Continuous Basalt Fiber Research Articles

Comparisons between basalt for continuous fiber and ordinary basalt.

Continuous basalt fiber (CBF) is a novel, green and eco-friendly material drawn with basalt, featuring exceptional properties such as high-temperature resistance, corrosion resistance, and superior strength. It finds extensive applications in various fields including defense and military industry, aviation and aerospace, construction and bridges. Basalt is the most widely distributed aluminosilicate volcanic rock on Earth. However, not all basalts are suitable for the stable CBF production due to the variations in composition and structure across different regions, which result in differences in the crystallization characteristics of basalt melts that impact the stability and continuity of the wire drawing process. Therefore, investigating the crystallization characteristics of basalt glass melt holds significant value for CBF production. This paper focuses on the various types of high-quality basalt for CBF and ordinary basalt in China. They were melted at a temperature of 1450 °C for 1 h, followed by cooling in the furnace and quenching with water, resulting in the preparation of 18 pieces of basalt glasses. The basalt glasses were characterized using DSC, XRD, FT-IR, SEM, EDS and polarizing microscope techniques. The research findings suggest that: (1) The chemical compositions of high-quality basalt for CBF do not exhibit significant differences from that of ordinary basalt; (2) All the basalt glasses quenched with water produced from high-quality basalt for CBF and ordinary basalt exhibit an amorphous phase, uniform glass structure, and enhanced melting behavior at this temperature; (3) In the furnace-cooled process, the glasses from high-quality basalt for CBF lacks any crystalline phase while the glasses from ordinary basalt display varying degrees of crystallization primarily due to cooling-induced crystallization. This work holds great significance for evaluating and screening the basalt raw materials for CBF.

Enhanced mechanical properties of sandwich panels via integrated 3D printing of continuous fiber face sheet and TPMS core

Sandwich panel structures have widespread applications in various components, owing to their excellent lightweight properties. However, conventional manufacturing methods involve multiple steps, which limits the exploration of innovative sandwich panel structure. In this study, an integrated 3D printing method for continuous fibers reinforced sandwich panel with Triply Periodic Minimal Surface (TPMS) core structure is proposed via Fused Deposition Modelling (FDM). A bridging layer and a continuous basalt fiber pre-impregnated by stiff thermoset epoxy resin are utilized to address the issue of overhanging printing for the upper face sheet. Two kinds of TPMS are employed as the core, as well as two kinds of honeycomb. Multi-step printed samples using a bonding process and counterpart samples without fiber were prepared for the comparison. 3-point bending tests were conducted and a finite element model which can represent the structure characteristic is proposed to investigate the mechanical properties. The results show that the integrated printed sample exhibits better performance in terms of printing quality, flexural modulus, strength and energy absorption (EA) compared with the multi-step printed sample. It has an excellent ability to avoid the catastrophic damage which is usually encountered in the multi-step printed sample due to the introduction of brittle epoxy resin, showing a notable 162.88 % augmentation in specific energy absorption (SEA). The significant improvement lies in that it uses the reinforcement of fiber and the energy absorption capacity of core to full advantage via the strong binding. In addition, as one kind of TPMS, Schwarz Primary structure exhibits the maximum flexural modulus, strength and energy absorption among the four cores. The proposed design and fabrication methodology pave the way for the creation of high-performance sandwich panels with different core structures.

Phase equilibria of SiO2–Al2O3–Fe3O4-5 wt.% CaO system at 1400 °C in air relevant to the production of continuous basalt fibers: Emphasis on spinel solid solution phase

A long-term foundational study aimed at developing a thermodynamic database for continuous basalt fiber systems is in progress. In this work, the equilibrium phase relations of the SiO2–Al2O3–Fe3O4-5 wt.% CaO system at 1400 °C in air atmosphere were determined experimentally using the equilibrium-quenching technique. Subsequent analyses were conducted using Electron Probe Micro-Analysis (EPMA), X-ray Diffraction (XRD), and Scanning Electron Microscopy (SEM) to validate the experimental results and further investigate the microstructural characteristics. The results revealed a single liquid region and three distinct two-phase regions as Liquid-Cristobalite, Liquid-Mullite solid solution, and Liquid-Spinel solid solution. Additionally, two three-phase regions were identified as liquid-cristobalite-mullite solid solution, and liquid-mullite solid solution-spinel solid solution. This work contributes to a deeper understanding of the phase behavior during the melting of basalt ore systems, which is crucial for optimizing their production and enhancing their applications.

A novel and precise method to determine the upper limit of crystallization temperature of basalt melts for the production of continuous basalt fibers

The upper limit of crystallization temperature (Tc) of basalt melt is crucial for the production of continuous basalt fibers (CBFs). However, the precisely measuring Tc for basalt systems has been a challenging and time-consuming task. As a result, there is often a mismatch between the fiber-drawing temperature (Td) and the Tc of basalt melt during CBF production, which hinders the improvement of the mechanical properties and leads to the fiber fracture. To address these limitations, a new approach has been proposed to determine Tc by analyzing the inflection point of the viscosity-temperature curve, This is achieved by fitting an exponential function (y = y0 + A*exp(R0*x)). The results of this viscosity fitting technique were compared to the microstructure and morphology of basalt melts quenched at different temperatures, which were assessed using X-ray diffraction (XRD) and scanning electron microscopy (SEM). The findings indicate that the results from XRD and micro-observations are in agreement with the viscosity fitting method. Furthermore, the variations of Tc and Td in binary basalt systems were quantified, and it was revealed that their behavior follows the linear superposition principle based on the mass percentage Wi (i = 1, 2) of the two end members. Empirical formulas have been developed to describe this relationship, which are given as TcW1 × Tc1 + W2 × T c1 and Td = W1 × Td1 + W2 × Td2. These findings not only contribute to the precise measurement of Tc but also provide new insights for modeling the prediction formula of Tc for binary basalt systems.

Effect of Crystallization Properties of Continuous Basalt Fibers on Thermal Stability of Composite Materials

The thermal stability of composite materials based on basalt fibers is determined by the strength of fibers under thermal stress. The decrease in strength occurs due to the crystallization of the original fibers and the development of microcrystalline nuclei in them during heating. Experimental studies of the influence of the processing temperature of continuous basalt fibers on their strength have been carried out. It has been established that the strength of fibers during their heat treatment up to 400оС decreases by 25 % from the initial one. At the temperature of approximately 500оС, the strength of the fibers is almost half. At 600оС, the fiber strength is 20 % of the initial strength. At a processing temperature of 700оС, the fiber is completely destroyed. The main reasons for the decrease in fiber strength are the development of microcrystalline nuclei that have formed in the fibers at the drawing stage in the crystallization zone. From above, this zone is determined by the temperature of the upper limit of melt crystallization, and from below it is limited by the glass transition temperature. The residence time of the melt in this range is the crystallization time. Calculations the speed of movement and the cooling rate of the melt stream during fiber drawing were carried out, which made it possible to determine the temperature zone and time of crystallization. The results of theoretical studies have shown that for the production of fibers used in composites, it is necessary to select such basalts and conditions for the fiber drawing, under which the values of the temperature zone and time of crystallization will be the smallest.

Establishment of the iron-containing phase of the gavasaia porphyrite by the method of mössbauer spectroscopy for obtaining basalt fibers

The results of studies on the determination of the iron-bearing phase of trachybasalt porphyrite of the Karabulak site of the Gavasay deposit of Uzbekistan and their suitability for obtaining basalt fiber by the method of Mössbauer spectroscopy are presented. It has been established that on the basis of this igneous rock it is possible to obtain a continuous basalt fiber without corrective additives for heat-insulating materials.

Continuous basalt fibers into fireproof and thermal insulation architectures using an additive manufacturing manipulator

Continuous basalt fiber is an emerging high-performance foundational material that can be widely used in fields such as road construction, energy conservation and environmental protection, aerospace, military equipment, and marine ships. However, it is difficult for existing processing techniques to form continuous basalt architectures with three-dimensional (3D) complex shapes. In addition, the basalt fibers in the architectures are filled with polymers, which cannot fully utilize the performance of basalt fibers. Therefore, here, we report the fabrication of continuous basalt fibers with fireproof and thermal insulation performance through the combination of an Additive manufacturing (AM) manipulator, two-step precursor infiltration and pyrolysis (PIP) processes. Using SiOC ceramics to fill between continuous basalt fibers will help improve the architectures' fire and thermal insulation performance. The continuous basalt fibers coated with thermoplastic polyurethanes (TPU) were processed into 3D architectures under the action of the laser. Through the vacuum infiltration of the SiOC precursor and debinding process, TPU in the 3D architectures was removed. In order to reduce the structural defects generated by the first PIP process, the final part with fireproof and thermal insulation performance was fabricated through the second PIP process. We further demonstrated the final part with excellent fireproof and thermal insulation performance. The final part had a shell temperature of 788.8 ℃ and an internal temperature of about 50 ℃ under the flame spray gun for the 20 s. By replacing polymers with inorganic materials, our basalt architectures exhibit their potential applications in military, aviation, and civil fireproof and thermal insulation equipment.

Effect of addition of SiO2 and Al2O3 on the dielectric properties of basalt glasses

The present research focuses on the influence of SiO2 and Al2O3 additives on the structure and dielectric properties of basalt glasses. Upon the introduction of SiO2 and Al2O3, all the prepared basalt glasses were found to exhibit a non-crystalline nature. The initial dielectric constant of the basalt glass without the addition of SiO2 and Al2O3 was 7.893. However, as the content of SiO2 and Al2O3 increased, the dielectric constant of the basalt glasses initially decreased, but then started to rise. Remarkably, the lowest dielectric constant, achieved with the addition of 1 wt% Al2O3, was measured at 6.561. Similarly, the lowest dielectric constant, attained with the addition of 1 wt% SiO2, was recorded at 6.368. This value was lower than that produced by Al2O3 addition. These findings provide a new perspective on the dielectric properties of basalt glasses and continuous basalt fibers.

Physical and Mechanical Properties of Modified Continuous Basalt Fiber for the Production of Polymer Composite Materials: Experimental Study

Physical and Mechanical Properties of Modified Continuous Basalt Fiber for the Production of Polymer Composite Materials: Experimental Study

Roles of different organic-inorganic hybrid interfaces in enhancing the mechanical properties of continuous basalt fiber/epoxy composites

ABSTRACT In order to enhance the interfacial adhesion between continuous basalt fibers (CBFs) and epoxy (EP) matrix and the mechanical properties of resultant composites, the organic – inorganic hybrid compatibilization layer (OIHCL) composed of flexible 1,6-hexanediol diglycidyl ether (HDE) chains and rigid nano-silica (SiO2) is grafted on CBFs surface. With increasing the SiO2 content in the OIHCL, the structure and composition of the OIHCL change from a single layer composed of a well-dispersed SiO2 phase and continuous HDE phase to a double layer composed of an HDE/SiO2 inner-layer and aggregated SiO2 outer-layer. And, the effects of different OIHCLs on the mechanical performances of resultant composite are studied in details. The results show that the single-layer OIHCL exhibits stronger reinforcing effects in the interfacial shear strength (IFSS), tensile strength, and flexural strength of resultant composite. For example, the IFSS, tensile strength, and flexural strength of the CBFs-g-12.5%-(HDE/SiO2)/EP composite can reach 47.1 MPa, 466.1 MPa, and 660.5 MPa, respectively. Furthermore, the impact strength of the CBF/EP composites can be effectively enhanced by only grafting a flexible HDE layer on CBF surfaces. Finally, the aggregated SiO2 derived from the outer-layer of double-layer OIHCLs can deteriorate the interfacial adhesion, and all mechanical performances of resultant composites.

An investigation into mechanical properties of a 3D printed two-matrix continuous fiber composites with multi-cavity structure

A continuous fiber reinforced two-matrix composites with multi-cavity structure was fabricated by a co-extrusion method, combining the excellent wettability of thermosetting resin to fiber and the wonderful extrusion forming ability of thermoplastic for nozzle based additive manufacturing (AM). Diversified component materials were utilized to enrich database for the AM of continuous fiber composites, including continuous carbon fiber (CCF), continuous basalt fiber (CBF), short fiber reinforced polyamide (SFRPA), polyamide (PA), polylactic acid (PLA) and epoxy resin. The tensile and flexural tests were conducted to investigate the effect of component materials on the mechanical properties. The micro-structures of printing filament and the fracture morphology of samples were characterized by optical microscope (OM) and scanning electron microscopy (SEM), respectively. A novel numerical model based on Peridynamics (PD) was proposed for the simulation of failure model. The three-dimensional (3D) printed continuous fiber reinforced two-matrix composites with multi-cavity structure show dissimilar mechanical behavior and failure characteristic for different combinations of component materials. The micro-structure of the fiber bundle pre-impregnated by epoxy resin after printing has a great influence on the mechanical properties and fracture modes of the samples. The failure modes mainly include pullout and breakage of fiber, stress whitening and crack of matrix, and interfacial debonding. The PD model effectively captures the tensile and flexural failure characteristic of 3D printed composites with multi-cavity structure. The results from experimental analysis and numerical simulation have reference significance for structural optimization and failure prediction of continuous fiber composites printed by co-extrusion process.

EFFECT OF COOLING RATE OF BASALT MELTS ON STRENGTH OF CONTINUOUS FIBER IN THE DRAWING PROCESS

The questions of optimizing the operation parameters of basalt fiber drawing with the view to raising fiber strength are considered. To find out the interdependency between mechanical properties of fibers and thermal characteristics of basalt melt in the drawing process both mathematical modeling and experimental investigations have been undertaken in this study. The accurate numerical model, which describe adequately heat transfer in the drawing process of glass fiber has been used to determine the cooling rate of a melt jet in the vitrification stage. The fiber strength is found to be proportional to the melt cooling rate which is specified completely by the initial conditions of drawing. The results provide the theoretical basis of cnoosing and regulating technological parameters in the production of basalt and glass fibers. Fiber materials of various purpose, obtained from basalt continuous fibers, have high physicochemical characteristics, which are inferior only to expensive composites based on carbon and carbidities. Basalt continuous fibers are characterized by increased strength and elastic module. By strength properties, continuous basalt fibers are compared to glass fibers, and by module
 The elasticity exceeds them. The ability to control the properties of fibers in the production of basalt fibers is an important stage in the way of improving and optimizing the technology of their production. Obtaining basalt fibers with high strength and elasticity module requires understanding of the basic factors that affect these parameters. First of all, the chemical and mineralogical composition of the raw material.

Effect of TiO2 on preparation condition, mechanical properties and alkali resistance of continuous basalt fibers

The low alkali resistance of basalt fiber limits its utilization in the strong alkaline environment such as cement and concrete as the reinforcing material. Adding additive in the basalt rocks is the feasible method to enhance the alkali resistance. However, it is necessary to develop the efficient additive for basalt fiber. In this work, the effect of TiO2 on the preparation condition, alkali resistance and mechanical properties of basalt fiber was investigated. The preparation conditions were studied by DSC, XRD and high-temperature rotational viscometer. Then the corrosion behavior of TiO2-basalt fibers in NaOH solution was studied via SEM/EDX, FIB/SEM and FTIR. The results indicated that the viscosity of basalt melt decreased significantly with the increasing TiO2 content from 0% to 2%, but the crystallization tendency was not changed with TiO2 below 2%, the upper limit for TiO2 addition. The tensile strength increased by 20–60% because Ti4+ promoted Al3+ into the network structure and intensify the polymerization by entering the network structure as network precursor in the form of [TiO4]. Meanwhile, TiO2 in the basalt fibers formed insoluble titanium hydroxide, so the weight loss of TiO2-basalt fibers in NaOH solution was reduced up to 50%. Through FIB/SEM/EDX, the corrosion of basalt fiber in alkali condition is controlled by ion diffusion. The outward diffusion of Fe, Mg and Ti to the surface of fiber formed the insoluble layer, so the rate of substitution reaction between the OH− and basalt fibers was slowed down, but it also leaded to the non-uniform corrosion.

Phase separation and properties of glasses of the system MgO–CaO–Fe <sub>2</sub>O<sub>3</sub>–Al<sub>2</sub>O<sub>3</sub>–В<sub>2</sub>O<sub>3</sub>–SiO<sub>2</sub>

The synthesis and study of model glasses of the MgO–CaO–Fe2O3–Al2O3–SiO2 system, which is the base for obtaining continuous basalt fiber, has been carried out. Systematized data on the effect of components on the glasses structure and the sequence of phase separation processes occurring during their heat treatment have been obtained. It is shown that during phase separation, crystalline phases are separated in the following sequence: magnetite–pyroxene–plagioclase with a predominance of the anorthite component. Glasses of the MgO–CaO–Fe2O3–Al2O3–SiO2 system were modified by adding B2O3, and the active role of this component in the processes of glass formation and crystallization was shown. The ratio of glass-forming and modifying components of model glasses is established, at which an increase in the strength of glasses from 110 to 180 MPa is achieved. Based on the study of the technological properties of model glasses and strength characteristics, components were determined for modifying basalt glasses in order to increase the strength of the fiber.

Mechanical properties and failure behavior of 3D printed thermoplastic composites using continuous basalt fiber under high-volume fraction

Continuous basalt fiber (CBF) is an outstanding inorganic fiber produced from nature, which has a wide range of applications in the field of armor protection of national defense military. However, the mechanical response and failure mechanism of 3D printed CBF reinforced components are still not well understood. Here, the 3D printing thermoplastic composites with high volume fraction CBF have been successfully prepared by fused deposition modelling (FDM) method. The effects of fiber printing direction and polymer matrix type on the tensile and flexural properties of the 3D printed composites have been explored, and the detailed failure morphology has been characterized using scanning electron microscopy and optical microscopy. It was found that under high fiber volume fraction, 3D printed CBF reinforced polyamides (PA) composites have the best ability to maintain material integrity of the composites, followed by acrylonitrile butadiene styrene (ABS) and high impact polystyrene (HIPS). Besides, the results from rule of mixtures can accurately predict the longitudinal Young’s modulus of the 3D printed specimens, but there exists a large discrepancy for the prediction of the tensile strength. The microstructure analysis shows that the failure modes of 3D printed composites mainly include fiber debonding, fiber pull-out, stress whitening and matrix cracking.

ЕКСПЕРИМЕНТАЛЬНІ ДОСЛІДЖЕННЯ АДГЕЗІЇ БАЗАЛЬТОВИХ ЕЛЕМЕНТІВ ТА ЦЕМЕНТНО-ПІЩАНОГО РОЗЧИНУ ДЛЯ ДОЦІЛЬНОСТІ ВИКОРИСТАННЯ В КАНАЛІЗАЦІЙНОМУ СЕРЕДОВИЩІ

At present, there is a tendency in the world to replace steel and cast iron with composite materials with high chemical resistance and durability, which primarily include fiberglass, which has a set of high performance properties. However, currently the requirements for composites have increased, especially in terms of their heat and chemical resistance, resistance to microorganisms, groundwater and wastewater. Composites based on basalt fibers are significantly superior to traditional materials and alloys in their mechanical and physicochemical properties. They have corrosion resistance, chemical inertness, low thermal conductivity, high specific mechanical properties, low specific gravity. Basalt-based products have a number of advantages: high strength, relatively low weight, reliability in operation over a wide range of temperatures, not prone to corrosion and have high chemical resistance. Production and use of basalt fiber materials, composites and products from them are promising and economically feasible. Taking into account the physical- chemical properties of basalt fibers, the use of basalt elements from them as lining of sewer networks and structures is a promising method of their restoration. However, the durability of this depends primarily on the adhesion of basalt elements with cement-sand mortar. The article analyzes the mineral resource base of rocks as a one-component raw material for the manufacture of basalt fiber materials and composites based on them. The analysis of the properties of basalt continuous fibers in comparison with glass fibers of type E and S, carbon and aramid fibers is carried out. The results of the experimental study of the adhesion of basalt elements and cement-sand mortar are presented. The results of the research allow the use of basalt materials to perform repair and restoration work on sewers and structures.

Enhancing the interfacial adhesion between continuous basalt fibers and epoxy resin by depositing silicon dioxide nanonparticles

Herein, inorganic silicon dioxide (SiO2) nanoparticles are deposited on the surface of continuous basalt fibers (CBFs) to enhance the interfacial interactions between CBFs and epoxy matrix (EP) and the tensile strength of composites. According to results from scanning electron microscopy and atomic force microscopy, the surface morphology of CBFs changes from smooth to rough with the increase of SiO2 deposition content. The rough surface plays a role of chock to make CBFs implant into the EP better, offering strong mechanical engagement effect to the interface between CBFs and EP. Therefore, the interfacial shear strength (IFSS) between CBFs and EP and the tensile strength of composites both increase. However, depositing excessive SiO2 nanoparticles also brings some porous structures on CBFs surface, becoming defects and stress concentration points to weaken the IFSS and the tensile strength of composites. Finally, a comparison between grafting organic aliphatic chains and depositing inorganic rigid nanoparticles about their effects on the surface roughness of modified CBFs and the interfacial interactions between modified fibers and matrix is carried out to clarify the reinforcing mechanisms of interfacial adhesion and the tensile strength of composites.

The effects of chemical grafting 1,6-hexanediol diglycidyl ether on the interfacial adhesion between continuous basalt fibers and epoxy resin as well as the tensile strength of composites

The poor interfacial adhesion between continuous basalt fibers (CBFs) and epoxy resin (EP) is enhanced via chemical grafting aliphatic chains on CBFs surface. 3-aminopropyltriethoxysilane (KH550) play a role of bridge to link 1,6-hexanediol diglycidyl ether (HDE) chains and CBFs surface. Subsequently, CBFs-g-KH550-g-HDE/EP composites are fabricated from laminating process. The existence of HDE chains on CBFs surface not only improve the mutual infiltration between CBFs-g-KH550-g-HDE and EP matrix to reduce the structural defects at interface, but also enhance the interfacial adhesion to promote the effective load transfer between CBFs-g-KH550-g-HDE and EP matrix. Based on these factors, the tensile strength of composite is significantly improved. The reinforcing effect of CBFs-g-KH550-g-HDE is also related with its surface roughness. When sufficient aliphatic chains covered the entire surface of CBFs with a homogeneous thickness (smooth surface), the tensile strength of composite increased by 56 % compared with the neat CBFs/EP counterpart. When limited or excessive molecules are decorated on CBFs surface, the rough surface become structural defects to weaken the reinforcing effects of fibers.

One-step drawing of continuous basalt fibers coated with palladium nanoparticles and used as catalysts in benzyl alcohol oxidation

The continuous basalt fibers (CBFs) coated with palladium (Pd) nanocatalysts were prepared via one-step drawing strategy by using dispersion of Pd/montmorillonite (Pd@MMT) as the sizing. The prepared composite fibers (Pd@MMT/CBFs) were woven into fabrics and were used as fixed-bed catalyst for oxidation of benzyl alcohol (BzOH). The woven Pd@MMT/CBFs monolith was featured with “three-dimensional architecture” which afforded excellent catalytic performance (conversion 96%, selectivity 90%) and superior resistance to sustaining liquid flow shock. It was found that the tensile strength of CBFs was well preserved even the catalyst was exposed to a violent flow of BzOH+H2O2 at velocity of 0.1–0.6 m/s, and the mass loss was < 2.0% demonstrating rockiness stability of such CBFs-based catalysts.

Вплив умов і параметрів формування базальтових неперервних волокон на їх міцність і стан поверхні

Basalt continuous fibers are used in the development of new composite materials. The influence of various factors on the strength and formation of the surface microstructure of basalt continuous fibers is considered. An experimental determination of tensile strength was performed and the surface condition of continuous andesite-basalt fibers with a diameter of 8 to 10 μm fibers was investigated. It is established that the strength of fibers, among other factors, is influenced by the conditions of their production, which are determined by the drawing parameters: the production temperature, the level of melt in the feeder and the winding speed. The effect of production temperature on the strength of the fibers was the greatest. It was found that the fibers obtained at a production temperature of 1450 °C had a strength of 24—28% greater than that of the fibers obtained at a production temperature of 1400 °C. The separate influence of other parameters of drawing, the level of melt in the feeder and the winding speed on the strength of the fibers is less significant. A qualitative relationship between the state of the surface of the fibers and the conditions of their production at different parameters of formation. The greatest influence on the change in the state of the surface of the fibers has the temperature of fiber production. It is established that the surface of the fibers obtained at a production temperature of 1450 °C is more homogeneous with a small number of visible defects. On the other hand, on the surface of the fibers, which are obtained at a production temperature of 1400 ºC, there is a large number of defects. There is also an increase in the defect of the surface of the fibers, which are obtained at low levels of melt in the feeder and the winding speed. Keywords: continuous fibre, surface structure, strength, cooling rate, production temperature, winding speed, melt level in the feeder.