Nanofibrous-structured polymers and their engineering applications

Monolithic materials cannot always satisfy the demands of today’s advanced requirements. Only by combining several materials at different length-scales, as nature does, the requested performances can be met. Polymer nanocomposites are intended to overcome the common drawbacks of pristine polymers, with a multidisciplinary collaboration of material science with chemistry, engineering, and nanotechnology. These materials are an active combination of polymers and nanomaterials, where at least one phase lies in the nanometer range. By mimicking nature’s materials is possible to develop new nanocomposites for structural applications demanding combinations of strength and toughness. In this perspective, nanofibers obtained by electrospinning have been increasingly adopted in the last decade to improve the fracture toughness of Fiber Reinforced Plastic (FRP) laminates. Although nanofibers have already found applications in various fields, their widespread introduction in the industrial context is still a long way to go. This thesis aims to develop methodologies and models able to predict the behaviour of nanofibrous-reinforced polymers, paving the way for their practical engineering applications. It consists of two main parts. The first one investigates the mechanisms that act at the nanoscale, systematically evaluating the mechanical properties of both the nanofibrous reinforcement phase (Chapter 1) and hosting polymeric matrix (Chapter 2). The second part deals with the implementation of different types of nanofibers for novel pioneering applications, trying to combine the well-known fracture toughness enhancement in composite laminates with improving other mechanical properties or including novel functionalities. Chapter 3 reports the development of novel adhesive carriers made of nylon 6,6 nanofibrous mats to increase the fracture toughness of epoxy-bonded joints. In Chapter 4, recently developed rubbery nanofibers are used to enhance the damping properties of unidirectional carbon fiber laminates. Lastly, in Chapter 5, a novel self-sensing composite laminate capable of detecting impacts on its surface using PVDF-TrFE piezoelectric nanofibers is presented.

IDeS methodology applied to automotive component re-engineering focused on lightweight and high-strength by additive manufacturing

The project aims to gather an understanding of additive manufacturing and other manufacturing 4.0 techniques with an eyesight for industrialization. First the internal material anisotropy of elements created with the most economically feasible FEM technique was established. An understanding of the main drivers for variability for AM was portrayed, with the focus on achieving material internal isotropy. Subsequently, a technique for deposition parameter optimization was presented, further procedure testing was performed following other polymeric materials and composites. A replicability assessment by means of the use of technology 4.0 was proposed, and subsequent industry findings gathered the ultimate need of developing a process that demonstrate how to re-engineer designs in order to show the best results with AM processing. The latest study aims to apply the Industrial Design and Structure Method (IDES) and applying all the knowledge previously stacked into fully reengineer a product with focus of applying tools from 4.0 era, from product feasibility studies, until CAE – FEM analysis and CAM – DfAM. These results would help in making AM and FDM processes a viable option to be combined with composites technologies to achieve a reliable, cost-effective manufacturing method that could also be used for mass market, industry applications.