Magnetic Filler Polymer Composites-Morphology Characterization and Experimental and Stochastic Finite Element Analyses of Mechanical Properties

Polymer composites containing magnetic fillers are promising materials for a variety of applications, such as in energy storage and medical fields. To facilitate the engineering design of respective components, a comprehensive understanding of the mechanical behavior of such inhomogeneous and potentially highly anisotropic materials is important. Therefore, the authors created magnetic composites by compression molding. The epoxy polymer matrix was modified with a commercial-grade thickening agent. Isotropic magnetic particles were added as the functional filler. The microstructural morphology, especially the filler distribution, dispersion, and alignment, was characterized using microscopy techniques. The mechanical properties of the composites were experimentally characterized and studied by stochastic finite element analysis (SFEA). Modeling was conducted employing four cases to predict the elastic modulus: fully random distribution, randomly aligned distribution, a so-called "rough" interface contact, and a bonded interface contact. Results from experiments and SFEA modeling were compared and discussed.

Multifunctional Hybrid Fiber Composites for Energy Transfer in Future Electric Vehicles

Reducing the weight of electric conductors is an important task in the design of future electric air and ground vehicles. Fully electric aircraft, where high electric energies have to be distributed over significant distances, are a prime example. Multifunctional composite materials with both adequate structural and electrical properties are a promising approach to substituting conventional monofunctional components and achieving considerable mass reductions. In this paper, a hybrid multifunctional glass-fiber-reinforced composite containing quasi-endless aluminum fibers with a diameter of 45 μm is proposed for electric energy transfer. In addition to characterizing the material’s behavior under static and fatigue loads, combined electrical-mechanical tests are conducted to prove the material’s capability of carrying electric current. Light microscopy, thermal imaging and potentiometry-based resistance characterization are used to investigate the damage behavior. It is found that a volume fraction of about 10% work-hardened aluminum fibers does not affect the static fiber-parallel material properties significantly. Under transverse loading, however, the tensile strength is found to decrease by 17% due to the weak bonding of the aluminum fibers. The fiber-parallel fatigue strength of the multifunctional laminate containing work-hardened aluminum fibers is comparable to that of the reference material. In contrast, the integration of soft-annealed aluminum fibers decreases the tensile strength (−10%) and fatigue life (−21%). Concerning the electrical properties, electrical resistance is nearly unchanged until specimen rupture under quasi-static tensile loads, whereas under cyclic loading, it increases up to 60% within the last third of the fatigue life. Furthermore, the material’s capability of carrying currents up to 0.32 A/mm2 (current density of 4.5 A/mm2 in the aluminum phase) is proven. Under combined electrical-mechanical loads, a notable reduction in the fatigue life (−20%) is found at low fatigue loads, which is attributed to ohmic specimen heating. To the best knowledge of the authors, this is the first study on the electrical and mechanical material properties and damage behavior of glass-fiber-reinforced composites containing aluminum fibers tested under combined electrical-mechanical loads.

In Situ Testing of Polymers Immersed in Aging Fluids at Elevated Temperature and Pressure

A novel elevated-temperature and high-pressure in situ punch-shear-test cell was developed to qualify materials for reliable service in harsh environments representative of those typically encountered in oil and gas operations. The proposed modular and compact test device is an extension of the ASTM D 732 punch-shear method. Conventionally, materials are first exposed to harsh environments, then removed from the aging environment for mechanical testing. This practice can lead to the generation of unrealistic (often optimistic) mechanical properties. This is especially true in the case of materials for which fluid ingress is reversible. The present contribution elaborates on the developed in situ punch-shear device that has been successfully used to realistically assess the tensile yield strength and modulus properties of in-service polymer materials based on experimentally established correlations between shear and tensile tests.

Characterization of swelling behavior of carbon nano-filler modified polydimethylsiloxane composites

Polymers may absorb fluids from their surroundings via the natural phenomenon of swelling. Dimensional changes due to swelling can affect the function of polymer components, such as in the case of seals, microfluidic components and electromechanical sensors. An understanding of the swelling behavior of polymers and means for controlling it can improve the design of polymer components, for example, for the previously mentioned applications. Carbon-based fillers have risen in popularity to be used for the property enhancement of resulting polymer composites. The present investigation focuses on the effects of three carbon-based nano-fillers (graphene nano-platelets, carbon black, and graphene nano-scrolls) on the dimensional changes of polydimethylsiloxane composites due to swelling when immersed in certain organic solvents. For this study, a facile and expedient methodology comprised of optical measurements in conjunction with digital image analysis was developed as the primary experimental technique to quantify swelling dimensional changes of the prepared composites. Other experimental techniques assessed polymer cross-linking densities and elastic mechanical properties of the various materials. The study revealed that the addition of certain carbon-based nano-fillers increased the overall swelling of the composites. The extent of swelling further depended on the organic solvent in which the composites were immersed in. Experimental findings are contrasted with published models for swelling prediction, and the role of filler morphology on swelling behavior is discussed.

Development and Characterization of Field Structured Magnetic Composites

Polymer composites containing ferromagnetic fillers are promising for applications relating to electrical and electronic devices. In this research, the authors modified an ultraviolet light (UV) curable prepolymer to additionally cure upon heating and validated a permanent magnet-based particle alignment system toward fabricating anisotropic magnetic composites. The developed dual-cure acrylate-based resin, reinforced with ferromagnetic fillers, was first tested for its ability to polymerize through UV and heat. Then, the magnetic alignment setup was used to orient magnetic particles in the dual-cure acrylate-based resin and a heat curable epoxy resin system in a polymer casting approach. The alignment setup was subsequently integrated with a material jetting 3D printer, and the dual-cure resin was dispensed and cured in-situ using UV, followed by thermal post-curing. The resulting magnetic composites were tested for their filler loading, microstructural morphology, alignment of the easy axis of magnetization, and degree of monomer conversion. Magnetic characterization was conducted using a vibrating sample magnetometer along the in-plane and out-of-plane directions to study anisotropic properties. This research establishes a methodology to combine magnetic field induced particle alignment along with a dual-cure resin to create anisotropic magnetic composites through polymer casting and additive manufacturing.

Rheology-Assisted Microstructure Control for Printing Magnetic Composites-Material and Process Development

Magnetic composites play a significant role in various electrical and electronic devices. Properties of such magnetic composites depend on the particle microstructural distribution within the polymer matrix. In this study, a methodology to manufacture magnetic composites with isotropic and anisotropic particle distribution was introduced using engineered material formulations and manufacturing methods. An in-house developed material jetting 3D printer with particle alignment capability was utilized to dispense a UV curable resin formulation to the desired computer aided design (CAD) geometry. Formulations engineered using additives enabled controlling the rheological properties and the microstructure at different manufacturing process stages. Incorporating rheological additives rendered the formulation with thixotropic properties suitable for material jetting processes. Particle alignment was accomplished using a magnetic field generated using a pair of permanent magnets. Microstructure control in printed composites was observed to depend on both the developed material formulations and the manufacturing process. The rheological behavior of filler-modified polymers was characterized using rheometry, and the formulation properties were derived using mathematical models. Experimental observations were correlated with the observed mechanical behavior changes in the polymers. It was additionally observed that higher additive content controlled particle aggregation but reduced the degree of particle alignment in polymers. Directionality analysis of optical micrographs was utilized as a tool to quantify the degree of filler orientation in printed composites. Characterization of in-plane and out-of-plane magnetic properties using a superconducting quantum interference device (SQUID) magnetometer exhibited enhanced magnetic characteristics along the direction of field structuring. Results expressed in this fundamental research serve as building blocks to construct magnetic composites through material jetting-based additive manufacturing processes.

Stochastic Finite Element Analysis Framework for Modelling Electrical Properties of Particle-Modified Polymer Composites

Properties such as low specific gravity and cost make polymers attractive for many engineering applications, yet their mechanical, thermal, and electrical properties are typically inferior compared to other engineering materials. Material designers have been seeking to improve polymer properties, which may be achieved by adding suitable particulate fillers. However, the design process is challenging due to countless permutations of available filler materials, different morphologies, filler loadings and fabrication routes. Designing materials solely through experimentation is ineffective given the considerable time and cost associated with such campaigns. Analytical models, on the other hand, typically lack detail, accuracy and versatility. Increasingly powerful numerical techniques are a promising route to alleviate these shortcomings. A stochastic finite element analysis method for predicting the properties of filler-modified polymers is herein presented with a focus on electrical properties, i.e., conductivity, percolation, and piezoresistivity behavior of composites with randomly distributed and dispersed filler particles. The effect of temperature was also explored. While the modeling framework enables prediction of the properties for a variety of filler morphologies, the present study considers spherical particles for the case of nano-silver modified epoxy polymer. Predicted properties were contrasted with data available in the technical literature to demonstrate the viability of the developed modeling approach.

Stochastic Finite Element Analysis Framework for Modelling Mechanical Properties of Particulate Modified Polymer Composites

Polymers have become indispensable in many engineering applications because of their attractive properties, including low volumetric mass density and excellent resistance to corrosion. However, polymers typically lack in mechanical, thermal, and electrical properties that may be required for certain engineering applications. Therefore, researchers have been seeking to improve properties by modifying polymers with particulate fillers. In the research presented herein, a numerical modeling framework was employed that is capable of predicting the properties of binary or higher order composites with randomly distributed fillers in a polymer matrix. Specifically, mechanical properties, i.e., elastic modulus, Poisson's ratio, and thermal expansion coefficient, were herein explored for the case of size-distributed spherical filler particles. The modeling framework, employing stochastic finite element analysis, reduces efforts for assessing material properties compared to experimental work, while increasing the level of accuracy compared to other available approaches, such as analytical methods. Results from the modeling framework are presented and contrasted with findings from experimental works available in the technical literature. Numerical predictions agree well with the non-linear trends observed in the experiments, i.e., elastic modulus predictions are within the experimental data scatter, while numerical data deviate from experimental Poisson's ratio data for filler volume fractions greater than 0.15. The latter may be the result of morphology changes in specimens at higher filler volume fractions that do not comply with modelling assumptions.

Effect of Temperature on Electrical Resistivity of Carbon Nanotubes and Graphene Nanoplatelets Nanocomposites

The effect of the temperature on the electrical resistivity of polymer nanocomposites with carbon nanotube (CNT) and graphene nanoplatelets (GNP) fillers was investigated. A three-dimensional (3D) continuum Monte Carlo (MC) model was developed to first form percolation networks. A 3D resistor network was subsequently created to evaluate the nanocomposite electrical properties. The effect of temperature on the electrical resistivity of nanocomposites was thus investigated. Other aspects such as polymer tunneling and filler resistivities were considered as well. The presented comprehensive modeling approach is aimed at providing a better understanding of the electrical resistivity behavior of polymer nanocomposites in conjunction with experimental works.

Current-voltage characteristics of nanoplatelet-based conductive nanocomposites

In this study, a numerical modeling approach was used to investigate the current-voltage behavior of conductive nanoplatelet-based nanocomposites. A three-dimensional continuum Monte Carlo model was employed to randomly disperse the nanoplatelets in a cubic representative volume element. A nonlinear finite element-based model was developed to evaluate the electrical behavior of the nanocomposite for different levels of the applied electric field. Also, the effect of filler loading on nonlinear conductivity behavior of nanocomposites was investigated. The validity of the developed model was verified through qualitative comparison of the simulation results with results obtained from experimental works.

Multiscale model to investigate the effect of graphene on the fracture characteristics of graphene/polymer nanocomposites

In this theoretical research work, the fracture characteristics of graphene-modified polymer nanocomposites were studied. A three-dimensional representative volume element-based multiscale model was developed in a finite element environment. Graphene sheets were modeled in an atomistic state, whereas the polymer matrix was modeled as a continuum. Van der Waals interactions between the matrix and graphene sheets were simulated employing truss elements. Fracture characteristics of graphene/polymer nanocomposites were investigated in conjunction with the virtual crack closure technique. The results demonstrate that fracture characteristics in terms of the strain energy release rate were affected for a crack lying in a polymer reinforced with graphene. A shielding effect from the crack driving forces is considered to be the reason for enhanced fracture resistance in graphene-modified polymer nanocomposites.

Representative volume element to estimate buckling behavior of graphene/polymer nanocomposite

The aim of the research article is to develop a representative volume element using finite elements to study the buckling stability of graphene/polymer nanocomposites. Research work exploring the full potential of graphene as filler for nanocomposites is limited in part due to the complex processes associated with the mixing of graphene in polymer. To overcome some of these issues, a multiscale modeling technique has been proposed in this numerical work. Graphene was herein modeled in the atomistic scale, whereas the polymer deformation was analyzed as a continuum. Separate representative volume element models were developed for investigating buckling in neat polymer and graphene/polymer nanocomposites. Significant improvements in buckling strength were observed under applied compressive loading when compared with the buckling stability of neat polymer.