Manufacture Of Composite Materials Research Articles

Influence of variable viscosity on existing sheet thickness in the calendering of non-isothermal viscoelastic materials

Abstract The calendering process is pivotal in enhancing various materials’ surface properties and characteristics, making them indispensable for achieving desired product quality and performance. Also, this process holds significant relevance in various industrial applications, such as polymer processing, food production, and the manufacturing of composite materials. So, the aim of this study is to theoretically examine the calendering process applied to third-grade materials. It specifically explores how temperature variations impact material behavior during passage through two counter-rotating heated rolls. Particular consideration is given to the influence of temperature-dependent viscosity via Reynold’s model. The complexities of mass, momentum, and energy balance equations are reduced through the application of the Lubrication approximation theory. Solutions to these equations for variables such as velocity, flow rate, and temperature fields are accomplished by combining perturbation and numerical techniques. In relation to the calendering process, the thickness of the exiting sheet is specifically explored. Furthermore, this study quantifies substantial engineering parameters such as roll-separating force, pressure distribution, and power transferal from the rolls to the fluid. The governing equations belong to three key dimensionless parameters, namely, the Brinkman number, which is a product of Eckert number and Prandtl number, the temperature-dependent consistency index μ \mu , and a parameter η \eta correlating to non-Newtonian behavior. The outcomes of this study are presented both graphically and in tabular form. It has been observed that a rise in the third-grade parameter decreases detachment point and sheet thickness due to increased material rigidity. Furthermore, established results in the literature regarding the calendering of Newtonian fluids are validated.

Utilization of Silica Filler as Reinforcement Material of Polylactic Acid (PLA) in 3D Printing Applications: Thermal, Rheological, and Mechanical Performance

Glass was introduced as an additive to filaments used for the manufacturing of composite materials, employed by Additive Manufacturing applications. Glass accounts for a large waste electric and electronic equipment (WEEE) percentage, and its recovery and recycling can lead to the production of sustainable composite materials. In this work, poly(lactic acid) (PLA)/commercially available silicon oxide composite filaments were manufactured and their structural, thermal, rheological, and mechanical properties were assessed. Scanning Electron Microscopy confirmed the 1:2 ratio of silicon: oxygen, along with the relatively low adhesion between the filler and the matrix. Differential Scanning Calorimetry presented steady glass transition and melting temperatures of composites, whereas a crystallization temperature of 10% wt. and a crystallinity of 15% wt. composite slightly increased. Rheological analysis showcased that the viscosity of the composite filaments decreased compared to PLA (10–100 compared to 300–400 Pa·s), with a more shear-thinning behavior. Dynamic mechanical analysis exhibited increased elastic, flexural moduli, and flexural strength of composites (up to 16, 23, and 11%, respectively), whereas tensile strength and elongation decreased. The affordability of raw materials (with the future introduction of recycled ones) and the minimal processing steps can lead to the potential scaling up of the study.

Challenges and Advancements in Additive Manufacturing of Nylon and Nylon Composite Materials: A Comprehensive Analysis of Mechanical Properties, Morphology, and Recent Progress

Challenges and Advancements in Additive Manufacturing of Nylon and Nylon Composite Materials: A Comprehensive Analysis of Mechanical Properties, Morphology, and Recent Progress

WEAR RESISTANT OF CACO3/FLY-ASH CERAMIC MATRIX COMPOSITE

This study aimed to investigate the potential of utilising fly ash, a harmful byproduct of coal waste, in the manufacturing of composite materials to reduce its environmental impact. Calcium carbonate (CaCO3) and fly ash were mixed with zinc stearate using the powder metallurgy method to create wear-resistant samples. The compaction load was adjusted to achieve optimal low-pressure compaction, with pressures of 22.75 MPa, 23.45 MPa, 24.14 MPa, and 24.83 MPa used for single punch pressing. After 10 minutes of holding time, sintering was conducted at 900 OC for 1 hour. The raw materials were tested using X-ray diffraction (XRD) and sieved based on the mesh size. The composite was characterised through various tests, including density testing, wear testing, and scanning electron microscopy (SEM) to observe the microstructure. The density value increased with the compaction load, with a maximum apparent density of 1.794 g/cm3 and the highest porosity percentage at a pressure of 22.75 Mpa of 31.155%. Furthermore, the specific wear value decreased as the compaction load increased, with the lowest specific abrasion value of 1.17 x 10-6 mm2/kg. Therefore, using fly ash to produce composite materials is a promising solution to reduce the negative impact of coal waste while producing wear-resistant materials.

PEMANFAATAN WASTE PENGOLAHAN AIR SEBAGAI AIR UMPAN BOILER PT. NLP

NLP isafurniture manufacturing company that uses three types of wood, namely mahogany, pine, and teak. Handling and processing sawdust waste is a challenge that needs to be overcome effectively so that the waste can become a product that has added value. The value-dded product in question is souvenir craft. The utilization of coarse sawdust can be mixed with epoxy resin to form composite materials, which can be used as the basic material for souvenir crafts. It is known that the strength of composite materials increases with the increasing composition of the resin in composite materials, and the character of composite materials If the composition of sawdust is higher, the resulting composite material will be opaque and lighter. Then the manufacture of composite materials will use a ratio of 1:1. Regional attributes, cultural elements, innovation in form, design, and ease of application are important factors to consider when designing a product for souvenirs. The collected data is needed to be translated into the interpretation of product requirements to be used in making the Objective Tree and Morphological Diagrams. Evaluation of alternative product designs is carried out by considering the minimum risks.

INFLUENCE OF FILLERS ON THE STRUCTURE AND PROPERTIES OF POLYMER MATRIX

Purpose. Enhancement of the mechanical properties of the polymer matrix through the incorporation of finely dispersed fillers, namely aluminum oxide and talc, as potential modifiers.
 Research methods. Research was conducted on polymer specimens subjected to tensile testing according to DSTU EN ISO 527-5:2018. The tests were performed using a URM-5 tensile testing machine with a maximum force of 50 kN. Metallographic analysis was carried out using a KEYENCE VHX microscope at magnifications of 50 and 500. The microstructure of the polymer matrix was assessed through etching-free procedures.
 Results. The study demonstrates that the incorporation of finely dispersed aluminum oxide particles increased the strength parameter from 4.69 MPa to 13.07 MPa, as compared to the unfilled sample. Additionally, it was observed that the introduction of finely dispersed talc particles at a concentration of 0.75 % by mass led to an enhancement in strength values from 4.69 MPa to 12.74 MPa, in comparison to the unfilled sample.
 Scientific novelty. A polymer matrix with enhanced mechanical properties was achieved through the addition of fillers acting as modifiers. The optimal concentration of aluminum oxide and talc additives was determined. By comparing the results with previous studies involving aluminum oxide and talc at various concentrations in different types of polymer matrices, it can be concluded that the investigated concentrations of modifiers with epoxy resin ED-20 led to the production of a polymer composite with superior mechanical characteristics. The obtained results underscore the significant potential of aluminum oxide and talc as effective modifiers for improving the strength and other crucial properties of composite materials.
 Practical value. The obtained results highlight the significant potential of utilizing aluminum oxide and talc as modifiers for polymer matrices to enhance their mechanical characteristics. From a practical standpoint, the use of these fillers can exert a substantial impact on the development of new composite materials with improved properties, finding application in composite reinforcement production. Considering the heightened strength and resilience of the resulting materials, these composites can be effectively employed to create lighter and stronger structures in construction and other industries. Additionally, their application may lead to reduced repair and maintenance costs due to increased durability and resistance to mechanical loads. Thus, the implementation of the obtained results could have a substantial influence on the practice of composite material manufacturing, ensuring the creation of products with enhanced characteristics for various applications.

Mechanical properties for composites with dammar resin reinforced with crushed corn cob

The study focused on the potential use of agricultural waste (corn cob) in the manufacturing of composite materials. In the first stage, composite materials were manufactured and tested using synthetic matrices (epoxy and acrylic) and hybrid matrices based on dammar resin (50% dammar, 60% dammar, and 70% dammar). Since it was observed that the samples had low mechanical properties under tensile and bending loads, the study was expanded to the production of sandwich-type composites with silk fabric facings. It was found that, by utilizing silk fiber, both tensile and bending strength increased from a few hundred percent up to a few thousand percent, compared to the samples that are only reinforced with crushed corn cob.

Sustainability in the Manufacturing of Eco-Friendly Aluminum Matrix Composite Materials

The purpose of this work was to consolidate the eco-friendly Al–SiC composites prepared with various weight fractions of ceramic particles (0; 2.5; 5; 10; 15 wt.% SiC) in the energy-saving sintering process under vacuum and in a nitrogen atmosphere at 600 °C. The density of the manufactured composites was determined using Archimedes’ method. The mechanical properties and strength characteristics of the metal–ceramic interface were measured using three-point flexural and uniaxial compression tests, as well as the Brinell hardness measurement. The tribological properties were evaluated by determining the coefficients of friction and weight losses of the tested materials and identifying the tribological wear mechanisms. Advanced microstructural observation methods, such as scanning electron microscopy (SEM) and transmission electron microscopy (TEM), were used to analyze the microstructure of the composites in detail, including the identification of the phase composition using X-ray analysis methods. Low-cost composites with a porosity not exceeding 7% were successfully produced via energy-saving production routes. Simultaneously, owing to the formation of aluminum nitrides during sintering in a nitrogen atmosphere, these composites exhibited mechanical and tribological properties superior to those of materials sintered under vacuum.

Enhanced interfacial and mechanical properties of carbon fabric/PA12 composites via grafting silanized nano hexagonal boron nitride onto the fibers

ABSTRACT The purpose of this work was to create thermoplastic composites based on carbon fiber fabric reinforced enhanced mechanical and interfacial properties, based on PA12 (polyamide 12). In line with these objectives, it is aimed to develop carbon fiber reinforced thermoplastic composite materials with improved interfaces by sizing chemical modification and interfacial compatibility suspension development using hBN (hexagonal boron nitride) nanomaterial. The production of bare and silanized hBN sizing grafted CF (carbon fiber)-PA12 plates was followed by various mechanical, thermal, and SEM analyses. When the mechanical test results of CF-PA12 and hBN-APTES (3-Aminopropyltriethoxysilane) Sizing Coated Composite Specimens are compared; it is proved that hBN-APTES sizing improves the mechanical properties. Furthermore, sizing coated CF-PA12 composite specimens showed improvements in flexural strength of 20.67% and compressive strength of 19%, respectively. The significance of these results is to enhance the critical interfacial properties in the manufacturing of carbon fiber composite materials based on PA12, and to produce high-quality products that can be used in a variety of industries, including sports equipment, automotive, and aerospace, all of which have a constant demand worldwide.

Physical and Chemical Properties of Horns Sheaths Particles for the Manufacture of Composite Materials

Physical and Chemical Properties of Horns Sheaths Particles for the Manufacture of Composite Materials

Optimization of conditions for the formation of functional coatings based on carboxymethylcellulose with chromium

The possibility of increasing the strength and improving the functional properties of coatings based on biopolymers by adding metal powders is considered. An approach has been proposed that makes it possible to form composites based on carboxymethylcellulose with specified mechanical properties. The procedure for adjusting the process of formation and increasing the strength of a protective coating based on carboxymethylcellulose with chromium powder is shown. For the numerical calculation of the composition and temperature conditions for the manufacture of composite materials, a software module developed in the Microsoft Visual Studio environment was used. The calculation makes it possible to determine the combination of components of the coating composition that provides the highest mechanical strength for a given value of the relative deformation of the biocomposite. An example of calculation is given for a protective coating based on carboxymethylcellulose with chromium powder. The calculation results were confirmed experimentally. Using the proposed approach makes it possible to increase the mechanical strength of coatings by 40% and improve the adhesive strength to 1 point.

Optimization of geometrical factors for enhanced performance of carbon fiber reinforced polymer cores under transverse loading

The high strength-to-weight ratio and ease of manufacturing of composite materials make them widely used across a variety of industries. A commonly used method of improving composite structure load-bearing capacity is to employ carbon fiber-reinforced polymer (CFRP) cores. The mechanical properties of CFRP, however, vary in different directions due to its anisotropic behavior. Due to higher tensile strength along the fibers, anisotropy can lead to failure based on directions other than the fiber orientation. A thorough analysis of CFRP core failure modes has been conducted. Experimental analysis, finite element analysis, and micromechanical modeling techniques have been used in these studies. In this research, specific emphasis has been placed on understanding failure behavior under transverse loading conditions. Failure modes have been thoroughly examined in relation to geometric parameters such as interference, wedge angle, and friction coefficient. Modeling CFRP core failure and displacement behavior was carried out using FEA simulations to validate the research findings. A comparison of the obtained results with existing literature ensured that they were accurate and reliable. Additionally, response surface methodology was employed for optimization, aiming to minimize two critical factors: radial compressive stress and core displacement. By minimizing these factors, the performance and reliability of CFRP cores in applications related to grid capacity can be enhanced. The analysis of the research data revealed that the friction coefficient and interference play significant roles as interacting factors, albeit with opposite impacts on the stresses within the CFRP cores. The optimal values for interference and friction coefficient were found to be 0.0224 mm and 0.4, respectively, to minimize radial stress. Furthermore, the wedge angle exhibited a substantial influence on core displacement, with an optimal value of 3.5°.

Impact of the natural structure of cortex and pith ring on water loss and deformation in bamboo processing

The function of the pith ring and cortex in biological and fluid exchanges with the surrounding environment implies a natural intelligence. Their ingenious structure enables bamboo to thrive and impacts its processing and utilization. As drying is an essential step in bamboo product manufacturing, in this study, the effects of the pith ring and cortex on the water loss, deformation, and cracking of bamboo at the macroscopic, tissue, and cellular levels were investigated. Our study revealed a previously unknown mechanism of bamboo drying deformation. The cortex significantly affected the rate of water loss, whereas the pith ring did not significantly reduce the drying rate. Three deformation mechanisms originating from the pith ring were identified: the cell structure and orientation, self-flattening during drying, and excellent bending performance in the chord direction. These pith ring characteristics led to a larger radius of the bamboo splits during drying. These findings expand our understanding of the natural intelligence of the inner and outer layers of bamboo and provide important insights into bamboo drying, deformation, cracking, bionics, and composite material manufacturing.

Thermal and Mechanical Characterization of 3D Printed Continuous Fiber Reinforced Composites

Additive manufacturing of composite materials is a nascent technology that is being investigated for manufacturing optimized structural composite designs. By combining additive manufacturing of continuous fiber composites with topology optimization, fibers can be steered in the loading direction. Steered fibers allow for decreased weight, decreased manufacturing time, and reduced cost. Realizing the benefit of printed composites enables production of low cost unmanned vehicles at a higher rate with high specificity. Mechanical properties of printed composites, which are needed for design, are measured in this work. Composite properties were comparable to traditionally manufactured composites, especially when normalized by cured ply thickness. Transverse properties were limited by the brittleness of the photopolymer matrix. Matrix cure characteristics and thermal properties were also measured which revealed the high temperature capabilities of the matrix with a Tg of 198°C.

Alignment of 3D woven textile composites towards their ideal configurations

The objective of the present study is to create a parametric model of an ideal 3D woven textile from a computed tomography at mesoscale without prior knowledge of the fabric architecture. The model is constructed by identifying a minimal number of parameters from the tomography and includes further assumptions about the textile properties (e.g., equally-spaced vertical yarn columns). A novel registration procedure called Model-based Digital Image Correlation (MDIC) is introduced for mapping the whole textile image onto its own model. It leads to a realignment of the yarn columns after deforming the textile image, from which the model is updated. Model extraction and registration steps are iterated up to a stationary solution. The final result is a perfect textile geometry with straight and orthogonal yarn columns and its mapping onto the original tomography image. The proposed procedure is applied successfully to a 3D woven textile and a 3D-injected woven composite. This novel technique is useful as a pre-processing step to image segmentation procedures or to ease the visual inspection performed by operators in correcting the yarn paths and yarn column deformations occurring during composite material manufacturing. Additionally, this alignment procedure could be used to deform a numerical ideal model to better fit the geometry of a real weave.

Specific features of preparation of natural and technogenic mineral raw materials for the manufacture of photocatalytic composite materials

Specific features of preparation of natural and technogenic mineral raw materials for the manufacture of photocatalytic composite materials

Near-infrared photothermal dual crosslinking strategy for precise and efficient direct ink writing of high solids ceramic slurries

During the ceramic photocuring 3D printing process, the penetration ability of incident light is hindered by the extinction effects of ceramic powders in ceramic slurry. This limitation in light penetration negatively impacts printing efficiency, especially in ceramic slurries with high solid contents. In this work, an in-situ photothermal dual crosslinking strategy, which capitalizes on the combined benefits of near-infrared photothermal energy, was proposed to realize precise and efficient direct ink writing of high solids ceramic slurries. The in-situ curing of ceramic slurries with an alumina content of up to 90 wt% (74.5 vol%) was successfully achieved by integrating photochemical and photothermal crosslinking strategies to recycle excess heat to enhance the energy utilization of near-infrared light. Under near-infrared irradiation (538.25 W/cm2, 3 s), the high solids ceramic photothermal dual curing slurry achieved a curing depth of 2.79 mm, which improved the printing rate and printing throughput compared with the photocuring slurry (2.34 mm) and the thermocuring slurry (0.98 mm). The sintered samples showed a sinter shrinkage of 8.85 % and relative density of 95.08 %. This method has great potential for application in the manufacturing of thick composite materials and high solid content slurry printing.

Biomaterial composed of chitosan, riboflavin, and hydroxyapatite for bone tissue regeneration

Biomaterial engineering approaches involve using a combination of miscellaneous bioactive molecules which may promote cell proliferation and, thus, form a scaffold with the environment that favors the regeneration process. Chitosan, a naturally occurring biodegradable polymer, possess some essential features, i.e., biodegradability, biocompatibility, and in the solid phase good porosity, which may contribute to promote cell adhesion. Moreover, doping of the materials with other biocompounds will create a unique and multifunctional scaffold that will be useful in regenerative medicine. This study is focused on the manufacturing and characterization of composite materials based on chitosan, hydroxyapatite, and riboflavin. The resulting films were fabricated by the casting/solvent evaporation method. Morphological and spectroscopy analyses of the films revealed a porous structure and an interconnection between chitosan and apatite. The composite material showed an inhibitory effect on Staphylococcus aureus and exhibited higher antioxidant activity compared to pure chitosan. In vitro studies on riboflavin showed increased cell proliferation and migration of fibroblasts and osteosarcoma cells, thus demonstrating their potential for bone tissue engineering applications.

Investigation of technological parameters for the manufacture of a polymer composite material based on aramid fibers and polyurethane binders by wet winding

Experimental studies have been carried out to determine the technological parameters for the manufacture of polymer composite materials based on aramid fibers and polyurethane binders by wet winding and the effect of polyurethane binder compositions on the strength of aramid fibers in plastic.

Study on the Manufacturing of Composite Materials Made from Glass Fiber Reinforced Polymer (GFRP) in Indonesia for Use as Lining in Open Channels

This study explained the potential use of glass fiber-reinforced polymer (GFRP) composite materials as an alternative lined material for irrigation channels in Indonesia. Currently, only four recommended materials are used as lining in irrigation channels in Indonesia, i.e., stone masonry, concrete, soil-cement, and ferrocement. Almost all lined material's main constituents are sourced from nature/environment. The exploitation of these mined materials will impact environmental destruction. This study focused on the manufacturing process of GFRP material, GFRP surface roughness testing, and the water flow characteristics in the hydraulic model experimental testing. The manufacturing process of GFRP material used polyester resin as the polymer matrix, E-glass type with a combination of woven roving mat covered by non-woven standard mat as the glass fiber reinforcement, and manufacturing process with a combination of hand lay-up and spray-up techniques. The GFRP material product has an average surface roughness coefficient value of Ra around 5.19 to 5.97 μm. The GFRP manufacturing has a good uniform product, as the average surface roughness coefficients of GFRP material have relatively the same values. It is shown that a factory in Indonesia has sufficient capacity to manufacture GFRP material for lining in open channels. The water flow characteristics in the flume were turbulent during testing in the hydraulic laboratory. The experimental study concluded that the GFRP composite materials could be implemented as preliminary references for alternative lined material in irrigation channels in Indonesia.