Search Results (1,070)

Owing to the substantial polarity difference and weak interfacial interaction, the large-scale application of fly ash (FA) in rubber materials still faces substantial challenges. To solve this issue, this study prepared a modified hybrid SSBR@FA filler through a solution mechanochemical reaction between solution-polymerized styrene-butadiene rubber (SSBR) and FA in a lab planetary ball mill. Fourier transform infrared spectroscopy (FTIR) and energy-dispersive spectroscopy (EDS) analyses demonstrated the in situ grafting-neutralization between the carboxyl in the SSBR chains and metal oxides in FA. Transmission electron microscopy (TEM) showed that surface-grafted SSBR formed a rubber-constrained layer on FA particle surfaces, which can reduce their surface energy and improve the wettability between FA and SBR matrix. Compared with the SBR vulcanizate, the mechanical properties, thermal conductivity, and flame-retardant properties of the SBR/SSBR@FA vulcanizates were obviously improved. This was because of the uniform distribution of FA and the improved interfacial interaction between FA and the rubber matrix. For example, the tensile strength, tear strength, and elongation at break increased by 66.3%, 52.9%, and 17.7%, respectively. This easy, efficient, and environmentally modified method for FA was expected offer a practical and creative solution for its application in rubber manufacturing. Full article

Powder Injection Molding (PIM) is a versatile manufacturing technology widely used for fabricating components with complex geometries from metals and ceramics, yet its application to high-performance thermoplastics remains underutilized. This study explores the feasibility of manufacturing products from Polyphenylene Sulfide (PPS)—a promising linear aromatic polymer synthesized in powder form—using PIM technology and investigates the development of PE-based feedstocks with PPS and solid fillers. Regarding the matrix formulation, it was found that using pure paraffin as a binder limited the maximum PPS content to 20%. Consequently, a modified binder system consisting of Low-Density Polyethylene (LDPE) and paraffin in a 70:30 wt.% ratio was utilized, which successfully increased the PPS loading in the feedstock to 50% and enabled stable molding. Following matrix optimization, the study examined composites incorporating various fillers, including chalk, talc, and carbon fibers. Systematic rheological analysis confirmed that these composite suspensions possess characteristics necessary for molding products with complex geometries. Key results indicate that optimal sintering conditions were established to achieve the required mechanical properties. Among the tested fillers, carbon fibers were the most effective reinforcement, increasing the elastic modulus by 33% and flexural strength by 20%. Representative examples of samples successfully manufactured via this approach are presented. Full article

This study aims to investigate the feasibility and performance effects of using waste chestnut shells (CNS), derived from agricultural biomass, as a filler replacement material in hot mix asphalt mixtures. The influence of CNS on the mechanical behavior of hot mix asphalt mixtures was evaluated through a comprehensive experimental program. Initially, the physical and conventional properties of the B50/70 asphalt binder, aggregates, and CNS material were characterized to establish a reference framework for mixture design. The optimum asphalt content (OAC) for the control mixture was established using the Marshall mix design procedure. Mixture specimens incorporating CNS were produced by introducing the material at four different proportions, corresponding to filler substitution levels ranging from 5% to 20% by weight. The prepared specimens were evaluated through a series of mechanical and durability-related tests, including Marshall stability and flow, Retained Marshall, moisture damage, dynamic creep stiffness, indirect tensile strength (ITS), fatigue performance, and indirect tensile stiffness modulus (ITSM). The results indicated that mixtures with 10% CNS replacement exhibited notable improvements in stability, water sensitivity, ITS, ITSM, dynamic creep, and fatigue resistance, suggesting that CNS has the potential to enhance the performance characteristics of hot mix asphalt pavements. Full article

This study examines magnesium potassium phosphate cements (MKPCs) modified with industrial wastes for extrusion-based 3D concrete printing, evaluating the rheological properties (workability, setting time), mechanical performance and printability of formulations incorporating secondary materials: Mg dross waste (up to 20 wt.%, replacing MgO), calcined sewage sludge (up to 10 wt.%, replacing KH₂PO₄), alternative fillers such as glass from municipal solid waste glass and from construction and demolition waste and ground blast furnace slag, benchmarked against volcanic ash. The baseline MKPC exhibited initial/final setting times of 34/109 min, good workability and compressive strengths of 29 MPa (1 day)/28 MPa (28 days). Optimal low-waste mixes (e.g., using municipal glass or 20 wt.% Mg dross) shortened the initial setting to 19–25 min (decreasing 24–42%), reduced the slump by 9–18% yet remained printable at laboratory-scale and achieved 1-day strengths > 23 MPa/28-day > 31 MPa (comparable or superior). Glass from municipal waste proved most promising, due to superior workability, lighter aesthetics and strength gains, supporting circular economy goals while substantially reducing material costs; higher waste levels compromised fluidity and buildability. Mineralogical analyses confirmed K-struvite formation alongside residual periclase, validating these formulations for upscaling sustainable 3D printing. Full article

Thermoplastic starch (TPS) nanocomposites with unprecedentedly high loadings of up to 15 wt.% of the nano-clays Laponite (LAP; a synthetic product capable of good dispersion in suitable media) or Montmorillonite (MMT; modified with dialkyldimethylammonium chloride) were prepared by means of our new, two-step TPS preparation protocol. In both the TPS/LAP and TPS/MMT composites, we achieved perfect dispersion and extensive exfoliation of the nano-clays, resulting in pronounced improvements in mechanical performance (modulus increased up to one order of magnitude) and in excellent gas-barrier properties (extremely small permeabilities for O₂, CO₂, and even H₂). MMT, owing to its larger platelet size and to the formation of partially exfoliated multi-layer structures, generated a percolating filler network that provided particularly strong reinforcement, especially at 15 wt.% loading. LAP, though more completely exfoliated, generated a somewhat smaller mechanical reinforcement, but it more strongly increased processing viscosity due to its high specific surface area, which generated highly stable physical crosslinking that persisted even at processing temperatures of T ≥ 120 °C. Efficient matrix–filler interactions were confirmed by thermogravimetric analysis, where the better-exfoliated LAP generated a higher stabilization. The combination of strong mechanical reinforcement with outstanding gas-barrier properties makes the TPS/MMT and TPS/LAP nanocomposites attractive for food-packaging applications, where their natural origin, non-toxicity, bio-degradability, and abundance of nanocomposite components are an additional bonus. Full article

This study investigates the use of the fine fraction of Brazilian residual kaolin, a material with no pozzolanic activity according to the modified Chapelle test, as a partial cement replacement in rendering mortars. The kaolin was classified into three granulometric fractions (coarse: 150–300 µm, intermediate: 75–150 µm, and fine: <75 µm) and incorporated at two filler contents (10% and 20% by weight). Mineralogical and chemical analyses revealed that the fine fractions contained higher proportions of kaolinite and accessory oxides, while medium and coarse fractions were dominated by quartz. Intensity ratios from XRD confirmed greater structural disorder in the fine fraction, which was associated with higher water demand but also improved particle packing and pore refinement. Fresh state tests showed that mortars with fine kaolin maintained higher density and exhibited moderate increases in air content, whereas medium and coarse fractions promoted greater entrainment. In the hardened state, fine kaolin reduced water absorption by immersion and capillary rise, while medium and coarse fractions led to higher porosity. Mechanical tests confirmed these trends: although compressive and flexural strengths decreased with increasing substitution, mortars containing the fine kaolin fraction consistently exhibited more moderate strength losses than those with medium or coarse fractions, reflecting their enhanced packing efficiency and pore refinement. Tensile bond strength results further highlighted the positive contribution of the kaolin additions, as the mixtures with 10% coarse kaolin and 20% fine kaolin achieved adhesion values only about 7% and 4% lower, respectively, than the control mortar after 28 days. All mixtures surpassed the performance requirements of NBR 13281, demonstrating that the incorporation of residual kaolin—even at higher substitution levels—does not compromise adhesion and remains compatible with favorable cohesive failure modes in the mortar layer. Despite the lack of pozzolanic activity, residual kaolin was used due to its filler effect and capacity to enhance particle packing and pore refinement in rendering mortars. A life cycle assessment indicated that the partial substitution of cement with residual kaolin effectively reduces the environmental impacts of mortar production, particularly the global warming potential, when the residue is modeled as a by-product with a negligible environmental burden. This highlights the critical role of methodological choices in assessing the sustainability of industrial waste utilization. Full article

This study investigates the valorisation of mixed municipal waste glass (MMWG; EWC 20 01 02) as a sustainable supplementary material in cement mortars. In contrast to most existing studies, which focus almost exclusively on homogeneous container glass, this work addresses a heterogeneous waste stream derived from municipal selective collection, containing flat glass, mirrors, ceramics, porcelain, and metallic residues. Such mixed household glass has not previously been systematically evaluated in cement mortars, thereby addressing a clear research gap. The MMWG was washed, dried, and ground in a Los Angeles drum with corundum abrasives to obtain a fine glass powder (FGP < 63 µm) with a median particle size of approximately 20 µm and a Blaine fineness of 360 m²/kg. Microstructural and chemical characterisation of the milled glass confirmed its highly amorphous nature and angular particle morphology resulting from grinding. In addition, coarse glass granules (0–4 mm) were used as partial replacements for natural sand in mortar mixtures. The incorporation of FGP led to a 4–12% reduction in flowability, attributable to the angular shape and increased specific surface area of the ground-glass particles. At 28 days, mortars containing 5–10% FGP exhibited mechanical properties comparable to the reference mix, while at 56 days their compressive strength increased by up to 8%, indicating delayed pozzolanic activity typical of finely milled, amorphous glass. Mortars containing coarse glass primarily reflected a filler and aggregate-replacement effect. Leaching tests conducted in accordance with PN-EN 12457-4 demonstrated that all mortars, both reference and MMWG-modified, complied with the non-hazardous waste limits defined in Council Decision 2003/33/EC. Minor exceedances of Ba and Cr relative to inert-waste thresholds were observed; however, these values remained within the permissible range for non-hazardous classification and were attributed to ceramic and metallic contaminants inherently present in the mixed glass fraction. Overall, this study demonstrates that mixed municipal waste glass—a widely available yet rarely valorised heterogeneous waste stream—can be effectively utilised as a finely ground supplementary material and as a partial aggregate replacement in cement mortars, provided that particle fineness is adequately controlled and durability-related effects are monitored. The findings extend the applicability of glass waste beyond container cullet and support the development of circular-economy solutions in construction materials. Full article

This paper investigates the applicability of plasma transferred arc (PTA) cladding for extending the service life of biomass shredder tools. The study evaluates the possibility of replacing Hardox 500 steel with a lower-cost structural steel S355J2 whose functional surfaces are modified by PTA cladding. Three commercially available powder fillers were examined: CoCrWNi (PL1), FeCoCrSi (PL2), and NiCrMoFeCuBSi (PL3). The quality and performance of the cladded layers were assessed through hardness measurements, microstructural analysis using SEM and EDX, and tribological testing focused on abrasive and adhesive wear at room temperature. The results showed that the PL1 cladding achieved the highest surface hardness, reaching up to 602 HV0.1, due to the presence of hard carbide phases. In contrast, the PL2 cladding exhibited the best resistance to abrasive wear, demonstrating the lowest mass loss for both as-deposited and machined surfaces. The PL3 cladding showed intermediate performance in terms of wear resistance. Overall, the findings indicate that PTA cladding using an FeCoCrSi-based filler on an S355J2 substrate represents a promising and cost-effective alternative to Hardox 500 for biomass shredder applications. Full article

Driven by environmental concerns, the packaging industry is shifting toward high-performance and bio-based coating alternatives. In this research, poly(methylmethacrylate) (PMMA) and modified cellulose nanocrystal (m-CNC) were employed as reinforcing agents to develop sustainable poly (lactic acid)-based coatings for packaging applications. Various formulations, influenced by polymer matrix blends and m-CNC loadings (1–5%), were prepared using solvent and applied as protective coating on cardboard paper substrates. The grammage of polymeric coatings (CG) on paper was also investigated using various wet film thicknesses (i.e., 150–250 μm). Accordingly, key parameters including water contact angle, thermal behavior, mechanical performances and barrier properties were systematically evaluated to assess the effectiveness of the developed nanocomposite coatings. As a result, nonylphenol ethoxylate surfactant-modified cellulose nanocrystals exhibited good dispersion and stable suspension in chloroform for one hour, improving compatibility and interaction of polymer–CNC fillers. The water vapor permeability (WVP) of PLA-coated papers was significantly reduced by blending PMMA and increasing the content of m-CNC nanofillers. Furthermore, CNC incorporation enhanced the oil resistance of PLA/PMMA-coated cardboard. Pronounced improvements in barrier properties were observed for paper substrates coated with dry coat weight or CG of ~20 g/m² (corresponding to 250 μm wet film thickness). Coatings based on blended polymer—particularly those reinforced with nanofillers—markedly enhanced the hydrophobicity of the cardboard papers. SEM-microscopy confirmed the structural integrity and morphology of the nanocomposite coatings. Regarding mechanical properties, the upgraded nanocomposite copolymer (PLA-75%/PMMA-25%/m-CNC3%) exhibited the highest bending test and tensile strength, achieved on coated papers and free-standing polymeric films, respectively. Based on DSC analysis, the thermal characteristics of the PLA matrix were influenced to some extent by the presence of PMMA and m-CNC. Overall, PLA/PMMA blends with an optimal amount of CNC nanofillers offer promising sustainable coatings for the packaging applications. Full article

Epoxy-based composites are crucial insulating and structural materials for superconducting magnets, providing mechanical strength, winding fixation, and heat transfer. However, future superconducting devices with higher integration and power will place even higher demands on their toughness, thermal conductivity, electrical insulation, and radiation resistance at low temperatures. Otherwise, problems such as cracking, detachment, and low heat dissipation efficiency will arise, which may lead to quenching of low-temperature superconductors (Nb₃Sn, NbTi) and a decline in the performance of high-temperature superconductors (YBCO). Research focuses on summarizing the recent progress in modifying epoxy resin to address these issues. The current strategies include formula optimization using mixed curing and toughening agents to enhance mechanical properties, incorporating functional fillers to improve cryogenic thermal conductivity and reduce the coefficient of thermal expansion. Studies also evaluate cryogenic electrical insulation performance (DC breakdown strength, flashover voltage) and radiation resistance under cryogenic conditions. These advancements aim to develop reliable epoxy composites, ensuring the stability and safety of superconducting magnets in applications such as particle accelerators and fusion reactors. Full article

In this article, the thermal and mechanical properties of mortars reinforced with polypropylene (PP) fibres have been studied. Particularly, the effect of polypropylene fibres’ addition on the thermal behaviour of fine-grained building mortars at high temperatures was studied using simultaneous thermal analysis. Two types of polypropylene fibres, differing in shape and size, were used as fillers. The thermal behaviour of cement mortar samples with and without fibres was described. Special attention was given to the thermal behaviour of fibre-reinforced cement mortars subjected to the high temperatures of 100 °C, 200 °C, 300 °C, 400 °C, 500 °C, and 600 °C. Comparative studies using simultaneous thermal analysis (STA) were also performed for non-heated samples (20 °C). The TG, DTG, and DTA curves were analysed to investigate the effects related to the dehydration and the decomposition of hydration and carbonation products. Compared to mortar samples without fibres, the results showed that the presence of polypropylene fibres contributes to an increase in the thermal stability of the samples. It has been proven that the impact of the type and amount of PP fibres in the tested range (1.8 kg/m³ vs. 3.6 kg/m³) on the thermal stability of specimens of tested cement composites was found not to be significantly visible. Next, extensive research was performed on the impact of fire environmental exposure on the variability in the strength parameters of the mortars. Tensile strength tests were conducted based on the standards specified by the Polish Committee for Standardization. The research material consisted of high-strength, fine-grained building mortars, modified by an original method with polypropylene fibres at concentration of 1.8 kg/m³, 3.0 kg/m³, and 3.6 kg/m³. For reference, ordinary mortars without fibres were used, as well. Tensile strength was evaluated for mortar samples, which were exposed to temperatures of 100 °C, 200 °C, 300 °C, 400 °C, 500 °C, and 600 °C, respectively. Special attention was paid to the thermal behaviour of cement mortars reinforced with polypropylene (PP) fibres, subjected to high temperatures. Based on the obtained test results, a detailed statistical analysis was developed, along with comprehensive temperature–parameter relationships, which could enable an approximate post-failure assessment of the mortar’s condition. The main outcomes of this paper include optimal fibre dosage, which is 3.6 kg/m³, identified optimal fibre type, namely F fibre, as well as plateau in tensile strength for temperatures between 200 °C and 400 °C for fibre-reinforced samples. Full article

Aluminum–based brazing alloys have been developed for joining 7072 high–strength aluminum alloys. However, challenges related to their high melting points and joint softening still require further exploration. This study employs a combination of first–principles calculations and experimental techniques to examine the microstructure and mechanical properties of 7072 aluminum alloy joints brazed with (Ni, Y)–modified Al–Si–Cu–Zn filler alloys. Through the virtual crystal approximation (VCA) method, it was observed that the Al–10Si–10Cu–5Zn–xNi–yY (x = 0, 1.0, 2.0, 3.0, y = 0.2, 0.4, 0.6) filler alloy exhibits excellent mechanical stability, combining both high strength and reasonable ductility. Seven brazed joint samples with varying Ni and Y contents were fabricated using melting brazing and analyzed. The findings showed that Ni reduces the liquidus temperature of the filler, narrowing the melting range. This facilitates the conversion of the brittle Al₂Cu phase into a more ductile Al₂(Cu,Ni) phase, thus enhancing joint strength. Y acts as a heterogeneous nucleation site, promoting local undercooling, increasing the nucleation rate, and refining the microstructure. When the Ni content was 2.0 wt.% and the Y content was 0.4 wt.%, the tensile strength of the brazed joint reached a peak value of 295.1 MPa. Computational predictions align with the experimental results, confirming that first–principles calculations are a reliable method for predicting the properties of aluminum alloy brazing materials. Full article

Phenolic aerogels offer low thermal conductivity, excellent thermal stability, and high char yield, but they suffer from intrinsic brittleness, low compressive modulus, and limited compressive strain. To overcome these limitations, phenolic aerogels modified with graphene oxide were synthesized and their structural, mechanical, and thermal insulation properties were evaluated. The GO fillers were uniformly dispersed in the phenolic matrix without disrupting its porous structure. Mechanical testing revealed that the modified aerogel achieved a compressive modulus of 265.52 MPa, representing a 67% increase over the pure phenolic aerogel’s value of 158.49 MPa, and a compressive strength of 40.19 MPa, compared to 6.18 MPa, for the pure sample. At the same time, the composite maintained good thermal insulation performance, with a thermal conductivity of 0.063 W·m⁻¹·K⁻¹. This work demonstrates a feasible approach to tailoring the structure–property relationship of phenolic aerogels via GO modification, supporting their potential use in high-temperature insulation and lightweight structural applications. Full article

Background/Objectives: This in vitro study examined the potential enhancement in resistance to accelerated aging in room-temperature vulcanized (RTV) maxillofacial silicone, intrinsically pigmented in two skin tones, through the use of zirconium oxide (ZrO₂) nanoparticles. Methods: A total of 128 disc-shaped specimens were created in rose silk and soft brown shades, each containing zirconium oxide concentrations of 0%, 1%, 2%, and 3% by weight. Color variation (ΔE*) was assessed initially and following 252, 750, and 1252 h of artificial aging, tested with a colorimeter. Surface roughness characteristics (R_a, R_q, R_t) were evaluated before and after 1252 h using atomic force microscopy (AFM). Structural, vibrational, and morphological characteristics were analyzed through X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), and field emission scanning electron microscopy (FESEM). Results: Non-parametric tests (Friedman, Kruskal–Wallis, and Bonferroni-adjusted paired testing; p < 0.05) indicated that accelerated aging significantly increased ΔE* in all specimens. The addition of ZrO₂ reduced these changes; however, the optimal concentration differed by pigment: 1% for rose silk and 3% for soft brown. The effect on surface roughness depended on pigment type. Higher nanoparticle concentrations generally improved post-aging smoothness in soft brown samples, whereas rose silk showed a more variable response. XRD and FTIR analyses confirmed successful nanoparticle incorporation without altering the fundamental silicone structure, while FESEM demonstrated improved filler–matrix interaction in modified groups. Conclusions: Adjusting ZrO₂ concentration according to pigment type can improve the future color retention and surface characteristics of maxillofacial silicone. Full article

This study investigates the influence of synthetic fibers and rubber powder derived from end-of-life tires (ELTs) on the rheological behavior of asphalt mastics composed of paving-grade bitumen and mineral filler. Nine asphalt mastic formulations were prepared with varying fiber and rubber contents, reflecting the composition of stone mastic asphalt mixtures. Dynamic shear rheometer tests were conducted to assess dynamic stiffness modulus, phase angle, non-recoverable creep compliance, and elastic recovery. The results demonstrated that ELT-derived additives significantly enhanced high-temperature stiffness and elasticity, while maintaining satisfactory viscoelastic balance at lower temperatures. Synergistic effects between fibers and rubber were observed, improving both non-recoverable compliance and percent recovery, particularly at elevated shear stresses. Prolonged exposure to production temperatures (175 °C) confirmed the thermal stability of the modified mastics, with the most notable performance gains occurring during the first hour of heating. Based on the findings, it was concluded that ELT-based fiber–rubber additives can improve high-temperature performance of asphalt mastics without negative effects in intermediate and, possibly, also low service temperatures. This permits expanding the use cases for these kinds of additives beyond the role of inert stabilizers in stone mastic asphalt to an active modifier for extending asphalt mix performance. Full article