Manufacturing Of Nanocomposites Research Articles

Carbon nanostructures synthesis by catalyst-free atmospheric pressure plasma jet

In this study, carbon nanostructures were synthesized utilizing a warm plasma jet at atmospheric pressure in a continuous and catalyst-free process. The procedure and apparatus were designed and constructed in our laboratory. Plasma was generated with 600 W of electrical energy, using a high-voltage, high-frequency alternating current power source. The working gas utilized was a propane/butane mixture, with a concentration ratio of 60:40, respectively. A production rate of 300 mg min−1 of powdered material was achieved, with a particle size between 20 and 100 nm. The product was characterized by Fourier transform infrared spectroscopy, thermogravimetric analysis, Raman spectroscopy, x-ray diffraction, and transmission electron microscopy. Results show the formation of multilayer carbon nanostructures with a low content of functional groups; the obtained material presented structural defects and amorphous carbon. This work demonstrates that, with adequate control, warm plasma jet discharges can be employed for the synthesis of carbon nanostructures. The process is scalable and can be utilized for hydrocarbon reforming and hydrogen production. However, further studies are needed to improve the quality of the nanostructures and process efficiency. The synthesized material can potentially be used in gas adsorption or in the manufacture of polymeric nanocomposites with enhanced thermal, electrical, and mechanical properties.

Strain‐Tolerant Nanocomposite Conductors with Engineered Bicontinuous Phase System by Additive Liquid/Solid Assembly

AbstractIntrinsically stretchable conductors are vital components in next‐generation flexible electronics. However, solid conductive networks are generally vulnerable to external deformations due to their incompatible mechanical properties with the highly elastic substrates or matrixes. It is still challenging to achieve precisely controlled conductive structure with stable electromechanical performances. Herein, a nanocomposite conductor with 3D engineered bicontinuous phase system is developed, which is constructed by alternately arranged robust solid‐phase and conductive liquid‐phase via additive liquid/solid assembly. The proper rheological properties and extraordinary structural compatibility of the liquid‐phase prompt the formation of bridged structure within the 3D periodic solid‐phase main skeleton, giving rise to stable and even strain‐enhanced electrical and electromagnetic interference (EMI) shielding properties under external deformation. A negative resistance change of −37% along with unabated EMI shielding effectiveness and mechanical properties are obtained at 100% strain, showing negligible performance degradation even after 10,000 cycles of rigorous stretching and releasing. A strain‐tolerant pressure‐sensing device is further demonstrated using the liquid/solid nanocomposite structure, delivering a unique function of precisely recognizing the local pressure at large tensile loading interference. This work provides a new paradigm for the manufacturing of nanocomposites with desired functionalities using the adequate nanofiller reserve toward practical strain‐tolerant applications.

Modernizations of graphene nanocomposites using synthesis strategies—State-of-the-art

Graphene has been ranked among one of the most remarkable nanostructure of the carbon world. Graphene modification and nanocomposite formation have been used to expand the practical potential of graphene nanostructure. The overview is an effort to highpoint the indispensable synthesis strategies towards the formation of graphene nanocomposites. Consequently, graphene has been combined with useful matrices (thermoplastic, conducting, or others) to attain the desired end material. Common fabrication approaches like in-situ method, solution processing, and melt extrusion have been widely involved to form the graphene nanocomposites. Moreover, advanced sophisticated methods such as three or four dimensional printing, electrospinning, and others have been used to synthesize the graphene nanocomposites. Focus of all synthesis strategies has remained with the standardized graphene dispersion, physical properties, and applications. However, continuous future efforts are required to resolve the challenges in synthesis strategies and optimization of the parameters behind each technique. As the graphene nanocomposite design and properties directly depend upon the fabrication techniques used, there is obvious need for the development of advanced methods having better control over process parameters. Here, main challenging factors may involve the precise parameter control of the advanced techniques used for graphene nanocomposite manufacturing. Hence, there is not only need of current and future research to resolve the field challenges related to material fabrication but also reporting compiled review articles can be useful for interested field researchers towards challenge solving and future developments in graphene manufacturing.

Modernizations of graphene nanocomposites using synthesis strategies—State-of-the-art

Graphene has been ranked among one of the most remarkable nanostructure of the carbon world. Graphene modification and nanocomposite formation have been used to expand the practical potential of graphene nanostructure. The overview is an effort to highpoint the indispensable synthesis strategies towards the formation of graphene nanocomposites. Consequently, graphene has been combined with useful matrices (thermoplastic, conducting, or others) to attain the desired end material. Common fabrication approaches like in-situ method, solution processing, and melt extrusion have been widely involved to form the graphene nanocomposites. Moreover, advanced sophisticated methods such as three or four dimensional printing, electrospinning, and others have been used to synthesize the graphene nanocomposites. Focus of all synthesis strategies has remained with the standardized graphene dispersion, physical properties, and applications. However, continuous future efforts are required to resolve the challenges in synthesis strategies and optimization of the parameters behind each technique. As the graphene nanocomposite design and properties directly depend upon the fabrication techniques used, there is obvious need for the development of advanced methods having better control over process parameters. Here, main challenging factors may involve the precise parameter control of the advanced techniques used for graphene nanocomposite manufacturing. Hence, there is not only need of current and future research to resolve the field challenges related to material fabrication but also reporting compiled review articles can be useful for interested field researchers towards challenge solving and future developments in graphene manufacturing.

Advancements in polymer nanocomposite manufacturing: revolutionizing medical breakthroughs via additive manufacturing

Advancements in polymer nanocomposite manufacturing: revolutionizing medical breakthroughs via additive manufacturing

Additive manufacturing of carbon nanocomposites for structural applications

Additive manufacturing (AM), also known as 3D printing, has attracted a lot of attention in science and technology in recent years. Improvement in AM processes and materials are necessary, particularly for structural and load-bearing components in mechanical applications. The addition of nano-fillers can potentially improve the mechanical properties of additively manufactured components, making them suitable for structural applications. Carbon nanofillers like graphene and carbon nanotubes are of special interest due to their exceptional properties. Several studies have already demonstrated the use of carbon nanofillers for improving the electrical properties of 3D printed components, facilitating their use in electrical and electronic applications. However, studies focusing on structural and mechanical applications have been limited, and are not widely known. This review seeks to fill this gap by exploring the effect of carbon nanofillers on the mechanical and thermal properties of AM parts and their use in structural applications. The effect of parameters like print orientation, nanofiller addition method, and nanofiller dispersion are also explored. The review points out that there are improvements in mechanical and thermal properties due to carbon nanofiller addition, which makes the AM components more suitable for structural application.

Advancing the additive manufacturing of PLA-ZnO nanocomposites by fused filament fabrication

ABSTRACTPoly(lactic acid)-zinc oxide (PLA-ZnO) nanocomposites for fused filament fabrication have potential applications in the biomedical field as they combine the bio-compatibility of PLA with the antibacterial properties of ZnO. This work investigates the effects of masterbatch mixing strategy, ZnO concentration and ZnO surface treatment (silanisation) on the printability and the mechanical performance of the nanocomposites as a pre-requirement to the wider uptake of these materials. The results showed that the printability decreased as the filler loading increased. However, the surface treatment of the ZnO powder enhanced the matrix-filler interfacial interactions and reduced the thermal degradation of PLA. This ameliorated the printability and the tensile properties of the nanocomposites filled with up to 5 wt.% of ZnO. Moreover, despite the additional thermal treatment, melt-mixing prevented the degradative effect induced by the solvent used for solvent mixing. Future work will focus on assessing the antibacterial properties of the nanocomposite FFF parts.

Multi Jet Fusion of surface-modified ZnO nanorod–reinforced PA12 nanocomposites

ABSTRACT Metal oxide nanorods exhibit promising potential as reinforcement fillers in various polymer matrices, but their application in the Multi Jet Fusion (MJF) technique is rarely reported. In this work, surface-modified zinc oxide nanorods (SMZnO) were synthesized and incorporated into polyamide 12 (PA12) powder to enhance the mechanical properties of the MJF-printed parts. Compared to ZnO, SMZnO exhibited better dispersion, resulting in markedly enhanced mechanical performances. The ultimate tensile strength and the Young's modulus of the MJF-printed SMZnO/PA12 nanocomposites were 62.02 MPa and 2.28 GPa in the X orientation and 64.07 MPa and 2.34 GPa in the Y orientation, equivalent to 27.85%, 59.44%, 29.12%, and 54.97% increments, respectively. The flexural strength and modulus demonstrated similar improvements in the X and Y orientations, confirming the uniform mechanical enhancement effect of homogenously distributed SMZnO. This work provides a novel and facile approach for the additive manufacturing of polymeric nanocomposites with superior mechanical performance.

Manufacturing of Aluminum Nano-Composites Reinforced with Nano-Copper and High Graphene Ratios Using Hot Pressing Technique.

In this study, the nano-aluminum powder was reinforced with a hybrid of copper and graphene nanoplatelets (GNPs). The ratios of GNPs were 0 wt%, 0.4 wt%, 0.6 wt%, 1.2 wt% and 1.8 wt%. To avoid the reaction between aluminum and graphene and, consequently, the formation of aluminum carbide, the GNP was first metalized with 5 wt% Ag and then coated with the predetermined 15 wt% Cu by the electroless coating process. In addition, the coating process was performed to improve the poor wettability between metal and ceramic. The Al/(GNPs-Ag)Cu nanocomposites with a high relative density of 99.9% were successfully prepared by the powder hot-pressing techniques. The effects of (GNPs/Ag) and Cu on the microstructure, density, hardness, and compressive strength of the Al-Cu nanocomposite were studied. As a result of agitating the GNPs during the cleaning and silver and Cu-plating, a homogeneous distribution was achieved. Some layers formed nano-tubes. The Al4C3 phase was not detected due to coating GNPs with Cu. The Cu9Al4 intermetallic was formed during the sintering process. The homogeneous dispersion of Cu and different ratios of GNs, good adhesion, and the formation of the new Cu9Al4 intermetallic improved in hardness. The pure aluminum sample recorded 216.2 HV, whereas Al/Cu reinforced with 1.8 GNs recorded 328.42 HV with a 51.9% increment. The compressive stress of graphene samples was improved upon increasing the GNPs contents. The Al-Cu/1.8 GNs sample recorded 266.99 MPa.

Promising New Horizons in Medicine: Medical Advancements with Nanocomposite Manufacturing via 3D Printing.

Three-dimensional printing technology has fundamentally revolutionized the product development processes in several industries. Three-dimensional printing enables the creation of tailored prostheses and other medical equipment, anatomical models for surgical planning and training, and even innovative means of directly giving drugs to patients. Polymers and their composites have found broad usage in the healthcare business due to their many beneficial properties. As a result, the application of 3D printing technology in the medical area has transformed the design and manufacturing of medical devices and prosthetics. Polymers and their composites have become attractive materials in this industry because of their unique mechanical, thermal, electrical, and optical qualities. This review article presents a comprehensive analysis of the current state-of-the-art applications of polymer and its composites in the medical field using 3D printing technology. It covers the latest research developments in the design and manufacturing of patient-specific medical devices, prostheses, and anatomical models for surgical planning and training. The article also discusses the use of 3D printing technology for drug delivery systems (DDS) and tissue engineering. Various 3D printing techniques, such as stereolithography, fused deposition modeling (FDM), and selective laser sintering (SLS), are reviewed, along with their benefits and drawbacks. Legal and regulatory issues related to the use of 3D printing technology in the medical field are also addressed. The article concludes with an outlook on the future potential of polymer and its composites in 3D printing technology for the medical field. The research findings indicate that 3D printing technology has enormous potential to revolutionize the development and manufacture of medical devices, leading to improved patient outcomes and better healthcare services.

3D Printed and Embedded Strain Sensors in Structural Composites for Loading Monitoring and Damage Diagnostics

The development of novel embedded sensors for structural health monitoring (SHM) is crucial to provide real-time assessments of composite structures, ensuring safety, and prolonging their service life. Early damage diagnostics through advanced sensors can lead to timely maintenance, reducing costs and preventing potential catastrophic failures. This paper presents the synthesis, 3D printing, and characterization of novel embedded strain sensors using multi-walled carbon nanotube (MWCNT) -enhanced nanocomposites in fiberglass reinforced composites for potential damage diagnostics and SHM applications. MWCNTs are dispersed within structural epoxy for the additive manufacturing of nanocomposites with piezoresistive sensing capability. The 3D-printed nanocomposite sensors are embedded in fiberglass-reinforced composite laminates. The piezoresistive sensing capabilities of the 3D-printed sensors within composites are characterized by applying different levels of maximum loads and load rates under three-point bending loads. Additionally, the long-term reliability of the developed strain sensors is evaluated up to 1000 cycles. The recorded piezoresistive sensing signals show high sensitivity for the externally applied bending loads with advanced gauge factor up to 100, resulting in potential load sensing capability for in-situ damage diagnostics and real-time SHM for structural composites.

Nano-Additive Manufacturing and Non-Destructive Testing of Nanocomposites.

In the present work, the recent advancements in additive manufacturing (AM) techniques for fabricating nanocomposite parts with complex shaped structures are explained, along with defect non-destructive testing (NDT) methods. A brief overview of the AM processes for nanocomposites is presented, grouped by the type of feedstock used in each technology. This work also reviews the defects in nanocomposites that can affect the quality of the final product. Additionally, a detailed description of X-CT, ultrasonic phased array technology, and infrared thermography is provided, highlighting their potential application in non-destructive inspection of nanocomposites in the future. Lastly, it concludes by offering recommendations for the development of NDT methods specifically tailored for nanocomposites, emphasizing the need to utilize NDT methods for optimizing nano-additive manufacturing process parameters, developing new NDT techniques, and enhancing the resolution of existing NDT methods.

The Effects of Nanoparticle Reinforcement on the Micromilling Process of A356/Al2O3 Nanocomposites

Improving scientific knowledge around the manufacturing of nanocomposites is key since their performance spreads across many applications, including those in meso/micro products. Powder metallurgy is a reliable process for producing these materials, but usually, machining postprocessing is required to achieve tight tolerances and quality requirements. When processing these materials, cutting force evolution determines the ability to control the microcutting operation toward the successful surface and part quality generation. This paper investigates cutting force and part quality generation during the micromilling of A356/Al2O3 aluminum nanocomposites produced via powder metallurgy. A set of micromilling experiments were carried out under various process parameters on nanocomposites with different nano-Al2O3 reinforcements (0–12.5 vol.%). The material’s ductility, internal porosity, and lack of interparticle bonding cause the cutting force generation to be irregular when nanoparticle reinforcements were absent or small. Reinforcement ratios higher than 2.5 vol.% strongly affect the cutting process by regularizing the milling force generation but lead to a proportionally increasing average force magnitudes. Hardening due to nano-reinforcement positively affects cutting mechanisms by reducing the plowing tendency of the cutting process, resulting in better surface quality. Therefore, a threshold on the nano-Al2O3 particles’ volumetric loadings enables an optimal design of these composite materials to support their micromachinability.

Water-Assisted Transformation of Aluminum Alloys to Ceramic Nanowires and Aerogels

Ceramic nanowires (NWs) and their-based aerogels hold great promise for manufacturing and applications of polymer nanocomposites with otherwise unattainable mechanical and thermal properties. Unfortunately, conventional routes for the synthesis of ceramic NWs commonly suffer from the use of costly or toxic chemicals, low production rate, and complex and expensive procedures. Here, we report on a water-assisted route for the cost-effective, scalable transformation of bulk aluminum–lithium alloys into ceramic alumina NWs and aerogels. In this study, we employ water as the intermediary solvent for dealloying to form monolithic porous Li-doped aluminum metal, which can then be converted to ultralong metal–organic NWs, then to hydroxide NWs after hydrolysis and finally to NW aerogels after freeze-drying. As a high-performance thermal interface material for electronic devices, the oxidized alumina NW aerogels infiltrated with epoxy show significantly improved thermal properties. Our study shows great potential for the scalable production of ceramic NWs using a low-cost and environmental-friendly route for various applications.

Revisión sistemática de nanocompuestos obtenidos por técnicas de fotopolimerización VAT: un enfoque de evaluación de costos y ciclo de vida térmicos

Additive manufacturing has shown advantages for nanocomposite fabrication. Despite VAT-photopolymerization being one of the first developed 3D printing technologies, high device costs made it a technology that was difficult to access. The massive production of these devices in recent years has opened this technology to everyone. Stereolithography and Digital light processing are the most prominent technologies used in this field. This systematic review studied 217 articles regarding SLA and DLP for additive manufacture of nanocomposites. The main finding of this systematic review shows that further research on circular economy and life cycle assessment of the SLA and DLP technologies is urgently needed. Also, a deeper discussion on the technology and material costs is recommended in order to give a more detailed insight on the final cost of these 3D-printed nanocomposites.

Revisión sistemática de nanocompuestos obtenidos por técnicas de fotopolimerización VAT: un enfoque de evaluación de costos y ciclo de vida térmicos

Additive manufacturing has shown advantages for nanocomposite fabrication. Despite VAT-photopolymerization being one of the first developed 3D printing technologies, high device costs made it a technology that was difficult to access. The massive production of these devices in recent years has opened this technology to everyone. Stereolithography and Digital light processing are the most prominent technologies used in this field. This systematic review studied 217 articles regarding SLA and DLP for additive manufacture of nanocomposites. The main finding of this systematic review shows that further research on circular economy and life cycle assessment of the SLA and DLP technologies is urgently needed. Also, a deeper discussion on the technology and material costs is recommended in order to give a more detailed insight on the final cost of these 3D-printed nanocomposites.

Highly Flexible Triboelectric Nanogenerator Using Porous Carbon Nanotube Composites.

The rapid development of portable and wearable electronic devices has led researchers to actively study triboelectric nanogenerators (TENGs) that can provide self-powering capabilities. In this study, we propose a highly flexible and stretchable sponge-type TENG, named flexible conductive sponge triboelectric nanogenerator (FCS-TENG), which consists of a porous structure manufactured by inserting carbon nanotubes (CNTs) into silicon rubber using sugar particles. Nanocomposite fabrication processes, such as template-directed CVD and ice freeze casting methods for fabricating porous structures, are very complex and costly. However, the nanocomposite manufacturing process of flexible conductive sponge triboelectric nanogenerators is simple and inexpensive. In the tribo-negative CNT/silicone rubber nanocomposite, the CNTs act as electrodes, increasing the contact area between the two triboelectric materials, increasing the charge density, and improving charge transfer between the two phases. Measurements of the performance of flexible conductive sponge triboelectric nanogenerators using an oscilloscope and a linear motor, under a driving force of 2-7 N, show that it generates an output voltage of up to 1120 V and a current of 25.6 µA. In addition, by using different weight percentages of carbon nanotubes (CNTs), it is shown that the output power increases with the weight percentage of carbon nanotubes (CNTs). The flexible conductive sponge triboelectric nanogenerator not only exhibits good performance and mechanical robustness but can also be directly used in light-emitting diodes connected in series. Furthermore, its output remains extremely stable even after 1000 bending cycles in an ambient environment. In sum, the results demonstrate that flexible conductive sponge triboelectric nanogenerators can effectively power small electronics and contribute to large-scale energy harvesting.

Novel triple hydrothermal method for preparation of CuO/Fe2O3/Ag2O nanocomposite with antimicrobial application

In this work, copper oxide (CuO)\\iron oxide (Fe2O3) decorated with silver oxide (Ag2O) nanoparticles (NPs) was prepared using a triple hydrothermal process. The XRD results confirm the presence of the diffraction phases for CuO, Fe2O3, and Ag2O with an average crystallite size of nanocomposite equal to 24 nm. EDS/elemental mapping results confirm that Ag2O acts as a decoration for CuO and Fe2O3. The optical characteristics displayed the presence of a surface plasmon (coherent delocalized electron oscillations) with a bandgap of 3.1 eV and blueshift to short wavelengths. The antimicrobial activity against Gram-negative bacteria (Klebsiella pneumoniae and Escherichia coli), Gram-positive bacteria (Staphylococcus epidermidis and Staphylococcus aureus), and gram-positive fungi (Candida albicans) displayed inhibition zones of 11, 13, 15,12, and 13 mm, respectively. The author suggests that the current work is original and can contribute to the development of a new methodology for the manufacture of nanocomposites for antibacterial applications.

Vat photopolymerization-based 3D printing of polymer nanocomposites: current trends and applications.

The synthesis and manufacturing of polymer nanocomposites have garnered interest in recent research and development because of their superiority compared to traditionally employed industrial materials. Specifically, polymer nanocomposites offer higher strength, stronger resistance to corrosion or erosion, adaptable production techniques, and lower costs. The vat photopolymerization (VPP) process is a group of additive manufacturing (AM) techniques that provide the benefit of relatively low cost, maximum flexibility, high accuracy, and complexity of the printed parts. In the past few years, there has been a rapid increase in the understanding of VPP-based processes, such as high-resolution AM methods to print intricate polymer parts. The synergistic integration of nanocomposites and VPP-based 3D printing processes has opened a gateway to the future and is soon expected to surpass traditional manufacturing techniques. This review aims to provide a theoretical background and the engineering capabilities of VPP with a focus on the polymerization of nanocomposite polymer resins. Specifically, the configuration, classification, and factors affecting VPP are summarized in detail. Furthermore, different challenges in the preparation of polymer nanocomposites are discussed together with their pre- and post-processing, where several constraints and limitations that hinder their printability and photo curability are critically discussed. The main focus is the applications of printed polymer nanocomposites and the enhancement in their properties such as mechanical, biomedical, thermal, electrical, and magnetic properties. Recent literature, mainly in the past three years, is critically discussed and the main contributing results in terms of applications are summarized in the form of tables. The goal of this work is to provide researchers with a comprehensive and updated understanding of the underlying difficulties and potential benefits of VPP-based 3D printing of polymer nanocomposites. It will also help readers to systematically reveal the research problems, gaps, challenges, and promising future directions related to polymer nanocomposites and VPP processes.

Additive manufacturing of polypropylene micro and nano composites through fused filament fabrication for automotive repair applications

AbstractThe emerging Additive manufacturing technologies are being adopted by different industries, which require developing new materials and procedures. Here we report the development of polypropylene (PP) based composite materials for fused filament fabrication (FFF) process with the aim of enabling fully automatic robotic repair application of plastic components in automotive industry. A key challenge in repair and joining of polyolefins, which are widely used in such applications, is understanding the interplay of microstructural features and the joining mechanisms employed to achieve a uniform and fully functional repaired components. Specifically, for components manufactured from polypropylene based material, we show that the addition of ethylene propylene diene monomer (EPDM), polyisobutylene (PIB) and carbon black (CB) successfully modifies its matrix and produces a composite material ideal for additively repairing of complex geometries found in the automotive applications. This was brought about by effective reduction of the crystallinity of the composite PP matrix from 46.2% to 34.4% and resulting in a net reduction in warpage of the FFF 3D printed samples. Further, the thermal stability of the developed composite was improved with the addition of a moderate amount of carbon filler, enabling an FFF process with higher hot‐end temperatures, which subsequently allowed for tuning of the raw material's viscosity, and hence ensuring consistent deposition of molten filaments for building successive layers. Mechanical properties' analysis revealed that the addition of 10 wt.% CB increased the true stiffness (storage modulus) by 20%, the impact strength by 62%, with the drop in ultimate tensile strength of 11%. The optimal elongation at break and toughness were achieved for the samples containing 2 wt.% CB increasing these key properties by 62% and 58%, respectively. In terms of the melt flow index (MFI), as a key rheological indicator, the measured value ranged between 12.5 and 19.0 for all compositions suitable for the FFF process. Morphological analysis of the extruded filaments and fracture surface of impact test samples showed a mesoscale interspersion of polymer phases and a proper filler dispersion in the matrix material with sizes ranging from hundreds of nanometers to hundreds of microns. The developed 3D‐printable PP composite filament was successfully used in a robotic cell to repair broken plastic lugs of a car headlight assembly.