Search Results (136)

Particulate-reinforced polymer composites (PRPCs) are susceptible to cracking under tensile loading, severely limiting their service life. Here, we propose a pressure-gradient-driven infiltration method that rapidly repairs narrow (<10 μm) cracks in a highly filled PRPC (95 wt.% BaSO₄/5 wt.% fluororubber). Microstructural evidence confirms that the adhesive completely fills the tortuous crack and forms a continuous adhesive–matrix interface capable of supporting load transfer. Semi-circular bend (SCB) testing demonstrates a substantially higher peak load and increased apparent structural stiffness after repair under the present semi-circular bend configuration, indicating apparent mechanical enhancement beyond simple load-bearing recovery. Digital image correlation (DIC) and fracture morphology show that repair suppresses notch-tip strain localization, reduces the strain concentration factor, shifts the failure-controlling zone away from the original notch tip, and deflects the crack propagation path. Phase-field simulations further show that the post-repair load-bearing capacity is governed by the adhesive–matrix interfacial strength; once this strength approaches or exceeds the tensile strength of the intact PRPC (~8.3 MPa), the repaired crack path is stabilized, enabling peak-load enhancement while suppressing damage localization along the original crack path and shifting failure to adjacent weaker regions. Overall, this work establishes a promising crack repair approach for highly filled PRPCs, while the underlying interface-controlled mechanism provides guidance for adhesive selection and repair design. Full article

Predictive modeling of thermal aging in solid propellants is challenging because HTPB-based propellants are highly filled particle-reinforced polymer systems with sparse experimental data, nonlinear parameter coupling, and partially unclear aging mechanisms. This study proposes a Physics-Informed Manifold Neural Operator (PIMANO) framework for multi-parameter prediction of polymer aging in HTPB solid propellants. Accelerated thermal aging, stress relaxation, and swelling experiments were used to obtain aging temperature, aging time, crosslinking density, and viscoelastic Prony-series parameters. A continuous aging-state field was first reconstructed over the temperature–time domain by radial basis function interpolation. Crosslinking density was then introduced as a physically interpretable bridge-state variable linking aging conditions with viscoelastic responses. Among three candidate kinetic models, the modified Arrhenius–Avrami model gave the best fitting performance for crosslinking-density evolution, with R² = 0.988 and MRE = 0.0199. By combining local multi-scale neighborhood features, manifold latent representations, and DeepONet-based operator learning, PIMANO established a unified mapping from aging conditions to multi-parameter viscoelastic responses while incorporating bridge-state consistency, parameter non-negativity, and evolution-direction constraints. Under the RBF-augmented validation setting, PIMANO-ae achieved RMSE = 0.7847, MAE = 0.3366, R² = 0.9995, and MRE = 0.0027. Compared with the traditional model, RMSE, MAE, and MRE were reduced by 94.93%, 96.47%, and 96.85%, respectively. Temperature leave-one-out validation further yielded average R² values of 0.9469–0.9647 and MRE values of 4.98–6.21% at unseen aging temperatures. These results demonstrate that PIMANO provides an accurate, stable, and physically interpretable framework for multi-parameter aging prediction and life-assessment modeling of polymer-based energetic materials. Full article

The fracture of bituminous polymer composites is fundamentally dictated by microstructural heterogeneity and the complex viscoelasticity of the asphalt matrix. This study develops a robust numerical framework coupling a random polygonal aggregate distribution algorithm with a bilinear cohesive zone model (CZM) to simulate fracture mechanics in heterogeneous asphalt-based composites. A key feature of the model is the explicit accounting for the stochastic distribution of the coarse aggregate and the time-dependent mechanical response of the fine aggregate matrix (FAM). Following experimental validation via frequency sweep and semi-circular bending (SCB) tests, a multi-scale parametric analysis was conducted to quantify the impacts of aggregate gradation, volume fraction, and shape. Results demonstrate that mixtures with high percentages of large-sized aggregates effectively delay macroscopic fracture by increasing the energy dissipation required for cracks to bypass the aggregate phase. While increasing the volume fraction of aggregates improves peak strength, it simultaneously accelerates post-peak load deterioration and reduces total fracture work, indicating a critical loss in the composite’s deformation capacity. Furthermore, particles with higher angularity provide superior blocking effects compared to rounded counterparts. This research offers a high-efficiency computational tool for the structural optimization of highly filled composites and provides critical insights into their internal stress states and macroscopic fracture mechanics. Full article

Environmentally friendly radiation shielding materials for medical institutions require lightweight characteristics and high flexibility as key performance indicators. One promising approach is the incorporation of lead-free materials that combine high-density shielding fillers with polymer matrices. High filler loading is necessary to maintain shielding performance while preserving the inherent flexibility of the polymer. However, during the mixing of shielding materials with polymers, microvoids may form. Therefore, strategies are required to enhance structural densification of the composite by reducing microvoid formation. This study aims to investigate the effects of interfacial design using an anchor–chain dispersant (APTES: 3-aminopropyltriethoxysilane) on micropore formation, effective density, and X-ray shielding performance in highly filled tungsten/thermoplastic polyurethane (TPU) composites. TPU-based composite shielding sheets containing 75–90 wt% tungsten were fabricated. The dispersant (APTES) can adsorb onto the surface of metal particles and form a stabilization layer. In this study, the observed reduction in particle agglomeration and porosity upon addition of the dispersant suggests that interfacial stabilization was induced. As a result, in the 85 wt% composite sheet, the porosity decreased from 5.89% without the dispersant to 0.56% with the dispersant, leading to an improvement in the densification level and effective density of the sheet. Under the same thickness condition (0.25 mm), the dispersant-containing sheet exhibited a shielding efficiency that was 3–4% p higher than that of the sheet without dispersant in the 100–120 kVp range. Meanwhile, as the tungsten content increased, the overall density and shielding efficiency of the sheets also increased. At 90 wt% tungsten loading, the composite demonstrated shielding performance approaching that of conventional lead shielding even at a reduced thickness. These results indicate that interfacial design using an anchor–chain dispersant is an effective processing strategy for improving density uniformity and radiation shielding performance in highly filled tungsten/TPU composite shielding materials by controlling microvoid formation. Full article

This work explores a sustainable route for producing recycled AlNiCo-based magnetic composites by incorporating end-of-life AlNiCo-5 particles into a polyamide 12 (PA12) matrix, thereby eliminating conventional debinding requirements. The study emphasizes material circularity through the reuse of mechanically recovered magnetic waste and polymeric residues. Virgin PA12 powder was used as the matrix material for high magnetic filler loadings of 40, 60, and 70 wt.% AlNiCo-5, while stearic acid was introduced to enhance interfacial compatibility and overall processability. The resulting composites were shaped into filaments and processed via material extrusion additive manufacturing, demonstrating that commercially available fused filament fabrication systems can successfully handle highly filled metal-polymer blends when supported by appropriate formulation and process parameter optimization. The findings confirm the feasibility of manufacturing flexible, functional, and resource-efficient magnetic components using widely accessible equipment, highlighting a promising pathway toward the cost-effective recycling and reuse of AlNiCo magnetic materials. Full article

Unsaturated polyester resin (UPR)–quartz composites have become increasingly important in structural, sanitary, and architectural applications. However, their manufacturing processes still rely heavily on empirical knowledge. This review compiles recent developments in materials science, curing kinetics, and digital manufacturing, outlining a pathway toward data-driven, adaptive production of quartz-filled thermosets. The chemical and physical fundamentals of UPR polymerization are summarized, including the influence of initiator systems, filler characteristics, and thermal management on network formation. Challenges associated with highly filled formulations—such as viscosity control, dispersion, shrinkage, and exothermic peak prediction—are discussed in detail. Recent advances in digital twins (DTs) and artificial intelligence (AI) are reviewed, demonstrating how physics-based simulations, machine learning models, and hybrid mechanistic–data-driven approaches improve the prediction of rheology, curing behavior, and quality outcomes in thermoset polymer processes. A practical application example demonstrates the prediction of peak time in quartz–UPR composites using Random Forest and Gradient Boosting ensemble models. Two prediction scenarios are evaluated: Scenario A with gel time by Leave-One-Out cross-validation, and Scenario B without gel time, representing post-mixing and pre-process prediction contexts, respectively. Stratified bootstrap augmentation improves Gradient Boosting in both scenarios. Principal component analysis confirms that the curing process is governed by three independent physical dimensions: curing reactivity, thermal environment and resin thermal state. Full article

Polymer modification is a well-established strategy for improving the performance and extending the service life of cementitious and other construction materials, with direct implications for environmental sustainability and infrastructure resilience. Among these polymers, polyvinylpyrrolidone (PVP), a non-ionic, water-soluble, and highly compatible polymer, has emerged as a uniquely versatile additive for mitigating degradation in aggressive environments. This review provides a critical and comprehensive synthesis of the state-of-the-art research on PVP’s roles in cement, mortar, concrete, and asphalt systems. The novelty of this work lies in its mechanistic integration and system-level interpretation, which consolidate fragmented knowledge across multiple domains—ranging from rheology and durability to nanotechnology and interfacial engineering—into a unified and coherent framework. Through cross-study comparison, this approach establishes a comprehensive understanding of PVP’s role in cementitious systems while outlining clear pathways for future research and practical implementation. This review provides the first integrated framework that connects PVP’s molecular structure, adsorption behavior, and ion-coordination mechanisms to its macroscopic influence on rheology, hydration, microstructure, and long-term durability. The review critically analyzes the underlying mechanisms, including physical pore-filling and crack-bridging, as well as chemical ion-coordination, which collectively govern PVP’s performance. Key quantitative findings are consolidated, showing that optimal PVP addition can reduce water absorption by over 35%, increase fracture toughness by ~47%, and, when used as an interfacial modifier, enhance the strain capacity of fiber-reinforced composites by over 100%. Reported benefits include improved workability, enhanced mechanical performance and toughness, superior durability under chemical and frost exposure, and the development of functional materials such as self-sensing concretes and photocatalytic coatings that support structural health monitoring and pollution mitigation. Overall, this review synthesizes current knowledge, consolidates experimental evidence in tabular form, and identifies future opportunities for leveraging PVP in the design of sustainable, low-impact, and environmentally resilient construction materials and infrastructures. Full article

This study aims to address a major challenge and find solutions for developing less expensive, lighter, and more efficient energy storage materials while remaining environmentally friendly. This work combines the study of the structural, morphological, and optical properties of epoxy nanocomposites containing ZnO and SnO₂ and highlights the influence of oxide filler content on their energy storage performance. To this end, epoxy nanocomposites filled with metal oxides (ZnO and SnO₂) prepared by extrusion, a simple, economical, and reliable industrial method, were studied and compared. The materials obtained are inexpensive, lightweight, and highly efficient, and can replace traditional glass-based systems in the energy sector. The results of XRD, SEM, and FTIR analyses show the absence of impurities, the stability of the structures in humid environments, and the homogeneity of the prepared films. They also indicate that the nature and charge content of the oxide integrated into the polymer matrix play a significant role in the properties of the nanocomposites. Optical measurements were used to determine the film thickness, the type of electronic transition, the band gap energy, and the Urbach energy. Based on the results obtained, the prepared nanocomposite films appear to be promising materials for energy-based optical applications. Full article

Large-format additive manufacturing (LFAM) is an enabling manufacturing technology capable of producing large parts with highly complex geometries for a wide variety of applications, including automotive, infrastructure/construction, and aerospace mold and tooling. In the past decade, the LFAM industry has seen widespread use of bio-based, glass, and/or carbon fiber reinforced thermoplastic composites which, when printed, serve as a lower-cost alternative to metallic parts. One of the highest-volume materials utilized by the industry is carbon fiber (CF)-filled polycarbonate (PC), which in out-of-autoclave applications can achieve comparable mechanical performance to metal at a significantly lower cost. Previous work has shown that if this material is recovered at various points throughout the manufacturing process for both the lab and pilot scale, it can be mechanically recycled with minimal impacts on the functional performance and printability of the material while significantly reducing the feedstock costs. End-of-life (EOL) CF-PC components were processed through industrial shredding, melt compounding, and LFAM equipment, followed by evaluation of the second-life material properties. Experimental assessments included quantitative analysis of fiber length attrition, polymer molecular weight degradation using gel permeation chromatography (GPC), density changes via pycnometry, thermal performance using dynamic mechanical analysis (DMA), and mechanical performance (tensile properties) in both the X- and Z-directions. Results demonstrated a 24.6% reduction in average fiber length compared to virgin prints, accompanied by a 21% decrease in X-direction tensile strength and a 39% reduction in tensile modulus. Despite these reductions, Z-direction tensile modulus improved by 4%, density increased by 6.8%, and heat deflection temperature (HDT) under high stress retained over 97% of its original value. These findings underscore the potential for integrating mechanically recycled CF-PC into industrial LFAM applications while highlighting the need for technological innovations to mitigate fiber degradation and enhance material performance for broader adoption. This critical step toward circular material practices in LFAM offers a pathway to reducing feedstock costs and environmental impact while maintaining functional performance in industrial applications. Full article

This article demonstrates that 3D-printed parts can replace metal parts in optomechanics in the correct circumstances. Three examples are shown: a clamping fork for pedestal holders where stability is important, an adjustable mirror holder where the rigidity is the main criterion, and a stray light shield where the transmissivity is critical. By combining carbon-fiber-reinforced polymers (CFRPs) with 3D printing, it is possible to produce components that fill the gap between standard 3D-printed plastics and metal parts in terms of strength and stability. These parts are designed to be lighter, more compact, and easier to modify, while keeping good mechanical properties such as resistance to vibration, shape accuracy, and controlled thermal expansion. The article focuses on the application of composite 3D printing on optomechanical components. It compares different methods of composite 3D printing, including fused filament fabrication (FFF) with either chopped fibers or with continuous fiber reinforcement. Three examples from the HiLASE Centre demonstrate how these parts are used in practice, confirming that it is indeed possible to 3D print components that are lighter and cheaper yet still highly functional compared to their off-the-shelf counterparts—for example, lightweight and stiff mounts, shielding against stray laser light, or flexible elements allowing fine mechanical adjustments. Simulations of the deformations are included to compare the printed and metal versions. The article ends with a summary of the benefits and limitations of using 3D-printed composites in optomechanics. Full article

In this work, we investigated the use of a piezoelectric flexible device for energy harvesting. The main goal of the study was to fill the nanostructured pores of anodic aluminum oxide (AAO) films with piezoelectric polymer (PVDF-TrFE) via a modified conventional screen printing technique using blade printing. In this way, it is possible to obtain a composite from nanostructured thin films of polymer nanorods that shows improved charge generation ability compared to other non-nanostructured composites or pure (non-composite) aluminum with similar dimensions. This behavior is due to the effect of the highly developed surface of the material used to fill in the AAO nanopore template and its ability to withstand the application of higher mechanical loads to the structured piezoelectric material during deformation. The contact blade print filling technique can produce nanostructured piezoelectric polymer films with precise geometric parameters in terms of thickness and nanorod diameters, at around 200 nm, and a length of 12 μm. At a low frequency of 17 Hz, the highest root-mean-square (RMS) voltage generated using the nanostructured AAO/PVDF-TrFE sample with aluminum electrodes was around 395 mV. At high frequencies above 1700 Hz, the highest RMS voltage generated using the nanostructured AAO/PVDF-TrFE sample with gold electrodes was around 680 mV. The RMS voltage generated using a uniform (non-nanostructured) layer of PVDF-TrFE was 15% lower across the whole frequency range. Full article

Metal Injection Molding (MIM) is based on the processing of highly filled polymers via the well established polymer injection molding process. It offers a highly efficient processing route for the indirect manufacturing of especially small and complex metal parts. In this regard, polyoxymethylene (POM) is often used as a primary binder component in MIM feedstocks due to its high debinding rate through a time-saving catalytic debinding process, utilizing the acid-catalyzed degradation of POM for polymer removal. However, thermally induced degradation of POM under processing conditions can also lead to changes in processing behavior, which is particularly important in highly filled polymers due to their already challenging processability. In this context, the present work demonstrates the impact of POM homopolymers (POM-H) and copolymers (POM-C) with varying viscosities on feedstock characteristics, their influence on the thermal processing stability, and their significance for the properties of the green parts. Within the study, the thermal degradation of both material types was assessed by viscosity measurements and thermogravimetry, with POM-H exhibiting more significant degradation compared to the thermally more stable POM-C, especially at higher temperatures. Catalytic debinding performance was found to be adequate for all materials. However, lower viscosity POM-C grades are preferred to optimize processability in MIM. Full article

Nano-silica is widely used to enhance gel properties, but its size, concentrations, and aggregation behaviors all matter. The influencing rules of these factors remain unclear especially in harsh reservoir conditions. This study presented a comprehensive investigation into the gelation, rheological, and plugging properties of phenolic polymer gels reinforced by modified nano-silica (GSNP) of different sizes and concentrations in harsh reservoir conditions. Specifically, the nano-silica was modified with a highly soluble silane, and gel properties were evaluated through rheological, differential scanning calorimetry (DSC), and sandpack flooding tests. The results showed that the incorporation of GSNP prolonged the gelation time, enhanced gel strength, and improved stability, allowing the gelation solution to enter deeper into the formation while maintaining long-time effectiveness. The optimal gel system was obtained with 0.4 wt.% GSNP-30, under which condition the storage modulus increased by approximately 14 times, and the content of non-freezable bound water more than doubled. This system exhibited plugging efficiency exceeding 80% in formations with permeabilities ranging from 1000 to 6000 millidarcy and enhanced the oil recovery factor by over 25%. The reinforcement mechanisms were attributed to the adsorption of GSNP onto polymer chains and its role in filling the gel matrix, which enhanced polymer hydrophilicity, suppressed polymer aggregation/curling, prevented ion penetration, and promoted the formation of a more uniform gel network. Careful optimization of nanoparticle size and concentration was essential to avoid the detrimental effects due to nanoparticle overfilling and aggregation. The novelty of this study lies in the practicable formulation of thermal and salt-tolerant gel systems with facile modified nano-silica of varying sizes and the systematic study of size and concentration effects. These findings offer practical guidance for tailoring nanoparticle parameters to cater for high-temperature and high-salinity reservoir conditions. Full article

In metal fused deposition modeling (FDM), performance is governed by feedstock formulation, most critically the metal solid loading, while binder selection is constrained by environmental impacts and limited recyclability. This study investigates the development and performance of highly filled 17-4PH stainless steel (17-4PH) feedstocks formulated with a low-molecular-weight polymer binder system, specifically designed for FDM in metal additive manufacturing (AM). The binder system, composed of low-cost, recyclable paraffin wax and stearic acid, was used to prepare feedstocks containing 93.0–96.0 wt.% metal powder. Rheological analysis indicated that intermediate powder loadings (95.0–95.5 wt.%) yielded optimal shear-thinning behavior, essential for stable extrusion during printing. Printing trials identified 95.5 wt.% as the critical powder loading, delivering superior print fidelity and structural integrity relative to both under-filled (93.0–94.5 wt.%) and overfilled formulations. Green part characterization revealed increased density and flexural modulus with rising powder content, while thermal debinding and sintering trials indicated enhanced thermal stability and dimensional retention at higher loadings. The as-sintered specimens from the 95.5 wt.% feedstock achieved a relative density (RD) of 96.5% and significantly improved mechanical performance, including an ultimate tensile strength (UTS) of 758 MPa and 5.2% elongation, clearly outperforming the 95.0 wt.% variant. Tribocorrosion testing further validated these improvements, with the higher-density samples showing a lower coefficient of friction and a reduced wear coefficient of 2.1 × 10⁻⁵ mm³·(N·m)⁻¹ in 3.5% NaCl solution. Full article

The paper proposes a manufacturing technology for the non-woven/3D-printed (N3DP) hybrid material (HM) with improved radio-absorbing properties. We have fabricated the needle-punched non-woven felt and impregnated it with the carbon fibers containing UV-curable photopolymer resin. The functional 3D-printed layer was attached to the highly porous, deformable polymer substrate by the fused deposition modeling (FDM) technique. The preliminary bulk modification of the filament was realized with the IR- and UV-pigment microcapsules filling. The combination of additive prototyping and non-woven needle-punched fabrics surface modification (by the electrically conductive elements 2D-periodic system applying) expands the frequency range of the electromagnetic radiation effective absorption. It provides the possibility of a reversible change in the color characteristics of the hybrid material surface under the influence of the UV and IR radiation. Full article