Production Of Composites Research Articles

Effect of expandable graphite content on the physical, thermal and mechanical properties of novolac matrix composites: Halogen-free flame-retardant polymer composites

Flame-retardant properties are particularly important for materials used in high-temperature applications. This study focuses on novolac matrix composites reinforced with expandable graphite (EG) particles, produced through a hot pressing process using powders prepared by mechanical milling. The research examines the particle size of both the matrix and the reinforcing particles used in composite production. Additionally, the morphology of the powders, the microstructural properties of the composites, and the fracture surfaces after tensile testing were analyzed using scanning electron microscopy (SEM). Phase analysis of the samples was performed using X-ray diffraction (XRD). Hardness and tensile tests were conducted to evaluate the mechanical properties. The effect of EG particles on the thermal stability of the composites was assessed using thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), and thermal conductivity tests. Furthermore, flammability was evaluated by determining the Limit Oxygen Index (LOI) values. The experimental results identified the optimum reinforcement ratio as 20 wt% EG. TGA results showed residue values of approximately 37.39 % for pure novolac and 57.87 % for novolac matrix composites reinforced with 20 wt% EG. The highest thermal conductivity (0.72 W/mK) and LOI values (40.64 %) were achieved with 20 wt% EG reinforcement, resulting in an LOI value approximately 1.25 times greater than that of the pure novolac sample (32.45 %). Additionally, tensile strength increased by approximately 2.7 times compared to the pure novolac sample. This research highlights the potential of the novolac/EG composites for advanced high-temperature applications where enhanced flame retardancy and structural integrity are essential.

Quantification of fungal biomass in mycelium composites made from diverse biogenic side streams

AbstractMycelium composite materials are comprised of renewable organic substrates interconnected by fungal mycelium, allowing full biodegradability after use. Due to their promising material properties, adaptability, and sustainable nature, these biomaterials are investigated intensively. However, one crucial aspect that has hardly been covered so far is the proportion of fungal biomass in the composites, which would be necessary to assess its contribution to the material characteristics. Since a complete physical separation of mycelium and substrate is not feasible, we approached this issue by isolating the fungal DNA and relating it to the mass of mycelium with the help of quantitative PCR. Overall, 20 different combinations of fungi and biogenic side streams were evaluated for their handling stability, and growth observations were related to the quantification results. Ganoderma sessile was able to form stable composites with almost all substrates, and a positive correlation between mycelial biomass and composite stability could be found. However, the amount of mycelium required for fabricating firm materials strongly depends on the combination of substrate and fungal species used. Less than five mass percent of fungal biomass can suffice to achieve this, as for example when combining Trametes versicolor with sugar beet pulp, whereas a mass fraction of twenty percent leads to crumbly materials when using Pleurotus pulmonarius on green waste. These results indicate that the mycelial biomass is an important factor for the composite’s stability but that the properties of the fungal hyphae, as well as those of the substrate, are also relevant. The presented quantification method not only allows to estimate fungal growth during composite production but can also improve our understanding of how the mycelium influences the material.

Study on the impact of water absorption processes on the application of wood waste in composite material production

The issue of recycling and reusing waste from the wood processing industry has garnered significant attention from researchers, as effective solutions could yield economic benefits while mitigating environmental impacts. This article focuses on the development of artificial wood using unsaturated polyester resin combined with waste materials from carpentry workshops, specifically investigating its water absorption properties. Research findings indicate that the water absorption coefficient of the samples increased with longer immersion times, higher organic filler content, and larger particle diameters. The calculated density reveals a broad spectrum of solid industrial boards that can be produced from these compositions, suggesting that consistent forming conditions enhance economic viability. Notably, optimal results were achieved with samples made from mixed wood powder without prior sorting, which contributes to reduced production costs, aligning with the study's objectives. Furthermore, the investigation highlighted that the water absorption coefficient escalates with increased soaking time, organic filler content, and particle size, indicating that in humid environments, it is advisable to limit both filler content and particle size to maintain performance. Overall, the studies confirm the feasibility of utilizing wood powder as a filler, with varying particle diameters imparting distinct characteristics to the final product. These findings underscore the potential for innovative approaches to wood waste management in the industry.

Turning mine-tailing streams into sources of water and mineral salts in a membrane-sustained circular scenario

The discharge of wastewater from the mining industry has a critical ecological impact, potentially endangering both soil and marine ecosystems. Alternatively, recovering pure water and valuable materials from these hypersaline streams through a technologically efficient process, would help reduce the ecological impact of the waste, while providing a viable supply chain for raw materials such as magnesium, potassium and others, considered critical to the economy. In this context, this work aimed to simultaneously recover pure water and mineral salts from mine wastewater by membrane-assisted crystallization (MAC). A prior theoretical study based on thermodynamic parameters attempted to predict salts precipitation at different temperatures. MAC tests were then performed at specific thermal gradients and feed pretreatment conditions, achieving preferential precipitation of solids products of different composition containing large quantities of Ca or Mg/K minerals from the real mine tailing wastewater. The experiments also demonstrated the central impact of heterogeneous nucleation effects.

Sustainable production of Pleurotus sajor-caju mushrooms and biocomposites using brewer’s spent and agro-industrial residues

Brazil is one of the world’s largest beer producers and also a major food producer. These activities generate a large amount of residues which, if disposed of inappropriately, can have adverse effects on the environment. The objective of this research was to evaluate the potential of using these residues for both mushroom cultivation (traditional use) and the production of mycelium-based composites (innovative use). Mushroom production (Pleurotus sajor-caju) was conducted using only brewer’s spent grains (fresh and dried) and also mixed with banana leaves (1:1) or peach palm leaves (1:1), which are residues widely available in the northern region of Santa Catarina, Brazil. The productivity of mushrooms cultivated using fresh and dried brewer’s spent grains did not exhibit a statistically significant difference, indicating that this residue can be utilized shortly after its generation in the industrial process, thereby reducing costs associated with production. Combining brewer’s spent grains with banana or peach palm leaves resulted in enhanced mushroom production (0.41 and 0.38 g day−1, respectively) compared to using the leaves as a sole substrate. The mushrooms produced contain sugars and a minimal sodium content, and are considered a source of phosphorus. In addition, no toxic elements (Hg and Pb) were present. The mycelium-based composites produced using the residual substrate (after the mushroom harvest) exhibited better mechanical properties (compressive strength = 0.04 MPa, density = 242 kg m−3, and low humidity sorption) than those produced using fresh substrate. The results demonstrate the synergistic effect of combining the two approaches under investigation. The use of brewer´s spent enhance the mushroom productivity and the residual substrate enhance the mechanical properties of mycelium-based composites. The compressive strength, density, and air humidity sorption properties are essential for determining the potential applications of mycelium-based composites. The use of brewer’s spent grains mixed with banana leaves demonstrated significant promise for mushroom production and subsequent application in the development of mycelium-based composites. These sequential approaches contribute to waste valorization and the rational utilization of natural resources, as the mycelium-based composites are considered for substitution of synthetic materials, thereby promoting sustainability for future generations.

Bio-based composite film from konjac flour and dialdehyde starch: Development, properties and structural features

The development of environmental-friendly composite products from renewable resources has been considered as an excellent approach to address the negative impact of petroleum-based plastics on environment. Konjac flour (KF), as an excellent polysaccharide material, has a broad application in food field. It shows a promising future in the film field due to its excellent film-forming properties. In this work, KF was selected as primary film-forming matrix, and dialdehyde starch (DAS) as the reinforcing component. A series of KF/DAS composite films were prepared by adjusting the addition ratio of DAS component. Then, their physical and mechanical properties were characterized and analyzed. The results showed that KF/DAS composite film with 25 % DAS content exhibited the optimal mechanical properties, including tensile strength (TS) of 13.1 MPa and elongation at break (EAB) of 93.7 %, indicating that an excellent cross-linked system formed among KF and DAS utilizing the method described in this study. Furthermore, much evidences from the fourier transform infrared spectroscopy (FT-IR) and X-ray diffraction (XRD) confirmed that a strong chemical cross-linkages between DAS and KF via Schiff base and esterification reactions. Based on the thermogravimetry (TG) and scanning electron microscopy (SEM) results, KF/DAS composite films also had excellent thermal stability and a dense microstructure, although there are also changes with the DAS usage.

Effect of Rotational Speed on Microstructure and Properties of Al‐Based Composite Reinforced with High‐Entropy‐Alloy Particles Fabricated by Friction Stir Processing

In the present investigation, the production of composites based on 7075Al is involved, reinforced with particles of high‐entropy alloy (AlCoCrFeNi), using the friction stir processing (FSP) technique. The primary objective is to examine how varying the rotational speed during processing affects the uniformity of the composite microstructure, the strength of the bonding between different materials, and the mechanical properties of the composite. In these findings, it is indicated that higher processing rotational speeds lead to enhanced homogeneity of the composite material and promote strong bonding with the matrix. The Al13Co4 phase is generated at the interface before the formation of the Al5Co2 phase. The microhardness of the composites exhibits an increase in hardness of 78%, 84%, 86%, and 83% compared to the hardness of the 7075Al. Similarly, the tensile strength is enhanced by 26%, 36.7%, 49%, and 40%, respectively. The broken surface shows an even spread of particles with many small depressions, which is a clear sign of a common type of fracture that can stretch without breaking. The primary processes that enhance the strength of the FeCoNiCrAl/7075Al composite manufactured by FSP include the load‐transfer effect, dispersion strengthening, grain refinement strengthening, and thermal mismatch strengthening.

Improving Indoor Air Quality: Using Polymate-777A as a Formaldehyde Scavenger to Decrease Formaldehyde Emission in Plywood Panels

Indoor air quality is significantly impacted by volatile organic compounds, with formaldehyde being a prominent concern due to its emission from wood composite products. Formaldehyde emissions from wood composite products is a big concern for the environment and people's health. This study focused at how effective a product called Polymate-777A, the additive used as a formaldehyde scavenger is in reducing the formaldehyde emissions from plywood. This study investigates the efficacy of Polymate-777A, a formaldehyde scavenger, in reducing formaldehyde emissions from plywood panels. Through a series of controlled experiments, it was evaluated the impact of varying concentrations of Polymate-777A on formaldehyde release, utilizing standardized testing methods to quantify emissions. Results indicate that the incorporation of Polymate-777A significantly reduces formaldehyde levels, enhancing the safety and environmental sustainability of plywood products. The Results revels that when 1.5% or more Polymate-777A was used as scavenger for plywood manufacturing, the plywood met the emission standards set by Japan and Europe for formaldehyde emissions. This study suggests that using Polymate-777A could be a good way to reduce formaldehyde emissions from wood products, which would be better for the environment and people's health.

Production of Autoclaved Cementitious Composites Using Recycled Waste Glass

ABSTRACTOne of the major negative environmental implications of economic growth and the advancement of information technology is the large quantity of electronic waste dumped in landfills. Cathode ray tubes (CRTs) from outdated televisions and computer monitors are a significant source of electrical waste. The CRT funnel primarily consists of silica, significant alkalis (Na2O‐K2O), and heavy metals like barium‐strontium, along with a substantial lead (Pb) content that may contaminate the soil. Owing to its heavy metal content, CRT is considered hazardous waste, and regulations require its glass to be recycled or repurposed instead of landfill disposal. The low pozzolanic activity of CRT silica suggests that its high content, when paired with an optimized particle size and specific curing conditions, can enhance the mechanical properties of cement‐based products. Hydrothermal treatment has been found to speed up both the hydration of ordinary Portland cement (OPC) and the pozzolanic reactions. Since the main objective was to safely recycle large amounts of CRT, three mixes were proposed with 10%, 20%, and 30% OPC + 90%, 80%, and 70% CRT, respectively, and the effect of hydrothermal curing conditions on mechanical properties and durability of these blends was investigated. CRT‐70, a blend containing 70% CRT glass waste, showed enhanced strength due to the formation of zeolitic phases and calcium silicate hydrate (CSH). These phases also provided CRT‐70 with notable fire resistance, ensuring its structural stability under elevated temperatures. These results demonstrate the possibility of production of precast building products via high‐volume recycling of hazardous CRT waste.

Aligning halloysite nanotubes in elastomer toward flexible film with enhanced dielectric constant

Naturally occurring halloysite nanotubes (HNTs) are considered electrically insulating counterparts of carbon nanotubes, and they are always randomly distributed in the reported polymer composites. With the recent optimization in advanced processing techniques for the production of muti-functional polymer composites, efficiently aligning micro-/nano-fillers in polymer matrix have been available. Here, we fabricate such aligned HNTs-silicon elastomer (PDMS) composites enabled by alternating current (AC) electric field driven alignment and report that at 7 wt% HNTs loading, the dielectric constant of aligned HNTs/PDMS composite film is almost 150 % (8.46 vs 5.71) higher than that of unaligned one at measurement frequency of 1 kHz. It is also observed that such high loading of nanoparticles brings negligible increase in dielectric loss and does not compromise much of the flexibility. This work provides a renewed understanding of the potential of aligning fillers in polymer matrix, allowing the proper utilization of the high polarization and extremely low dielectric loss predicted for HNTs in the fabrication of polymer composite dielectrics.

Research on mechanism of controlling water and stabilizing production in heavy oil reservoirs with edge-bottom water

The development of edge-bottom water heavy oil reservoirs typically involves short water-free production period and a rapid increase in water cut, leading to generally low oil recovery factors. Combining the advantages of foam and viscosity reducers for composite development can effectively address the challenges in edge-bottom water reservoirs; however, the mechanism of action remains unclear. In this study, the concentrations of foaming agent and viscosity reducer were initially determined using a foam evaluator and an Anton Paar rheometer. Subsequently, a 2D large flat plate model was employed to conduct a composite group production experiment after water flooding, and then the change in oil saturation during flooding was analyzed by measuring electrical resistance. Finally, the dynamic curves of flooding were compared to analyze the mechanism of water control and oil stabilization (WCOS). The results indicate that the 2D large flat plate model and the method of inverting saturation field maps can effectively simulate the oil-water flow behavior during the composite flooding process after water flooding. The synergistic mechanism of N2 foam controlling bottom water coning and CO2 enhanced viscosity reducer to reduce viscosity in deep areas was revealed, increasing the overall recovery factor by 10.3% compared to water flooding. The mechanism of the combined oil recovery is clarified, which providing a reference for formulating WCOS plans following water flooding.

Evaluation of Mechanical Energy Consumption in WPC Production from Pine (Pinus sylvestris) and Hemp (Cannabis sativa L.) with ABS Thermoplastic Additions.

This study investigates lignocellulosic biocomposites' physicochemical properties and strength parameters with varying thermoplastic content. Biocomposites were prepared using wood (Pinus sylvestris) or hemp shives (Cannabis sativa L.) combined with 25% and 50% ABS regranulate. The research focused on evaluating the mechanical energy consumption during the compaction of wood-ABS biocomposites with different pine fractions pretreated with hot water extraction (HWE) and analyzing the relationship between strength and thermoplastic content. Results indicate that the composition of the mixture and the size of the hemp shives fraction did not significantly influence energy consumption during densification. Energy values ranged from 1.234 × 10⁻8 J to 8.296 × 10⁻8 J. While the densification of pine after HWE was unsuccessful without ABS, preheating the mixtures with ABS facilitated the production of a uniform composite. The work required for densification ranged from 1.404 × 10⁻5 J to 2.711 × 10⁻5 J for fractions without ABS. For mixtures with ABS, the work required was 1.954 × 10⁻5 J for fraction 0 ÷ 0.4 (f1) and 0.042 × 10⁻5 J for fraction 0.4 ÷ 0.8.

Assessment of the possibility of using waste aggregate dust for the production of vibro-pressed concrete paving blocks

Significant amounts of rock dust with a grain size similar to cement are generated during aggregate dedusting in the production of mineral-asphalt masses. These wastes are collected in tanks or silos and must be managed in such a way as not to generate costs related to disposal. On the other hand, the use of natural resources must be reduced in the production of cement composites. The objective of this research is to investigate the possibility of utilising aggregate dedusting waste (ADW) in vibro-pressed concrete paving blocks (VPCPB). Stage one of this research includes testing the compressive strength of concrete samples where cement was partially replaced by ADW or/and fly ash (FA). Stage two discusses the effect of cement replacement by ADW or FA on the splitting tensile strength of VPCPB. Using ADW in VPCPB is a promising option. Splitting tensile strength increased after both 7 and 28 days when ADW was used.

Control of the parameters of thermosetting binders directly during the molding of products made of polymer composite materials

For aviation binders at the moment there is no necessary methodological base on the basis of which it is possible to control the conditions of their curing by viscosity, reaction rate and glass transition temperature in real time. The paper presents a method of control of thermosetting binder parameters directly during the molding process. The epoxy binder VSE-59 was studied. A mathematical model of the relationship between the frequency maximum parameter of the imaginary component of the electrical impedance and the degree of curing is given, the results of dielectric analysis are compared with laboratory methods (differential scanning calorimetry and rheometry). It is shown that the convergence of the values of the degree of conversion is high. Rheological and dielectric analyses revealed a direct correlation between electrical and rheological properties in the range of injection temperatures. Equations were determined and coefficients were experimentally selected to describe the correlation between viscosity and glass transition temperature and dielectric parameters, which provides the possibility of their control in real time. The obtained results can be used to create a hardware and software base, which makes it possible to control the state of the binder at each moment of the process of forming products from polymer composite materials, as well as to carry out optimization to eliminate the emergence of conditions of uneven polymerization. Realization of the detailed control of the binder state in different parts of the product will allow to carry out verification of calculations, to predict and avoid the occurrence of warping and, accordingly, to increase the quality of composite products.

Experimental Research on Basalt Fabric-Based Composites for Protection Against Contact Heat

ABSTRACT The unique properties of basalt fibers, i.e. low thermal conductivity, thermal resistance up to 800°C, biodegradability, resistance to acids and alkalis, corrosion, ultraviolet radiation, and non-flammability, make them increasingly used in personal protective equipment. The design and production of basalt fabric-based composites were performed, and composite layers were directly modified by depositing thin coatings using the magnetron sputtering method. The designing and testing were performed in five stages. For direct basalt fabric modification and basalt fabric-based composites, resistance to contact heat was tested for contact temperatures of 100°C and 250°C. Moreover, the uncertainty budgets of the threshold time measurement results were determined and analyzed for all composites. New basalt fabric-based composites were designed to protect users from contact heat in hot work environments. As a result of the research, it was found that applying composite coatings: aluminum and zirconium dioxide or aluminum and zirconium dioxide and titanium dioxide to both composite layers proved to be effective in obtaining composites that guarantee perfect resistance to contact heat up to 250°C.

Production and evaluation of the polyester composites containing pyrite and niobium diboride for radiation protection

The presented study focused on investigating the radiation shielding properties of polyester/pyrite/niobium diboride (FeSNbB) composites. Various gamma-ray shielding parameters were evaluated with help of a HPGe detector system. Theoretical and simulation results are further evaluated by WinXCOM, GEANT4 and FLUKA codes, and the obtained results are compared with experimental values in the energy region 59.5 keV–1332.5 keV. The prepared samples are additionally evaluated using kerma relative to air values and Exposure build-up factors. Then, for the evaluation of neutron radiation shielding, effective removal cross sections for fast neutrons were determined for FeSNbB composites. Electron attenuation efficiency (AE%) for the produced composites was assessed across the energy spectrum of 4 MeV–18 MeV, utilizing experimental data from a Linac machine and theoretical predictions from Eclipse TPS. The results were found to be compatible with each other. FeSNbB50 has the best shielding properties among the studied composites.

An Evaluation of Sentinel-3 SYN VGT Products in Comparison to the SPOT/VEGETATION and PROBA-V Archives

Sentinel-3 synergy (SYN) VEGETATION (VGT) products were designed to provide continuity to the SPOT/VEGETATION (SPOT VGT) base products archive. Since the PROBA-V mission acted as a gap filler between SPOT VGT and Sentinel-3, and in principle, a continuous series of data products from the combined data archives of SPOT VGT (1998–2014), PROBA-V (2013–2020) and Sentinel-3 SYN VGT (from 2018 onwards) are available to users, the consistency of Sentinel-3 SYN VGT with both the latest SPOT VGT (VGT-C3) and PROBA-V (PV-C2) archives is highly relevant. In past years, important changes have been implemented in the SYN VGT processing baseline. The archive of SYN VGT products is therefore intrinsically inconsistent, leading to different consistency levels with SPOT VGT and PROBA-V throughout the years. A spatio-temporal intercomparison of the combined time series of VGT-C3, PV-C2 and Sentinel-3 SYN VGT 10-day NDVI composite products with an external reference from LSA-SAF, and an intercomparison of Sentinel-3 SYN V10 products with a climatology of VGT-C3 resp. PV-C2 for three distinct periods with different levels of product quality have shown that the subsequent processing baseline updates have indeed resulted in better-quality products. It is therefore essential to reprocess the entire Sentinel-3 SYN VGT archive; a uniform data record of standard SPOT VGT, PROBA-V and Sentinel-3 SYN VGT products, spanning over 25 years, would provide valuable input for a wide range of applications.

Comparative Study of Interfacial and Conventional Techniques for Nanosilica Incorporation in Natural Rubber Latex-Based Composites with Varied TEOS Content

This study investigates the preparation of natural rubber latex (NRL) composites with varying nanosilica contents of 5, 15, 30, and 45 phr, using both interfacial and conventional mixing techniques. Analysis focused on viscosity, plasticity, morphology, and FTIR spectra to evaluate the impact of these methods on composite properties. The interfacial techniquemaintained lower viscosity values, indicating better latex stability, and achieved higher silica yields and conversion rates (94 - 99%) at elevated TEOS contents. Plasticity analysis revealed that the interfacial method produced more uniform and stable plasticity values, suggesting improved resistance to oxidation and enhanced mechanical properties. SEM and FTIR analyses confirmed superior dispersion with the interfacial technique, especially at higher silica contents. These findings highlight the efficacy of the interfacial technique in optimizing the properties of NRL composites, making it a promising approach for advanced material applications. HIGHLIGHTS Analysis of interfacial and conventional mixing techniques reveals their impact on NRL composite properties, demonstrating the interfacial method's superior stability, silica dispersion, and enhanced mechanical properties. The interfacial method maintains lower, stable viscosity, prevents latex destabilization, achieves higher silica yields, and ensures economic and sustainable production of high-quality composites. SEM and FTIR analyses confirm better silica dispersion and morphology with the interfacial method, enhancing composite performance, durability, and informing industrial applications and future research directions. GRAPHICAL ABSTRACT

Investigations on the leak resistance performance and the difference mechanism of composite materials under several typical curing processes

This study aims to investigate the leak resistance of carbon fiber composite products formed by various typical curing processes. Firstly, the leak rates of specimens produced through different curing methods were measured, and the defect were statistically analyzed. After that, the simulation approach was applied to numerically study the impact of these defect characteristics on leak rates was examined from the three factors of porosity, void distribution and void morphology, specimen with prefabricated defects was prepared, and its leak performance were tested to validate the simulation results. Finally, the differences in leak resistance among specimens under different curing processes were analyzed from the perspective of curing defects, and specific defect characteristics contributing to enhanced leak resistance were identified.

EVOLUTION OF THE PRESS BONDING PROPERTIES OF Al/Cu BIMETAL BULK COMPOSITES (EXPERIMENTAL AND NUMERICAL INVESTIGATION)

Nowadays, the application of bimetallic laminates with special capabilities is increasing and has experienced high growth. These properties include high corrosion resistance, mechanical properties, thermal stability, and lightweight. In the midst of the technologies of multilayer composite materials, accumulative press bonding (APB) as a solid-phased method of welding is one of the most common techniques for the production of multilayer composites. One of the most important aims for this choice is the press pressure, which can generate a suitable mechanical connection and strong bonding between produced metal layer components. In this study, bimetal aluminum/copper bulk composites have been fabricated via the APB technique. Then, the effect of pressing parameters such as plastic strain and the number of layers on the stress distribution has been investigated. For samples with eight layers, the shear stress between the layers reached 3.1 MPa which is a suitable condition to generate a successful bonding. The stress applied on the layers has also increased with increasing the thickness reduction ratio. The interlayer shear stresses also increase with decreeing the thickness. With a higher reduction in thickness ratios, the amount of sinking layers was greater along the entire length of the sample, which led to the crushing of copper layers. During the APB process at higher pressing passes, increasing the volume of virgin material in the direction of the press led to increasing the compaction and better bonding of Al and Cu layers to each other.