Phase behavior, crystallization, and hierarchical nanostructures in self-organized thermoset blends of epoxy resin and amphiphilic poly(ethylene oxide)-block-poly(propylene oxide)-block-poly(ethylene oxide) triblock copolymers

Nanostructured thermoset blends of bisphenol A-type epoxy resin (ER) and amphiphilic poly(ethylene oxide)-block-poly(propylene oxide)-block-poly(ethylene oxide) (PEO-PPO-PEO) triblock copolymers were successfully prepared. Two samples of PEO-PPO-PEO triblock copolymer with different ethylene oxide (EO) contents, denoted as EO30 with 30 wt % EO content and EO80 with 80 wt % EO content, were used to form the self-organized thermoset blends of varying compositions using 4,4'-methylenedianiline (MDA) as curing agent. The phase behavior, crystallization, and morphology were investigated by differential scanning calorimetry (DSC), transmission electron microscopy (TEM), atomic force microscopy (AFM), and small-angle X-ray scattering (SAXS). It was found that macroscopic phase separation took place in the MDA-cured ER/EO30 blends containing 60-80 wt % EO30 triblock copolymer. The MDA-cured ER/EO30 blends with EO30 content up to 50 wt % do not show macroscopic phase separation but exhibit nanostructures on the order of 10-30 nm as revealed by both the TEM and SAXS studies. The AFM study further shows that the ER/EO30 blend at some composition displays structural inhomogeneity at two different nanoscales and is hierarchically nanostructured. The spherical PPO domains with an average size of about 10 nm are uniformly dispersed in the 80/20 ER/EO30 blend; meanwhile, a structural inhomogeneity on the order of 50-200 nm is observed. The ER/EO80 blends are not macroscopically phase-separated over the entire composition range because of the much higher PEO content of the EO80 triblock copolymer. However, the ER/EO80 blends show composition-dependent nanostructures on the order of 10-100 nm. The 80/20 ER/EO80 blend displays hierarchical structures at two different nanoscales, i.e., a bicontinuous microphase structure on the order of about 100 nm and spherical domains of 10-20 nm in diameter uniformly dispersed in both the continuous microphases. The blends with 60 wt % and higher EO80 content are completely volume-filled with spherulites. Bundles of PEO lamellae with spacing of 20-30 nm interwoven with a microphase structure on the order of about 100 nm are revealed by AFM study for the 30/70 ER/EO80 blend.

Characterization of melded carbon fibre/epoxy laminates

‘Melding’ is a novel in situ method for joining thermosetting composite structures, without the need of adhesives. Laminate joining is achieved using uncrosslinked resin matrix of the pre-preg. This study used Hexply914C pre-preg material to characterize melded CFRP structures produced using the melding method. A designated area of a laminate was maintained at temperatures below 40 °C retaining uncured (B-staged) material, while the remainder of the laminate was cured at 175 °C. After a 2.5 h cure cycle, the cured region showed a high degree of cure (0.88) and glass transition temperature (176 °C). The uncured area of the same laminate was cured in a second stage, simulating an in situ melded joint. By controlling the temperature and duration of the intermediate dwell and affecting minimum viscosity values prior to final cure, low values of porosity (<0.5%) were achieved. The mechanical properties of the resulting joint were consistent throughout the melded laminate. Flexural strength (1600 MPa), flexural modulus (100–105 MPa) and short beam strength (105–115 MPa) values observed where equivalent or greater than those found in the recommended autoclave cured control specimens. After the entire laminate was post cured, glass transition temperatures of 230 °C (peak tan δ) were observed in all areas of the laminate.

Consistent model predictions for isothermal cure kinetics investigation of high performance epoxy prepregs

An accurate kinetics model is essential for understanding the curing mechanism and predicting the end properties of polymer materials. Graphite/epoxy AS4/ 8552 prepreg is a recent high-performance thermosetting composite modified with thermoplastic, which is being used in the manufacture of aircraft and military structures. The isothermal cures of this system along with another thermoplastic toughened high-performance prepreg, the T800H/3900-2 system, were investigated by real-time Fourier transform infrared (FTIR) spectroscopy. The cure rate was quantitatively analyzed based on the concentration profiles of both the epoxy and primary amine groups. Three autocatalytic models were used to determine kinetics parameters for both composite systems. The model which utilizes an empirical term, the final relative conversion (at different isothermal curing temperatures), describes the experimental data of both systems more satisfactorily than the model which applies a diffusion factor. The modeling results suggest that the curing of epoxy within both prepregs can be assumed to be a second order process.

Nanostructures and nanoporosity in thermoset epoxy blends with an amphiphilic polyisoprene-block-poly(4-vinyl pyridine) reactive diblock copolymer

Nanostructured thermoset blends were prepared based on a bisphenol A-type epoxy resin and an amphiphilic reactive diblock copolymer, namely polyisoprene-block-poly(4-vinyl pyridine) (PI-P4VP). Infrared spectra revealed that the P4VP block of the diblock copolymer reacted with the epoxy monomer. However, the non-reactive hydrophobic PI block of the diblock copolymer formed a separate microphase on the nanoscale. Ozone treatment was used to create nanoporosity in nanostructured epoxy/PI-P4VP blends via selective removal of the PI microphase and lead to nanoporous epoxy thermosets; disordered nanopores with the average diameter of about 60 nm were uniformly distributed in the blend with 50 wt% PI-P4VP. Multi-scale phase separation with a distinctly different morphology was observed at the air/sample interface due to the interfacial effects, whereas only uniform microphase separated morphology at the nanoscale was found in the bulk of the blend.

Structural and material properties of a rapidly cured thermoplastic-toughened epoxy system

Thermoplastic-toughened epoxy resins are widely used as matrices in modern composite prepreg systems. Rapid curing of thermoplastic-toughened epoxy matrix composites results in different mechanical properties. To investigate the structure–property relationship, we investigated a poly(ether sulfone)-modified triglycidylaminophenol/ 4,4'-diamino diphenyl sulfone system that was cured at different heating rates. An intermediate dwell was also applied during the rapid heating of the thermoplasticmodified epoxy system. We found that a higher heating rate led to a larger domain size of the phase-separated macrostructure and also facilitated more complete phase separation. The intermediate dwell helped phase separation to proceed even further, leading to an even larger domain size of the macrostructure. A carbon-fiber-reinforced polymer matrix composite prepreg based on the poly(ether sulfone)-modified multifunctional epoxy system was cured with the same schedule. The rapidly heated composite laminates exhibited higher mode I delamination fracture toughness than the slowly heated material.

Thermal and mechanical properties of a dendritic hydroxyl-functional hyperbranched polymer and tetrafunctional epoxy resin blends

Blends of a tetrafunctional epoxy resin, tetraglycidyl- 4,40'-diaminodiphenylmethane (TGDDM), and a hydroxylfunctionalized hyperbranched polymer (HBP), aliphatic hyperbranched polyester Boltorn H40, were prepared using 3,3'-diaminodiphenyl sulfone (DDS) as curing agent. The phase behavior and morphology of the DDS-cured epoxy/HBP blends with HBP content up to 30 phr were investigated by differential scanning calorimetry (DSC), dynamic mechanical analysis (DMA), and scanning electron microscopy (SEM). The phase behavior and morphology of the DDS-cured epoxy/HBP blends were observed to be dependent on the blend composition. Blends with HBP content from 10 to 30 phr, show a particulate morphology where discrete HBP-rich particles are dispersed in the continuous cured epoxy-rich matrix. The cured blends with 15 and 20 phr exhibit a bimodal particle size distribution whereas the cured blend with 30 phr HBP demonstrates a monomodal particle size distribution. Mechanical measurements show that at a concentration range of 0–30 phr addition, the HBP is able to almost double the fracture toughness of the unmodified TGDDM epoxy resin. FTIR displays the formation of hydrogen bonding between the epoxy network and the HBP modifier.

Surface analysis of carbon fibre epoxy composites

This thesis investigated the surface finish of rapidly cured composites for automotive body panels. Findings showed that curing composites with rapid heating rates increased surface roughness, although it improved paint adhesion to the substrate. This thesis also highlighted the need for surface barriers to reduce fibre print through during aging.

Fracture behaviour of a rapidly cured polyethersulfone toughened carbon fibre/epoxy composite

An out-of-autoclave rapid heating/low pressure technique has been used to cure polyethersulfone (PES) toughened HexPly 8552. Mode I and mode II tests were conducted to evaluate the fracture toughness of the composites and the effectiveness of cure was determined through thermal analysis. When compared to the autoclave process, the out-of-autoclave process resulted in a 52% reduction in processing time, without any sacrifice to the matrix intrinsic properties. Thermal analysis indicated an 8 °C improvement in glass transition temperature (T_g) as a result of an increased degree of cure. The out-of-autoclave process did lack in the ability to facilitate the removal of porosity which affected the fracture toughness results. The porosity is believed to have increased the mode I propagation fracture toughness. However its effect on mode II was quite deleterious, shown by scanning electron microscopy (SEM). This study managed to identify a number of key parameters associated with the out-of-autoclave process essential for further optimisation.

Investigation of the postcure reaction and surface energy of epoxy resins using time-of-flight secondary ion mass spectrometry and contact-angle measurements

Time-of-flight secondary ion mass spectrometry (ToF-SIMS) was used to investigate correlations between the molecular changes and postcuring reaction on the surface of a diglycidyl ether of bisphenol A and diglycidylether of bisphenol F based epoxy resin cured with two different amine-based hardeners. The aim of this work was to present a proof of concept that ToF-SIMS has the ability to provide information regarding the reaction steps, path, and mechanism for organic reactions in general and for epoxy resin curing and postcuring reactions in particular. Contact-angle measurements were taken for the cured and postcured epoxy resins to correlate changes in the surface energy with the molecular structure of the surface. Principal components analysis (PCA) of the ToFSIMS positive spectra explained the variance in the molecular information, which was related to the resin curing and postcuring reactions with different hardeners and to the surface energy values. The first principal component captured information related to the chemical phenomena of the curing reaction path, branching, and network density based on changes in the relative ion density of the aliphatic hydrocarbon and the C₇H₇O⁺ positive ions. The second principal component captured information related to the difference in the surface energy, which was correlated to the difference in the relative intensity of the C_xH_yN_z⁺ ions of the samples. PCA of the negative spectra provided insight into the extent of consumption of the hardener molecules in the curing and postcuring reactions of both systems based on the relative ion intensity of the nitrogen-containing negative ions and showed molecular correlations with the sample surface energy.

Time-of-flight secondary ion mass spectrometry investigation of epoxy resin curing behavior in real time

Time-of-flight secondary ion mass spectrometry and principal components analysis were used in real time to monitor the progress of curing reactions on the surface of a diglycidyl ether of bisphenol A (DGEBA) and diglycidyl ether of bisphenol F (DGEBF) epoxy resin blend reacted with the diamine hardener isophorone diamine at different time intervals. Molecular ions in the mass spectra that characterized the curing reactions steps, including blocking, coupling, branching, and crosslinking, were identified. The aliphatic hydrocarbon ions were correlated to the curing reaction rate, and this indicated that coupling and branching occurred much faster than the blocking and crosslinking curing reactions steps. The total conversion of the coupling and branching reaction steps were followed on the basis of changes with time in the relative ion intensity of molecular ions assigned to the DGEBA/DGEBF, aliphatic hydrocarbon, epoxide, and aromatic ring structures. Indicative measures of crosslinking density were monitored through the observation of changes in the ratio of the relative intensities of the aliphatic hydrocarbon and hydroxyl molecular ions over time. The curing reaction conversion was established by the observation of the changes in the relative ion intensity of the molecular ions that were related to the DGEBA/ DGEBF molecules.

High-performance composite from epoxy and glass fibers : morphology, mechanical, dynamic mechanical, and thermal analysis

Diglycidyl ether of bisphenol-A type epoxy resin cured with diamino diphenyl sulfone was used as the matrix for fiber-reinforced composites to get improved mechanical and thermal properties for the resulting composites. E-glass fiber was used for fiber reinforcement. The morphology, tensile, flexural, impact, dynamic mechanical, and thermal properties of the composites were analyzed. The tensile, flexural, and impact properties showed dramatic improvement with the addition of glass fibers. Dynamic mechanical analysis was performed to obtain the Tg of the cured matrix as well as the composites. The improved thermal stability of the composites was clear from the thermogravimetric analysis. Scanning electron micrographs were taken to understand the interfacial adhesion between the fiber and the matrix. The values of mechanical properties were compared with modified epoxy resin composite system. Predictive models were applied using various equations to compare the mechanical data obtained theoretically and experimentally.

Structure and properties of epoxy nanocomposites

This study investigated the structure-property relationships of epoxy nanocomposites when processing the materials under various conditions. A sonication technique, rapid heating rate and mechanical vibration during curing facilitated the dispersion of nanoclay in an epoxy resin. This led to the successful manufacture of fibre reinforced nanocomposites.