Search Results (54)

As a novel carbon material, multi-walled carbon nanotubes (MWCNTs) have attracted significant research interest in energetic applications due to their high aspect ratio and exceptional physicochemical properties. However, their inherent structural characteristics and poor dispersion severely limit their practical utilization in solid propellant formulations. To address these challenges, this study developed an innovative reverse-engineering strategy that precisely confines MWCNTs within a three-dimensional Fe₂O₃ gel framework through a controllable sol-gel process followed by low-temperature calcination. This advanced material architecture not only overcomes the traditional limitations of MWCNTs but also creates abundant Fe-C interfacial sites that synergistically catalyze the thermal decomposition of glycidyl azide polymer-based energetic thermoplastic elastomer (GAP-ETPE). Systematic characterization reveals that the MWCNTs@Fe₂O₃ nanocomposite delivers exceptional catalytic performance for azido group decomposition, achieving a >200% enhancement in decomposition rate compared to physical mixtures while simultaneously improving the mechanical strength of GAP-ETPE-based propellants by 15–20%. More importantly, this work provides fundamental insights into the rational design of advanced carbon-based nanocomposites for next-generation energetic materials, opening new avenues for the application of nanocarbons in propulsion systems. Full article

The possibility of reinforcing polymeric matrices with multifunctional fillers for improving structural and functional properties is widely exploited. The compatibility between the filler and the polymeric matrix is crucial, especially for high filler content. In this paper, polymeric matrices of Nylon 6,6 with pyrene chains were successfully synthesized to improve the compatibility with carbonaceous fillers. The compatibility was proven using graphite as a carbonaceous filler. The different properties, including thermal stability, crystallinity, morphology, and local mechanical properties, have been evaluated for various filler contents, and the results have been compared to those of synthetic Nylon 6,6 without pyrene chain terminals. XRD results highlighted that the compatibilization of the composite matrix may lead to an intercalation of the polymeric chains among the graphite layers. This phenomenon leads to the protection of the polymer from thermal degradation, as highlighted by the thermogravimetric analysis (i.e., for a filler content of 20%, the beginning degradation temperature goes from 357 °C for the non-compatibilized matrix to 401 °C for the compatibilized one and the residual at 750 °C goes from 33% to 67%, respectively. A significant improvement in the interphase properties, as proven via Atomic Force Microscopy in Harmonix mode, leads to a considerable increase in local mechanical modulus values. Specifically, the compatibilization of the matrix hosting the graphite leads to a less pronounced difference in modulus values, with more frequent reinforcements that are quantitatively similar along the sample surface. This results from a significantly improved filler distribution with respect to the composite with the non-compatibilized matrix. The present study shows how the thermoplastic/filler compatibilization can sensitively enhance thermal and mechanical properties of the thermoplastic composite, widening its potential use for various high-performance applications, such as in the transport field, e.g., for automotive components (engine parts, gears, bushings, washers), and electrical and electronics applications (heat sinks, casing for electronic devices, and insulating materials). Full article

Fused filament fabrication of thermoplastic composites has grown exponentially owing to its efficiency, thereby meeting numerous engineering demands. However, these materials have limitations owing to their structural vulnerability to elevated temperatures. To address this drawback, this study aims to investigate the tensile behavior of 3D-printed composites in a broad thermal domain from ambient temperature to the crystallization point. For this purpose, a commercial high-temperature-resilient polyamide carbon fiber was selected. To assess the optimal bead configuration and application range, the methodology includes tensile testing of five infill orientations across the four principal thermal domains of the polymers. The results highlight different bead arrangements under constant thermal conditions and demonstrate how temperature effects the tensile performance at similar raster angles, as further correlated with fracture mechanism analysis via scanning electron microscopy. The key findings indicate that raster orientation has a minor influence compared to temperature change. In accordance with the literature, a significantly decreased strength and an abrupt increase in plasticity is observed above the glass transition temperature. Nevertheless, the material retains one-third of its ambient tensile strength at 150 °C, demonstrating its potential for high-temperature applications. Full article

Thermoplastic carbon fiber/aluminum alloy hybrid composite laminates fully integrate the advantages of fiber-reinforced composites and metallic materials, exhibiting high fatigue resistance and impact resistance, with broad applications in fields such as national defense, aerospace, automotive engineering, and marine engineering. In this paper, thermoplastic carbon fiber/aluminum alloy hybrid composite laminates were first prepared using a hot-press machine; then, high-velocity impact tests were conducted on the specimens using a first-stage light gas gun test system. Comparative experimental analyses were performed to evaluate the energy absorption performance of laminates with different ply thicknesses and layup configurations. High-speed cameras and finite element analysis software were employed to analyze the failure process and modes of the laminates under impact loading. The results demonstrate that fiber–metal laminates exhibit higher specific energy absorption than carbon fiber composite laminates. Meanwhile, the numerical simulation results can effectively reflect the experimental outcomes in terms of the velocity–time relationship, failure modes during the laminate impact process, and failure patterns after the laminate impact. Full article

Previous research has demonstrated the possibility to produce wheat flour-based thermoplastics, whose tensile properties depend on flour characteristics that are affected by wheat variety and crop nitrogen (N) fertilization management. This work further investigates the reinforcing effect on thermoplastic composites determined by wheat straw obtained from two wheat varieties (Bologna, BL; Bora, BR) grown under four N fertilization treatments differing in rate and application timing as follows: (1) always well N fed (N300: fertilized with 300 kg N ha⁻¹ and split into five applications of 60 kg N ha⁻¹ each across the growing cycle), (2) N fed only very early (N60+0: fertilized only in one early application of 60 kg N ha⁻¹), (3) N fed only very late (0+120: fertilized only in one application of 120 kg N ha⁻¹ at pollination) and (4) never N fed (N0). The finely cut straw was added by 15% (w:w) to the flour of treatment N300 of each corresponding wheat variety to produce thermoplastic bulk samples. We performed the analysis of straw composition, FESEM imaging of straw stems, X-Ray diffraction analysis of flours and straws, thermal analysis of straw, and tensile tests on bulk samples. The results demonstrate that, for both cultivars, the reinforcing effect of the straw was maximum when the straw came from crops grown with low and early N availability (i.e., N0 and N60+0) and minimum when the straw came from crops grown with high and late N availability (i.e., N300 and N0+120). The greater reinforcing effect of straw from N0 and N60+0 was likely due to greater stem compactness, higher cellulose proportion and higher crystalline fractions. The reinforcing effect decreased for all plasticized composites when they were stabilized for 48 h at higher ambient humidity (53% RH vs. 11% RH) before performing the tensile tests. Overall, our results confirm that plant-based materials engineering needs to carefully consider the variability of source material characteristics as affected by crop growing conditions. Full article

Poly(phenylene sulfide) (PPS) is a high-performance thermoplastic engineering material with excellent comprehensive performance that finds application in many fields due to its good processability, excellent heat resistance, and mechanical properties. However, the poor friction and wear properties of PPS limit its wide application in industrial sectors. In this work, polytetrafluoroethylene (PTFE) was adopted as the solid tribo-modifier to improve the tribological performance of PPS. The efficacy of using three types of PTFE fillers, namely PTFE fiber, micropowder, and nanopowder, was comparatively investigated. The results revealed that the incorporation of PTFE was beneficial to improving the tribological properties of PPS and PTFE nanopowders, which were prepared by irradiation treatment technology that demonstrated the best modification effect in terms of both tribological and mechanical performance among the studied systems. In addition, the coefficient of friction and specific wear rate of PPS composites with 30 wt% nanopowders reached 0.165 and 3.59 × 10⁻⁵ mm³/Nm, respectively, which were 70.7% and 99.0% lower than their pure PPS counterparts. The above finding was attributed to the improved compatibility between the PTFE nanopowders and the PPS substrate as well as the easier formation of intact PTFE transfer film on the contact surface. This work shows some perspective for designing self-lubricating polymer composites that broaden their application in industrial sectors. Full article

The leather tanning industry generates a substantial quantity of solid waste, which, in part, is discarded in the environment in landfills or incinerated. One alternative end-of-life solution is to manufacture engineered materials by forming composites with a thermoplastic polymer/binder. In this work, leather fibres (LFs) were melt-compounded into partially bio-based thermoplastic polyurethane (TPU), at leather fibre contents between 10 and 30% (TPU/LF), followed by compression moulding or 3D printing. The results showed that the incorporation of LF into the polymer matrix produced materials with a Young’s modulus comparable to that of leather. The melt extrusion processing influenced the polymer chain orientation and the resulting mechanical performance. The cyclic stress softening and abrasion resistance of the TPU/LF materials were evaluated to understand the potential of this material to be used in the footwear industry. The level of LF incorporation could be tailored to produce the specific targeted mechanical properties. This work demonstrates that LF could be used to produce materials with a high potential to be used in the fashion industry. Full article

Conventional material aging and testing protocols involve exposing coupon samples to saturation in application fluid(s) at temperature and pressure conditions typically encountered during service, followed by mechanical testing at ambient conditions. This practice can generate misleading results for materials for which fluid ingress is rapidly reversible, most notably at elevated temperatures. A recently developed in situ punch–shear device has been successfully used to establish experimental correlations between the tensile properties (ASTM D638) and shear properties (ASTM D732) of Polyethylene of Raised Temperature (PERT) under dry conditions. It also enabled measurement of shear properties of select polymers while immersed (saturated) in fluids at elevated pressure and temperature. The present work extends the treatment to a suite of commercially available thermoplastic polymers spanning the commodity, engineering, and high-performance polymer grades with varying degrees of hygroscopicity. The objectives of this contribution are three-fold, namely: (i) assess the effect of sample preparation method on measured mechanical properties, (ii) compare the experimentally established correlations between shear and tensile tests for the different class of polymer grades before fluid exposure, and (iii) gauge reversibility of the measured tensile and shear properties after aging in deionized water to saturation at 95 °C. Results indicate that (i) the test coupon preparation method affects the tensile to shear correlation and must be standardized to enable systematic comparison of in situ properties, (ii) individual correlations segregate by polymer family, and (iii) conventional tensile testing after a saturation–dehydration cycle yields optimistic mechanical properties. Full article

Microfluidic technology is an emerging interdisciplinary field that uses micropipes to handle or manipulate tiny fluids in chemistry, fluid physics, and biomedical engineering. As one of the rapid prototyping methods, the three-dimensional (3D) printing technique, which is rapid and cost-effective and has integrated molding characteristics, has become an important manufacturing technology for microfluidic chips. Polymethyl-methacrylate (PMMA), as an exceptional thermoplastic material, has found widespread application in the field of microfluidics. This paper presents a comprehensive process study on the fabrication of fused deposition modeling (FDM) 3D-printed PMMA microfluidic chips (chips), encompassing finite element numerical analysis studies, orthogonal process parameter optimization experiments, and the application of 3D-printed integrated microfluidic reactors in the reaction between copper ions and ammonium hydroxide. In this work, a thermal stress finite element model shows that the printing platform temperature was a significant printing parameter to prevent warping and delamination in the 3D printing process. A single printing molding technique is employed to fabricate microfluidic chips with square cross-sectional dimensions reduced to 200 μm, and the microchannels exhibited no clogging or leakage. The orthogonal experimental method of 3D-printed PMMA microchannels was carried out, and the optimized printing parameter resulted in a reduction in the microchannel profile to Ra 1.077 μm. Finally, a set of chemical reaction experiments of copper ions and ammonium hydroxide are performed in a 3D-printed microreactor. Furthermore, a color data graph of copper hydroxide is obtained. This study provides a cheap and high-quality research method for future research in water quality detection and chemical engineering. Full article

Polyether ether ketone (PEEK) is a high-performance thermoplastic polymer known for its unique combination of properties that make it suitable for a wide range of applications. Despite significant advancements in the characterization of PEEK, its high melting point (343 °C) presents challenges in both sample preparation and post-processing treatments such as annealing. Due to the high melting temperature of PEEK, there is a large change in temperature that occurs during the deposition of each layer during the print, causing a lack of strong adhesion between each filament layer. Therefore, annealing becomes a necessary post-processing step to ensure strong bonding within the parts. Hence, there is a need to establish precise post-processing parameters to enhance the material’s structural integrity and performance. This study aims to characterize PEEK at both the nanoscale and the macroscale by utilizing Atomic Force Microscopy (AFM) and mechanical testing methods such as tensile and three-point bending tests. AFM imaging, which offers high-resolution surface analysis, was used to assess PEEK’s surface morphology before and after annealing, providing insights into roughness, mechanical properties, and structural integrity at the nanoscale. Tensile and bending tests evaluated PEEK’s mechanical performance under macroscale conditions. Microscale AFM revealed that annealing at higher temperatures and for longer durations enhances polymer chain mobility. This promotes structural reorganization, recrystallization, and a reduction in surface roughness. These findings correlate to the macroscale properties where the tensile strength of the sample with the longest annealing duration and highest temperature increased 6.0 MPa from the sample that was not annealed. Three-point bending tests showed a 16 MPa increase from the unannealed sample to the sample annealed at 360 °C for 6 h. The findings from this research will help optimize post-processing parameters for PEEK, improving material quality while contributing to the broader understanding of its surface and mechanical properties. This work provides valuable data for future studies and applications involving high-performance polymers, especially within engineering and biomedical fields. Full article

The evolution of thermoplastic materials has played a critical role in advancing high-speed Fused Filament Fabrication (FFF) and Fused Deposition Modeling (FDM) 3D printing technologies. This study explores the performance and challenges associated with next-generation thermoplastics specifically designed for high-speed printing, such as high-speed PLA, ABS, and PETG, in comparison to conventional materials. A systematic analysis was conducted to evaluate the key parameters, including the mechanical properties, layer adhesion, surface finish, and dimensional accuracy, under varying high-speed printing conditions. The results reveal that high-speed thermoplastics, when coupled with advanced hardware and optimized motion control systems, achieve up to a 70% reduction in printing time without significant trade-offs in mechanical integrity or precision. Additionally, the study identifies challenges, such as increased thermal stresses, warping, and the need for precise cooling strategies, which can impact material performance at elevated speeds. Opportunities for future development are also discussed, including the design of novel polymer formulations and hardware innovations to further enhance the reliability and scalability of high-speed FFF/FDM printing. This work underscores the potential of adopting such advanced thermoplastic materials in the high-speed 3D printing era and highlights the critical interplay between material science and hardware engineering for achieving next-generation manufacturing capabilities. Full article

Epoxy-based vitrimers represent a paradigm shift in material science, offering an unprecedented combination of mechanical robustness, environmental sustainability, and reconfigurability. These dynamic polymer systems utilize associative dynamic covalent bonds (DCBs) such as transesterification to blend the structural integrity of thermosets with the recyclability and self-healing properties of thermoplastics. This unique combination makes vitrimers ideal candidates for high-performance applications in industries such as civil engineering, where material durability, repairability, and environmental compatibility are critical. Epoxy-based vitrimers, in particular, exhibit exceptional self-healing capabilities, allowing them to autonomously repair microcracks and damage, restoring mechanical properties under appropriate stimuli such as heat or light. Their recyclability further aligns with global sustainability goals by reducing material waste and lifecycle costs. Recent advancements have also integrated bio-based feedstocks and scalable manufacturing methods, enhancing the feasibility of these materials for industrial applications. This review explores the underlying self-healing mechanisms, dynamic recycling processes, and the emerging role of epoxy-based vitrimers in civil engineering. Challenges related to scalability, mechanical optimization, and regulatory acceptance are also discussed, with a focus on their potential to drive sustainable innovation in infrastructure materials. Full article

Additive manufacturing (AM) processes, such as Fused Filament Fabrication (FFF), enable the production of lightweight parts with high stiffness-to-weight ratios, making them highly suitable for a wide range of engineering applications. However, ensuring the mechanical reliability of these components, particularly for load-bearing purposes, requires systematic mechanical testing of well-designed specimens to asses their suitability. While the tensile properties of additively manufactured materials have been extensively studied, the compressive behavior of components produced via AM, particularly those made from thermoplastic materials, remains comparatively underexplored and insufficiently characterized in the existing body of research. Among these materials, polylactic acid (PLA)—a biodegradable thermoplastic derived from renewable resources—has gained prominence in AM applications. Recent studies have investigated the compression properties of PLA in reinforced materials; however, the focus has primarily been on solid, semi-solid, or porous specimens. These investigations largely overlook thin-walled structures, which are integral to weight-saving designs and commonly feature in topology-optimized structures. Understanding the mechanical behavior of monolayers, the fundamental building blocks of most AM components, is essential for accurately predicting the overall performance of multilayer structures. Monolayers represent the smallest, most basic structural elements of AM parts, and their properties directly influence the behavior of the final, more complex assemblies. Establishing a methodology that correlates monolayer properties with those of multilayer components could significantly streamline testing procedures. By performing mechanical tests on monolayers, instead of on more intricate multilayer specimens, manufacturers could reduce testing complexity and cost while accelerating the development process. The current literature reveals a gap in the design and analysis of thin-walled AM specimens, especially monolayers, under compressive loads. Specifically, the design of monolayer or thin-walled AM compression specimens without infill has not been thoroughly explored. This article addresses this gap by investigating the design and testing of AM monolayer compression specimens produced using FFF of PLA. Three distinct specimen geometries are considered—circular, helicoidal, and S-shaped—to evaluate their potential for understanding and predicting the compressive behavior of AM monolayer structures. Full article

This study introduces a novel composite construction material composed of lunar regolith combined with PEEK in dry powder form. The work demonstrates significant advantages over alternative methods, primarily by reducing production power consumption and simplifying the manufacturing process. Building on previous research that explored binder optimization through process simplification and targeting predefined shapes, this work delves deeper into a comparative analysis of high-performance thermoplastics. Among the various options, PEEK demonstrates the most favorable properties. The study investigates key processing parameters and evaluates the effects of vacuum processing and temperature testing on mechanical properties. The research also evaluates the effects of vacuum processing and temperature testing to assess the material’s performance under lunar conditions. Comparative analysis is performed with standard performance of various reinforced and unreinforced concretes and with standard requirements for construction bricks as per ASTM standards. This shows that the composite, with an organic binder content as low as 5 wt%, has great potential. Notably, the improvements achieved through vacuum curing ensure compliance with lunar environmental conditions and alignment with most Earth-based engineering standards. Samples compacted at 7.50 MPa with 10 wt% binder, and tested at room temperature, achieve a compression strength of 16.3 MPa, exceeding that of industrial floor bricks and matching that of building bricks used on Earth. Bending strength (7.4 MPa) aligns with steel fiber-reinforced and high-strength concretes. Vacuum curing further enhances these properties, with an observed increase of +66% in bending strength and +33% in compression strength. Full article

Triboelectric nanogenerators (TENGs) have garnered significant attention due to their high energy conversion efficiency and extensive application potential in energy harvesting and self-powered devices. Recent advancements in electrospun nanofibers, attributed to their outstanding mechanical properties and tailored surface characteristics, have meant that they can be used as a critical material for enhancing TENGs performance. This review provides a comprehensive overview of the developments in electrospun nanofiber-based TENGs. It begins with an exploration of the fundamental principles behind electrospinning and triboelectricity, followed by a detailed examination of the application and performance of various polymer materials, including poly (vinylidene fluoride) (PVDF), polyamide (PA), thermoplastic polyurethane (TPU), polyacrylonitrile (PAN), and other significant polymers. Furthermore, this review analyzes the influence of diverse structural designs—such as fiber architectures, bionic configurations, and multilayer structures—on the performance of TENGs. Applications across self-powered devices, environmental energy harvesting, and wearable technologies are discussed. The review concludes by highlighting current challenges and outlining future research directions, offering valuable insights for researchers and engineers in the field. Full article