Search Results (477)

This study investigates the effect of the surface functionalization of tungsten disulfide (WS₂) nanoparticles with aminoacetic acid (glycine) on the structure, curing behavior, and mechanical performance of epoxy nanocomposites. Aminoacetic acid, as a non-toxic, bio-based modifier, enables a sustainable approach to producing more efficient nanofillers. Functionalization, as confirmed by FTIR, EDS, and XRD analyses, led to elevated surface polarity and greater chemical affinity between WS₂ and the epoxy matrix, thereby promoting uniform nanoparticle dispersion. The strengthened interfacial bonding resulted in a notable decrease in the curing onset temperature—from 51 °C (for pristine WS₂) to 43 °C—accompanied by an increase in polymerization enthalpy from 566 J/g to 639 J/g, which reflects more extensive crosslinking. The SEM examination of fracture surfaces revealed tortuous crack paths and localized plastic deformation zones, indicating superior fracture resistance. Mechanical testing showed marked improvements in flexural and tensile strength, modulus, and impact toughness at the optimal WS₂ loading of 0.5 phr and a 7.5 wt% aminoacetic acid concentration. The surface-modified WS₂ nanoparticles, which perform dual functions, not only reinforce interfacial adhesion and structural uniformity but also accelerate the curing process through chemical interaction with epoxy groups. These findings support the development of high-performance, environmentally sustainable epoxy nanocomposites utilizing amino acid-modified 2D nanofillers. Full article

Epoxy-based nanocomposites have drawn much interest in high-voltage insulation applications due to their improved dielectric properties. The determination of the optimal nanoparticle (NP) concentration required to achieve a significant enhancement in nanocomposite dielectric properties remains a subject of ongoing research. Previous work has employed iterative experimental methodologies, often characterized by the hit-and-trial method, in attempts to find the optimal nanoparticle concentration. However, these efforts have yielded suboptimal or inconsistent results. Moreover, experimental procedures for optimizing the nanoparticle concentration require significant time and cost. This research study proposed the predictive capabilities of machine learning (ML) for the selection of the nanoparticle concentration in epoxy-based nanocomposite insulators. The authors employed a novel systematic approach in this research work, comprising dataset preparation, ML model implementation, and experimental validation. A real-time dataset with varying concentrations of NPs (TiO₂, SiO₂, Al₂O₃) was developed in the High Voltage Lab, KFUEIT, Pakistan. Several advanced machine learning models are trained on this dataset. Support Vector Regression (SVR) exhibits the highest prediction accuracy, with an R² score of 0.97. SVR predicted a breakdown voltage (BDV) of 46.26 kV, with a (w/w %) concentration of 5% TiO₂, 1.17631% SiO₂, and 3.95755% Al₂O₃. To validate the SVR prediction, a hardware prototype with predicted NP concentration is developed and tested. The experimentally measured BDV of the predicted nanocomposite sample, registering 44.72 kV, authenticates the predictive accuracy of machine learning. This work demonstrates the efficacy of machine learning as a viable and efficient alternative to traditional experimental methods for optimizing nanoparticle concentrations using a predictive approach in epoxy-based nanocomposites for high-voltage insulation applications. Full article

This study presents a multi-modal investigation into the wear behavior of bio-based epoxy composites reinforced with multi-walled carbon nanotubes (MWCNTs) at 0–0.75 wt%. A Taguchi L16 orthogonal array was employed to systematically assess the influence of MWCNT content, load (20–50 N), and sliding speed (1–2.5 m/s) on wear rate (WR), coefficient of friction (COF), and surface roughness (Ra). Statistical analysis revealed that MWCNT content contributed up to 85.35% to wear reduction, with 0.5 wt% identified as the optimal reinforcement level, achieving the lowest WR (3.1 mm³/N·m) and Ra (0.7 µm). Complementary morphological characterization via SEM and AFM confirmed microstructural improvements at optimal loading and identified degradation features (ploughing, agglomeration) at 0 wt% and 0.75 wt%. Regression models (R² > 0.95) effectively captured the nonlinear wear response, while a Random Forest model trained on GLCM-derived image features (e.g., correlation, entropy) yielded WR prediction accuracy of R² ≈ 0.93. Key image-based predictors were found to correlate strongly with measured tribological metrics, validating the integration of surface texture analysis into predictive modeling. This integrated framework combining experimental design, mathematical modeling, and image-based machine learning offers a robust pathway for designing high-performance, sustainable nanocomposites with data-driven diagnostics for wear prediction. Full article

Carbon nanotubes (CNTs) and graphene nanoplatelets (GNPs) have attracted significant interest as hybrid reinforcements in epoxy (Ep) composites for enhancing mechanical performance in structural applications, such as aerospace and automotive. These 1D and 2D nanofillers possess exceptionally high aspect ratios and intrinsic mechanical properties, substantially improving composite stiffness and tensile strength. In this study, epoxy nanocomposites were fabricated with 0.1 wt.% and 0.3 wt.% of CNTs and GNPs individually, and with 1:1 CNT:GNP hybrid fillers at equivalent total loadings. Scanning electron microscopy of fracture surfaces confirmed that the CNTGNP hybrids dispersed uniformly, forming an interconnected nanostructured network. Notably, the 0.3 wt.% CNTGNP hybrid system exhibited minimal agglomeration and voids, preventing crack initiation and propagation. Mechanical testing revealed that the 0.3 wt.% CNTGNP/Ep composite achieved the highest tensile strength of approximately 84.5 MPa while maintaining a well-balanced stiffness profile (elastic modulus ≈ 4.62 GPa). The hybrid composite outperformed both due to its synergistic reinforcement mechanisms and superior dispersion despite containing only half the concentration of each nanofiller relative to the individual 0.3 wt.% CNT or GNP systems. In addition to mechanical performance, electrical conductivity analysis revealed that the 0.3 wt.% CNTGNP hybrid composite exhibited the highest conductivity of 0.025 S/m, surpassing the 0.3 wt.% CNT-only system (0.022 S/m), owing to forming a well-connected three-dimensional conductive network. The 0.1 wt.% CNT-only composite also showed enhanced conductivity (0.0004 S/m) due to better dispersion at lower filler loadings. These results highlight the dominant role of CNTs in charge transport and the effectiveness of hybrid networks in minimizing agglomeration. These findings demonstrate that CNTGNP hybrid fillers can deliver optimally balanced mechanical enhancement in epoxy matrices, offering a promising route for designing lightweight, high-performance structural composites. Further optimization of nanofiller dispersion and interfacial chemistry may yield even greater improvements. Full article

As a key insulating material in power equipment, epoxy resins (EP) are often limited in practical applications due to space charge accumulation and mechanical degradation. This study systematically investigates the effects of SiO₂ nanoparticle doping on the electrical and mechanical properties of SiO₂/EP composites through molecular dynamics simulations and first-principles calculations. The results demonstrate that SiO₂ doping enhances the mechanical properties of EP, with notable improvements in Young’s modulus, bulk modulus, and shear modulus, while maintaining excellent thermal stability across different temperatures. Further investigations reveal that SiO₂ doping effectively modulates the interfacial charge behavior between EP and metals (Cu/Fe) by introducing shallow defect states and reconstructing interfacial dipoles. Density of states analysis indicates the formation of localized defect states at the interface in doped systems, which dominate the defect-assisted hopping mechanism for charge transport and suppress space charge accumulation. Potential distribution calculations show that doping reduces the average potential of EP (1 eV for Cu layer and 1.09 eV for Fe layer) while simultaneously influencing the potential distribution near the polymer–metal interface, thereby optimizing the interfacial charge injection barrier. Specifically, the hole barrier at the maximum valence band (VBM) after doping significantly increased, rising from the initial values of 0.448 eV (Cu interface) and 0.349 eV (Fe interface) to 104.02% and 209.46%, respectively. These findings provide a theoretical foundation for designing high-performance epoxy-based composites with both enhanced mechanical properties and controllable interfacial charge behavior. Full article

In this work magnetic nanoparticles (Fe₃O₄, or ZnFe₂O₄, or SrFe₁₂O₁₉) and BaTiO₃ microparticles were embedded in an epoxy resin for the synthesis of three series of hybrid magnetic polymer nanocomposites. Barium titanate content was kept constant, while magnetic phase content was varied. Fabricated specimens were structurally and morphologically characterized by employing scanning electron microscopy images and X-ray diffraction patterns. Results implied successful synthesis of the hybrid nanocomposites. The magnetic behavior of the pure magnetic nanoparticles and the fabricated nanocomposites was investigated via a Vibrating Sample Magnetometer. The magnetic performance of each type of magnetic phase (i.e., soft and hard) was induced in the nanocomposites, and magnetic performance is strengthened with the increase in magnetic phase content. Initial magnetization curves were used for the determination of mass magnetic susceptibility of all nanocomposites. Magnetic saturation and magnetic remanence have been found to follow a linear relationship with magnetic phase content, giving the opportunity to predict the system’s response in advance. Full article

Corrosion is a major issue in many industries, leading to material degradation, increased maintenance costs, and safety hazards. Conventional protective coatings frequently rely on hazardous chemicals, which has driven demand for environmentally friendly materials that can enhance the durability of infrastructure. The present study investigates the structural, mechanical, anticorrosive, and tensile properties of a novel polymer composite based on tannic acid-benzoxazine monomer (TA-BZ), reinforced with epoxy resin and zinc oxide (ZnO) nanoparticles. The composite formulations are designated as Epoxy-TA-BZ1-ZnO (A), Epoxy-TA-BZ2-ZnO (B), and Epoxy-TA-BZ4-ZnO (C). The objective of this research is to develop a sustainable material system with improved anticorrosive and mechanical performance. The composites were synthesized through the crosslinking of TA-BZ with epoxy resin and the incorporation of ZnO nanoparticles, known for their corrosion-inhibiting properties and contributions to tensile strength. The materials were evaluated using Fourier Transform Infrared (FT-IR) spectroscopy, Thermogravimetric Analysis (TGA), Differential Scanning Calorimetry (DSC), Scanning Electron Microscopy (SEM), Transmission Electron Microscopy (TEM), potentiodynamic polarization techniques, and tensile testing. Among the tested formulations, Epoxy-TA-BZ4-ZnO exhibited outstanding anticorrosive performance, achieving a minimal corrosion rate of 0.06 mm/year. This performance is attributed to the favorable dispersion of ZnO nanoparticles at 5 wt%, which serve as effective barriers to corrosive agents under the conditions studied. These findings highlight the potential of TA-BZ-based composites as environmentally sustainable alternatives to conventional coatings in corrosion-sensitive applications. Full article

Bisphenol S (BPS), a key ingredient in polycarbonate plastics and epoxy resins, is a known endocrine-disrupting compound that poses significant risks to human health and the environment. As such, the development of rapid and reliable analytical techniques for its detection is essential. In this work, we present a newly engineered electrochemical sensor designed for the sensitive and selective detection of BPS using a straightforward and effective fabrication approach. The sensor was constructed by grafting molecularly imprinted polymers (MIPs) onto vinyl-functionalized multiwalled carbon nanotubes (f-MWCNTs). Ethylene glycol dimethacrylate and acrylamide were used as the cross-linker and functional monomer, respectively, in the synthesis of the MIP layer. The resulting MIP@f-MWCNT nanocomposite was characterized using Fourier-transform infrared spectroscopy (FT-IR) and scanning electron microscopy (SEM). The MIP@f-MWCNT material was then combined with chitosan, a biocompatible binder, to fabricate the final MIP@f-MWCNT/chitosan-modified glassy carbon electrode (GCE). Electrochemical evaluation showed a broad linear detection range from 1 to 60 µM (R² = 0.992), with a sensitivity of 0.108 µA/µM and a detection limit of 2.00 µM. The sensor retained 96.0% of its response after four weeks and exhibited high selectivity against structural analogues. In spiked plastic extract samples, recoveries ranged from 95.6% to 105.0%. This robust, cost-effective, and scalable sensing platform holds strong potential for environmental monitoring, food safety applications, and real-time electrochemical detection of endocrine-disrupting compounds like BPS. Full article

In the pursuit of environmental sustainability, reduced emissions, and alignment with circular economy principles, bio-epoxy resin nanocomposites have emerged as a promising alternative to traditional petroleum-based resins. This study investigates the development of novel bio-epoxy nanocomposites incorporating iron-oxide nanoparticles (Fe₂O₃, MnP) as multifunctional fillers at loadings of 0.5 wt.% and 3.0 wt.%. MnP nanoparticles were synthesized and subsequently functionalized with citric acid (MnP-CA) to enhance their surface properties. Comprehensive characterization of MnP and MnP-CA was performed using X-ray diffraction (XRD) to determine the crystalline structure, attenuated total reflection Fourier-transform infrared spectroscopy (ATR-FTIR), thermogravimetric analysis (TGA), and zeta potential measurements to confirm surface functionalization. The bio-epoxy resins matrix (bio-EP), optimized for compatibility with MnP and MnP-CA, was thoroughly analyzed in terms of chemical structure, thermal stability, curing behavior, dynamic–mechanical properties, and surface characteristics. Non-isothermal differential scanning calorimetry (DSC) was employed to evaluate the curing kinetics of both the neat (bio-EP) and the MnP/MnP-CA-reinforced composites, offering insights into the influence of nanoparticle functionalization on the resin system. Surface zeta potential measurements further elucidated the effect of filler content on the surface charge and hydrophilicity. Magnetic characterization revealed superparamagnetic behavior in all MnP- and MnP-CA-reinforced (bio-EP) composites. This research provides a foundational framework for the design of green bio-epoxy nanocomposites, demonstrating their potential as environmentally friendly materials and representing an emerging class of sustainable alternatives. The results underscore the viability of bio-epoxy systems as a transformative solution for advancing sustainable resin technologies across eco-conscious industries. Full article

In this work, the critical properties of epoxy resin reinforced with carbon-based nanoparticles were examined in order to improve its performance in protective coating applications. Epoxy resin composites with commercial multi-walled carbon nanotubes (MWCNTs) and graphene (GP) nanoplates were prepared via solution mixing. In addition, hybrid composites with 50:50 w/w MWCNTs/GP were also examined. The characterization of the EMI shielding effectiveness revealed that epoxy resin composites reinforced with MWCNTs presented the best performance. Composites with the same content of graphene exhibited much lower shielding results. As confirmed by electrical conductivity measurements, this outcome can be explained by the fact that the electrical percolation threshold in the composites reinforced with MWCNTs was met (around 5 phr), while the conductive network in the composites with graphene was not completely developed. An analysis of the mechanisms that contributed to EMI shielding for each type of specimen showed that, in the case of MWCNT composites, the main mechanism that determined the response of the material was reflection rather than absorption. It was also observed that by increasing the MWCNT content, the shielding efficiency of the composites was enhanced. In the case of graphene composites, the absorption and reflection remained at low levels, resulting in high transmission and therefore poor shielding. Regarding the examined hybrid composites (MWCNTs:GP at 50:50 w/w), it seemed that the MWCNT content determined their shielding performance. Full article

The effect of the interaction between silica (nS) and hydroxyapatite (nHap) nanomaterials on the characteristics of unidirectional glass-fiber-reinforced epoxy (GF/Ep) composite systems is investigated in this work. The goal of the study is to use these nanofillers to improve the microstructure and mechanical characteristics. Pultrusion was used to produce hybrid nanocomposites while keeping the GF loading at a consistent 75% by weight. The hybrid nanocomposites were made with a total filler loading of 6 wt.%, including nHap, and a nS loading ranging from 2 to 4 wt.%. The mechanical performance of the composite was greatly improved by the use of these nanofillers. Compared to neat GF/Ep, hybrid nanocomposites with 6 wt.% combined fillers exhibited increased hardness (14%), tensile strength (25%), interlaminar shear strength (21.3%), and flexural strength (33%). These improvements are attributed to efficient filler dispersion, enhanced fiber-matrix adhesion, and crack propagation resistance. Incorporating 4 wt.% nS alone improved hardness (6%), tensile strength (9%), tensile modulus (21%), interlaminar shear strength (11.4%), flexural strength (12%), and flexural modulus (14%). FTIR analysis indicated Si-O-Si network formation and increased hydrogen bonding, supporting enhanced interfacial interactions. Ultraviolet reflectance measurements showed increased UV reflectivity with nS, especially in hybrid systems, due to synergistic effects. Impact strength also improved, with a notable 11.6% increase observed in the hybrid nanocomposite. Scanning and transmission electron microscopy confirmed that the nanofillers act as secondary reinforcements within the matrix. These hybrid nanocomposites present a promising material choice for various industries, including marine structural applications and automotive components. Full article

This study prepared epoxy–clay nanocomposites (ECNs) by incorporating organophilic clays modified with either non-redox cetyltrimethylammonium bromide (CTAB) or redox-active aniline pentamer (AP), then compared their anticorrosion performance on metal substrates in saline environments. The test solution contained 2 wt% alkaline copper quaternary (ACQ) wood preservatives. Cold-rolled steel (CRS) panels coated with the ECNs were evaluated via electrochemical impedance spectroscopy (EIS) in saline media both with and without ACQ. For CRS coated with unmodified epoxy, the Nyquist plot showed impedance dropping from 255 kΩ to 121 kΩ upon adding 2 wt% ACQ—indicating that Cu²⁺ ions accelerate iron oxidation. Introducing 1 wt% CTAB–clay into the epoxy increased impedance from 121 kΩ to 271 kΩ, while 1 wt% AP–clay raised it to 702 kΩ. This improvement arises because the organophilic clay platelets create a more tortuous path for Cu²⁺ and O₂ diffusion, as confirmed by ICP–MS measurements of Cu²⁺ after EIS and oxygen permeability tests (GPA), thereby slowing iron oxidation. Moreover, ECN coatings containing AP–clay outperformed those with CTAB–clay in corrosion resistance, suggesting that AP not only enhances platelet dispersion but also promotes formation of a dense, passive metal oxide layer at the coating–metal interface, as shown by TEM, GPA, and XRD analyses. Finally, accelerated salt-spray exposure following ASTM B-117 yielded corrosion behavior consistent with the EIS results. Full article

This review article focuses on providing an accumulated knowledge on state-of-the-art composite polymer coating technologies that are studied for corrosion protection. A specific focus has been given to epoxy resin-based composite systems, considering their wide use due to remarkable chemical resistance, excellent adhesion to substrate, thermal stability, and mechanical strength. The addition of various functional polymers to the epoxy matrix has spurred significant advancements in the prevention of corrosion. Light has been shed on the epoxy resin composite systems that are produced by blending with functional polymers like conductive polymers, hydrophobic polymers, etc., and nanofillers. In many cases, the formation of a passive layer at the metal/polymer interface was aided by the addition of such a functional polymer and nanofiller to the epoxy matrix. As a result, corrosive ions are prevented from penetrating by the physical barrier that composite coatings provide. Comparable blends of epoxy and polyamide, epoxy and polyester, and epoxy/poly(vinyl alcohol) and epoxy/polyurethane have superior adhesion, wear, barrier, and anticorrosion properties due to the fine dispersion of nanocarbon and inorganic nanoparticles. The several strategies used to prevent metals from corroding are covered in this review article. Full article

Although the intercalation of sericite with cationic surfactants has been extensively studied, successful intercalation using anionic surfactants has yet to be achieved. This article aims to partially or fully intercalate sericite with an anionic surfactant, and to develop the corresponding sericite/polymer nanocomposite. To achieve this goal, we modified raw sericite by thermal modification, acid activation, and sodium modification. The modified sericite was then co-intercalated by cationic surfactant hexadecyl trimethyl ammonium bromide (CTAB) and anionic surfactant sodium dodecyl sulfate (SDS). The intercalated sericite was characterized by XRD, FTIR, SEM, DTA-TG, and a contact angle tester. The optimized sample had a layer-to-layer distance of 6.56 nm and an intercalation rate of 95.7%. Compared with raw sericite, the new organo-sericite showed increased hydrophobicity. A proposed mechanism for the intercalation by these surfactants was also discussed. Finally, sericite/epoxy composite was prepared by using the new organo-sericite as the raw material, demonstrating significantly improved mechanical properties compared to pure epoxy resin (72% improved for bending strength and 62% improved for tensile strength, compared with pure epoxy resin). The new organo-sericite is a promising filler in epoxy resin to enhance thermal stability and mechanical performance of the composite. Full article

The algae-derived bio-binder (ADBB) from hydrothermal liquefaction has been reported to be an effective and sustainable new alternative to petroleum-based curing agents for epoxy resin. However, there is still room for the epoxy/ADBB system to attain the comprehensive mechanical performance of conventional epoxy-based nanocomposites, typically reinforced with surface-functionalized nanofillers (e.g., glass nanoparticles (GNPs)) by petroleum-based silane coupling agents. Herein, we explored the use of ADBB as an innovative surface-modifying agent to functionalize GNPs and evaluated the potential of ADBB surface-functionalized GNPs (ADBB-GNPs) as a reinforcing agent in the epoxy/ADBB matrix nanocomposite by comparing them to pristine GNPs and (3-aminopropyl) triethoxysilane (APTES) (a popular silane coupling agent) surface-modified GNPs (APTES-GNPs). The surface functionalization of GNPs with ADBB was carried out and characterized by scanning electron microscopy (SEM), dynamic light scattering (DLS), and Fourier-transform infrared spectroscopy (FTIR). Material performance including tensile, flexural, and Izod impact properties and thermal properties of the resulting epoxy/ADBB nanocomposites were investigated by corresponding ASTM mechanical test standards and thermogravimetric analysis (TGA). Our results revealed that the ADBB is a sustainable and effective surface-modifying agent that can functionalize GNPs. The obtained ADBB-GNPs significantly improved the mechanical performance of the epoxy/ADBB system at ultra-low loading (0.5 wt.%) by up to 42% and the maximum decomposition rate temperature increased from 419 °C to 422 °C, both of which outperformed APTES-GNPs. This research sheds light on developing sustainable surface-modifying agents for nanofillers to create high-performance sustainable polymer composite materials. Full article