Hybrid Foams Research Articles

Porosity gradient control of 3D-printed hybrid foam structures

Porosity gradient control of 3D-printed hybrid foam structures

Construction of a Borophene-Based Hybrid Aerogel for Multifunctional Applications.

As a novel approach to pursue high-performance multifunctional materials, the structural design of cutting-edge two-dimensional (2D) materials has ignited substantial interests. Borophene, an emerging member in the realm of 2D materials, exhibits crucial attributes, including high theoretical carrier density, electrical conductivity, magnetism, and high aspect ratio, rendering it highly promising for diverse applications. Yet, the exploration of porous structural configurations of borophene remains untapped. Addressing this gap, our study focuses on the fabrication of a multifunctional borophene hybrid foam (CMB-foam). This hybridization leverages the exceptional multifunctionality of MXene alongside borophene within a three-dimensional porous framework, facilitating reflection and absorption of electromagnetic waves, thereby demonstrating remarkable electromagnetic interference (EMI) shielding capabilities. Moreover, this structural configuration exposes an enlarged surface area, thus shortening the transport pathway for electrolyte ions, leading to an excellent energy storage performance. Additionally, CMB-foam performs well in thermal management and thermal insulation. These findings underscore the potential of borophene-based materials in multifunctional applications and offer valuable insights into further performance explorations in this domain.

FeNi nanoparticle-modified reduced graphene oxide as a durable electrocatalyst for oxygen evolution

Clean energy transition and decarbonization through hydrogen technology hold a crucial role in revitalizing a sustainable world. The development of catalysts free of precious elements to facilitate the water splitting process in an electrolyser represents a key sustainable goal to lower the production cost of green hydrogen fuel, therefore improving its accessibility and affordability. Here we report a hybrid electrocatalyst for oxygen evolution reaction (OER) in alkaline media with high stability and low overpotential, free of precious metals and rare elements. The hybrid catalyst is composed of laser-generated Fe50Ni50 nanoparticles (FeNi NPs) dispersed on reduced graphene oxide (rGO) and deposited on FeNi layered double hydroxide (FeNi LDH) grown on Ni foam substrate. The prepared FeNi-rGO/FeNi/Ni foam hybrid catalyst requires an overpotential of only 234 mV at a current density of 10 mA/cm2, which is 37 mV lower than the tested commercial RuO2 catalyst on Ni foam substrate. Besides, the hybrid catalyst is extremely robust; it stands 10,000 cycles of accelerated deterioration and runs for more than 1,300 h at a current density of 10 mA/cm2 without performance decay.

Gas evolution in self-extinguishing and insulative nanopolysaccharide-based hybrid foams

Lightweight, energy-efficient materials in building construction typically include polymeric and composite foams. However, these materials pose significant fire hazards due to their high combustibility and toxic gas emissions, including carbon monoxide and hydrogen cyanide. This study delves into the latter aspects by comparing hybrid systems based on nanofiber-reinforced silica-based Pickering foams with a synthetic reference (polyurethane foams). The extent and dynamics of fire retardancy and toxic gas evolution were assessed, and the results revealed the benefits of combining the thermal insulation of silica with the structural strength of biobased nanofibers, the latter of which included anionic and phosphorylated cellulose as well as chitin nanofibers. We demonstrate that the nanofiber-reinforced silica-based Pickering foams are thermal insulative and provide both fire safety and energy efficiency. The results set the basis for the practical design of hybrid foams to advance environmental sustainability goals by reducing energy consumption in built environments.

Aluminium Hydroxide/Graphene-reinforced Rigid Polyurethane Foam Hybrid Composites

In this study, rigid polyurethane foams (RPUF) were successfully modified using 30 wt.% aluminium hydroxides (ATH), 1.0 pphp silicone surfactant, and different concentrations of graphene, using a one-shot one-step foaming method. This study aims to improve the compressive strength, flame retardancy, and thermal properties of RPUF by creating a synergistic effect between ATH and graphene in fire-retardant RPUF hybrid composites. The effects of a fixed amount of ATH and silicone surfactant and various loadings of graphene on RPUF were investigated. The results show that 0.5 wt.% graphene loading confers the best compression performance on the hybrid composite. Their compressive strength value of 12.58 KPa was higher than virgin RPUF (4.07 KPa) and RPUF/ATH (9.89 KPa). FTIR confirmed the functional groups in the virgin RPUF but could not identify new functional groups in most modified composites. The smallest amount of graphene addition (0.5 wt.%) produced a more stable hybrid composite structure. At 3.0 wt.% graphene addition, the maximum decomposition temperature of the RPUF/ATH hybrid composite was recorded (539oC), which was enhanced by 50% compared to virgin RPUF (296oC), and the highest char residue of 17.46% was observed. The incorporation of graphene enhanced the thermal firmness of the hybrid composite. The study also revealed an enhancement in the fire resistance of the hybrid composite. The LOI and UL-94 results showed that incorporating 3.0 wt.% enables increased LOI value and V-0 classification compared to virgin samples. This hybrid composite can be used in high-performance building insulation applications.

Smart Foams: Boron Nitride‐Graphene Nanoplatelet Foams for Tunable Radiation Shielding and Strain Sensing

AbstractAs space exploration advances, the demand for lightweight, multifunctional materials has substantially grown. Hybrid two‐dimensional (2D) material foams of different boron nitride nanoplatelets (BNNP)‐to‐graphene nanoplatelets (GNP) ratios are developed, which exhibit dual functionality: neutron radiation shields and strain sensors. The relationship between the composition, processing, microstructure, and their resultant neutron shielding and strain‐sensing properties are investigated. The hybrid foam properties can be finely tuned by adjusting BNNP:GNP compositions (1:0, 3:1, 1:1, 1:3, and 0:1). In terms of neutron radiation shielding, the mass absorption coefficient of hybrid foams increased with added BNNP, peaking at 14.9 cm2 g−1 for a pure BNNP foam. This mass absorption coefficient is 1.6 times that of pure GNP foams and almost 75 times that of aluminum. The radiation shielding properties are simulated using Geant4, a Monte Carlo‐based platform, and the simulations displayed a similar trend to the experimental results. The strain‐sensing properties of hybrid foams, measured by their gauge factor, exhibited exponential growth with rising GNP concentrations. Starting from the electrically insulating BNNP foam, the gauge factor increased to 53.4 with 25% GNP concentration and reached 201.8 for pure GNP foams. These findings highlight the versatility of the hybrid 2D material foams for space exploration.

Optimal design on fin-metal foam hybrid structure for melting and solidification phase change storage: An experimental and numerical study

A fin-metal foam composite structure is employed in the phase change energy storage coupled Organic Rankine Cycle system to enhance thermal performance. The 3-D numerical model is validated through an experimental system to analyze the impact of metal foam parameters and fluctuating heat source parameters (amplitude and half-period) on the system's storage-release process during heat source fluctuation. According to the Taguchi method, metal foam porosity significantly influences the total storage-release time. An increase in porosity leads to a continuous increase in the total storage-release time, while an increase in PPI and a decrease in heat source amplitude initially increase and then decrease the total storage-release time. Under constant metal foam PPI (10) and porosity (0.97), Case T (half period = 60 and amplitude = 1.0) demonstrates a 2.04 % increase in average heat transfer rate and a 1.78 % reduction in total storage-release time compared to Case 0 (constant heat source). The average heat release rate sees a 4.23 % increase, while total heat storage and heat release rise by 0.96 % and 1.87 %. The research has specific technical significance for the photothermal application of phase change energy storage technology to the variability and unpredictability of solar energy.

Influence of Heat Treatment on Microstructure Evolution and Yield Surfaces of Ni/PU Hybrid Foams

Metal foams are characterized by low weight, high resource efficiency, high relative stiffness, and exceptional energy absorption capacity under compressive load. Nickel/polyurethane (Ni/PU) hybrid foams consist of an open‐cell polyurethane foam coated with a layer of nickel produced by electrochemical deposition. The coating of the PU foams takes place in a flow reactor, in which the electrolyte is pumped through the foam at a defined flow velocity. The macromechanical properties of foam‐like structures depend on the structure of the skeleton, the inherent material properties and, in the case of Ni/PU hybrid foams, the properties of the electrochemically generated nickel layer. To influence their mechanical properties, the Ni/PU hybrid foams are subjected to heat treatment. In the given experimental setup, the parameters flow velocity, temperature, and duration of the heat treatment are each investigated at two different levels. Thus, interactions between the initial microstructure and the type of heat treatment are evaluated by means of X‐ray diffraction (XRD) and electron backscatter diffraction (EBSD) measurements. Interactions between initial mechanical properties and heat treatment are investigated by uniaxial compression tests and superimposed compression‐torsion tests. The knowledge gained is used to control the macromechanical properties of the hybrid foam.

Post-treatment induced anisotropic growth of MOF-derived surface modified heterogeneous catalyst for efficient oxygen evolution reaction

The advancement of electrocatalysts exhibiting outstanding performance in the oxygen evolution reaction (OER), crucial for hydrogen production, holds immense significance in addressing energy shortages and mitigating environmental pollution. In this study, a novel approach to synthesizing Co-MOF (Metal-Organic Framework) directly immobilized onto a Ni foam substrate through hydrothermal synthesis is presented. In contrast to conventional methods employing powder-based synthesis with binders, our direct attachment method offers a unique and efficient means of creating robust Co-MOF at Ni foam (Co-MOF@NF) hybrid catalysts. Subsequently, a chemical reduction approach utilizing sodium borohydride was employed to introduce surface modification into the Co-MOF structure. The resulting material, sodium borohydride treated Co-MOF@NF (Red. 1 h Co-MOF@NF), exhibited a remarkable enhancement in OER activity compared to the pristine Co-MOF@NF sample. Notably, Red.1 h Co-MOF@NF demonstrated a substantially reduced overpotential of 235 mV to achieve a current density of 10 mA cm⁻2, in contrast to the 300 mV overpotential required by the pristine Co-MOF@NF under the same conditions. Furthermore, the Red.1 h Co-MOF@NF catalyst displayed exceptional stability, sustaining a current density of 50 mA cm⁻2 for over 48 h, highlighting its promising potential for practical applications. The synergistic effects of direct hydrothermal attachment, surface modification, and improved OER performance make this study a significant contribution to the advancement of efficient and stable electrocatalysts for energy conversion applications.

Analysis of the Meso‐Mechanical Deformation Behavior of Al Foams and Ni/Al Hybrid Foams Using Time‐Lapse Micro‐Computed Tomography Measurements and 3D Optical Flow

Metal foams are an interesting class of bio‐inspired materials for lightweight construction and energy absorption. Commonly, aluminum (Al) foams are used. However, the mechanical properties have been improved by coating pure Al foams with a nanocrystalline nickel (Ni) coating resulting in Ni/Al hybrid foams. Herein, the meso‐mechanical deformation mechanisms in Al foams and the changes in the mechanisms in Ni/Al hybrid foams are studied using time‐lapse micro‐computed tomography measurements in comparison between numerical modeling using voxel finite element models and evaluation of displacement fields using 3D optical flow. This gives never‐seen insights into the highly localized 3D deformation mechanisms within the entire volume of the foams and not only on the surfaces as given by conventional digital image correlation methods. Displacements calculated by the 3D optical flow algorithm demonstrate its possibility to reveal a significant concentration of plastic deformation, particularly evident when deformation occurs within a distinct, slightly inclined band in the central region. Common numerical simulations using standard plasticity models do not accurately capture this localized deformation, underscoring the need to integrate damage and softening models into the simulation.

Facile synthesis of lignin/polyethyleneimine foams incorporating zeolitic imidazole framework-8 to efficiently remove tetracycline from aqueous solution

Lignin, as a by-product produced in the biological refining and papermaking processes, is often discarded or burned, resulting in environmental pollution and resource waste. Herein, a novel environmental-friendly ternary hybrid foams adsorbent (SLS/PEI/ZIF-8) was designed for effectively removal TC from aqueous solution. The adsorption properties of the adsorbent were systematically studied. The results show that the adsorption process for TC were fitted well by the pseudo-second-order kinetics model and the Langmuir isotherm model, respectively. The maximum Langmuir monolayer adsorption capacity of SLS/PEI/ZIF-8 for TC was calculated as 1098 mg/g at 30 °C, which was superior to most reported adsorbents. Thermodynamic analysis indicated the adsorption process for TC was spontaneous and endothermic. Moreover, the electrostatic interactions, hydrogen bonding interactions and π–π interactions were proposed as the possible adsorption mechanism. The adsorbent still maintained superior adsorption capacity for TC in ions solution, HA solution and actual water samples, and had good reusability. Therefore, it is a promising adsorbent for the removal of TC from wastewater.

Two-dimensional Ti3C2Tx anchored on three-dimensional SiC honeycomb framework for efficient and cyclic photocatalytic degradation of organic pollutants

The excellent recyclability of SiC foam renders it an ideal catalyst in the field of photocatalytic degradation, however to further improve its photocatalytic efficiency remains a major challenge in current research. In this regard, a honeycomb-like porous SiC foam was successfully constructed through freeze-drying and polymer-to-ceramic derivation method, with two-dimensional Ti3C2Tx nanosheets anchored on its three-dimensional framework. Their photocatalytic performances were evaluated by the degradation of methylene blue (MB) under visible-light irradiation. All Ti3C2Tx/SiC hybrid foams show superior photocatalytic degradation capability compared with SiC foam, with a highest removal rate (adsorption and degradation) reaching 94.4% for TSF-4, denoting an increasement of 50.4%. Even after five cycles, the removal rate remained at 91.4% with only a slightly loss of 3%, suggesting its excellent recycling performance. These desirable results stem from the unique structural design, in which the porous structure facilitates the contact between catalyst and pollutant, while the Ti3C2Tx/SiC heterojunction promotes effective separation of photogenerated carriers. This work paves the way for the development of lightweight, efficient and easily recyclable photocatalyst for wastewater purification.

Study on the Mechanical Properties of a Carbon-Fiber/Glass-Fiber Hybrid Foam Sandwich Structure.

Considering the different structural strength requirements of different parts of fiberglass yachts, carbon fiber/glass fiber hybrid reinforcement can be applied to the skins of sandwich panels in special areas. This paper designs and prepares 12 foam sandwich panel samples composed of pure carbon fiber, a carbon fiber/glass fiber hybrid, pure glass fiber skin, and PVC and SAN foam sandwich, with reference to the layup structure of the outer panel of a fiberglass yacht. Through a comparative analysis of low-speed impact experiments, edge compression experiments, and short beam three-point bending experiments, we seek the optimal carbon fiber/glass fiber hybrid layup design scheme for local structures to guide production. The results show that a reasonable hybrid carbon fiber layup in fiberglass skin can effectively reduce the low-speed impact damage of the sandwich structure, reduce edge compression damage, and improve the bending and compression resistance of sandwich structure. The impact resistance, compression resistance, and shear resistance of the SAN sandwich structure are stronger than the PVC sandwich structure. The carbon fiber/glass fiber hybrid SAN foam sandwich structure can be used for the local structural reinforcement of special parts such as the bow, side, and main deck of fiberglass yachts.

Effortless impregnation method for melamine formaldehyde foams exhibiting elevated thermal stability and exceptional flame retardant characteristics

AbstractMelamine‐formaldehyde (MF) foam, while intrinsically flame retardant, necessitates further refinement to meet stringent fire safety standards, particularly in terms of heat release rate and thermal stability. In this study, an innovative approach was adopted wherein an inorganic substance, potassium water glass (WG), was employed to create an encapsulation layer on the surface of the MF foam structure via a straightforward dip‐coating technique. The composite foam underwent a comprehensive analysis of its structure and flame retardant characteristics, using test evaluations such as micro‐scale combustion calorimeter (MCC) testing, cone calorimeter testing (CCT), and thermogravimetric‐Fourier infrared spectrometer (TG‐IR) assessments. It was found that the even coating of WG on the MF foam surface profoundly enhanced the foam's structural integrity. Utilizing the shielding properties of this inorganic layer, the hybrid foam's thermal stability experiences a remarkable augmentation. The peak of heat release rate (pHRR) and the total heat release rate (THR) of the MF foam experienced an impressive reduction of 85.2% and 78.8%, correspondingly. Notably, this advancement is concomitant with a substantial decrease of 39.2% in the total smoke release (TSR) and a notable amelioration in mechanical characteristics. Such developments undeniably broaden their application horizons across diverse domains.

Remanent Magnetic Field Scanning of Coating‐Graded Hybrid Foams

The manufacturing of hybrid materials such as nickel/polyurethane (Ni/PU) hybrid foams and 3D printed hybrid materials with the aid of electrochemical coating of lightweight structures leads to new materials, which can be used as crash absorbers, but also for lightweight design applications. Optimizing the coating quality of the developed hybrid materials necessitates a characterization on different scales regarding the coating thickness distribution. The ferromagnetic properties of the nickel coating enable a remanent magnetization of the produced hybrid foams and a subsequent measurement of resulting magnetic fields, so that the time‐consumption of a coating distribution determination could be enormously reduced by automating the quantification method. Previous studies have shown, that the local strength of these fields correlates with the deposited mass thus the coating thickness. The here presented automated measurement gives useful information about the homogeneity and the local coating thickness distribution according to an appropriate calibration. In order to optimize the coating quality of the newly developed hybrid materials, improved deposition conditions, as well as semi‐automated characterization methods, are studied to establish a large‐scale industrial production and a higher applicability of hybrid materials in the near future.

Evaluation of a Local Acoustic Resonance Method for Coating Thickness Determination on Stochastic Metal Hybrid Foams

Novel cellular materials promise a combination of high strength and low specific weight for sustainable and energy‐efficient material design. Inhomogeneities of the materials, such as varying coating thickness, are inherent to the production process but require advanced characterization in order to better understand mechanical properties. Herein, global and local acoustic analysis for nondestructive characterization of local coating thickness on an open‐porous hybrid metal foam system is studied. Experiments and numerical simulations are carried out to evaluate vibration behavior stimulated by a low‐energy impact. The novelty of the work is the use of local excitation and analysis of decay times to determine coating thickness gradients. This qualitative measurement can inform and speed up the material development process due to its simplicity, speed, and low cost. Furthermore, it provides a basis for quality control when scaling up the technology of metal hybrid foams for industrial applications.

Highly Electroconductive Metal-Polymer Hybrid Foams Based on Silver Nanowires: Manufacturing and Characterization.

Due to their electroconductive properties, flexible open-cell polyurethane foam/silver nanowire (PUF/AgNW) structures can provide an alternative for the construction of cheap pressure transducers with limited lifetimes or used as filter media for air conditioning units, presenting bactericidal and antifungal properties. In this paper, highly electroconductive metal-polymer hybrid foams (MPHFs) based on AgNWs were manufactured and characterized. The electrical resistance of MPHFs with various degrees of AgNW coating was measured during repeated compression. For low degrees of AgNW coating, the decrease in electrical resistance during compression occurs in steps and is not reproducible with repeated compression cycles due to the reduced number of electroconductive zones involved in obtaining electrical conductivity. For high AgNW coating degrees, the decrease in resistance is quasi-linear and reproducible after the first compression cycle. However, after compression, cracks appear in the foam cell structure, which increases the electrical resistance and decreases the mechanical strength. It can be considered that PUFs coated with AgNWs have a compression memory effect and can be used as cheap solutions in industrial processes in which high precision is not required, such as exceeding a maximum admissible load or as ohmic seals for product security.

Hybrid Foams based on Multi‐Walled Carbon Nanotubes and Cellulose Nanocrystals for Anisotropic Electromagnetic Shielding and Heat Transport

AbstractLightweight and mechanically robust hybrid foams based on cellulose nanocrystals (CNC) and multi‐walled carbon nanotubes (MWCNT) with an anisotropic structure are prepared by directional ice‐templating. The anisotropic hybrid CNC‐MWCNT foams displayed a combination of highly anisotropic thermal conductivity and an orientation‐dependent electromagnetic interference (EMI) shielding with a maximum EMI shielding efficiency (EMI‐SE) of 41–48 dB between 8 and 12 GHz for the hybrid foam with 22 wt% MWCNT. The EMI‐SE is dominated by absorption (SEA) which is important for microwave absorber applications. Modelling of the low radial thermal conductivity highlighted the importance of phonon scattering at the heterogeneous CNC‐MWCNT interfaces while the axial thermal conductivity is dominated by the solid conduction along the aligned rod‐like particles. The lightweight CNC‐MWCNT foams combination of an anisotropic thermal conductivity and EMI shielding efficiency is unusual and can be useful for directional heat transport and EMI shielding.

Eco-Friendly Flame-Retardant Phase-Change Composite Films Based on Polyphosphazene/Phosphorene Hybrid Foam and Paraffin Wax for Light/Heat-Dual-Actuated Shape Memory.

Multiactuated shape memory materials are a class of promising intelligent materials that have received great interest in the fields of self-healing, anticounterfeiting, biomedical, soft robotic, and smart thermal management applications. To obtain a light/heat-dual-actuated shape memory material for thermal management applications in fire safety, we have designed a type of halogen-free flame-retardant phase-change composite film based on polyaryloxyphosphazene (PDAP)/phosphorene (PR) hybrid foam as a support material and paraffin wax (PW) as a phase-change material (PCM). PDAP was synthesized as a flexible foam matrix through the ring-opening polymerization of hexachlorocyclotriphosphazene, followed by a substitution reaction of aryloxy groups. The porosity of the PDAP foam is improved by introducing PR nanosheets, facilitating a high latent heat capacity of the PDAP-PR/PW composite films for thermal management applications. The PDAP-PR/PW composite films can implement rapid shape recovery within 65 s in the heating process, which is much shorter than that of the corresponding film without PR nanosheets (185 s). Furthermore, the PDAP-PR/PW composite films also exhibit light-actuated shape memory behavior thanks to their good solar-to-thermal energy absorption and conversion contributed by PR nanosheets as a highly effective photothermal material. More importantly, the presence of PR nanosheets imparts an excellent flame-retardant property to the PDAP-PR/PW composite films. The PDAP-PR/PW composite film can be self-extinguished within 2 s after the flame. Through an innovative integration of flexible polyphosphazene foam, PR nanosheets, and solid-liquid PCM to obtain a sensitive actuating response to light and heat, this study offers a new approach for developing multiactuated and eco-friendly flame-retardant shape memory materials to meet the requirement of applications with a requirement of fire safety in soft actuators, thermal therapy, control devices, and so on.

Experimental investigation of compressive behavior and vibration properties of layered hybrid foam formed by aluminum foam/EPS-filled syntactic foam

Hybrid foams are a type of composite material created by combining two foam materials. They are preferred in many applications due to their lightweight, high strength, and ability to absorb more energy. In this research, a new hybrid foam was designed for use in sandwich cores of structural materials. The hybrid foam was formed by combining closed-cell aluminum foam and expanded polystyrene (EPS)-filled syntactic foam. The EPS-filled syntactic foams were produced with the conventional mold casting technique. Uniaxial compressive behaviors (0.5 mm/min) of layered hybrid foams consisting of EPS-filled syntactic foam with three different densities and closed-cell aluminum foam were investigated experimentally and compared with conventional single-foamed materials. These results exhibited that in general, layered hybrid foams outperform conventional single-foamed materials in terms of compressive strength. Moreover, the natural frequency and damping ratio of the layered hybrid foams were investigated by vibration tests under clamped-free and free-free boundary conditions and compared to conventional single-foamed materials. It was established that the vibration damping capacity of the layered hybrid foams improved compared to the closed-cell aluminum foam. Additionally, the microstructure of the conventional single-foamed materials was examined by SEM. In the outcome of the research, the experimental results showed that layered hybrid foam provides an opportunity to design lightweight cellular materials with effective mechanical properties.