Study on the Curing and Foaming of Surfactant-Modified Geopolymer Gels Based on Ash and Slag Waste from Coal Combustion

This study explores the influence of temperature-time conditions, surfactants, and varied waste compositions on the curing of geopolymer gels, a foam formation with the properties of porous geopolymers. Findings reveal that a 6 h curing period leads to a density of 435 kg/m3 and strength of 0.66 MPa, with notable improvements at 12 h. Comparing 12 to 24 h curing, differences in characteristics remain within 5%, highlighting the 12 h period as more energy-efficient. Sodium stearate-based samples exhibit excellent properties, significantly boosting strength while maintaining overall properties. Microwave curing achieves the lowest density (291 kg/m3) and closely parallels properties of samples cured conventionally for 12 h. However, it leads to complete destruction in sodium stearate-modified gels due to the Dumas reaction, making it unsuitable above 200 °C. Optimal properties emerge from compositions using sodium stearate and oven curing, achieving densities of 334 kg/m3 and strengths of 1.08 MPa (Severodvinsk CHPP-1) and 373 kg/m3 and 1.17 MPa (Novocherkassk SDPP). Although microwave curing allows for high energy efficiency, its high temperature demands necessitate careful material selection. This study offers insight into enhancing geopolymer properties while emphasizing the importance of tailored curing methods for sustainable material development.

Analysis of Deformation and Properties of Composite Melon Petals via Vibration Pretreatment-Microwave Compound Curing

The transition of large-scale cryogenic propellant tanks from metal to composite materials is the main trend in the global aerospace industry. Aiming to address the challenges of achieving the manufacturing of integrated and cost-effective manufacturing of aerospace cryogenic composite tanks that cannot be realized through the conventional autoclave process, and those of existing out-of-autoclave processes that are unable to effectively suppress defects under low-pressure conditions, a vibration pretreatment was innovatively introduced into the microwave curing process of composite materials in this study. Based on a systematic analysis of the inhibitory mechanisms of vibration pretreatment on void formation and the uniform heating mechanisms of microwaves in composite materials, the experimental results showed that the compound curing process enabled the production of components with complex structural features under low-pressure conditions while achieving equivalent surface precision and comprehensive properties, including porosity, interlaminar shear strength, and cryogenic permeation resistance, as those obtained through the standard 0.6 MPa autoclave process. This holds great promise for the application of out-of-autoclave processes in the manufacturing of large-scale aerospace cryogenic composite tanks.

Embedded 3D Printing of Architected Ceramics via Microwave-Activated Polymerization

Light- and ink-based 3D printing methods have vastly expanded the design space and geometric complexity of architected ceramics. However, light-based methods are typically confined to a relatively narrow range of preceramic and particle-laden resins, while ink-based methods are limited in geometric complexity due to layerwise assembly. Here, embedded 3D printing is combined with microwave-activated curing to generate architected ceramics with spatially controlled composition in freeform shapes. Aqueous colloidal inks are printed within a support matrix, rapidly cured via microwave-activated polymerization, and subsequently dried and sintered into dense architectures composed of one or more oxide materials. This integrated manufacturing method opens new avenues for the design and fabrication of complex ceramic architectures with programmed composition, density, and form for myriad applications.

Silica-Fiber-Reinforced Composites for Microelectronic Applications: Effects of Curing Routes

For curing of fiber-reinforced epoxy composites, an alternative to thermal heating is the use of microwave energy, which cures quickly and consumes less energy. Employing thermal curing (TC) and microwave (MC) curing methods, we present a comparative study on the functional characteristics of fiber-reinforced composite for microelectronics. The composite prepregs, prepared from commercial silica fiber fabric/epoxy resin, were separately cured via thermal and microwave energy under curing conditions (temperature/time). The dielectric, structural, morphological, thermal, and mechanical properties of composite materials were investigated. Microwave cured composite showed a 1% lower dielectric constant, 21.5% lower dielectric loss factor, and 2.6% lower weight loss, than thermally cured one. Furthermore, the dynamic mechanical analysis (DMA) revealed a 20% increase in the storage and loss modulus along with a 15.5% increase in the glass transition temperature (Tg) of microwave-cured compared to thermally cured composite. The fourier transformation infrared spectroscopy (FTIR) showed similar spectra of both the composites; however, the microwave-cured composite exhibited higher tensile (15.4%), and compression strength (4.3%) than the thermally cured composite. These results illustrate that microwave-cured silica-fiber-reinforced composite exhibit superior electrical performance, thermal stability, and mechanical properties compared to thermally cured silica fiber/epoxy composite in a shorter time and the expense of less energy.

Study of Geopolymers Obtained from Wheat Husk Native to Northern Mexico

Agro-industrial wastes such as wheat husk (WH) are renewable sources of organic and inorganic substances, including cellulose, lignin, and aluminosilicates, which can be transformed into advanced materials with high added value. The use of geopolymers is a strategy to take advantage of the inorganic substances by obtaining inorganic polymers, which have been used as additives, e.g., for cement and refractory brick products or ceramic precursors. In this research, the WH native to northern Mexico was used as a source to produce wheat husk ash (WHA) following its calcination at 1050 °C. In addition, geopolymers were synthesized from the WHA by varying the concentrations of the alkaline activator (NaOH) from 16 M to 30 M, namely Geo 16M, Geo 20M, Geo 25M, and Geo 30M. At the same time, a commercial microwave radiation process was employed as the curing source. Furthermore, the geopolymers synthesized with 16 M and 30 M of NaOH were studied for their thermal conductivity as a function of temperature, in particular at 25, 35, 60, and 90 °C. The chemical composition of the WHA, determined by ICP, revealed a SiO₂ content close to 81%, which is similar to rice husk. The geopolymers were characterized using various techniques to determine their structure, mechanical properties, and thermal conductivity. The findings showed that the synthesized geopolymers with 16M and 30M of NaOH had significant mechanical properties and thermal conductivity, respectively, compared to the other synthesized materials. Finally, the thermal conductivity regarding the temperature revealed that Geo 30M presented significant performance, especially at 60 °C.

Improvements in Temperature Uniformity in Carbon Fiber Composites during Microwave-Curing Processes via a Recently Developed Microwave Equipped with a Three-Dimensional Motion System

Curing processes for carbon-fiber-reinforced polymer composites via microwave heating are promising alternatives to conventional thermal curing because this technology results in nonhomogeneous temperature distributions, which hinder its further development in industries. This paper proposes a novel method for improving heating homogeneities by employing three-dimensional motion with respect to the prepreg laminate used in the microwave field by using a recently developed microwave system. The maximum temperature deviation on the surface of the laminate can be controlled within 8.7 °C during the entire curing process, and it produces an average heating rate of 1.42 °C/min. The FT-IR analyses indicate that microwave heating would slightly influence hydroxyl and methylene contents in the cured laminate. The DMA measurements demonstrate that the glass transition temperatures can be improved by applying proper microwave-curing processes. Optical microscopy and mechanical tests reveal that curing the prepreg laminate by using a multistep curing process that initially cures the laminate at the resin's lowest viscosity for 10 min followed by curing the laminate at a high temperature for a short period of time would be favorable for yielding a sample with low void contents and the desired mechanical properties. All these analyses are supposed to prove the feasibility of controlling the temperature difference during microwave-curing processes within a reasonable range and provide a cured laminate with improved properties compared with conventional thermally cured products.

Optimization of Vibration Pretreatment Microwave Curing in Composite Laminate Molding Process

Vibration pretreatment microwave curing is a high-quality and efficient composite out-of-autoclave molding process. Focusing on interlaminar shear strength, the effects of pretreatment temperature, pretreatment time and vibration acceleration on the molding performance of composite components were analyzed sequentially using the orthogonal test design method; a scanning electron microscope (SEM) and optical digital microscope (ODM) were used to analyze the void content and fiber-resin bonding state of the specimens under different curing and molding processes. The results show that the influence order of the different vibration process parameters on the molding quality of the components was: vibration acceleration > pretreatment temperature > pretreatment time. Within the parameters analyzed in this study, the optimal vibration pretreatment process parameters were: pretreatment temperature of 90 °C, pretreatment time of 30 min, and vibration acceleration of 10 g. Using these parameters, the interlaminar shear strength of the component was 82.12 MPa and the void content was 0.37%. Compared with the microwave curing process, the void content decreased by 71.8%, and the interlaminar shear strength increased by 31.6%. The microscopic morphology and mechanical properties basically reached the same level as the standard autoclave process, which achieved a high-quality out-of-autoclave curing and molding manufacturing of aerospace composite components.

Microwave Curing Characteristics of CFRP Composite Depending on Thickness Variation Using FBG Temperature Sensors

Microwave curing technology, which has seen increased commercialization recently due to its ability to cut the curing time and ensure high quality, requires an understanding of the curing characteristics of composite materials of varying thickness. Therefore, this study aimed to perform cure monitoring to evaluate the effects of variations in thickness on the quality of microwave curing. For this study, a fiber Bragg grating sensor was used to measure temperature changes in specimens during the curing cycle for cure monitoring which is generally used for optimization of the curing cycle; then, the time taken for temperature increase and overshoot of the specimen, and the times at which the specimen thickness varied, were quantitatively evaluated. Testing confirmed that microwave curing reduced the curing time in the sections in which the temperature rose; also, the specimen thickness caused overshoot of up to approximately 40 °C at the side, which can affect the curing quality of the composite materials. Furthermore, voids were observed on the side of all specimens. The results indicated that, in order to improve the quality of microwave curing of composite materials, the curing cycle should be optimized by considering the characteristics of the microwave curing equipment.

Bonded Repair Optimization of Cracked Aluminum Alloy Plate by Microwave Cured Carbon-Aramid Fiber/Epoxy Sandwich Composite Patch

Fiber-reinforced epoxy sandwich composites, which were designed as the bonded repair patches to better recover the mechanical performance of a central cracked aluminum alloy plate, were layered by carbon and aramid fiber layers jointly and cured by microwave method in this study. The static tensile and bending properties of both carbon-aramid fiber/epoxy sandwich composite patches and the cracked aluminum alloy plates after bonded repair were systematically investigated. By comparing the mechanical performance with traditional single carbon-fiber-reinforced composite patches, it can be found that the bending performance of carbon-aramid fiber sandwich composite patches was effectively improved after incorporation of flexible aramid fiber layers into the carbon fiber layers, but the tensile strength of sandwich composite patches was weakened to some extent. Especially, the sandwich patches with 3 fiber layers exhibited better tensile and bending performance in comparison to patches of 5 and 7 fiber layers. The optimized 3-layer carbon-aramid fiber sandwich patch repaired plate recovered 86% and 190% of the tensile and bending performance in comparison to the uncracked ones, respectively, showing a considerable repair majorization effect for the cracked aluminum alloy plate.

SEM Analysis of the Interfacial Transition Zone between Cement-Glass Powder Paste and Aggregate of Mortar under Microwave Curing

In order to investigate the effects of microwave curing on the microstructure of the interfacial transition zone of mortar prepared with a composite binder containing glass powder and to explain the mechanism of microwave curing on the improvement of compressive strength, in this study, the compressive strength of mortar under microwave curing was compared against mortar cured using (a) normal curing at 20 ± 1 °C with relative humidity (RH) > 90%; (b) steam curing at 40 °C for 10 h; and (c) steam curing at 80 °C for 4 h. The microstructure of the interfacial transition zone of mortar under the four curing regimes was analyzed by Scanning electron microscopy (SEM). The results showed that the improvement of the compressive strength of mortar under microwave curing can be attributed to the amelioration of the microstructure of the interfacial transition zone. The hydration degree of cement is accelerated by the thermal effect of microwave curing and Na⁺ partially dissolved from the fine glass powder to form more reticular calcium silicate hydrate, which connects the aggregate, calcium hydroxide, and non-hydrated cement and glass powder into a denser integral structure. In addition, a more stable triangular structure of calcium hydroxide contributes to the improvement of compressive strength.