested and compared with ordinary concrete. The effects of basalt fiber volume ratio (V_BF), PVA fiber volume ratio (V_PF) and rubber volume ratio (V_R) on the compressive strength, splitting tensile strength and flexural strength of HFRC were analyzed. The results show that the strength of HFRC is the best when the volume ratio of basalt fiber is 0.3%, the volume ratio of PVA fiber is 0.2% and the volume ratio of rubber is 5%. Basalt fiber has the greatest influence on the strength of HFRC. The strength of HFRC mixed with hybrid fiber is greatly improved, which reflects the good fiber “positive hybrid effect”. With the increase of rubber volume ratio, the strength of HFRC decreases gradually. With the help of SEM and EDS, the toughening and cracking resistance mechanism of the fiber to HFRC was analyzed. Finally, the strength of HFRC was predicted by model.     

Study of the Mechanical,Sound Absorption and Thermal Properties of Cellular Rubber Composites Filled with a Silica Nanofiller

This paper deals with the study of cellular rubbers, which were filled with silica nanofiller in order to optimize the rubber properties for given purposes. The rubber composites were produced with different concentrations of silica nanofiller at the same blowing agent concentration. The mechanical, sound absorption and thermal properties of the investigated rubber composites were evaluated. It was found that the concentration of silica filler had a significant effect on the above-mentioned properties. It was detected that a higher concentration of silica nanofiller generally led to an increase in mechanical stiffness and thermal conductivity. Conversely, sound absorption and thermal degradation of the investigated rubber composites decreased with an increase in the filler concentration. It can be also concluded that the rubber composites containing higher concentrations of silica filler showed a higher stiffness to weight ratio, which is one of the great advantages of these materials. Based on the experimental data, it was possible to find a correlation between mechanical stiffness of the tested rubber specimens evaluated using conventional and vibroacoustic measurement techniques. In addition, this paper presents a new methodology to optimize the blowing and vulcanization processes of rubber samples during their production.     

Effect of the Matrix Melt Flow Index and Fillers on Mechanical Properties of Polypropylene-Based Composites

In this work, mechanical properties of reinforced polypropylene composites were studied. PP in particulates shape with two different melt flow indexes (MFI) was used, i.e., 3 and 23 g/10 min, namely PP3 and PP23, respectively. Three different materials, namely TiO₂ nanoparticle (nTiO₂, spherical, 0D), micro-size short carbon fiber (SCF, fiber, 1D), and graphite nanoplatelet (GNP, sheet, 2D), were used as reinforcements/fillers. PP and fillers (in the desired composition) were first pre-mixed by a mechanical mixer. The mixture was then fed to a co-rotating twin-screw extruder for melt-compounding, followed by injection molding to fabricate testing samples. The microstructure and fracture surface of the composites were observed by a scanning electron microscope (SEM). Additionally, tensile, flexural, impact, and hardness tests were conducted to evaluate their mechanical properties. The SEM images stipulate that PP23 had better adhesion and dispersion with the fillers. The results from the SEM images support the mechanical testing results. PP23 composites exhibited more significant improvement in mechanical properties in comparison to PP3. At 5 wt. % filler loading, PP/GNP composite exhibited a greater improvement in mechanical properties compared with two other composites, which are PP/SCF and PP/nTiO₂ composites for both PPs.     

Study on Correlation of Mechanical and Thermal Properties of Coal-Based Carbon Foam with the Weight Loss Rate after Oxidation

With the increasing demand for high temperature-resistant heat insulation materials for hypersonic vehicles, carbon foam has been studied extensively, and its mechanical and thermal properties have been fully researched, but the oxidation behavior of carbon foams during service and the change in their properties after oxidation are rarely studied. This paper studied the relationship between both mechanical and thermal properties and oxidation degree of two kinds of foams, coal-based carbon foam and antioxidant coal-based carbon foam with chemical vapor deposition of SiC particles. The variation trend for the two kinds of foam was the same. When the oxidation degree was less than 15%, the compression modulus and strength weakened with the increase in weight loss rate, but the thermal conductivity decreased with the increase in weight loss rate, which was a favorable influence for the thermal protection system. The mechanical and thermal properties had a linear relationship with the weight loss rate, but the slope was different between 0% to 10% and 10% to 15%. The microscopic mechanism of these changes was also analyzed.     

Effect of Polymer Additives on the Microstructure and Mechanical Properties of Self-Leveling Rubberised Concrete

The materials based on concrete with an addition of rubber are well-known. The interaction between concrete components and rubber particles is in the majority cases insufficient. For this reason, different substances are introduced into concrete-rubber systems. The aim of this paper is to establish the influence of five different polymer additives, i.e., 1. an aqueous dispersion of a styrene-acrylic ester copolymer (silanised) (ASS), 2. water dispersion of styrene-acrylic copolymer (AS), 3. anionic copolymer of acrylic acid ester and styrene in the form of powder (AS.RDP), 4. water polymer dispersion produced from the vinyl acetate and ethylene monomers (EVA), 5. copolymer powder of vinyl acetate and ethylene (EVA.RDP)) on the properties of the self-leveling rubberised concrete. Scanning electron microscopy has allowed to establish the interaction between the cement paste and rubber aggregates. Moreover, the compressive strength and flexural strength of the studied materials were evaluated. The results indicate that the mechanical properties depend extensively on the type as well as the amount of the polymer additive introduced into the system.     

Effect of Carbon Nanofibers on Physical,Adhesion and Rheological Properties of Liquid Epoxidized Natural Rubber Modified Asphalt

This study aimed to evaluate the effects of carbon nanofibers (CNFs) on the performance of liquid epoxidized natural rubber (LENR)-modified asphalt. The physical, adhesion and rheological properties were determined by several tests such as penetration, elastic recovery, ring and ball softening point, Brookfield rotational viscometer, AFM and dynamic shear rheometer. LENR was used at concentrations of 3, 6, and 9%, while CNFs were used at contents of 0.3, 0.4, and 0.5% by weight of asphalt. Conventional test results showed that the increases in LENR and LENR/CNFs composite contents in binder leads to an increase in the hardness and consistency and a reduction in the temperature susceptibility of base asphalt. Adhesion results revealed that the addition of CNFs significantly increases the adhesion and bonding properties of base and rubberized binders. Rheological properties analysis exhibited that LENR improved the viscoelastic properties and permanent deformation resistance of asphalt at different temperatures and frequencies. On the other hand, it was found that the addition of CNFs significantly improves the stiffness, elasticity, and hardness of LENR-modified binders. The 6% LENR and 0.4% CNFs were found to be the optimum to enhance the physical, adhesion, and rheological properties of asphalt in this study. Thus, it can be stated that the addition of CNFs is promising to improve the performance of rubberized binders for high temperature applications.     

The Effect of Manufacture Process on Mechanical Properties and Burning Behavior of Epoxy-Based Hybrid Composites

The production of hybrid layered composites allows comprehensive modification of their properties and adaptation to the final expectations. Different methods, such as hand lay-up, vacuum bagging, and resin infusion were applied to manufacture the hybrid composites. In turn, fabrics used for manufacturing composites were made of glass (G), aramid (A), carbon (C), basalt (B), and flax (F) fibers. Flexural, puncture impact behavior, and cone calorimetry tests were applied to establish the effect of the manufacturing method and the fabrics layout on the mechanical and fire behavior of epoxy-based laminates. The lowest flammability and smoke emission were noted for composites made by vacuum bagging (approximately 40% lower values of total smoke release compared with composites made by the hand lay-up method). It was demonstrated that multi-layer hybrid composites made by vacuum bagging might enhance the fire safety levels and simultaneously maintain high mechanical properties designed for, e.g., the railway and automotive industries.     

Effect of Secondary Carbon Nanofillers on the Electrical,Thermal, and Mechanical Properties of Conductive Hybrid Composites Based on Epoxy Resin and Graphite

In this work, we present a comparative study of the impact of secondary carbon nanofillers on the electrical and thermal conductivity, thermal stability, and mechanical properties of hybrid conductive polymer composites (CPC) based on high loadings of synthetic graphite and epoxy resin. Two different carbon nanofillers were chosen for the investigation—low-cost multi-layered graphene nanoplatelets (GN) and carbon black (CB), which were aimed at improving the overall performance of composites. The samples were obtained by a simple, inexpensive, and effective compression molding technique, and were investigated by the means of, i.a., scanning electron microscopy, Raman spectroscopy, electrical conductivity measurements, laser flash analysis, and thermogravimetry. The tests performed revealed that, due to the exceptional electronic transport properties of GN, its relatively low specific surface area, good aspect ratio, and nanometric sizes of particles, a notable improvement in the overall characteristics of the composites (best results for 4 wt % of GN; σ = 266.7 S cm⁻¹; λ = 40.6 W mK⁻¹; fl. strength = 40.1 MPa). In turn, the addition of CB resulted in a limited improvement in mechanical properties, and a deterioration in electrical and thermal properties, mainly due to the too high specific surface area of this nanofiller. The results obtained were compared with US Department of Energy recommendations regarding properties of materials for bipolar plates in fuel cells. As shown, the materials developed significantly exceed the recommended values of the majority of the most important parameters, indicating high potential application of the composites obtained.     

Effect of Hemp Fiber Surface Treatment on the Moisture/Water Resistance and Reaction to Fire of Reinforced PLA Composites

The effects of surface pretreatment (water and alkali) and modification with silane on moisture sorption, water resistance, and reaction to fire of hemp fiber reinforced polylactic acid (PLA) composites at two fiber loading contents (30 and 50 wt.%) are investigated in this work. Moisture adsorption was evaluated at 30, 50, 75 and 95% relative humidity, and water resistance was determined after a 28-day immersion period. The cone calorimetry technique was used to investigate response to fire. The fiber surface treatment resulted in the removal of cell wall components, which increased fiber individualization and homogeneity as shown in scanning microscopic pictures of the composite cross-section. Although the improved fiber/matrix bonding increased the composite’s water resistance, the different fiber treatments generated equal moisture adsorption results for the 30 wt.% reinforced composites. Overall, increasing the fiber amount from 30 to 50 wt.% increased the composite sensitivity to moisture/water, mainly due to the availability of more hydroxyl groups and to the development of a higher pore volume, but fire protection improved due to a reduction in the rate of thermal degradation induced by the reduced PLA content. The new Oswin’s model predicted the composite adsorption isotherm well. The 30 wt.% alkali and silane treated hemp fiber composite had the lowest overall adsorption (9%) while the 50 wt.% variant produced the highest ignition temperature (181 ± 18 °C).     

Synergistic Enhanced Thermal Conductivity and Dielectric Constant of Epoxy Composites with Mesoporous Silica Coated Carbon Nanotube and Boron Nitride Nanosheet

Dielectric materials with high thermal conductivity and outstanding dielectric properties are highly desirable for advanced electronics. However, simultaneous integration of those superior properties for a material remains a daunting challenge. Here, a multifunctional epoxy composite is fulfilled by incorporation of boron nitride nanosheets (BNNSs) and mesoporous silica coated multi-walled carbon nanotubes (MWCNTs@mSiO₂). Owing to the effective establishment of continuous thermal conductive network, the obtained BNNSs/MWCNTs@mSiO₂/epoxy composite exhibits a high thermal conductivity of 0.68 W m⁻¹ K⁻¹, which is 187% higher than that of epoxy matrix. In addition, the introducing of mesoporous silica dielectric layer can screen charge movement to shut off leakage current between MWCNTs, which imparts BNNSs/MWCNTs@mSiO₂/epoxy composite with high dielectric constant (8.10) and low dielectric loss (<0.01) simultaneously. It is believed that the BNNSs/MWCNTs@mSiO₂/epoxy composites with admirable features have potential applications in modern electronics.     

Polypropylene/Short Glass Fibers Composites: Effects of Coupling Agents on Mechanical Properties,Thermal Behaviors,and Morphology

This study uses the melt compounding method to produce polypropylene (PP)/short glass fibers (SGF) composites. PP serves as matrix while SGF serves as reinforcement. Two coupling agents, maleic anhydride grafted polypropylene, (PP-g-MA) and maleic anhydride grafted styrene-ethylene-butylene-styrene block copolymer (SEBS-g-MA) are incorporated in the PP/SGF composites during the compounding process, in order to improve the interfacial adhesion and create diverse desired properties of the composites. According to the mechanical property evaluations, increasing PP-g-MA as a coupling agent provides the composites with higher tensile, flexural, and impact properties. In contrast, increasing SEBS-g-MA as a coupling agent provides the composites with decreasing tensile and flexural strengths, but also increasing impact strength. The DSC results indicate that using either PP-g-MA or SEBS-g-MA as the coupling agent increases the crystallization temperature. However, the melting temperature of PP barely changes. The spherulitic morphology results show that PP has a smaller spherulite size when it is processed with PP-g-MA or SEBS-g-MA as the coupling agent. The SEM results indicate that SGF is evenly distributed in PP matrices, but there are distinct voids between these two materials, indicating a poor interfacial adhesion. After PP-g-MA or SEBS-g-MA is incorporated, SGF can be encapsulated by PP, and the voids between them are fewer and indistinctive. This indicates that the coupling agents can effectively improve the interfacial compatibility between PP and SGF, and as a result improves the diverse properties of PP/SGF composites.