Composite Foams Research Articles

Performance optimization of hydrogen storage reactors based on PCM coupled with heat transfer fins or metal foams

Metal hydride is a type of solid hydrogen storage material that offers excellent hydrogen absorption and desorption reaction properties. However, there is a strong thermal effect during the reaction process when the materials are applied in reactors. Thus, effective thermal management techniques are crucial for promoting efficient reactions. Prior studies on the subject have shown that phase change materials can be coupled with metal hydride reactors to transfer the reaction heat. To further enhance the transfer of heat and reaction efficiency of the metal hydride reactors based on phase change materials, this study explored heat transfer enhancement methods on the phase change materials side, including adding heat transfer fins and discussing the fin parameters and composite foam metal. The findings of the study showed that in comparison to the reactor without fins, the absorption rate of adding 10 sets of fins can increase by 28%, and as the number of fins increased to 14, this value could increase to 39.4%. The use of Y-shaped fins did not substantially improve the reaction rate, mainly due to the sufficient number of straight fins, and the heat transfer area reaching the limit of the fin enhanced the process of heat transport. Thus, the improved method of using copper foam is further considered. Compared with the reactor with and without fins, the absorption rate of the copper foam coupled reactor is increased by 23.4% and 61.3%, respectively.

Synergistic Reinforcing Effect of Hazelnut Shells and Hydrotalcite on Properties of Rigid Polyurethane Foam Composites

Recently, the development of composite materials from agricultural and forestry waste has become an attractive area of research. The use of bio-waste is beneficial for economic and environmental reasons, adapting it to cost effectiveness and environmental sustainability. In the presented study, the possibility of using hazelnut shell (HS) and hydrotalcite (HT) mineral filler was investigated. The effects of fillers in the amount of 10 wt.% on selected properties of polyurethane composites, such as rheological properties (dynamic viscosity, processing times), mechanical properties (compressive strength, flexural strength, hardness), insulating properties (thermal conductivity), and flame-retardant properties (e.g., ignition time, limiting oxygen index, peak heat release), were investigated. Polyurethane foams containing fillers have been shown to have better performance properties compared to unmodified polyurethane foams. For example, the addition of 10 wt% of hydrotalcite filler leads to PU composite foams with improved compression strength (improvement by ~20%), higher flexural strength (increase of ~38%), and comparable thermal conductivity (0.03055 W m–1 K–1 at 20 °C). Moreover, the incorporation of organic fillers has a positive effect on the fire resistance of PU materials. For example, the results from the cone calorimeter test showed that the incorporation of 10 wt% of hydrotalcite filler significantly reduced the peak of the heat release rate (pHRR) by ca. 30% compared with that of unmodified PU foam, and increased the value of the limiting oxygen index from 19.8% to 21.7%.

Fabrication of ultra-high strength MWCNTs/CI /PI rigid composite foam with excellent microwave absorption performance by pressure foaming method

Polyimide (PI) foam exhibits excellent high-temperature resistance and outstanding physical and chemical stability, making it an ideal matrix for absorbing materials. However, the growing demand for absorbing materials that can serve as load-bearing components has revealed that existing polyimide composite foams often fall short of practical application requirements due to their low mechanical properties. The study employed a simple foaming method using isocyanate-based polyimide as the foam base under a 0.2 MPa atm. Multi-walled carbon nanotubes (MWCNTs) and carbonyl iron (CI) powder were added sequentially to the precursor solution. Under the filling parameters of 2.0 % MWCNTs and 10 % CI powder, the compressive strength of polyimide composite foam reaches 16.2 MPa and exhibits excellent microwave absorption properties, with a minimum reflection loss (RLmin) of −62.51 dB and an effective absorption bandwidth (EAB) of 7.86 GHz. Additionally, the prepared composite foam has potential infrared stealth capability. This work offers new insights for rapid and low-cost manufacturing of high-strength absorbing foam.

Fabrication of PBAT/lignin composite foam materials with excellent foaming performance and mechanical properties via grafting esterification and twin-screw melting free radical polymerization

As one of the mainstream biodegradable materials, poly(butylene adipate-co-terephthalate) (PBAT) foams offer a sustainable alternative to traditional plastic foams, effectively reducing environmental pollution. However, the high cost and poor mechanical performance of PBAT foams impede their practical application. Herein, the glycidyl methacrylate-grafted biomass lignin (GML) was used to produce a PBAT/GML composite foam with good foaming performance and mechanical properties at high lignin-filling amounts by twin-screw melting free radical polymerization and supercritical CO2 foaming process. The compatibility of GML in the PBAT matrix was improved due to the formation of ester bonds in modified lignin, endowing the PBAT/GML (PGML) composite foam with exceptional foaming performance. Additionally, the mechanical properties of PGML composite foam were remarkably enhanced due to the introduction of the abundant aromatic structures of GML and the construction of a stable covalent crosslinking network. The compressive strengths and compression modulus of the PGML foam were improved by 2.53 times and 2.47 times, while its bending strength and bending modulus were improved by 1.27 times and 3.92 times compared to the neat PBAT. This research affords a new strategy for developing low-cost biodegradable biomass PBAT/lignin composite foam materials with good foaming performance and mechanical properties.Graphical abstract

Scorpion-inspired multi-scale contact enabled multifunctional piezoresistive pressure sensor based on hybrid nanofiber decoration

Inspired by the slit organs of scorpions, an array narrow orifice configuration (ANOC) piezoresistive foam sensors are developed by decorating hybrid polypyrrole (PPy)/ carbon nanotubes (CNT) nanofibers on the foam strut. The developed ANOC composite foam exhibits a unique multi-scale contact sensing mechanism enabled by the macro-scale internal dome structures, the micro-scale struts of the porous foam, the nano-scale PPy/CNT hybrid conductive networks, and the nano-scale friction of the rough CNT/PPy hybrid nanofibers (NFs), which rendered the ANOC composite foam an ultra-high sensitivity of 1.8 kPa−1 at low pressure within 1.5 kPa. When used as a piezoresistive pressure sensor, the ANOC composite foam exhibits a wide detection range (0 %-70 %), fast response/recover time (120/90 ms), and long-term stability and fatigue resistance (over 80000 s), and demonstrated capability to monitor various human activities. A smart cushion integrated with an array of foam sensors can accurately identify the human sitting positions and posture rectifying. Moreover, owing to the highly porous conductive network and the doped ions, the ANOC composite foam can generate energy from saline water and serve as a water-induced energy generation (WIEG) device for direct energy supply. This research paves the way for the development of multifunctional high-performance.

Investigation on the microstructure and compressive behavior of open-cell copper- Al2O3 composite foams

The objective of this study is to evaluate the mechanical behavior and energy absorption characteristics of open-cell copper- Al2O3 composite foams fabricated using polyurethane foam with an average pore size of 1.2 mm and a combination of electroless and electrodeposition methods. During electroplating process, the composite foams were fabricated with varying amounts of Al2O3 particles (0.1, 0.6, 0.8, and 1 g/l) in electrolyte solution. To assess mechanical properties of the fabricated foams, uniaxial compression test was conducted to determine the maximum compressive strength, energy absorption density, efficiency, and specific energy absorption. The content of Al2O3 in the fabricated composite foams was evaluated using energy dispersive X-ray (EDX) analysis, and the microstructure was examined using scanning electron microscopy (SEM). The results indicate that the incorporation of Al2O3 particles significantly improves the mechanical properties of the copper-Al2O3 composite foam. Specifically, in the composite foam with 9.34 vol% of Al2O3 particles, the maximum compressive strength, total energy absorption, specific energy absorption, and energy absorption efficiency reach 1.03 MPa, 6.48 MJ m−3, 1.9 J g−1, and 75%, respectively. This amount of alumina particles enhances the maximum compressive strength and total energy absorption of open-cell copper foam by approximately 30% and 100%, respectively. However, the mentioned parameters slightly decreased with an increasing amount of Al2O3 particles up to 16.32 vol%. These significant improvements in the mechanical properties of these foams make them well-suited for high-strength applications.

An Interactive Fluid–Solid Approach for Numerical Modeling of Composite Metal Foam Behavior under Compression

Composite metal foams (CMF) are renowned for their high strength‐to‐density ratio, high stiffness, and energy absorption capabilities. Homogenized finite element models of CMF have been numerically solved to understand the mechanical behavior of the material under a variety of external loading conditions. This work aims to pioneer a comprehensive finite element model for steel–steel composite metal foam by incorporating the interactions between embedded stainless‐steel hollow spheres with entrapped air inside stainless‐steel matrix. The material behavior of hollow spheres, surrounding matrix, and air are modeled using Johnson–Cook (JC) plasticity, Deshpande–Fleck (D–F) foam, and linear polynomial equation of state in LS DYNA. Further, the finite element model utilizes a combination of Lagrangian solid elements and meshfree smooth particles hydrodynamics with appropriate contacts to effectively model the interaction of entrapped air within stainless‐steel hollow spheres with surrounding metallic spheres and matrix. The strain rate and the crosshead velocity of 65 s−1 and 2.4765 m s−1 are used for quasistatic compression analysis. Finally, the results obtained from the computational model are compared and validated using previously reported experimental quasistatic compression data. The numerical model corroborates stress–strain response of CMF with 5.6% error for plateau stresses average within 25% and 30% strain.

High mechanical strength, flame retardant, and waterproof silanized cellulose nanofiber composite foam for thermal insulation

High mechanical strength, flame retardant, and waterproof silanized cellulose nanofiber composite foam for thermal insulation

Dual Cross-Linked Networks Reinforced Polyimide Foams with Outstanding Piezoelectric Properties and Heat Resistance Performance.

The application of traditional isocyanate-based polyimide (PI) foams is highly hindered due to limited flame retardancy, poor mechanical properties, and relatively single functionality. Herein, we propose an effective method to fabricate dual cross-linked polyimide/bismaleimide (PI-BMI) foams with outstanding heat resistance and enhanced mechanical properties by incorporating bis(3-ethyl-5-methyl-4-maleimidophenyl)methane (ME-BMI) as the interpenetrating network. The results show that the prepared PI-BMI composite foams exhibit enhanced mechanical properties with lightweight characteristics (23-80 kg·m-3). When the ME-BMI loading reached 120 wt %, the tensile and compressive strength of PI-BMI composite foam can reach 1.9 and 7.8 MPa, which are 9.6 and 63.3 times higher than that of pure PI foam, respectively. In comparison with PIF-0, the 10% heat loss temperature (Td,10%) of PIF-90 improved by 156 °C. Moreover, the PI-BMI foam piezoelectric sensor containing fluorine groups presents a short response time (14.22 ms), high sensitivity (0.266 V/N), and outstanding stability (10 000 cycles). Besides, the sensor can accurately monitor human activity in different states. This work provides a promising strategy for designing multifunctional PI foams, making them suitable for applications in aerospace and microelectronics.

The effect of unintended porosity on the first compressive stress maximum of alumina hollow sphere-filled bimodal composite metal foams

Bimodal composite metal foams made from Al99.5 aluminium and quasi-eutectic Sr-modified AlSi12 matrix were investigated, where the bimodality was introduced by two alumina hollow sphere sets with nominal diameters of Ø7.0 and Ø2.4 mm in various volume concentrations. The research aimed to determine the effect of the cell structure (especially the unintended porosity) on the first compressive stress maximum, depending on the applied matrix material. The various features of the cell structure were quantitatively measured in composite metal foams by filtering raw computed tomography analysis data. The casting porosity, the wetting porosity, the porosity from the various-sized hollow spheres, and the partially matrix-filled hollow spheres have been successfully distinguished based on volumetric and geometrical conditions, such as sphericity and compactness. The unintended porosity (as the sum of the casting porosity and the wetting porosity) influences the first compressive stress maximum of the Al99.5 matrix composite metal foams. In contrast, for the AlSi12Sr bimodal foams, the results correlated with the total porosity values. The first compressive stress maximum could be estimated well from the compressive yield strength of the matrix and the total porosity of the foam.

The effect of the isocyanate trimerisation catalyst on the chemical composition and strength characteristics of polyurethane-polyisocyanate foams

Nowadays polyurethane-polyisocyanurate (PIR) foams are in a wide use as structural and thermal insulation materials. Isocyanate trimerisation catalysts for foams synthesis have low selectivity in terms of isocyanurate formation. As a consequence, a significant number of target (primary) and (secondary) chemical processes occur during the synthesis of PIR foams. We estimated the dependence of isocyanate group consumption for the formation of the main primary and secondary products on composition isocyanate index by methods based on the internal standard. Indeed, with an increase in the isocyanate index, the conversion of isocyanate to isocyanurate decreases significantly. The paper examines the influence of trimerisation catalyst type on chemical composition and strength characteristics of PIR foams. Hence, catalysts based on organic salts of alkali metals are more selective to the isocyanate trimerisation process than tertiary amines and derivatives of quaternary ammonium bases.

Ameliorating the comprehensive performance of rigid polyurethane foam insulating materials by green cork for building energy conservation

Biomass-modified polyurethane (PU) foam materials are vital to promote the sustainable development, but the balance between their mechanical strength and thermal insulating ability remains a challenge compared to the petrochemical-based PU foams. Herein, an appropriate amount of cork is introduced to fabricate PU composite foams with good thermal insulating performance and mechanical strength. The added cork could act as a nucleating agent during the foaming process, further tailor the foam structure and enhance their comprehensive performance. The optimal composite foams containing the peak cork usage of 24% also belong to the high-efficiency insulating materials, with a thermal conductivity of 0.043 W m–1 K–1, a tensile strength of 0.17 MPa, a bending strength of 0.16 MPa, and good impact resistance. This research provides valuable insights for developing the comprehensive PU insulating materials by utilizing eco-friendly cork as substitutes, and offers a reference for highly efficient utilization of biomass resources.

Hybrid lattice structure with micro graphite filler manufactured via additive manufacturing and growth foam polyurethane

The utilisation of lightweight structures is a common practice across a range of disciplines, including the construction of light steel frames, sandwich panels, and transportation infrastructure, among others. The advantages of lightweight structures include design flexibility, weight reduction, and the sustainability of materials that can be easily recycled. However, these advantages also present significant weaknesses. Compared to solid materials with compact weight, lightweight structures do not have the same characteristics. With the reduction in material weight, the strength of the lightweight structure decreases significantly compared to solid materials. In this study, the lightweight structure was made using additive manufacturing and reinforced with solid Composite Polyurethane Foam reinforced with graphite filler expanded into the lightweight structure. The results showed that in the compression test, the mixture with 2 % graphite filler had the highest value of 2.5 kN. The highest hardness test on the specimen with a 2 % graphite mixture was 19.8 HA. FT-IR testing showed that the carbon bonds from graphite in the 2 % specimen had the highest intensity. The test results showed that the addition of Polyurethane Foam into the structure could enhance material strength effectively without adding significant material weight.

Robust and multifunctional polyimide composite foams via microsphere foaming towards efficient thermal insulation and broadband microwave absorption

Robust and multifunctional polyimide composite foams via microsphere foaming towards efficient thermal insulation and broadband microwave absorption

Enhanced EMI Shielding Efficiency of Graphene Nanoplatelets and Glass Sphere Composite‐Loaded Ultralight Weight Flexible Polyurethane Foam

ABSTRACTGraphene nanoplatelets and glass sphere (GNP@GS) composite is prepared using a simple mixing process and is loaded in flexible polyurethane foam to produce ultralight weight, high‐performance, electromagnetic interference (EMI) shielding material. The presence of a glass sphere enhances the mobility of graphene nanoplatelets in a polymer matrix forming a continuous conductive network thereby achieving better electrical conductivity and enhanced EMI shielding efficiency. The electrical conductivity of the synthesized GNP@GS/PU foam composites was achieved between 5.69 × 10−8 and 13.25 × 10−4 S/cm at varying filler loading. The maximum shielding effectiveness (i.e., −24.43 dB) was found at 12 wt% GNP@GS‐loaded samples. The shielding results show that the composites have the potential to be employed as ultralight weight, flexible EM shielding materials. These materials are essential in many applications because they are good shield materials that prevent electronic equipment from electromagnetic‐interference, better heat dissipation from the device, and also flexible to support fall protection.

Cellulose nanofibers enabled strong and flexible plant-derived thermoplastic polyester elastomer foams for high-performance thermally insulating applications

Flexible thermal insulation materials have garnered significant attention owing to the proliferation of flexible electronic devices and their diverse application environments. Plant-derived thermoplastic polyester elastomer (TPEE) foams emerge as promising candidates in the field of flexible thermal insulation. However, inevitable shrinkage behavior of TPEE foams would result in reduced porosity and inferior thermal insulation performance. Hence, a pioneering approach is proposed wherein cellulose nanofibers (CNF) are integrated into TPEE matrixes, complemented by microcellular foaming, aimed at mitigating shrinkage process and enhancing thermal insulation properties. In this work, the relaxation behavior of nanocomposite, corresponding to shrinkage process, has been elucidated through dynamic mechanical analysis. It's found that entanglement of CNF could heighten the internal friction with TPEE molecular chains, coupled with establishment of hydrogen bonds, thereby curbing relaxation phenomena and facilitating the attainment of foams with enhanced and stable porosity. The shrinkage ratio of TPEE/CNF composite foam could be reduced by 20 % without compromising the final porosity. The thermal conductivity would decrease to 37.9 mW/m·K for the TPEE/CNF composite foam with the higher porosity of 0.947. Moreover, the utilization of CNF presents a novel avenue for fabricating TPEE/CNF nanocomposite foams endowed with flexibility, lightweightness, increased porosity, and reduced thermal conductivity.

Preparation of vanillin-based polyurethane/SiO2 nanocomposite foams with excellent flame retardancy and thermal insulation performance

In this work, vanillin based inherently flame retardant polyurethane/SiO2 composite foams were designed. Firstly, the vanillin based flame retarding diol (VDP) was synthesized. Then, the KH550 modified nano-SiO2 (KH550-g-SiO2) was prepared as the reinforcement. Subsequently, a series of flame-retardant polyurethane/SiO2 composite foams (PUF-0.5P-xSiO2) were synthesized by tailoring the hard-soft segments and KH550-g-SiO2 contents. The results showed that KH550-g-SiO2 significantly improve the thermal stability of the PUF-0.5P-xSiO2 foams. In addition, the compressive strength of PUF-0.5P-xSiO2 foams was enhanced from 0.18 MPa (PUF-0.5P) to 0.45 MPa (PUF-0.5P-2.0SiO2) under 20 % strain. The flame retardant properties of PUF-0.5P-2.0SiO2 reached UL-94 V-0 grade. Meanwhile, the addition of KH550-g-SiO2 also decreased the thermal conductivity from 0.046 W/m·k to 0.037 W/m·k for PUF-0.5P-2.0SiO2. This work may provide an approach to obtain the biobased lightweight polyurethane foams for the application in packaging and building areas.

Preparations of Polyurethane Foam Composite (PUFC) Pads Containing Micro-/Nano-Crystalline Cellulose (MCC/NCC) toward the Chemical Mechanical Polishing Process.

Polyurethane foam (PUF) pads are widely used in semiconductor manufacturing, particularly for chemical mechanical polishing (CMP). This study prepares PUF composites with microcrystalline cellulose (MCC) and nanocrystalline cellulose (NCC) to improve CMP performance. MCC and NCC were characterized using scanning electron microscopy (SEM) and X-ray diffraction (XRD), showing average diameters of 129.7 ± 30.9 nm for MCC and 22.2 ± 6.7 nm for NCC, both with high crystallinity (ca. 89%). Prior to preparing composites, the study on the influence of the postbaked step on the PUF was monitored through Fourier-transform infrared spectroscopy (FTIR). After that, PUF was incorporated with MCC/NCC to afford two catalogs of polyurethane foam composites (i.e., PUFC-M and PUFC-N). These PUFCs were examined for their thermal and surface properties using a differential scanning calorimeter (DSC), thermogravimetric analysis (TGA), dynamic mechanical analyzer (DMA), and water contact angle (WCA) measurements. Tgs showed only slight changes but a notable increase in the 10% weight loss temperature (Td10%) for PUFCs, rising from 277 °C for PUF to about 298 °C for PUFCs. The value of Tan δ dropped by up to 11%, indicating improved elasticity. Afterward, tensile and abrasion tests were conducted, and we acquired significant enhancements in the abrasion performance (e.g., from 1.04 mm/h for the PUF to 0.76 mm/h for a PUFC-N) of the PUFCs. Eventually, we prepared high-performance PUFCs and demonstrated their capability toward the practical CMP process.

Dynamic mechanical analysis of additively manufactured cenosphere-filled PETG syntactic foam composite

Syntactic foam composite (SFC) has the potential to substitute the conventional material used in damage-tolerance, thermal insulation, and weight-sensitive applications such as automotive parts, submarine structures, etc. Here, SFCs were developed by varying the weight fraction of cenosphere (CS) content from 0-40 wt. % in a polyethylene terephthalate glycol (PETG) matrix. This investigation provides the terse behavior of the viscoelastic properties of 3D-printed PETG/CS foam composites. The thermogravimetric analysis (TGA) results showed that the initial degradation temperature (Ti) and the temperature at 50% mass loss (T50) of the composite filament increased with the addition of CS particles, indicating improved thermal stability. The dynamic mechanical analysis (DMA) results revealed that the storage modulus of SFC increased with increasing cenosphere content. The foam composite’s glass transition temperature (78.9 ± 0.35 °C) is lower by 4 °C than pure PETG. This underscores the potential of the developed syntactic foam composite to effectively utilize industrial waste fly ash through 3D printing routine, thereby promoting sustainable manufacturing practices.

Analysis of Thermal Properties of Materials Used to Insulate External Walls.

This article emphasizes the significance of understanding the actual thermal properties of thermal insulation materials, which are crucial for avoiding errors in building design and estimating heat losses within the energy balance. The aim of this study was to analyse the thermal parameters of selected thermal insulation materials, particularly in the context of their stability after a period of storage under specific conditions. The materials chosen for this study include commonly used construction insulations such as polystyrene and mineral wool, as well as modern options like rigid foam composites. Experimental studies were conducted, including the determination of the thermal conductivity coefficient λ, as well as numerical analyses and analytical calculations of heat flow through a double-layer external wall with a window. The numerical analyses were performed using the TRISCO software version 12.0w, based on the finite element method (FEM). A macrostructural analysis of the investigated materials was also performed. The findings indicated that improper storage conditions adversely affect the thermal properties of insulation materials. Specifically, storing materials outdoors led to a deterioration in insulating properties, with an average reduction of about 4% for the standard materials and as much as 19% for the tested composite material. Insufficient understanding of the true thermal properties of insulation materials can result in incorrect insulation layer thickness, degrading the fundamental thermal parameters of external walls. This, in turn, increases heat loss through major building surfaces, raises heating costs, and indirectly contributes to greenhouse gas emissions.