Generation of strength in a drying film: How fracture toughness depends on dispersion properties

Enable Superior Performance of Solvent-Free Electrode With Ultra-High Loading Through Designed Conductive Binder

Compared to the traditional slurry-coating process, the solvent-free manufacturing process holds significant potential due to its advantages, including economic viability, thick electrodes, and avoidance of organic solvents. However, the currently dominant solvent-free process suffers from poor mechanical properties and electrochemical instability. Herein, a conductive binder (M@EP), composed of multi-walled carbon nanotubes (MWNT) and epoxy resin-based binders (EP), is designed and synthesized. The functional integration of the conductive agent and binder facilitates the formation of a 3D percolation network, significantly enhancing the conductivity of electrode. The abundant ether oxygen groups and nitrogen elements in EP promote the transmission of Li+ ions. Consequently, the dry electrodes exhibit outstanding cycling performance and rate capability. Furthermore, the combined enhancement of electronic and ionic conductivity enables the manufacturing of high-loading dry electrodes (HDEs-M@EP). The HDEs-M@EP (485 µm) have a maximum areal mass loading of 110.88 mg cm-2, and the corresponding areal capacity reaches 20.19 mAh cm-2. Finally, the structural design of M@EP facilitates an innovative method for the rapid recycling and reuse of spent batteries. It greatly simplifies the traditional procedure and enables the recycling of all types of electrode materials, offering new insights for future large-scale industrial recycling methods and green recycling systems.

Crack densification in drying colloidal suspensions

As sessile drops of aqueous colloidal suspensions dry, a close-packed particle deposit forms that grows from the edge of the drop toward the center. To compensate for evaporation over the solid's surface, water flows radially through the deposit, generating a negative pore pressure in the deposit associated with tensile drying stresses that induce the formation of cracks. As these stresses increase during drying, existing cracks propagate and additional cracks form, until the crack density eventually saturates. We rationalize the dynamics of crack propagation and crack densification with a local energy balance between the elastic energy released by the crack, the energetic cost of fracture, and the elastic energy released by previously formed cracks. We show that the final spacing between radial cracks is proportional to the local thickness of the deposit, while the aspect ratio of the crack segments depends on the shape of the deposit.

Criteria for Crack Formation and Air Invasion in Drying Colloidal Suspensions

The drying of sessile drops of aqueous colloidal suspensions leads to the formation of a close-packed particle deposit. As water evaporates, a solidification front propagates from the edge of the drop toward the center, leaving behind a thin disk-shaped deposit. For drops with sufficiently large particle volume fractions, the deposit eventually covers the entire wetted area. In this regime, the dynamics of the deposit growth is governed by volume conservation across a large range of particle volume fractions and drying times. During drying, water flows radially through the deposit to compensate for evaporation over the solid's surface, creating a negative pore pressure in the deposit which we rationalize with a hydrodynamic model. We show that the pressure inside the deposit controls both the onset of crack formation and the onset of air invasion. Two distinct regimes of air invasion occur, which we can account for using the same model that further provides a quantitative criterion for the crossover between the two regimes.

Cohesion Gain Induced by Nanosilica Consolidants for Monumental Stone Restoration

Mineral nanoparticle suspensions with consolidating properties have been successfully applied in the restoration of weathered architectural surfaces. However, the design of these consolidants is usually stone-specific and based on trial and error, which prevents their robust operation for a wide range of highly heterogeneous monumental stone materials. In this work, we develop a facile and versatile method to systematically study the consolidating mechanisms in action using a surface forces apparatus (SFA) with real-time force sensing and an X-ray surface forces apparatus (X-SFA). We directly assess the mechanical tensile strength of nanosilica-treated single mineral contacts and show a sharp increase in their cohesion. The smallest used nanoparticles provide an order of magnitude stronger contacts. We further resolve the microstructures and forces acting during evaporation-driven, capillary-force-induced nanoparticle aggregation processes, highlighting the importance of the interactions between the nanoparticles and the confining mineral walls. Our novel SFA-based approach offers insight into nano- and microscale mechanisms of consolidating silica treatments, and it can aid the design of nanomaterials used in stone consolidation.

Elastic plastic fracture mechanics investigation of toughness of wet colloidal particulate materials: Influence of saturation

HYPOTHESIS

Previous use of linear elastic fracture mechanics to estimate toughness of wet particulate materials underestimates the toughness because it does not account for plastic deformation as a dissipation mechanism. Plastic deformation is responsible for the majority of energy dissipated during the fracture of wet colloidal particulate materials. Plastic deformation around the crack tip increases with saturation of the particulate body. The toughness of the body increases with increasing saturation.

EXPERIMENTS

Elastic plastic fracture mechanics using the J-integral approach was used for the first time to measure the fracture toughness (J_IC) of wet micron sized alumina powder bodies as a function of saturation. The samples were prepared by slip casting. The saturation was controlled by treatment in a humidity chamber. The elastic modulus (E) and the energy dissipated by plastic flow (A_pl) were measured in uniaxial compression. The critical stress intensity factor (K_IC) was measured using a diametral compression sample with a flaw of known size. The fracture toughness (J_IC) was calculated from these measured quantities and the geometry of the specimen.

FINDINGS

Elastic plastic fracture mechanics was used for the first time to quantitively account for plastic deformation of wet particulate materials. The linear elastic fracture mechanics approach previously used accounted for less than 1% of the total energy dissipated in fracture. Toughness (J_IC) was found to increase with increasing saturation due to plastic deformation that increased with saturation level. The improved understanding of toughness as a function of saturation will aid in providing quantitative analysis of cracking in drying colloidal films and bodies.

Transport dynamics of charged colloidal particles during directional drying of suspensions in a confined microchannel

Directional drying of colloidal suspensions, experimentally observed to exhibit mechanical instabilities, is a nonequilibrium procedure that is susceptible to geometric confinement and the properties of colloidal particles. Here, we develop an advection-diffusion model to characterize the transport dynamics for unidirectional drying of a suspension consisting of charged particles in a confined Hele-Shaw cell. We consider the electrostatic interactions by means of the Poisson-Boltzmann cell approach with the viscous flow confined to the cell. By solving the nonequilibrium transport equations, we clarify how the multiple parameters, such as drying rate, confinement ratio, and the monovalent slat concentration, affect the transport dynamics of charged colloidal particles. We find that the drying front recedes into the cell with linear behavior, while the liquid-solid transition front recedes with power law behaviors. The faster evaporation rate creates a rapid formation of the drying front and produces a thinner transition layer. We show that confinement is equivalent to raising the effective concentration in the cell, and, accordingly, the drying front appears earlier and grows more rapidly. Under geometric confinement, a longer fully dried film is created while the total drying time is shortened. Moreover, we have theoretically illustrated that low salt loadings cause a large collective diffusivity of charged colloidal particles, which results in a colloidal network by aggregation. Thus, the drying behavior alters dramatically as salt loadings decrease, since the resulting compacted clusters of charged particles eventually convert the suspension into a gel-like material instead of a simple fluid. Our model is consistent with the current experiments and provides a simple insight for applications in directional solidification and microfluidics.

Integrating optical coherence tomography with gravimetric and video analysis (OCT-Gravimetry-Video method) for studying the drying process of polystyrene latex system

Latex, an aqueous dispersion of sub-micron polymer particles, is widely used as polymer binder in waterborne coatings and adhesives. Drying of a latex is inhomogeneous, during which the spatial distribution of particles is non-uniform and changes with time, usually resulting in a compromise of the integrity of a dried film. To study drying inhomogeneity of latex, we developed a system integrating optical coherence tomography (OCT) with gravimetric and video analysis (OCT-Gravimetry-Video method) to non-destructively monitor the drying process of non-film-forming latexes consisting of hard polystyrene spheres over time. OCT structural and speckle images of the latex’s internal structure show the packing process of particles, the detachment of latex and the formation of apparent shear bands in cross-sectional views. Video recordings show the formation of cracks and the propagation of the drying boundary in the horizontal direction. The drying curve, measured by gravimetry, shows the drying rate and the water content of the latex at each drying stage. Furthermore, we find that the particle size affects packing and cracking phenomena remarkably. The OCT-Gravimetry-Video method serves as a general and robust approach to investigate the drying process of waterborne latex system. This method can be employed for fundamental studies of colloids and for evaluations of industrial latex products.

Highly porous layers of silica nanospheres sintered by drying: scaling up of the elastic properties of the beads to the macroscopic mechanical properties

Layers obtained by drying a colloidal dispersion of silica spheres are found to be a good benchmark to test the elastic behaviour of porous media, in the challenging case of high porosities and nano-sized microstructures. Classically used for these systems, Kendall's approach explicitly considers the effect of surface adhesive forces onto the contact area between the particles. This approach provides the Young's modulus using a single adjustable parameter (the adhesion energy) but provides no further information on the tensorial nature and possible anisotropy of elasticity. On the other hand, homogenization approaches (e.g. rule of mixtures, and Eshelby, Mori-Tanaka and self-consistent schemes), based on continuum mechanics and asymptotic analysis, provide the stiffness tensor from the knowledge of the porosity and the elastic constants of the beads. Herein, the self-consistent scheme accurately predicts both bulk and shear moduli, with no adjustable parameter, provided the porosity is less than 35%, for layers composed of particles as small as 15 nm in diameter. Conversely, Kendall's approach is found to predict the Young's modulus over the full porosity range. Moreover, the adhesion energy in Kendall's model has to be adjusted to a value of the order of the fracture energy of the particle material. This suggests that sintering during drying leads to the formation of covalent siloxane bonds between the particles.