Analisi sperimentale degli effetti di temperature elevate sul comportamento strutturale dei rinforzi in FRP

In questa tesi si è voluta porre l’attenzione sulla suscettibilità alle alte temperature delle resine che li compongono. Lo studio del comportamento alle alte temperature delle resine utilizzate per l’applicazione dei materiali compositi è risultato un campo di studio ancora non completamente sviluppato, nel quale c’è ancora necessità di ricerche per meglio chiarire alcuni aspetti del comportamento. L’analisi di questi materiali si sviluppa partendo dal contesto storico, e procedendo successivamente ad una accurata classificazione delle varie tipologie di materiali compositi soffermandosi sull’ utilizzo nel campo civile degli FRP (Fiber Reinforced Polymer) e mettendone in risalto le proprietà meccaniche. Considerata l’influenza che il comportamento delle resine riveste nel comportamento alle alte temperature dei materiali compositi si è, per questi elementi, eseguita una classificazione in base alle loro proprietà fisico-chimiche e ne sono state esaminate le principali proprietà meccaniche e termiche quali il modulo elastico, la tensione di rottura, la temperatura di transizione vetrosa e il fenomeno del creep. Sono state successivamente eseguite delle prove sperimentali, effettuate presso il Laboratorio Resistenza Materiali e presso il Laboratorio del Dipartimento di Chimica Applicata e Scienza dei Materiali, su dei provini confezionati con otto differenti resine epossidiche. Per valutarne il comportamento alle alte temperature, le indagini sperimentali hanno valutato dapprima le temperature di transizione vetrosa delle resine in questione e, in seguito, le loro caratteristiche meccaniche. Dalla correlazione dei dati rilevati si sono cercati possibili legami tra le caratteristiche meccaniche e le proprietà termiche delle resine. Si sono infine valutati gli aspetti dell’applicazione degli FRP che possano influire sul comportamento del materiale composito soggetto alle alte temperature valutando delle possibili precauzioni che possano essere considerate in fase progettuale.

Idrogenazione selettiva del 5-idrossimetilfurfurale in fase omogenea: studio dell'attività catalitica del complesso di Shvo

Il presente lavoro di tesi è frutto di una collaborazione fra il Dipartimento di Chimica Fisica ed Inorganica (gruppo del Prof. Valerio Zanotti – Mattia Vaccari, Dr. Rita Mazzoni) ed il Dipartimento di Chimica Industriale e dei Materiali (gruppo del Prof. Angelo Vaccari – Dr. Thomas Pasini, Dr. Stefania Albonetti, Prof. Fabrizio Cavani) e si inserisce il un progetto volto a valutare l’attività e la selettività del catalizzatore di idrogenazione di Shvo 1, verso l’idrogenazione selettiva del doppio legame polare del 5-idrossimetilfurfurale (HMF) in fase omogenea. L’HMF è un composto di natura organica facilmente ottenibile dalle biomasse, il quale può essere impiegato come building block per ottenere prodotti ad alto valore aggiunto per la chimica fine o additivi per biocarburanti aventi un elevato potere calorifico. In particolare la nostra attenzione si è rivolta alla produzione del 2,5-diidrossimetilfurano (BHMF), un importante building block per la produzione di polimeri e schiume poliuretaniche. Il lavoro di tesi da me svolto ha riguardato la messa a punto di una nuova metodologia sintetica per la preparazione del catalizzatore di Shvo e lo studio della sua attività catalitica nella riduzione di HMF a BHMF. Il comportamento del catalizzatore è stato monitorato studiando la resa in BHMF in funzione di tutti i parametri di reazione: temperatura, pressione di H2, solvente, rapporto molare substrato/catalizzatore, concentrazione, tempo. Successivamente è stata valutata la possibilità di riciclare il catalizzatore recuperando il prodotto di estrazione con acqua, per precipitazione o eseguendo la reazione in miscela bifasica (toluene/H2O). The present work is a collaboration between the Department of Physics and Inorganic Chemistry (group of Prof. Valerio Zanotti - Mattia Vaccari, Dr. Rita Mazzoni) and the Department of Industrial Chemistry and Materials (Group of Prof. Angelo Vaccari - Dr. Thomas Pasini, Dr. Stefania Albonetti, Prof. Fabrizio Cavani), and it’s a project devoted to evaluate the activity and selectivity of the Shvo catalyst, in the selective hydrogenation of polar double bond of 5 -hydroxymethylfurfural (HMF) in homogeneous phase. The HMF is an organic compound easily obtained from biomass, which can be used as a building block for fine chemicals abd polymer production or additives for biofuels with a high calorific value. In particular, our attention turned to the production of 2.5-bishydroxymethylfuran (BHMF), an important building block for the production of polymers and polyurethane foams. This thesis has involved the development of a new synthetic methodology for the preparation of Shvo’s catalyst and the study of its catalytic activity in the reduction of HMF to BHMF. The behavior of the catalyst was monitored by studying the yield in BHMF as a function of all the reaction parameters: temperature, pressure of H2, solvent, substrate to catalyst molar ratio, concentration, time. Subsequently it was evaluated the possibility of recycling the catalyst recovering the product of extraction with water, by precipitation or performing the reaction in biphasic mixture (toluene/H2O).

Studio di catalisi termoattivate per compositi poliuretanici

One of the key processing parameters in thermoset composites manufacturing is to have an optimum balance between open time and cure time. Long open times followed with a fast cure profile (also referred as snap cure or “hockey stick” shaped profiles) are required on applications like Pultrusion, Filament Winding, Resin Transfer Molding (RTM) and Infusion. In this work, several factors affecting the reactivity of a base line polyurethane formulation were studied. The addition of different components such as internal mold release agents, cross-linker, polyols having different molecular structure and isocyanates having different functionality were studied. A literature search was conducted to identify the main catalyst packages existing in the market. The reactivity of catalyst based on tertiary amines, orgamometallic salts, and co-catalyst of amine-organometallic complexes was characterized. Addition of quelants agents such as thioglycerol and acetyl acetone to delay the catalyst activity were also considered. As a consequence of this work a vast reactivity map was generated. This should guide the formulation designer in future product generations for the further development of the mentioned applications. Recommendations on measurements systems and further areas of exploration are also given.

Preparation and assessment of immobilized laccase-based micro- and nanocatalysts for the degradation of anthropogenic compounds

Since the dawn of its presence on earth, the human being has been able to exploit the enzymes for its subsistence. More recent is the meeting between the enzymatic processes and the urgent need for technologies that aim to preserve our planet. In this field nowadays enzymatic catalysis is tested either to depollution/remediation as well as waste disposal. The work presented in this thesis, regarding both these two topics, is tailored on two European projects (EU 2020), MADFORWATER and TERMINUS respectively. Firstly, production of micro- and nanocatalysts via immobilization of laccases (a lignin-degrader enzyme) is performed. In the second part of the thesis laccase is applied to a tertiary treatment of wastewater with the aim to degrade 9 pharmaceutical active compounds in batch reactors. Despite several optimizations, poor degradation is reached and we did not proceed with the study of different bioreactor setups. Therefore, the focus is moved to a project concerning the production of smart multi-layer plastic packaging containing enzymes to improve the possibilities of recycling. In this field shielded nanocatalysts produced via coating techniques able to interact with redox mediators are investigated. The target substrate in this second project is produced in laboratory (i.e. polyurethane like compounds), starting from monomers whose degradation had already been tested, as a proof of concept. The first enzyme studied is still the laccase.

Sviluppo e applicazione di un reattore di prepolimerizzazione in continuo

Presso lo stabilimento DOW di Correggio (che è una system house per la produzione di prepolimeri poliuretanici) la ricerca è attualmente incentrata sullo sviluppo su scala industriale di un reattore pilota continuo di tipo plug flow che andrà a sostituire i tradizionali processi BATCH, con un guadagno in termini di sicurezza e costi di investimento. In particolare, il progetto prevedeva di sperimentare le “ricette” attuali di prepolimeri per applicazioni nel settore della calzatura per valutarne l’equivalenza con quelli fatti in BATCH, e di calibrare un modello del reattore pilota che permetta di prevedere le prestazioni del reattore e supporti lo scale-up attraverso la raccolta di dati sperimentali (profili di temperatura, tempi di residenza, titolo di NCO del prodotto, ecc...). Alla conclusione del progetto è possibile affermare che la tecnologia è robusta, scalabile e rispetto ai sistemi di produzione attuale presenta una maggiore produttività, sicurezza e minori costi di investimento. At the DOW plant in Correggio, which is a system house for the production of polyurethane prepolymers, the research is currently focused on the develompment and application of a plug flow type continuos reactor that will replace the traditional BATCH processes, with advantages in terms of process safety an investment costs. In particular, the project aims were to test in the pilot plant the prepolymer receipts for footwear application, find out if the result products were similar or better than the ones made with BATCH reactor and harvest experimental data (such as temperatures profiles, reaction time, residual NCO value, etc...) in order to calibrate a model that will support the scale-up to the industrial plant. Now that the project is ended, it is possibile to assert that this tecnology is reliable, scalable, safer and cheaper than the old processes.

Cure Induced Residual Stresses on Thick Composite Components Manufactured by Additive Process

This study investigates the effect of an additive process in manufacturing of thick composites. Airstone 780 E epoxy resin and 785H Hardener system is used in the analysis since it is widely used wind turbine blade, namely thick components. As a fiber, fabric by SAERTEX (812 g/m2) with a 0-90 degrees layup direction is used. Temperature overshoot is a major issue during the manufacturing of thick composites. A high temperature overshoot leads to an increase in residual stresses. These residual stresses are causing warping, delamination, dimensional instability, and undesired distortion of composite structures. A coupled thermo-mechanical model capable of predicting cure induced residual stresses have been built using the commercial FE software Abaqus®. The possibility of building thick composite components by means of adding a finite number of sub-laminates has been investigated. The results have been compared against components manufactured following a standard route. The influence of pre-curing of the sub-laminates has also been addressed and results compared with standard practice. As a result of the study, it is found that introducing additive process can prevent temperature overshoot to occur and benefits the residual stresses generation during the curing process. However, the process time required increases by 50%, therefore increasing the manufacturing costs. An optimized cure cycle is required to minimize process time and cure induced defects simultaneously.

Dalla Sintesi di Leganti Polimerici alla Realizzazione di Adesivi da Parquet

This final report is part of a research project by Kerakoll S.P.A aimed to the realization and optimization of hybrid adhesive for the parquet using hybrid polyurethane silanizated (STPU). Hybrid polymers belong to polyurethane polymers which undergo an hybridization process where the classic isocyanate groups are converted into a alkoxysilylether terminated chain. The aim of this thesis was to realize hybrid polymers with specific proprieties compared to the indexes wanted by the company; another goal of this project was to use this polymers STPU to realize adhesive for the parquet which should be competitive in the adhesive market. All activities were carried out in a chemistry laboratory with specific tools for the synthesis of polymers and characterization of the finals products. The study led to two prototypes; the second was obtained thanks to the use of the experimental design procedure known as DOE (Design Of Experiment), a recently acquired approach by the company, which allows the rationalization of the formulas and the creation of a database that can be extended and implemented indefinitely.