Hair-Reinforced Elastomer Matrix Composites: Formulation, Mechanical Testing, and Advanced Microstructural Characterization

Epoxy matrix composites reinforced with high-performance fibers, such as carbon, Kevlar, and glass, exhibit excellent specific stiffness and strength in many mechanical applications. However, these composites are disappointingly non-recyclable and are usually disposed of in landfill sites, with no realistic prospect for biodegradation in a reasonable time. In contrast, moldable composites with carbonized elastomeric matrices developed in the last decades possess attractive mechanical properties in final net-shape products and can also be incinerated or recycled. Many carbon and inorganic fillers have recently been evaluated to adjust the properties of carbonized elastomeric composites. Renewable organic fillers, such as human or animal hair, offer an attractive fibrous material with substantial potential for reinforcing composites with elastomeric matrices. Samples of unidirectional fiber composites (with hair volume fractions up to 7%) and quasi-isotropic short fiber composites (with hair volume fractions up to 20%) of human hair-reinforced nitrile butadiene rubbers (HH-NBRs) were produced in the peroxide-cured and carbonized states. The samples were characterized using scanning electron microscopy (SEM), Raman spectroscopy, and photoacoustic microscopy. Mechanical tests were performed under tension using a miniature universal testing machine. The expected effect of fiber reinforcement on the overall mechanical performance was demonstrated for both cured and carbonized composites. Considerable enhancement of the elastic modulus (up to ten times), ultimate tensile strength (up to three times), and damage tolerance was achieved. The evidence of satisfactory interfacial bonding between hair and rubber was confirmed via SEM imaging of fracture surfaces. The suitability of photoacoustic microscopy was assessed for 3D reconstructions of the fiber sub-system's spatial distribution and non-destructive testing.

The Analysis of Micro-Scale Deformation and Fracture of Carbonized Elastomer-Based Composites by In Situ SEM

Carbonized elastomer-based composites (CECs) possess a number of attractive features in terms of thermomechanical and electromechanical performance, durability in aggressive media and facile net-shape formability, but their relatively low ductility and strength limit their suitability for structural engineering applications. Prospective applications such as structural elements of micro-electro-mechanical systems MEMS can be envisaged since smaller principal dimensions reduce the susceptibility of components to residual stress accumulation during carbonization and to brittle fracture in general. We report the results of in situ in-SEM study of microdeformation and fracture behavior of CECs based on nitrile butadiene rubber (NBR) elastomeric matrices filled with carbon and silicon carbide. Nanostructured carbon composite materials were manufactured via compounding of elastomeric substance with carbon and SiC fillers using mixing rolling mill, vulcanization, and low-temperature carbonization. Double-edge notched tensile (DENT) specimens of vulcanized and carbonized elastomeric composites were subjected to in situ tensile testing in the chamber of the scanning electron microscope (SEM) Tescan Vega 3 using a Deben microtest 1 kN tensile stage. The series of acquired SEM images were analyzed by means of digital image correlation (DIC) using Ncorr open-source software to map the spatial distribution of strain. These maps were correlated with finite element modeling (FEM) simulations to refine the values of elastic moduli. Moreover, the elastic moduli were derived from unloading curve nanoindentation hardness measurements carried out using a NanoScan-4D tester and interpreted using the Oliver-Pharr method. Carbonization causes a significant increase of elastic moduli from 0.86 ± 0.07 GPa to 14.12 ± 1.20 GPa for the composite with graphite and carbon black fillers. Nanoindentation measurements yield somewhat lower values, namely, 0.25 ± 0.02 GPa and 9.83 ± 1.10 GPa before and after carbonization, respectively. The analysis of fractography images suggests that crack initiation, growth and propagation may occur both at the notch stress concentrator or relatively far from the notch. Possible causes of such response are discussed, namely, (1) residual stresses introduced by processing; (2) shape and size of fillers; and (3) the emanation and accumulation of gases in composites during carbonization.

Low-Temperature Carbonized Elastomer-Based Composites Filled with Silicon Carbide

Thermally stable composites obtained by the low-temperature carbonization of an elastomeric matrix filled with hard dispersed silicon carbide particles were obtained and investigated. Evolution of the microstructure and of mechanical and thermal characteristics of composites during thermal degradation and carbonization processes in a wide range of filling from 0 to 450 parts per hundred rubber was studied. For highly filled composites, the compressive strength values were found to be more than 200 MPa; Young's modulus was more than 15 GPa. The thermal conductivity coefficient of composites was up to 1.6 W/(m·K), and this magnitude varied slightly in the temperature range of 25-300 °C. Coupled with the high thermal stability of the composites, the observed properties make it possible to consider using such composites as strained friction units instead of reinforced polymers.