Simulation and optimization of lightweight insulating geopolymer composites via dual gradient slurry deposition

Abstract

High porosity over 50% is essential to achieving lightweight and thermal insulating properties in the green manufacturing of geopolymers. Recognizing that mechanical and thermal properties are highly related to pore distribution and orientation, we analyze and optimize the pore of the geopolymer composites with purposely designed different gradient variations via additive manufacturing (AM) and simulate the related properties. The results shows that adding 15 wt% diamond in the specimen reduced the heat flux and the maximum value of heat flux at 15 wt% part is 13.429 J/s. The dynamic nano hardness and Young's modulus values both increase with increasing diamond ratios in addition to the 12 wt%. Besides, the elongated shape of internal pores and throat is closely related to the layer-stacking printing method, playing a more significant role than material in the decreased thermal and ductile compressive behavior. 3D structure of Schwarz w with connected pores is proved to have the optimal mechanical and thermal performances among the eight typical triply periodic structures. This research establishes the guidelines to the pore analysis and simulation of multiple mineral composites with tailored, deigned-pore-dependent lightweight and thermal insulation properties.