Search Results (269)

Multi-field coupled numerical analysis and strain monitoring experiments were conducted for the curing process of a ring-shaped CFRP component. The curing kinetics and mechanical properties of LD-2184 epoxy resin were characterized using non-isothermal DSC, tensile testing, and CTE measurements. The curing reaction follows a single-stage autocatalytic mechanism with an activation energy of 54.73 kJ·mol⁻¹. A piecewise curing kinetics equation was established. The elastic modulus of the fully cured resin is 2.810 GPa, and the coefficient of thermal expansion is 6.060 × 10⁻⁵ K⁻¹. Composite ring specimens were fabricated using a wet winding process. FBG sensors were embedded to monitor axial strain during curing. A coupled numerical model was developed that includes heat conduction, curing kinetics, and curing deformation. ABAQUS was used to simulate the curing process of the composite ring. The results show a temperature gradient within the filament-wound layer. Thermo-chemical strain is similar between inner and outer regions. Total strain varies along the thickness due to mold constraint. Residual stress is governed by resin chemical shrinkage and thermal contraction during cooling. The difference between measured and simulated strain is 7.15%, which supports the validity of the multi-field coupled curing model. Full article

Efficient heat dissipation represents a critical challenge for maintaining device performance and reliability in modern electronic devices. Polymer composites reinforced with graphite sheets have attracted attention as thermal interface materials because of their lightweight nature and excellent thermal transport properties. Herein, the effects of graphite sheet volume fraction, sheet thickness, folding angle, and sheet orientation on the through-thickness thermal conductivity of epoxy/graphite sheet composites were investigated using finite element (FE) modeling. A reduced folding angle and increased graphite sheet thickness enhanced the through-thickness thermal conductivity. However, for the same graphite volume fraction, reducing the folding angle enhanced thermal conductivity more effectively than increasing the graphite sheet thickness, indicating the dominant role of sheet orientation in the heat transport behavior. The influence of the folding angle became significant at higher graphite volume fractions due to the formation of more continuous conductive pathways. At a graphite sheet volume fraction of 0.5, the thermal conductivity decreased from 22.27 to 11.52 W m⁻¹ K⁻¹ upon increasing the folding from 15° to 90°. Finally, a semi-empirical model exhibiting good agreement with the FE results was developed, demonstrating that optimization of graphite sheet geometry is essential for improving the thermal performance of polymer-based thermal interface materials. Full article

To meet the growing demand for materials combing high thermal conductivity and electrical insulation, we developed epoxy (EP) composites filled with zero-dimensional (0D) silver nanoparticles (AgNPs) and two-dimensional (2D) boron nitride nanosheets (BNNSs). This hybrid filler system synergistically enhances both thermal conductivity and dielectric properties, while retaining excellent electrical insulation. With only 1 wt% AgNPs and 15 wt% BNNSs, the composite achieved a dielectric constant of 4.17 at 100 Hz, outperforming pure EP. At 30 wt% BNNSs and the same AgNP loading, the in-plane and out-of-plane thermal conductivities reached 3.02 and 0.41 W·m⁻¹·K⁻¹, respectively, along with improved thermal stability. Moreover, the composite exhibited an electrical conductivity below 10⁻⁹ S/cm at 1000 Hz, confirming that the minimal metal filler content negligibly affects insulation. Thus, this work offers a feasible strategy for designing next-generation high-performance composites using 0D/2D hybrid fillers, highlighting their promising potential for advanced electronic packaging. Full article

The development of multifunctional and lightweight materials is increasingly shaping the design of next-generation sensing and communication systems for space applications. In CubeSat platforms, severe constraints on mass, volume, and structural complexity motivate the integration of antenna functionalities directly onto load-bearing structures. In this context, printed electronics, particularly inkjet-printed conductive materials, offer new opportunities for creating adaptive, flexible, and structure-integrated devices that support both sensing and communication functionalities. This work investigates the electrical performance of inkjet-printed conductive materials for structure-integrated patch antennas. Two silver-based inks and one carbon-based ink were deposited on fiberglass-reinforced epoxy substrates and electrically characterized over a temperature range from −20 °C to 50 °C, representative of CubeSat operational conditions. The silver-based inks exhibited electrical conductivities in the range of 10⁶ S/m with limited variation (<10%) under thermal cycling, whereas the carbon-based ink remained below 10¹ S/m, even after multilayer deposition, indicating insufficient performance for this application. Based on these results, the best-performing silver ink was selected to fabricate a proof-of-concept patch antenna directly on an S2-glass/epoxy structural substrate. The proposed approach demonstrates the feasibility of integrating conductive inkjet-printed layers onto composite structural substrates intended for future structure-integrated antenna applications in CubeSat platforms, offering a pathway toward mass-efficient, low-profile, and highly integrated communication structures. Full article

This work investigates the Mode I fracture behavior of adhesive joints manufactured from unidirectional carbon fiber-reinforced epoxy composites (CFRP) under static and fatigue loading. Specimens were exposed to two degradation environments: hygrothermal conditions (60 °C, 70% RH) and saline conditions (35 ± 2 °C, 89% RH), for 1 and 12 weeks, and compared with non-exposed material. Double Cantilever Beam (DCB) tests were conducted to evaluate the influence of aging on fracture toughness. Thermal (Differential Scanning Calorimetry, DSC) and spectroscopic (Fourier Transform Infrared Spectroscopy, FTIR) analyses were performed to identify degradation mechanisms. DSC results showed no significant variation in glass transition temperature (T_g) under saline exposure, whereas hygrothermal aging increased T_g, indicating post-curing effects. FTIR analysis revealed moisture uptake and oxidation under saline conditions, while hygrothermal exposure mainly led to structural rearrangement. Critical energy release rate (G_IC) values were used to define fatigue test conditions, enabling the construction of fatigue initiation (ΔG–N) and crack propagation (G–da/dN) curves. A Weibull-based model was applied to describe fatigue initiation behavior. Results show that saline exposure promotes progressive degradation, whereas hygrothermal conditions may enhance performance due to post-curing effects. Full article

The present research article deals with the thermal degradation study of epoxy resins filled with hybrid nanostructured forms of carbon under oxidative conditions. In particular, the formulated polymer composites (denoted as HYB_0.1%_CNTs:GNs and HYB_0.5%_CNTs:GNs, respectively) consist of two kinds of fillers, namely multi-walled carbon nanotubes (CNTs) and graphene nanosheets (GNs), mixed together with two different total mass amounts: 0.1 and 0.5%. In both kinds of nanocomposites, three different CNT:GN mixing ratios were considered (5:1, 1:1, and 1:5, respectively), thus providing a total of six hybrid samples. The thermal behavior of these samples was studied by simultaneous thermogravimetry and differential thermal analysis (TG/DTA) under flowing air, and two processes took place in distinct temperature ranges. In each step, about 50% of mass loss is detected with an exothermic effect in the corresponding DTA curve, with the second one accompanied by an intense heat release. The kinetic analysis of the two-stage oxidative thermal degradation was investigated using a model-free isoconversional approach. A non-Arrhenian behavior of the temperature function k(T) was assumed, and lifetime prediction was estimated at temperatures close to those of the possible applications. Isoconversional analysis shows nearly constant activation energies for all composites except HYB_0.1%_5:1 (from 142 to 96 kJ·mol⁻¹), while lifetime predictions indicate that thermal stability increases with graphene content at 0.1% loading (HYB_0.1%_1:5) and with CNT content at 0.5% loading (HYB_0.5%_5:1), with uncertainties below 7%. Finally, because of the π–π bond interactions between the CNTs and the GNs dispersed in the epoxy resin matrix, an effective and remarkable electrical performance was found and a correlation with both electrical and morphological properties was established. In this regard, Tunneling Atomic Force Microscopy (TUNA) proved to be particularly powerful in allowing the simultaneous mapping of topography and localized conductive networks with exceptional sensitivity to nanofiller dispersion, such as CNTs and GNs. DC conductivity increased by up to nine orders of magnitude at 0.1 wt% hybrid loading (up to 3.73 × 10⁻⁴ S/m vs. 1.06 × 10⁻¹³ S/m for CNT-only), with nanoscale TUNA currents (−1.9 to 4.5 pA) mirroring macroscopic trends, while at 0.5 wt% all hybrids reached 10⁻² S/m, indicating reduced synergy once a fully developed conductive network is established. Full article

With the demand for high-voltage electrical insulation systems increasing, the development of environmentally friendly anti-corona materials with reliable nonlinear electrical properties has become essential. In this work, a waterborne polyurethane/epoxy (WPU/EP) composite coating was fabricated using micron-sized SiC (α-SiC), nano-sized SiC (β-SiC), and n-ZnO as multi-scale fillers. Its microstructure, nonlinear conductivity, flashover characteristics, and electro-thermal aging performance were systematically investigated. The results indicate that the incorporation of α-SiC significantly enhances conductivity under high electric fields by forming conductive pathways, while β-SiC further improves nonlinear behavior through interfacial bridging effects. The addition of n-ZnO modifies interfacial characteristics and contributes to improved electrical response. Moreover, the flashover performance is strongly dependent on filler composition, showing a critical role of nano-fillers in charge trapping and transport regulation. Electro-thermal aging tests on simulated stator bars reveal that the developed coating exhibits improved resistance to degradation compared with conventional materials. These findings demonstrate the effectiveness of multi-scale filler design in tailoring the electrical and insulation performance of waterborne anti-corona coatings. Full article

With the capacity of generators continuing to increase, higher demands are placed on the heat dissipation of epoxy resin (EP), the main insulation material used in stator bars and windings. To overcome its low thermal conductivity, a multiscale hybrid filler strategy was adopted to investigate the effects of spherical Al₂O₃ (10 and 1 μm), platelet BN (1 μm), and SiO₂ (50 nm) on the thermal and insulating properties of EP composites. Unlike conventional studies focusing on individual fillers, this work highlights the synergistic design of fillers with different sizes and morphologies. The filler ratios were optimized by finite element simulation, and the composites were prepared by melt blending. The results show that, at a total filler loading of 38.5 wt%, the EP composite filled with spherical Al₂O₃ particles of 10 and 1 μm, platelet BN of 1 μm, and nano-SiO₂ of 50 nm achieves a thermal conductivity of 0.5497 W/(m·K), corresponding to an increase of 158.2% compared with pure EP (0.2129 W/(m·K)). This enhancement is attributed to the synergistic effect of multiscale and multishape fillers, where large Al₂O₃ particles form the main thermally conductive framework, small Al₂O₃ particles fill the gaps, platelet BN acts as a bridging filler, and nano-SiO₂ improves the interfacial region. In addition, the composite exhibits low relative permittivity and dissipation factor tanδ in the frequency range of 10⁻²–10⁶ Hz, and its breakdown strength reaches 65.99 kV/mm. These results demonstrate that simulation-guided multiscale hybrid filler design is an effective strategy for improving the thermal conductivity of EP while maintaining acceptable insulating performance. Full article

Epoxy-glass-mica composite materials are widely used as electrical insulating materials in high-voltage rotating machinery due to their layered structure and excellent dielectric properties. Taking the F-class epoxy glass with a small amount of rubber powder mica tape commonly used as the main insulation of wind turbine stator coils as the research object, 7-day, 14-day, 21-day, and 28-day low-temperature treatment tests were conducted at −50 °C. The surface morphology and chemical structure changes of the materials were characterized by SEM and FTIR, and the influence laws of low-temperature treatment on the electrical properties of the mica tape insulation materials were systematically studied. The experimental results show that the low-temperature environment will induce microcracks and interface delamination and other structural damages, but no obvious change in the chemical structure of the mica tape was observed. With the extension of the low-temperature treatment time, the electrical properties of the mica tape show a deteriorating trend, and after 28 days of low-temperature treatment, the breakdown field strength of the F-class mica tape decreased by approximately 18.5%, and the volume conductivity overall increased by about two orders of magnitude. This indicates that the microcrack defects induced by low-temperature will lead to an enhanced electrical-thermal coupling effect in the insulation structure, thereby accelerating the degradation process of the insulation material. This reveals the degradation mechanism of wind turbine stator main insulation from “structural damage” to “performance degradation” and then to “insulation aging” under low-temperature conditions, providing a theoretical basis for the design and reliability assessment of insulation systems in wind turbine generators in cold regions. Full article

In this work, we demonstrate that both carbon nanotubes (CNT) and graphene nanosheets (G) were successfully modified by π-stacking interactions with a pyrene derivative (PY), yielding the functionalized nanofillers CNT-PY and G-PY, which were subsequently dispersed within an aeronautical epoxy matrix. This functionalization is highly effective in preserving the remarkable electronic properties of carbon nanotubes and graphene nanosheets. At the same time, the non-covalent functionalization reduces the resin viscosity, enabling a more effective dispersion of the nanofillers. This results in improved rheological behavior and an overall enhancement of the structural performance of the nanocomposites compared to the resin containing unfunctionalized carbon nanofillers (CNT and G). Additional improvements are also observed in electrical properties, self-healing efficiency, and thermal stability. In particular, the samples containing functionalized carbon nanotubes (TBD + 1%CNT-PY) and functionalized graphene nanosheets (TBD + 1%G-PY) exhibit higher conductivities—0.391 S/m and 0.1 S/m, respectively—than the samples loaded with unfunctionalized carbon nanotubes (TBD + 1%CNT) and unfunctionalized graphene nanosheets (TBD + 1%G), which show conductivity values of 0.292 S/m and 4.82 × 10⁻³ S/m, respectively. The functionalized graphene nanosheets (G-PY) display significantly greater thermal stability, with degradation temperatures reaching 670 °C, compared to 310 °C for unfunctionalized ones (G). The functionalized carbon nanotubes (CNT-PY) show a 10% weight loss at 520 °C due to the degradation of the pyrene groups. Significant improvements in the final properties can be achieved when carbon-based nanofillers are homogeneously dispersed in the matrix and the external load is efficiently transferred through strong filler–polymer interfacial interactions, leading to composites with superior characteristics suitable for advanced applications. Tunneling Atomic Force Microscopy (TUNA) highlights the morphological features of the two types of carbon nanofillers, their dispersion within the polymer matrix and the effect of the functionalization on the electrical pathways and conductivity of the samples at both the micro- and nanometer-scale. The measured electrical conductivities are consistent with the electric currents detected at the micro/nanoscale. Full article

Olive pomace biochar, obtained through the pyrolysis of lignocellulosic biomass, has emerged as a sustainable and multifunctional additive for polymer composites. Its physicochemical properties, including porosity, surface area, and electrical conductivity, can be tailored by controlling feedstock type and pyrolysis conditions. Although mechanical reinforcement and thermal stability improvements are well documented, the influence of biochar on surface-related properties such as wettability and contact angle remains insufficiently explored for environmentally relevant composite systems. In this study, epoxy-based composites containing biochar synthesized at 750 °C were evaluated in terms of their water interaction behavior by monitoring the evaporation dynamics of ultra-pure water droplets (10 μL, 0.055 mS/cm conductivity) at eight time intervals between 20 and 580 s using high-resolution digital microscopy. Image enhancement and segmentation were performed prior to Discrete Cosine Transform (DCT) analysis to describe droplet geometry in the frequency domain. Time-dependent variations in the standard deviations of DCT coefficients were optimized using the Bat Algorithm, resulting in mathematical models capable of accurately representing droplet evolution and surface–fluid interactions. The primary novelty of this study lies in the development of a hybrid experimental–computational framework that integrates droplet-based wettability measurements with signal-domain analysis and metaheuristic optimization. Unlike conventional studies focusing solely on material characterization, this approach establishes quantitative relationships between surface behavior and numerical descriptors derived from DCT and the Bat Algorithm. The proposed methodology provides a data-driven tool for predicting wettability trends in biochar-reinforced composites and supports the development of moisture-resistant materials for coatings, packaging, and thermal insulation applications within the context of sustainable composite design. Full article

This study investigates the multi-scale tribo–thermo–viscoelastic performance of a sustainable bio-based FormuLITE epoxy reinforced with single and hybrid carbon nanofillers (0.1 wt.% total loading) under dry sliding up to 50 N. Pin-on-disk tests at 10, 30, and 50 N showed a consistent reduction in contact pressure and wear volume in the order: neat epoxy > 0.1 CNT > 0.1 GNP > 0.1 ND > 0.1 CNT/GNP > 0.1 CNT/ND > 0.1 GNP/ND. At 50 N and 1500 m sliding distance, neat epoxy exhibited a wear volume of 13.43 mm³ and contact pressure of 13.4 N/cm², while the GNP/ND hybrid reduced wear to 4.86 mm³ and contact pressure to 6.2 N/cm², corresponding to reductions of 64% and 54%, respectively. The accelerating wear coefficient decreased from 2.9 × 10⁻⁶ to 8.5 × 10⁻⁷, confirming slower damage accumulation in hybrid systems. Time-dependent contact pressure analysis revealed reduced asymptotic intensity and suppressed mid-cycle pressure spikes, indicating enhanced tribolayer stability. Effective surface hardness increased from 0.18 GPa (neat epoxy) to 0.30 GPa (GNP/ND), while normalized wear decreased from 1.00 to 0.36. Enhanced damping behavior and improved thermal conductivity in hybrid systems promoted stress redistribution and minimized flash-temperature localization. An interfacial energy-partition framework calibrated to experimental wear data quantitatively linked effective driving pressure, tribofilm stabilization, and surface hardness to material removal. The results demonstrate that wear mitigation in sustainable bio-epoxy systems is governed by coupled mechanical, viscoelastic, and thermal energy redistribution, with GNP/ND hybrids providing the most stable tribological interface under severe sliding. The findings contribute to the development of durable and sustainable bio-epoxy composite systems for engineering applications, supporting broader goals of responsible material utilization and sustainable industrial innovation aligned with the United Nations Sustainable Development Goals (SDG 9 and SDG 12). Full article

This study discusses the thermal behavior of glass fiber-reinforced SiO₂-filled polymers in dry milling. Focus is put on the effects of the addition of SiO₂ particles on cutting-generated heat and the fresh-surface integrity of the composite. Cutting trials were developed using a Spinner U-620 5-axis CNC machine. Real-time temperature histories owing to the dry milling of both Glass/Epoxy and Glass/Polyester composites were recorded using thermocouples preinstalled within the composite specimen. SEM inspections were conducted to elucidate the prevailing failure mechanisms during the material removal process. The results showed that fiber orientation significantly dominated thermal responses. Cutting perpendicular to the fiber orientation results in a critical temperature, while the addition of SiO₂ particles effectively reduces the temperature overlaps and peak values, causing the temperature to drop. The addition of SiO₂ serves to keep the temperature sufficiently lower than the glass transition point of the matrix. However, increasing the feed rate from 50 mm/min to 150 mm/min reduced the overall temperature during cutting. Under similar cutting conditions, Glass/Polyester composites exhibited lower peak temperatures and heat quantities than Glass/Epoxy regardless of the feed rate and fiber orientation. Observations revealed that fiber orientation and matrix type strongly influence the intensity of the thermal and mechanical damages induced. These findings suggest that the addition of silicon dioxide can adjust the thermal balance in dry cutting and may improve the composite’s structural integrity significantly. Such a composite design promotes the heat control of sensitive parts in advanced engineering applications. Full article

Dynamic mechanical thermal analysis (DMTA) is widely used to assess the effects of process- and environment-induced changes in polymer matrix composites, with the glass transition temperature (T_g) often reported from the tan d peak at a single excitation frequency. However, such an approach neglects the inherently kinetic nature of the glass transition and may obscure thermally induced changes in relaxation response. Multi-frequency DMTA was employed to investigate the evolution of glass transition response of a wet-layup unidirectional carbon/epoxy composite subjected to thermal aging at temperatures ranging from 66 °C to 260 °C for periods up to 72 h, using unexposed (23 °C) results as an ambient baseline reference. Tests were conducted using a single cantilever mode in both longitudinal and transverse configurations over a range of excitation frequencies from 0.3 to 30 Hz. Results demonstrate that thermal exposure affects not only the absolute value of the glass transition temperature, but also its frequency sensitivity and directional dependence. A frequency sensitivity parameter and a directional amplification factor are introduced to quantify frequency–direction coupling. While post-cure-dominated aging regimes exhibit relatively stable coupling behavior, degradation-dominated conditions at elevated temperatures and longer periods of thermal exposure lead to pronounced increases in transverse frequency sensitivity, which reflects early evolution of matrix- and interphase-level deterioration. These findings highlight the value of multi-frequency DMTA with tests in both primary directions for the mechanistic assessment of effects of thermo-oxidative response in polymer matrix composites. Full article

The increasing demand for sustainable and environmentally friendly construction materials has spurred interest in biopolymer composites reinforced with agricultural waste. Rice husk (RH), a byproduct of rice milling, is abundant and rich in lignocellulosic fibers and silica, making it excellent for use in fiber-reinforced biopolymers. The novelty of this study lies in its integrated and construction-oriented evaluation of rice husk (RH)-reinforced biopolymers, combining mechanical, thermal, environmental, and economic perspectives within a single framework. The study introduces a novel comparative approach by benchmarking multiple polymer matrices-including PP, recycled HDPE, epoxy, PLA, and bio-binders-under unified quantitative performance criteria. Another key novelty is the identification of the dual functional role of silica-rich RH in simultaneously enhancing structural strength and flame retardancy while contributing to carbon emission reduction. With a high silica content (15–20%) and lignocellulosic structure, RH serves as a natural filler that enhances the performance of polymer matrices such as polypropylene (PP), epoxy, polylactic acid (PLA), and recycled polyethylene. Mechanically, RH-reinforced composites demonstrate significant improvements in tensile, flexural, and impact strength. For example, PP composites with NaOH-treated RH and coffee husks achieved tensile strengths between 27.4 MPa and 37.4 MPa, with corresponding Young’s modulus values ranging from 1656 MPa to 2247.8 MPa. Recycled HDPE-RH blends reached tensile strengths up to 74 MPa and flexural values of 39 MPa, validating their structural applicability. Epoxy matrices embedded with 0.45 wt.% RH nanofibers showed degradation thresholds of 411 °C and 678 °C, reflecting substantial thermal resistance. Flame retardancy is further improved by the presence of RH biochar, which leads to reduced peak heat release rate (PHRR) and enhanced char formation. In building insulation applications, RH-based composites exhibit low thermal conductivity values between 0.08 and 0.14 W/m·K, contributing to energy efficiency. Economically, RH reduces material costs by 30–40%, while environmentally, its integration lowers carbon emissions in PP composites by up to 10%, and promotes biodegradability. Despite challenges such as moisture absorption and interfacial adhesion, these can be mitigated through alkali treatment, compatibilizers (e.g., MAPP), or hybrid reinforcement strategies. Full article