1
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Sarrafan S, Li G. On Lightweight Shape Memory Vitrimer Composites. ACS Appl Polym Mater 2024; 6:154-169. [PMID: 38230367 PMCID: PMC10788861 DOI: 10.1021/acsapm.3c01749] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 08/02/2023] [Revised: 11/10/2023] [Accepted: 11/13/2023] [Indexed: 01/18/2024]
Abstract
Lightweight materials are highly desired in many engineering applications. A popular approach to obtain lightweight polymers is to prepare polymeric syntactic foams by dispersing hollow particles, such as hollow glass microbubbles (HGMs), in a polymer matrix. Integrating shape memory vitrimers (SMVs) in fabricating these syntactic foams enhances their appeal due to the multifunctionality of SMVs. The SMV-based syntactic foams have many potential applications, including actuators, insulators, and sandwich cores. However, there is a knowledge gap in understanding the effect of the HGM volume fraction on different material properties and behaviors. In this study, we prepared an SMV-based syntactic foam to investigate the influence of the HGM volume fractions on a broad set of properties. Four sample groups, containing 40, 50, 60, and 70% HGMs by volume, were tested and compared to a control pure SMV group. A series of analyses and various chemical, physical, mechanical, thermal, rheological, and functional experiments were conducted to explore the feasibility of ultralight foams. Notably, the effect of HGM volume fractions on the rheological properties was methodically evaluated. The self-healing capability of the syntactic foam was also assessed for healing at low and high temperatures. This study proves the viability of manufacturing multifunctional ultralightweight SMV-based syntactic foams, which are instrumental for designing ultralightweight engineering structures and devices.
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Affiliation(s)
- Siavash Sarrafan
- Department of Mechanical & Industrial
Engineering, Louisiana State University, Baton Rouge, Louisiana 70803, United States
| | - Guoqiang Li
- Department of Mechanical & Industrial
Engineering, Louisiana State University, Baton Rouge, Louisiana 70803, United States
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2
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Abramovskis V, Zalite I, Maiorov M, Baronins J, Singh AK, Lapkovskis V, Goel S, Shishkin A. High-Temperature, Lightweight Ceramics with Nano-Sized Ferrites for EMI Shielding: Synthesis, Characterisation, and Potential Applications. Materials (Basel) 2023; 16:7615. [PMID: 38138758 PMCID: PMC10744912 DOI: 10.3390/ma16247615] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 11/02/2023] [Revised: 12/01/2023] [Accepted: 12/05/2023] [Indexed: 12/24/2023]
Abstract
The present study focuses on the synthesis and characterisation of a lightweight ceramic material with electromagnetic interference (EMI) shielding properties, achieved using mullite containing micrometre-sized hollow spheres (cenospheres) and CoFe2O4 nanoparticles. This research explores compositions with varying CoFe2O4 contents ranging from 0 up to 20 wt.%. Conventional sintering in an air atmosphere is carried out at a temperature between 1100 and 1300 °C. The addition of ferrite nanoparticles was found to enhance the process of sintering cenospheres, resulting in improved material density and mechanical properties. Furthermore, this study reveals a direct correlation between the concentration of ferrite nanoparticles and the electromagnetic properties of the material. By increasing the concentration of ferrite nanoparticles, the electromagnetic shielding effect of the material (saturation magnetisation (Ms) and remanent magnetisation (Mr)) was observed to strengthen. These findings provide valuable insights into designing and developing lightweight ceramic materials with enhanced electromagnetic shielding capabilities. The synthesized ceramic material holds promise for various applications that require effective electromagnetic shielding, such as in the electronics, telecommunications, and aerospace industries.
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Affiliation(s)
- Vitalijs Abramovskis
- Laboratory of Ecological Solutions and Sustainable Development of Materials, Institute of General Chemical Engineering, Faculty of Materials Science and Applied Chemistry, Riga Technical University, Pulka 3, K-3, LV-1007 Riga, Latvia; (V.A.); (J.B.); (V.L.)
| | - Ilmars Zalite
- Institute of Materials and Surface Technologies, Riga Technical University, P. Valdena Iela 7, LV-1048 Riga, Latvia;
| | - Mikhail Maiorov
- Institute of Physics, University of Latvia, Miera Iela 32, LV-2169 Salaspils, Latvia;
| | - Janis Baronins
- Laboratory of Ecological Solutions and Sustainable Development of Materials, Institute of General Chemical Engineering, Faculty of Materials Science and Applied Chemistry, Riga Technical University, Pulka 3, K-3, LV-1007 Riga, Latvia; (V.A.); (J.B.); (V.L.)
| | | | - Vjaceslavs Lapkovskis
- Laboratory of Ecological Solutions and Sustainable Development of Materials, Institute of General Chemical Engineering, Faculty of Materials Science and Applied Chemistry, Riga Technical University, Pulka 3, K-3, LV-1007 Riga, Latvia; (V.A.); (J.B.); (V.L.)
| | - Saurav Goel
- School of Engineering, London South Bank University, London SE1 0AA, UK;
- Department of Mechanical Engineering, University of Petroleum and Energy Studies, Dehradun 248007, India
| | - Andrei Shishkin
- Laboratory of Ecological Solutions and Sustainable Development of Materials, Institute of General Chemical Engineering, Faculty of Materials Science and Applied Chemistry, Riga Technical University, Pulka 3, K-3, LV-1007 Riga, Latvia; (V.A.); (J.B.); (V.L.)
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3
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Chitrakar R, Hossain MS, Nilufar S. The Effect of Microballoon Volume Fraction on the Elastic and Viscoelastic Properties of Hollow Microballoon-Filled Epoxy Composites. Materials (Basel) 2023; 16:7554. [PMID: 38138697 PMCID: PMC10744497 DOI: 10.3390/ma16247554] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 10/21/2023] [Revised: 11/30/2023] [Accepted: 12/05/2023] [Indexed: 12/24/2023]
Abstract
This paper reports the study of hollow microballoon-filled epoxy composites also known as syntactic foams with various volume fractions of microballoons. Different mechanical and thermomechanical investigations were carried out to study the elastic and viscoelastic behavior of these foams. The density, void content, and microstructure of these materials were also studied for better characterization. In addition to the experimental testing, a representative 3D model of these syntactic foams was developed to further investigate their elastic behavior. The results indicate that changes in the volume percentage of the microballoons had a substantial impact on the elastic and viscoelastic behavior of these foams. These results will help in designing and optimizing custom-tailored syntactic foams for different engineering applications.
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Affiliation(s)
| | | | - Sabrina Nilufar
- School of Mechanical, Aerospace, and Materials Engineering, Southern Illinois University Carbondale, Carbondale, IL 62901, USA
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4
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Abramovskis V, Drunka R, Csáki Š, Lukáč F, Veverka J, Illkova K, Gavrilovs P, Shishkin A. Preparation and Characteristics of High-Performance, Low-Density Metallo-Ceramics Composite. Materials (Basel) 2023; 16:7523. [PMID: 38138669 PMCID: PMC10744984 DOI: 10.3390/ma16247523] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 11/09/2023] [Revised: 11/29/2023] [Accepted: 12/01/2023] [Indexed: 12/24/2023]
Abstract
By applying the physical vapour deposition method, hollow ceramic microspheres were coated with titanium, and subsequently, they were sintered using the spark plasma sintering technique to create a porous ceramic material that is lightweight and devoid of a matrix. The sintering process was carried out at temperatures ranging from 1050 to 1200 °C, with a holding time of 2 min. The samples were subjected to conventional thermal analyses (differential scanning calorimetry, thermogravimetry, dilatometry), oxidation resistance tests, and thermal diffusivity measurements. Phase analysis of the samples was performed using the XRD and the microstructure of the prepared specimens was examined using electron microscopy. The titanium coating on the microspheres increased the compressive strength and density of the resulting ceramic material as the sintering temperature increased. The morphology of the samples was carefully examined, and phase transitions were also identified during the analysis of the samples.
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Affiliation(s)
- Vitalijs Abramovskis
- Laboratory of Ecological Solutions and Sustainable Development of Materials, Faculty of Materials Science and Applied Chemistry, Institute of General Chemical Engineering, Riga Technical University, Pulka 3, K-3, LV-1007 Riga, Latvia;
| | - Reinis Drunka
- Institute of Materials and Surface Technologies, Riga Technical University, P. Valdena iela 7, LV-1048 Riga, Latvia;
| | - Štefan Csáki
- Department of Physics, Faculty of Natural Sciences and Informatics, Constantine the Philosopher University in Nitra, Tr. A. Hlinku 1, 949 01 Nitra, Slovakia;
- Department of Horticultural Machinery, Mendel University in Brno, Valtická 337, 691 44 Lednice, Czech Republic
| | - František Lukáč
- Institute of Plasma Physics of the Czech Academy of Sciences, U Slovanky 2525/1a, 182 00 Prague, Czech Republic; (F.L.); (J.V.); (K.I.)
| | - Jakub Veverka
- Institute of Plasma Physics of the Czech Academy of Sciences, U Slovanky 2525/1a, 182 00 Prague, Czech Republic; (F.L.); (J.V.); (K.I.)
| | - Ksenia Illkova
- Institute of Plasma Physics of the Czech Academy of Sciences, U Slovanky 2525/1a, 182 00 Prague, Czech Republic; (F.L.); (J.V.); (K.I.)
| | - Pavels Gavrilovs
- Laboratory of Ecological Solutions and Sustainable Development of Materials, Faculty of Materials Science and Applied Chemistry, Institute of General Chemical Engineering, Riga Technical University, Pulka 3, K-3, LV-1007 Riga, Latvia;
| | - Andrei Shishkin
- Laboratory of Ecological Solutions and Sustainable Development of Materials, Faculty of Materials Science and Applied Chemistry, Institute of General Chemical Engineering, Riga Technical University, Pulka 3, K-3, LV-1007 Riga, Latvia;
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5
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Wang H, Yan R, Cheng H, Zou M, Wang H, Zheng K. Hollow glass microspheres/phenolic syntactic foams with excellent mechanical and thermal insulate performance. Front Chem 2023; 11:1216706. [PMID: 37324555 PMCID: PMC10267378 DOI: 10.3389/fchem.2023.1216706] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/04/2023] [Accepted: 05/15/2023] [Indexed: 06/17/2023] Open
Abstract
Syntactic foams with low density as well as low thermal conduction and proper mechanical performance are vitally important for aerospace, marine, and automotive industries. Here, phenolic-based syntactic foams were fabricated by combining the hollow glass microsphere (GMs) with phenolic resin of in situ synthesis. Benefited from the stirring and hot-pressing treatment, microspheres dispersed homogeneously in the resin matrix and it greatly reduced the density of the composites. Stretching and compression tests were performed to investigate the mechanical behavior of the foams. It is found that both the compressive and tensile strength decreased as the filler loadings increasing. While the elasticity modulus was improved. On the other hand, thermal properties tests revealed superior thermal stability and thermal insulate performance of the composites. The final residue content of the synthetic foam with 40 wt% filler was improved by ∼31.5% than that of the neat one at 700°C. And samples with 20 wt% microspheres reached a minimum thermal conductivity value of approximately 0.129 W (m·K)-1 which is ∼46.7% lower than that of neat resin [0.298 W (m·K)-1]. This work provides a feasible strategy to construct syntactic foams with low density and ideal thermal properties.
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Affiliation(s)
- Hui Wang
- Department of Chemistry and Chemical Engineering, Hefei Normal University, Hefei, China
- Institute of Solid State Physics, Hefei Institutes of Physical Science, Chinese Academy of Sciences, Hefei, China
| | - Rui Yan
- Department of Chemistry and Chemical Engineering, Hefei Normal University, Hefei, China
| | - Hua Cheng
- Department of Chemistry and Chemical Engineering, Hefei Normal University, Hefei, China
- Institute of Solid State Physics, Hefei Institutes of Physical Science, Chinese Academy of Sciences, Hefei, China
| | - Mingmin Zou
- Information Materials and Intelligent Sensing Laboratory of Anhui Province, Anhui University, Hefei, Anhui, China
| | - Hua Wang
- Institute of Solid State Physics, Hefei Institutes of Physical Science, Chinese Academy of Sciences, Hefei, China
| | - Kang Zheng
- Institute of Solid State Physics, Hefei Institutes of Physical Science, Chinese Academy of Sciences, Hefei, China
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6
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Thomas KK, Kannan S, Pervaiz S, Nazzal M, Karthikeyan R. Computational Analysis of Machining Induced Stress Distribution during Dry and Cryogenic Orthogonal Cutting of 7075 Aluminium Closed Cell Syntactic Foams. Micromachines (Basel) 2023; 14:174. [PMID: 36677235 PMCID: PMC9866457 DOI: 10.3390/mi14010174] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 11/20/2022] [Revised: 01/05/2023] [Accepted: 01/06/2023] [Indexed: 06/17/2023]
Abstract
The addition of hollow aluminium oxide bubbles to the 7075 aluminium matrix results in a lightweight syntactic foam with a reduced density and an increased peak compression strength. The presence of ceramic bubbles also aids in a reduced coefficient of thermal expansion and thermal conductivity in comparison to aluminium alloys. In spite of their enhanced material properties, the inclusion of hollow aluminium oxide bubbles presents the challenge of poor machinability. In order to elucidate the problem of poor surface machinability, an attempt has been made to develop a thermo-mechanical finite element machining model using AdvantEdgeTM software with which surface quality and machined syntactic foam material can be analyzed. If the novel model developed is combined with virtual reality technology, CNC technicians can observe the machining results to evaluate and optimize the machining program. The main novelty behind this software is that the material foam is assumed as a homogeneous material model for simplifying the material model as a complex heterogeneous material system. The input parameters used in this study are cutting speed, feed, average size and volume fraction of hollow aluminium oxide bubbles, and coolant. For the output parameters, the numerical analysis showed a 6.24% increase in peak tensile machining induced stress as well as a 51.49% increase in peak cutting temperature as cutting speed (25 m/min to 100 m/min) and uncut chip thickness (0.07 mm to 0.2 mm) were increased. The average size and volume fraction of hollow aluminium oxide bubbles showed a significant impact on the magnitude of cutting forces and the depth of tensile induced stress distribution. It was observed on the machined surface that, as the average size of hollow aluminium oxide bubbles became coarser, the peak machining induced tensile stress on the cut surface reduced by 4.47%. It was also noted that an increase in the volume fraction of hollow aluminium oxide bubbles led to an increase in both the peak machining induced tensile stress and the peak cutting temperature by 29.36% and 20.11%, respectively. This study also showed the influence of the ceramic hollow bubbles on plastic deformation behavior in 7075 aluminium matrix; the machining conditions for obtaining a favorable stress distribution in the machined surface and sub-surface of 7075 closed cell syntactic foam are also presented.
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Affiliation(s)
- Kevin K. Thomas
- Department of Mechanical Engineering, American University of Sharjah, Sharjah P.O. Box 26666, United Arab Emirates
| | - Sathish Kannan
- Department of Mechanical Engineering, American University of Sharjah, Sharjah P.O. Box 26666, United Arab Emirates
| | - Salman Pervaiz
- Department of Mechanical Engineering, Rochester Institute of Technology, Dubai P.O. Box 341055, United Arab Emirates
| | - Mohammad Nazzal
- Department of Mechanical Engineering, American University of Sharjah, Sharjah P.O. Box 26666, United Arab Emirates
| | - Ramanujam Karthikeyan
- Department of Mechanical Engineering, BITS Pilani, Dubai P.O. Box 345055, United Arab Emirates
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7
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Abstract
Herein, we report the first hybrid open-cell foam with revisable actuation. Open-cell foams with revisable actuation are favoable for many applications. However, it is challenging to fabricate such open-cell foams with very low density. This study presents a novel concept of creating hybrid two-way (2W) shape memory open-cell foams using two-way shape-memory-polymer-based syntactic foams as the matrix. Previously, a syntactic foam prepared by incorporating hollow glass microbubbles in the cross-linked semicrystalline cis-poly(1,4-butadiene) (cPBD) was proved to have enhanced strength and specific energy output compared to the neat cPBD. Here, the same syntactic foam was used as the matrix, and the open-cell structure was produced by the salt-leaching method. The hybrid foam exhibits very attractive properties, including reversible actuation strain up to 50%, density as low as 0.07 g/cm3, energy output up to 0.23 J/g, tensile strength up to 0.84 MPa, elongation at break as high as 339%, high thermal stability with peak decomposition temperature at 450 °C, and Joule heating and strain sensing capabilities. The tensile strength and stiffness are shown to follow the well-known Gibson-Ashby model for porous materials. Combining the open-cell structure with the reversible actuation and other functionalities enables numerous potential applications for the prepared hybrid foam, including adjustable filters, insulators, sealers, and smart scaffolds.
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Affiliation(s)
- Siavash Sarrafan
- Department of Mechanical & Industrial Engineering, Louisiana State University, Baton Rouge, Louisiana70803, United States
| | - Guoqiang Li
- Department of Mechanical & Industrial Engineering, Louisiana State University, Baton Rouge, Louisiana70803, United States
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8
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Afolabi OA, Kanny K, Mohan TP. Analysis of Particle Variation Effect on Flexural Properties of Hollow Glass Microsphere Filled Epoxy Matrix Syntactic Foam Composites. Polymers (Basel) 2022; 14. [PMID: 36432973 DOI: 10.3390/polym14224848] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/23/2022] [Revised: 10/30/2022] [Accepted: 11/01/2022] [Indexed: 11/12/2022] Open
Abstract
Syntactic foam made from hollow glass microspheres (HGM) in an epoxy matrix has proven to be a good material with a strong structural strength. Understanding filler particle size variation is important in composite material formation, especially in syntactic foam, because of its numerous applications such as aerospace, marine, and structural purposes. In this present work, the effects of particle variation in different sizes (20-24 µm, 25-44 µm, 45-49 µm, and 50-60 µm) on the mechanical properties of the syntactic foam composites with a focus on flexural strength, modulus, and fracture surfaces are investigated. The particle sizes are varied into five volume fractions (5, 10, 15, 20, and 25 vol%). The results show that the highest flexural strength is 89 MPa at a 5 vol% fraction of 50-60 µm particle size variation with a 69% increase over the neat epoxy. This implies that the incorporation of HGM filler volume fraction and size variation has a strong effect on the flexural strength and bending modulus of syntactic foam. The highest particle size distribution is 31.02 at 25-44 µm. The storage modulus E' increased at 30 °C, 50 °C, and 60 °C by 3.2%, 47%, and 96%, respectively. The effects of wall thickness and aspect ratio on the size of the microstructure, the fracture surfaces, and the viscoelastic properties are determined and reported accordingly.
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Abedin R, Feng X, Pojman J, Ibekwe S, Mensah P, Warner I, Li G. A Thermoset Shape Memory Polymer-Based Syntactic Foam with Flame Retardancy and 3D Printability. ACS Appl Polym Mater 2022; 4:1183-1195. [PMID: 35178525 PMCID: PMC8845046 DOI: 10.1021/acsapm.1c01596] [Citation(s) in RCA: 7] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 11/13/2021] [Accepted: 01/18/2022] [Indexed: 06/14/2023]
Abstract
Here we report a thermoset shape memory polymer-based syntactic foam inherently integrated with flame retardancy, good mechanical properties, excellent shape memory effect, and 3D printability. The syntactic foam is fabricated by incorporating a high-temperature shape memory polymer (HTSMP) as the matrix, with 40 vol % hollow glass microspheres (HGM) K20, K15, and K1 as fillers. Compressive behavior, strain-controlled programming followed by free recovery, stress recovery, and flame retardancy of these three syntactic foams were studied. Dynamic mechanical analysis and thermal characterization validate their high glass transition temperature (T g = ∼250 °C) and excellent thermal stability. Our results suggest that the foam consisting of K20 HGM exhibits high compressive strength (81.8 MPa), high recovery stress (6.8 MPa), and excellent flame retardancy. Furthermore, this syntactic foam was used for three-dimensional (3D) printing by an extruder developed in our lab. Honeycomb, sinusoidal shapes, and free-standing helical spring were printed for demonstration. This high-temperature photopolymer-based syntactic foam integrated with high T g, flame retardancy, high recovery stress, and 3D printability can be beneficial in different sectors such as aerospace, construction, oil and gas, automotive, and electronic industries.
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Affiliation(s)
- Rubaiyet Abedin
- Department
of Mechanical Engineering, Southern University
and A&M College, Baton
Rouge, Louisiana 70813, United States
| | - Xiaming Feng
- Department
of Mechanical & Industrial Engineering, Louisiana State University, Baton Rouge, Louisiana 70803, United States
| | - John Pojman
- Department
of Mechanical & Industrial Engineering, Louisiana State University, Baton Rouge, Louisiana 70803, United States
| | - Samuel Ibekwe
- Department
of Mechanical Engineering, Southern University
and A&M College, Baton
Rouge, Louisiana 70813, United States
| | - Patrick Mensah
- Department
of Mechanical Engineering, Southern University
and A&M College, Baton
Rouge, Louisiana 70813, United States
| | - Isiah Warner
- Department
of Chemistry, Louisiana State University, Baton Rouge, Louisiana 70803, United States
| | - Guoqiang Li
- Department
of Mechanical Engineering, Southern University
and A&M College, Baton
Rouge, Louisiana 70813, United States
- Department
of Mechanical & Industrial Engineering, Louisiana State University, Baton Rouge, Louisiana 70803, United States
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Weise J, Lehmhus D, Sandfuchs J, Steinbacher M, Fechte-Heinen R, Busse M. Syntactic Iron Foams' Properties Tailored by Means of Case Hardening via Carburizing or Carbonitriding. Materials (Basel) 2021; 14:4358. [PMID: 34442879 DOI: 10.3390/ma14164358] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 05/31/2021] [Revised: 07/28/2021] [Accepted: 07/29/2021] [Indexed: 11/17/2022]
Abstract
Metal foam inserts are known for their high potential for weight and vibration reduction in composite gear wheels. However, most metal foams do not meet the strength requirements mandatory for the transfer of sufficiently high levels of torque by the gears. Syntactic iron and steel foams offer higher strength levels than conventional two-phase metal foams, thus making them optimum candidates for such inserts. The present study investigates to what extent surface hardening treatments commonly applied to gear wheels can improve the mechanical properties of iron-based syntactic foams. Experiments performed thus focus on case hardening treatments based on carburizing and carbonitriding, with subsequent quenching and tempering to achieve surface hardening effects. Production of samples relied on the powder metallurgical metal injection molding (MIM) process. Syntactic iron foams containing 10 wt.% of S60HS hollow glass microspheres were compared to reference materials without such filler. Following heat treatments, the samples’ microstructure was evaluated metallographically; mechanical properties were determined via hardness measurements on reference samples and 4-point bending tests, on both reference and syntactic foam materials. The data obtained show that case hardening can indeed improve the mechanical performance of syntactic iron foams by inducing the formation of a hardened surface layer. Moreover, the investigation indicates that the respective thermo-chemical treatments can be applied to composite gear wheels in exactly the same way as to monolithic ones. In the surface region modified by the treatment, martensitic microstructures were observed, and as consequence, the bending limits of syntactic foam samples were increased by a factor of three.
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Kannan S, Pervaiz S, Jahan MP, Venkatraghaven D. Cryogenic Drilling of AZ31 Magnesium Syntactic Foams. Materials (Basel) 2020; 13:ma13184094. [PMID: 32942677 PMCID: PMC7560411 DOI: 10.3390/ma13184094] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 08/15/2020] [Revised: 09/05/2020] [Accepted: 09/11/2020] [Indexed: 11/28/2022]
Abstract
Machined surface quality and integrity affect the corrosion performance of AZ31 magnesium composites. These novel materials are preferred for temporary orthopedic and vascular implants. In this paper, the drilling performance of AZ31-magnesium reinforced with hollow alumina microsphere syntactic foam under LN2 cryogenic, dry, and Almag® Oil is presented. Cutting tests were conducted using TiAlN physical vapor deposition (PVD) coated multilayer carbide and K10 uncoated carbide twist drills. AZ31 magnesium matrices were reinforced with hollow alumina ceramic microspheres with varying volume fractions (5%, 10%, 15%) and average bubble sizes. Experimental results showed that the drilling thrust forces increased by 250% with increasing feed rate (0.05 to 0.6 mm/tooth) and 46% with the increasing volume fraction of alumina microspheres (5% to 15%). Cryogenic machining generated 45% higher thrust forces compared to dry and wet machining. The higher the volume fraction and the finer the average size of hollow microspheres, the higher were the thrust forces. Cryogenic machining (0.42 µm) produced a 75% improvement in surface roughness (Ra) values compared to wet machining (1.84 µm) with minimal subsurface machining-induced defects. Surface quality deteriorated by 129% with an increasing volume fraction of alumina microspheres (0.61 µm to 1.4 µm). Burr height reduction of 53% was achieved with cryogenic machining (60 µm) compared to dry machining (130 µm). Overall, compared to dry and wet machining methods, cryogenic drilling can be employed for the machining of AZ31 magnesium syntactic foams to achieve good surface quality and integrity.
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Affiliation(s)
- Sathish Kannan
- Department of Mechanical Engineering, American University of Sharjah, Sharjah 26666, UAE;
| | - Salman Pervaiz
- Department of Mechanical and Industrial Engineering, Rochester Institute of Technology—Dubai Campus, Dubai 341055, UAE
- Correspondence: ; Tel.: +971-50-6355390
| | - Muhammad Pervej Jahan
- Department of Mechanical and Manufacturing Engineering, Miami University, Oxford, OH 45056, USA;
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Zhi C, Du M, Sun Z, Wu M, He X, Meng J, Yu L. Warp-Knitted Spacer Fabric Reinforced Syntactic Foam: A Compression Modulus Meso-Mechanics Theoretical Model and Experimental Verification. Polymers (Basel) 2020; 12:polym12020286. [PMID: 32024154 PMCID: PMC7077404 DOI: 10.3390/polym12020286] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/27/2019] [Revised: 01/28/2020] [Accepted: 01/29/2020] [Indexed: 12/01/2022] Open
Abstract
In this study, a new type ternary composite, called warp-knitted spacer fabric reinforced syntactic foam (WKSF-SF), with the advantages of high mechanical properties and a lower density, was proposed. Then, a meso-mechanics theoretical model based on the Eshelby–Mori–Tanaka equivalent inclusion method, average stress method and composite hybrid theory was established to predict the compression modulus of WKSF-SF. In order to verify the validity of this model, compression modulus values of theoretical simulations were compared with the quasi-static compression experiment results. The results showed that the addition of suitable WKSF produces at least 15% improvement in the compressive modulus of WKSF-SF compared with neat syntactic foam (NSF). Meanwhile, the theoretical model can effectively simulate the values and variation tendency of the compression modulus for different WKSF-SF samples, and is especially suitable for the samples with smaller wall thickness or a moderate volume fraction of microballoons (the deviations is less than 5%). The study of the meso-mechanical properties of WKSF-SF will help to increase understanding of the compression properties of this new type composite deeply. It is expected that WKSF-SF can be used in aerospace, marine, transportation, construction, and other fields.
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Xie C, Li H, Yuan B, Gao Y, Luo Z, Zhu M. Ti 3Sn-NiTi Syntactic Foams with Extremely High Specific Strength and Damping Capacity Fabricated by Pressure Melt Infiltration. ACS Appl Mater Interfaces 2019; 11:28043-28051. [PMID: 31310102 DOI: 10.1021/acsami.9b08145] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/10/2023]
Abstract
NiTi shape-memory alloy foams have attracted much attention due to their unique superelasticity, excellent mechanical properties, and damping capacities, but their high-temperature damping capacity and compressive strength remain to be a challenge. Herein, we demonstrate the preparation of Ti3Sn-NiTi syntactic foams using Ti58Ni34Sn8 alloy and alumina microspheres by novel pressure melt infiltration and air-cooling strategies. The syntactic foams with 45% porosity contain spherical and well-distributed pores of average size 500-600 μm. A fine lamellar Ti3Sn/NiTi eutectic with an interspacing distance of 600-900 nm and a Ti2Ni interfacial layer of 10 μm thickness were formed between the alumina microspheres and the matrix. The syntactic foams achieved a high specific compressive strength (110.2-110.8 MPa cm3/g) at a wide temperature range because of the large interfacial area and good lattice strain matching in the lamellar Ti3Sn/NiTi. They also exhibited 2% recoverable strain and high specific energy absorption capacity (31.5 kJ/kg). Moreover, the foams showed ultrahigh damping capacity (0.066) at a temperature range of -150 to 200 °C. Most interestingly, the Ti3Sn-NiTi syntactic foams showed the highest comprehensive coefficient, (σ/ρ)·tan δ, of 5.07 to date. Because of these impressive features, Ti3Sn-NiTi syntactic foams become a promising material for energy absorption and damping applications.
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Affiliation(s)
- Changchun Xie
- School of Materials Science and Engineering , South China University of Technology , Guangzhou 510640 , China
| | - Hua Li
- School of Materials Science and Engineering , South China University of Technology , Guangzhou 510640 , China
| | - Bin Yuan
- School of Materials Science and Engineering , South China University of Technology , Guangzhou 510640 , China
- Key Laboratory of Advanced Energy Storage Materials of Guangdong Province , Guangzhou 51640 , China
| | - Yan Gao
- School of Materials Science and Engineering , South China University of Technology , Guangzhou 510640 , China
- Key Laboratory of Advanced Energy Storage Materials of Guangdong Province , Guangzhou 51640 , China
| | - Zhengtang Luo
- Department of Chemical and Biological Engineering , Hong Kong University of Science and Technology , Clear Water Bay , Kowloon , Hong Kong 999077 , China
| | - Min Zhu
- School of Materials Science and Engineering , South China University of Technology , Guangzhou 510640 , China
- Key Laboratory of Advanced Energy Storage Materials of Guangdong Province , Guangzhou 51640 , China
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Yu Q, Zhao Y, Dong A, Li Y. Preparation and Properties of C/C Hollow Spheres and the Energy Absorption Capacity of the Corresponding Aluminum Syntactic Foams. Materials (Basel) 2018; 11:ma11060997. [PMID: 29895777 PMCID: PMC6025182 DOI: 10.3390/ma11060997] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 05/17/2018] [Revised: 06/02/2018] [Accepted: 06/05/2018] [Indexed: 11/25/2022]
Abstract
The present study focuses on the preparation and characterization of lab-scale aluminum syntactic foams (ASFs) filled with hollow carbon spheres (HCSs). A new and original process for the fabrication of HCSs was explored. Firstly, expanded polystyrene beads with an average diameter of 6 mm and coated with carbon fibers/thermoset phenolic resin were produced by the “rolling ball” method. In the next step, the spheres were cured and post-cured, and then carbonized at 1050 °C under vacuum to form the HCSs. The porosity in the shell of the HCSs was decreased by increasing the number of impregnation–carbonization cycles. The aluminum syntactic foams were fabricated by casting the molten aluminum into a crucible filled with HCSs. The morphology of the hollow spheres before and after carbonization was investigated by scanning electron microscope (SEM). The compressive properties of the ASF were tested and the energy absorption capacities were calculated according to stress–strain curves. The results showed that the ASF filled with HCSs which had been treated by more cycles of impregnation–carbonization had higher energy absorption capacity. The aluminum syntactic foam absorbed 34.9 MJ/m3 (28.8 KJ/Kg) at 60% strain, which was much higher than traditional closed cell aluminum foams without particles. The HCSs have a promising future in producing a novel family of metal matrix syntactic foams.
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Affiliation(s)
- Qiyong Yu
- School of Materials Science and Engineering, Beihang University, Beijing 100191, China.
| | - Yan Zhao
- School of Materials Science and Engineering, Beihang University, Beijing 100191, China.
| | - Anqi Dong
- School of Materials Science and Engineering, Beihang University, Beijing 100191, China.
| | - Ye Li
- School of Materials Science and Engineering, Beihang University, Beijing 100191, China.
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Manakari V, Parande G, Doddamani M, Gupta M. Enhancing the Ignition, Hardness and Compressive Response of Magnesium by Reinforcing with Hollow Glass Microballoons. Materials (Basel) 2017; 10:E997. [PMID: 28841189 DOI: 10.3390/ma10090997] [Citation(s) in RCA: 41] [Impact Index Per Article: 5.9] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 07/23/2017] [Revised: 08/20/2017] [Accepted: 08/23/2017] [Indexed: 01/24/2023]
Abstract
Magnesium (Mg)/glass microballoons (GMB) metal matrix syntactic foams (1.47–1.67 g/cc) were synthesized using a disintegrated melt deposition (DMD) processing route. Such syntactic foams are of great interest to the scientific community as potential candidate materials for the ever-changing demands in automotive, aerospace, and marine sectors. The synthesized composites were evaluated for their microstructural, thermal, and compressive properties. Results showed that microhardness and the dimensional stability of pure Mg increased with increasing GMB content. The ignition response of these foams was enhanced by ~22 °C with a 25 wt % GMB addition to the Mg matrix. The authors of this work propose a new parameter, ignition factor, to quantify the superior ignition performance that the developed Mg foams exhibit. The room temperature compressive strengths of pure Mg increased with the addition of GMB particles, with Mg-25 wt % GMB exhibiting the maximum compressive yield strength (CYS) of 161 MPa and an ultimate compressive strength (UCS) of 232 MPa for a GMB addition of 5 wt % in Mg. A maximum failure strain of 37.7% was realized in Mg-25 wt % GMB foam. The addition of GMB particles significantly enhanced the energy absorption by ~200% prior to compressive failure for highest filler loading, as compared to pure Mg. Finally, microstructural changes in Mg owing to the presence of hollow GMB particles were elaborately discussed.
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Diel S, Huber O. A Continuum Damage Mechanics Model for the Static and Cyclic Fatigue of Cellular Composites. Materials (Basel) 2017; 10:ma10080951. [PMID: 28809806 PMCID: PMC5578317 DOI: 10.3390/ma10080951] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 05/24/2017] [Revised: 08/07/2017] [Accepted: 08/08/2017] [Indexed: 11/16/2022]
Abstract
The fatigue behavior of a cellular composite with an epoxy matrix and glass foam granules is analyzed and modeled by means of continuum damage mechanics. The investigated cellular composite is a particular type of composite foam, and is very similar to syntactic foams. In contrast to conventional syntactic foams constituted by hollow spherical particles (balloons), cellular glass, mineral, or metal place holders are combined with the matrix material (metal or polymer) in the case of cellular composites. A microstructural investigation of the damage behavior is performed using scanning electron microscopy. For the modeling of the fatigue behavior, the damage is separated into pure static and pure cyclic damage and described in terms of the stiffness loss of the material using damage models for cyclic and creep damage. Both models incorporate nonlinear accumulation and interaction of damage. A cycle jumping procedure is developed, which allows for a fast and accurate calculation of the damage evolution for constant load frequencies. The damage model is applied to examine the mean stress effect for cyclic fatigue and to investigate the frequency effect and the influence of the signal form in the case of static and cyclic damage interaction. The calculated lifetimes are in very good agreement with experimental results.
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Affiliation(s)
| | - Otto Huber
- Competence Center for Lightweight Design (LLK), University of Applied Sciences Landshut, D-84036 Landshut, Germany.
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Cho YJ, Kang Y, Lee YC, Park Y, Lee W. Influence of Partially Debonded Interface on Elasticity of Syntactic Foam: A Numerical Study. Materials (Basel) 2017; 10:ma10080911. [PMID: 28786959 PMCID: PMC5578277 DOI: 10.3390/ma10080911] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 06/26/2017] [Revised: 08/02/2017] [Accepted: 08/03/2017] [Indexed: 11/24/2022]
Abstract
The effect of interfacial bonding of glass hollow microspheres and a polymer matrix on the elastic properties of syntactic foam was investigated using representative volume element (RVE) models, including partially debonded interfaces. Finite element analysis, with models having different debonding geometries, was performed to numerically estimate the elastic behavior of the models. The models consisted of bonded and debonded regions of interfaces; the bonded region was treated as the perfectly bonded interface, while the Coulomb friction model was used to describe the debonded region with a small friction coefficient. The changes in the tensile and compressive moduli of the foams were investigated in terms of the degree of interfacial debonding and debonding geometry.
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Affiliation(s)
- Yi Je Cho
- Department of Materials Science and Engineering, Pusan National University, Busandaehak-ro 63beon-gil 2, Busan 46241, Korea.
| | - Youngjeong Kang
- Korea Institute of Industrial Technology (KITECH), Namyangsan 1-gil 14, Yangsan 50635, Korea.
| | - Young Cheol Lee
- Korea Institute of Industrial Technology (KITECH), Namyangsan 1-gil 14, Yangsan 50635, Korea.
| | - Yongho Park
- Department of Materials Science and Engineering, Pusan National University, Busandaehak-ro 63beon-gil 2, Busan 46241, Korea.
| | - Wookjin Lee
- Korea Institute of Industrial Technology (KITECH), Namyangsan 1-gil 14, Yangsan 50635, Korea.
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Rugele K, Lehmhus D, Hussainova I, Peculevica J, Lisnanskis M, Shishkin A. Effect of Fly-Ash Cenospheres on Properties of Clay-Ceramic Syntactic Foams. Materials (Basel) 2017; 10:ma10070828. [PMID: 28773190 PMCID: PMC5551871 DOI: 10.3390/ma10070828] [Citation(s) in RCA: 13] [Impact Index Per Article: 1.9] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 06/19/2017] [Revised: 06/19/2017] [Accepted: 07/11/2017] [Indexed: 11/21/2022]
Abstract
A low-density clay ceramic syntactic foam (CSF) composite material was successfully synthesized from illitic clay added by fly ash cenospheres (CS) using the semi-dry formation method. The content of CS varied in the range of 10, 30, 50 and 60 vol %. Furthermore, reference samples without cenospheres were produced for property comparison. The materials comprising different amount of the additives were fired at temperatures of 600, 950, 1000, 1050, 1100, 1150 and 1200 °C. Firing times were kept constant at 30 min. Processing characteristics of the materials were evaluated in terms of density achieved and shrinkage observed as functions of both the CS content and the sintering temperature. The compressive strength and water uptake were determined as application-oriented properties. Except for the reference and the low CS level samples, the materials show an increase in strength with the increase in firing temperature, and a decrease of mechanical reliability with a decrease in density, which is typical for porous materials. Exceptions are the samples with no or low (10 vol %) content of cenospheres. In this case, the maximum strength is obtained at an intermediate sintering temperature of 1100 °C. At a low density (1.10 and 1.25 g/cm3), the highest levels of strength are obtained after sintering at 1200 °C. For nominal porosity levels of 50 and 60 vol %, 41 and 26 MPa peak stresses, respectively, are recorded under compressive load.
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Affiliation(s)
- Kristine Rugele
- Rudolfs Cimdins Riga Biomaterials Innovations and Development Centre of Riga Technical University (RTU), Institute of General Chemical Engineering, Faculty of Materials Science and Applied Chemistry, Riga Technical University, Pulka 3, LV-1007 Riga, Latvia.
| | - Dirk Lehmhus
- ISIS Sensorial Materials Scientific Centre, University of Bremen, D-28359 Bremen, Germany.
- MAPEX Center for Materials and Processes, University of Bremen, D-28359 Bremen, Germany.
| | - Irina Hussainova
- Department of Mechanical and Industrial Engineering, Tallinn University of Technology, 19086 Tallinn, Estonia.
| | - Julite Peculevica
- Rudolfs Cimdins Riga Biomaterials Innovations and Development Centre of Riga Technical University (RTU), Institute of General Chemical Engineering, Faculty of Materials Science and Applied Chemistry, Riga Technical University, Pulka 3, LV-1007 Riga, Latvia.
| | | | - Andrei Shishkin
- Rudolfs Cimdins Riga Biomaterials Innovations and Development Centre of Riga Technical University (RTU), Institute of General Chemical Engineering, Faculty of Materials Science and Applied Chemistry, Riga Technical University, Pulka 3, LV-1007 Riga, Latvia.
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Newsome DB, Schultz BF, Ferguson JB, Rohatgi PK. Synthesis and Quasi-Static Compressive Properties of Mg-AZ91D-Al₂O₃ Syntactic Foams. Materials (Basel) 2015; 8:6085-95. [PMID: 28793553 DOI: 10.3390/ma8095292] [Citation(s) in RCA: 20] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 08/07/2015] [Revised: 08/28/2015] [Accepted: 09/03/2015] [Indexed: 11/29/2022]
Abstract
Magnesium alloys have considerably lower density than the aluminum alloy matrices that are typically used in syntactic foams, allowing for greater specific energy absorption. Despite the potential advantages, few studies have reported the properties of magnesium alloy matrix syntactic foams. In this work, Al2O3 hollow particles of three different size ranges, 0.106–0.212 mm, 0.212–0.425 mm, and 0.425–0.500 mm were encapsulated in Mg-AZ91D by a sub-atmospheric pressure infiltration technique. It is shown that the peak strength, plateau strength and toughness of the foam increases with increasing hollow sphere wall thickness to diameter (t/D) ratio. Since t/D was found to increase with decreasing hollow sphere diameter, the foams produced with smaller spheres showed improved performance—specifically, higher energy absorption per unit weight. These foams show better performance than other metallic foams on a specific property basis.
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Zhang L, Roy S, Chen Y, Chua EK, See KY, Hu X, Liu M. Mussel-inspired polydopamine coated hollow carbon microspheres, a novel versatile filler for fabrication of high performance syntactic foams. ACS Appl Mater Interfaces 2014; 6:18644-18652. [PMID: 25286083 DOI: 10.1021/am503774a] [Citation(s) in RCA: 23] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/03/2023]
Abstract
Syntactic foams, which can be synthesized by mechanical mixing of hollow microspheres with a matrix material, are a special class of lightweight composite materials. Developing of high-performance syntactic foams remains challenges. In this work, a facile and environmentally friendly surface modification method employing polydopamine (PDA) as a surface treatment agent for hollow carbon microspheres (HCMs) was used, aiming to extend the application of syntactic foams to seldom touched areas. The PDA coating was used as a strategy for interfacial interaction enhancement and also as a platform for further metal coating meant for electromagnetic interference (EMI) shielding. The stronger interfacial interaction between microspheres and polymer matrix provided effective interfacial stress transfer, as a result of the syntactic foams with high strength to weight ratio. Furthermore, the PDA coating on HCMs served as a versatile platform for the growth of noble metals on the surface of PDA-HCMs. Silver nanoparticles was grown by PDA medium. The silver coated HCMs (Ag-PDA-HCMs) impacted the complex permittivity of the syntactic foams leading to high EMI shielding effectiveness (SE). The specific EMI SE reached up to 46.3 dB·cm(3)/g, demonstrated the Ag-PDA-HCMs/epoxy syntactic foam as a promising candidate for lightweight high-performance EMI shielding material.
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Affiliation(s)
- Liying Zhang
- Temasek Laboratories, Nanyang Technological University , 50 Nanyang Drive, Singapore 637553, Singapore
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