Search Results (25)

Additive manufacturing has recently become popular and more cost-effective for building construction. This study presents a prospective life cycle assessment (LCA) of 3D-printed foamed geopolymer composites (3D-FOAM materials) incorporating construction and demolition waste. The materials were developed using fly ash, slag, sand, and a foaming agent, with recycled clay brick waste (CBW) and autoclaved aerated concrete waste (AACW) added as alternative raw materials. The material formulations were evaluated for their compressive strength and thermal conductivity to define two functional units that reflect structural and thermal performance. A prospective life cycle assessment (LCA) was conducted under laboratory-scale conditions using the ReCiPe 2016 method. Results show that adding CBW and AACW reduces environmental impacts across several categories, including global warming potential and ecotoxicity, without compromising material performance. Compared to conventional wall systems, the 3D-FOAM materials offer a viable low-impact alternative when assessed on a functional basis. These findings highlight the potential of integrating recycled materials into additive manufacturing to support circular economy goals in the construction sector. Full article

TNR@Ni-foam structures were prepared by an alkaline hydrothermal method in an autoclave in a strongly alkaline medium (10 M NaOH) at 150 °C with further acid washing (0.1 M HNO₃) and a second hydrothermal treatment in an autoclave at 180 °C. Two TiO₂ samples were used for preparation: anatase and P25 of mixed anatase and rutile phases. After the first step of hydrothermal treatment, a layered titanate structure was obtained (Na₂Ti₃O₇). Acid washing caused the substitution of Na⁺ by H⁺ and launched the formation of TNR. After the second hydrothermal treatment at 180 °C, for the optimal quantity of acid used for washing (10 mL per 0.75 g of TiO₂), titania was crystallized to an anatase phase with small quantities of brookite and rutile. The structures obtained from P25 exhibited more brookite and rutile than those based on the anatase precursor. The morphology of TNR@Ni-foam structures was observed by SEM. The obtained composites were tested for acetaldehyde photodegradation (240 ppm in air) during the continuous flow of gas (5 mL/min) through the reactor coupled with FTIR. The most active samples were those obtained from P25, which had a crystalline structure of TiO₂ and contained the lowest quantity of residue Na species. Full article

Conventional PP with a linear chain structure is not suitable for foam processing due to its poor rheological properties. In this study, PP was modified with PE through reactive melt blending of maleic anhydride-grafted PP (MA-PP) with a small amount of PE bearing glycidyl groups on its backbone (G-PE), with the aim of enhancing the melt rheological properties of PP to make it suitable for foam processing. An anhydride–epoxy reaction occurred between MA-PP and G-PE during the melt processing, resulting in the formation of a crosslinked polymer network, which was confirmed by FTIR spectroscopy, a solubility test, and the presence of a rubbery plateau above the melting point. Melt rheological tests demonstrated that the modified PP showed a pronounced shear-thinning effect and higher elasticity compared to pristine PP. Foaming tests using supercritical carbon dioxide as a foaming agent in an autoclave demonstrated that the modified PP could produce a microcellular foam with a closed-cell structure, which was not achievable with neat PP. Full article

Cellular materials such as aluminum and polyurethane foams are recognized for their effectiveness in energy absorption. They commonly serve as crushable cores in sacrificial cladding for blast mitigation purposes. This study delves into the effectiveness of autoclaved aerated concrete (AAC), a lightweight, porous material known for its energy-absorbing properties as a crushable core in sacrificial cladding. The experimental set-up features a rigid frame made of steel measuring 1000 × 1000 × 15 mm³ with a central square opening (300 × 300 mm²) holding a 2 mm thick aluminum plate representing the structure. The dynamic response of the aluminum plate is captured using two high-speed cameras arranged in a stereoscopic configuration. Three-dimensional digital image correlation is used to compute the transient deformation fields. Blast loading is achieved by detonating 20 g of C4 explosive set at 250 mm from the plate’s center. The study assesses the mineral foam’s absorption capacity by comparing out-of-plane displacement and mean permanent deformation of the aluminum plate with and without the protective solution. Six foam configurations (A to F) are tested experimentally and numerically, varying in the foam’s free space for expansion relative to its total volume. Results show positive protective effects, with configuration F reducing maximum deflection by at least 30% and configuration C by up to 70%. Foam configuration influences energy dissipation, with an optimal lateral surface-to-volume ratio (ζ) enhancing protective effects, although excessive ζ leads to non-uniform foam crushing. To address the influence of front skin deformability, a non-deformable front skin has been adopted. The latter demonstrates an increased effectiveness of the sacrificial cladding, particularly for ζ values above the optimal value obtained when using a deformable front skin. Notably, using a non-deformable front skin increases maximum deflection reduction and foam energy absorption by up to approximately 30%. Full article

Poly(propylene carbonate-co-phthalate) (PPC-P) is an amorphous copolymer of aliphatic polycarbonate and aromatic polyester; it possesses good biodegradability, superior mechanical performances, high thermal properties, and excellent affinity with CO₂. Hence, we fabricate PPC-P foams in an autoclave by using subcritical CO₂ as a physical blowing agent. Both saturation pressure and foaming temperature affect the foaming behaviors of PPC-P, including CO₂ adsorption and desorption performance, foaming ratio, cell size, porosity, cell density, and nucleation density, which are investigated in this research. Moreover, the low-cost PPC-P/nano-CaCO₃ and PPC-P/starch composites are prepared and foamed using the same procedure. The obtained PPC-P-based foams show ultra-high expansion ratio and refined microcellular structures simultaneously. Besides, nano-CaCO₃ can effectively improve PPC-P’s rheological properties and foamability. In addition, the introduction of starch into PPC-P can lead to a large number of open cells. Beyond all doubt, this work can certainly provide both a kind of new biodegradable PPC-P-based foam materials and an economic methodology to make biodegradable plastic foams. These foams are potentially applicable in the packaging, transportation, and food industry. Full article

Iron ore tailings (IOTs) are byproducts of the iron mining industry that have gained significant attention in recent years due to their potential for comprehensive utilization. This study investigates how blending steel slag with IOTs (a siliceous raw material) instead of lime (a calcareous raw material) affects slurry foaming properties, mechanical properties, and reaction mechanisms of autoclaved aerated concrete (AAC). The results indicate that the sample containing 24% IOT content exhibited the best performance, with a bulk density of 640 kg/m³ and a compressive strength of 4.1 MPa. In addition, IOTs not only served as a filling material but also acted as a carrier for the growth of tobermorite. Tobermorite was combined with the unreacted iron tailing and its neighboring tobermorite to form a cohesive whole. This study provides valuable insights into the potential for IOTs to improve the properties of AAC when used as a supplementary material. The findings also suggest that the comprehensive utilization of IOTs and other industrial byproducts have the potential to contribute to the development of sustainable building materials and reduce the environmental impact of the mining industry. Full article

This study examines the impact of the porous structure on the density and mechanical behavior of a new foamed concrete incorporating hemp shives. The specific aim is to gain a better understanding of how the inclusion of hemp shiv, as well as different additions and foaming methods, influence the density and mechanical strength of the concrete. A total of eight batches of foam concrete were produced and tested, made with a protein-based surfactant agent, with cement, ground granulated blast furnace slag, and metakaolin as binders and hemp shiv as natural aggregates. The effect of several parameters is studied, including elaboration method (direct and preformed), amount of pozzolanic additions (0% and 30 of cement weight%), and incorporation of hemp shiv (5 and 15 vol%) on the resulting physical properties, microstructure, porous structure and mechanical behavior of the concrete. Pozzolanic additions improve slightly the uniformity of pore sizes, which increases the mechanical resistance, especially at 28 days. While hemp shiv incorporation results in increased concrete porosity and air bubble radius, it also decreased uniformity, mechanical strength, and lower cohesion with the cement matrix compared to standard concrete. The results contribute to the development of eco-friendly construction materials and promote the utilization of agricultural waste in the construction industry. Full article

Our experiment revealed that the addition of Janus nanosheets to polypropylene (PP) has a significant impact on the viscoelasticity of the composite system. Specifically, when 0.10 wt% of Janus nanosheets were added, the complex viscosity of the composite system increased. However, when we added less than 0.05 wt% of Janus nanosheets, there was a reduction in complex viscosity, which is known as the non-Einstein phenomenon. The Cole–Cole plot showed that the nanosheet network structure did not have a significant effect on the viscosity of the composite system. Additionally, we used carbon dioxide as a foaming agent to autoclave foaming using modified PP from Janus nanosheets, and the results demonstrated that increasing the number of Janus nanosheets decreased the apparent density and strengthened the cell structure of foaming beads, resulting in improved closed porosity. Full article

The reduced solubility of inorganic salts in supercritical water has a significant impact on the stable operation of desalination facilities as it may lead to surface fouling due to salt deposition. In this study, the solubility of Na₂SO₄ was experimentally determined to be 0.04–15.34 mmol/kg water at 23–25 MPa and 390–420 °C. To investigate the precipitation behavior of Na₂SO₄ in supercritical water, a reactor with a heating bar was designed and the deposition effect of salt on the superheated surface in an autoclave was tested at a temperature of 390 °C and a pressure of 23 MPa. Then, the deposition mechanism of salt in the autoclave was analyzed and the temperature field in the reactor was simulated using CFD commercial software. The experimental results showed that Na₂SO₄ was present on both the heating rod and the bottom of the autoclave with a loose salt layer. The simulation results indicated that the temperature near the heating rod was significantly higher than the bulk fluid temperature and it provided the temperature condition where the inorganic salt preferentially nucleated and precipitated. Nickel foam was chosen as the porous media carrier to investigate the selective precipitation of salt on different superheated surfaces. The results showed that nickel foam could collect a large amount of salt on the heating rod and change the state of the compact salt layer on the kettle bottom wall, providing a technical choice for salt recovery under supercritical conditions. Full article

The two-step batch foaming process of solid-state assisted by supercritical CO₂ is a versatile technique for the foaming of polymers. In this work, it was assisted by an out-of-autoclave technology: either using lasers or ultrasound (US). Laser-aided foaming was only tested in the preliminary experiments; most of the work involved US. Foaming was carried out on bulk thick samples (PMMA). The effect of ultrasound on the cellular morphology was a function of the foaming temperature. Thanks to US, cell size was slightly decreased, cell density was increased, and interestingly, thermal conductivity was shown to decrease. The effect on the porosity was more remarkable at high temperatures. Both techniques provided micro porosity. This first investigation of these two potential methods for the assistance of supercritical CO₂ batch foaming opens the door to new investigations. The different properties of the ultrasound method and its effects will be studied in an upcoming publication. Full article

Wearable flexible sensors with high sensitivity and wide detection range are applied in motion detection, medical diagnostic result and other fields, but poor resilience and hysteresis remain a challenge. In this study, a high-resilience foam sensor was prepared through a combination of additive manufacturing and green physical foaming method. The conductive filaments were prepared by using MWCNTs-modified TPU by the physical method of melt blending. Samples were prefabricated using the FFF printer and then saturated with CO₂ in an autoclave before being removed and heated to foam. The composite foam effectively reduced residual strain, demonstrating the high resilience of the 3D-printed composite materials with a foam porous structure. The residual strain of the sample before foaming was >6% after a single cycle, and then gradually increased. The residual strain of the foamed samples is less than 5%. In addition, composite foam has high sensitivity and can monitor subtle pressure changes (0~40 kPa). The sensing performance of the composite foam was evaluated, and the current signal remained stable under different loading rates and small compression strains (2~5%). By using this highly resilient conductive composite material, a hierarchical shoe insole was designed that successfully detected human walking and running movements. Full article

This cutting-edge review highlights the fundamentals, design, and manufacturing strategies used for sandwich composites. Sandwich composite structures have the advantages of light weight, high strength, impact resistance, stability, and other superior features for advanced applications. In this regard, different core materials have been used in the sandwich composite structures, such as cellular polymer foam, metallic foam, honeycomb, balsa, tubular, and other core geometries. Among these, honeycomb sandwich composite materials have been effectively applied in space engineering, marine engineering, and construction applications. The foremost manufacturing techniques used for sandwiched composite structures include hand lay-up, press method, prepreg method, vacuum bagging/autoclave, vacuum assisted resin infusion, resin transfer molding, compression molding, pultrusion, three-dimensional (3D) printing, four-dimensional (4D) printing, etc. In advanced composite manufacturing, autoclave processes have been the method of choice for the aerospace industry due to less delamination between plies and easy control of thickness dimensions. Moreover, machining processes used for sandwich composites are discussed in this article. In addition to aerospace, the high-performance significance of sandwiched composite structures is covered mainly in relation to automobile engineering and energy absorption applications. The structure-, fabrication-, and application-related challenges and probable future research directions are also discussed in this article. Full article

In recent decades, geopolymer concrete has often been viewed as an alternative to traditional concrete. Although its comparatively lower production of greenhouse gas emissions during a lifecycle is usually mentioned at the top of the list of benefits, the possibility of using various waste materials in its production is a clear advantage as well. This literature review summarizes and analyses the existing information on the different available construction wastes for the production of geopolymer and foamed geopolymer concrete and analyzes the curing conditions, constituents in the aluminosilicate precursor, mechanical properties, and the activator type. As part of the literature review, the use of autoclaved aerated concrete and brick wastes has been evaluated. Autoclaved concrete has been chosen because it is a typical low-strength, cement-based construction material and demolition waste that is currently disposed of in landfills, making it quite a challenge for direct use as a supplementary cementitious material. On the other hand, brick waste, one of the most common construction wastes, can be feasibly used in the form of brick dust. This literature review uses data from randomly selected studies. Full article

The direction of construction science that is associated with the development of the theory and practice of creating a new generation of foam concrete is particularly interesting and relevant. The development of improved structural foam concrete using polypropylene fiber and industrial waste, namely fly ash (FA), is prompted by the existing environmental threat posed by FA; this threat is a result of the operation of the fuel energy industry, as well as the possibility of using foam concrete not only as thermal insulation, but as the main material for load-bearing structures that have a certain level of responsibility. The aim of this work was to create and optimize the recipe technological parameters to produce non-autoclaved fiber foam concrete (FFC) using FA as a component. The study used standardized methods for assessing the properties of FFC, and the method of optical microscopy to analyze the structural characteristics of the material. It has been revealed that the replacement of cement with FA in an amount of 10% to 40% helps to reduce the dry density (DD) of FFC. The lowest DD was recorded for samples with 40% FA. The best results for the compressive strength (CS) and flexural strength (FS) were recorded for FFC samples with 10% FA instead of cement. The increase in CS was 12%, and the increase in FS was 23%. The best thermal insulation properties of FFC, and in terms of resistance to freezing and thawing, were recorded in samples with a 10% replacement of cement with FA. The maximum decrease in thermal conductivity was 14%. Full article

In this study, new foam concretes incorporating hemp shives without the use of autoclaving have been developed and studied. Several protocols and parameters were investigated. Firstly, the influence of the addition of pozzolanic additives on the resulting density, mechanical behaviour and thermal conductivity was examined. Secondly, the effects of the incorporation of hemp shives at 5, 10 and 15 vol% on the previous three properties in such concretes were investigated. Moreover, economic cost and CO₂ emissions were estimated to outline an optimized formulation of non-autoclaved biobased foam concretes. First, the target characteristics in terms of compressive strength (minimum of 2 MPa), thermal conductivity (less than 0.2 Wm⁻¹K⁻¹) and density (800 kg/m³) were achieved. It was noted that pozzolanic additions slightly improved the mechanical and thermal strength of non-autoclaved foamed concrete, while the addition of hemp shives improved the thermal strength but had an unfavourable effect on the mechanical strength. Moreover, both reduced the CO₂ emissions. Full article