Individual dispersion of carbon nanotubes in epoxy via a novel dispersion-curing approach using ionic liquids

The effective dispersion of carbon nanotubes (CNTs) in a thermoset was achieved using ionic liquid as the dispersion-curing agent. We preferentially dispersed multiwalled carbon nanotubes (MWCNTs) down to individual tube levels in epoxy resin. Here the dispersion is ruled by the depletion of physical bundles within the MWCNT networks, for which molecular ordering of ionic liquids is considered responsible. The quantitative analyses using ultra small angle X-ray scattering (USAXS) confirmed the dispersion of individual MWCNTs in the matrix. The distance between the dispersed nanotubes was calculated at different nanotube loadings using the power law fitting of the USAXS data. The fine dispersion and subsequent curing, both controlled by ionic liquid, lead to composites with substantially enhanced fracture mechanical and thermomechanical properties with no reduction in thermal properties. Merging processing techniques of nanocomposites with ionic liquid for efficient dispersion of nanotubes and preferential curing of thermosets facilitates the development of new, high performance materials.

The effect of a rapid heating rate, mechanical vibration and surfactant chemistry on the structure-property relationships of epoxy/clay nanocomposites

The role of processing conditions and intercalant chemistry in montmorillonite clays on the dispersion, morphology and mechanical properties of two epoxy/clay nanocomposite systems was investigated in this paper. This work highlights the importance of employing complementary techniques (X-ray diffraction, small angle X-ray scattering, optical microscopy and transmission electron microscopy) to correlate nanomorphology to macroscale properties. Materials were prepared using an out of autoclave manufacturing process equipped to generate rapid heating rates and mechanical vibration. The results suggested that the quaternary ammonium surfactant on C30B clay reacted with the epoxy during cure, while the primary ammonium surfactant (I.30E) catalysed the polymerisation reaction. These effects led to important differences in nanocomposite clay morphologies. The use of mechanical vibration at 4 Hz prior to matrix gelation was found to facilitate clay dispersion and to reduce the area fraction of I.30E clay agglomerates in addition to increasing flexural strength by over 40%.

Toughening epoxy thermosets with block ionomers : the role of phase domain size

Herein we report a novel approach to toughen epoxy thermosets using a block ionomer, i.e., sulfonated polystyrene-block-poly(ethylene-co-butylene)-block- polystyrene (SSEBS). SSEBS was synthesized by sulfonation of SEBS with 67 wt % polystyrene (PS). Phase morphology of the epoxy/SSEBS blends can be controlled at either nanometer or micrometer scale by simply adjusting the sulfonation degree of SSEBS. It has been found that there exists a critical degree of sulfonation (10.8 mol %) forming nanostructures in these epoxy/SSEBS blends. Above this critical value, macrophase separation can be avoided and only microphase separation occurs, yielding transparent nanostructured blends. All epoxy/SSEBS blends display increased fracture toughness compared to neat epoxy. But the toughening efficiency varies with the phase domain size, and their correlation has been established over a broad range of length scales from nanometers to a few micrometers. In the nanostructured blends with SSEBS of high sulfonation degrees, the fracture toughness decreases with decreasing size of the phase domains. In the macrophase-separated blends, only a slight improvement in toughness can be obtained with SSEBS of low sulfonation degrees. The epoxy blend with submicrometer phase domains in the range 0.05-1.0 μm containing SSEBS of a moderate degree of sulfonation (5.8 mol %) displays the maximum toughness. This study has clearly clarified the role of phase domain size on toughening efficiency in epoxy thermosets.

Nanostructure toughening of epoxy thermosets with block Ionomer complexes

This thesis addresses an important issue in polymer materials science, the toughening of thermosetting polymers. A novel approach has been developed, i.e., the use of block ionomers/complexes to promote compatibilization with thermosetting epoxies. The morphology and mechanical properties of the resulting nanostructured epoxies were intensively studied to establish structure-property correlation.

Energy absorption behaviour of rapidly manufactured carbon/epoxy and glass/polypropylene structures

In this thesis the crashworthiness of composite tubular structures was investigated along with the property structure relationships of a glass/polypropylene material. The energy absorption capacity of tubular structures in a number of different testing configurations was made. Two materials; carbon/epoxy pre-preg and a glass/polypropylene dry pre-preg were investigated.

Improving performance of CFRP retrofitted RC members using rubber modified epoxy (ongoing research)

Although the method of external attachment of CFRP to the concrete members is the most effective and economical solution for strengthening and repairing concrete structure in the century, the bonding issue between CFRP and the hosting surface still a challenge for the structural engineers. Many solutions are proposed to overcome the early debonding failure in the strengthened members. This paper reports an ongoing experimental program for testing CFRP retrofitted RC beams and slabs. Fifteen RC beams of dimensions 150x250x2300mm and twelve two- way RC slabs of size 85x1670x1670mm will be strengthened using different types of epoxies, different configurations and variable number of layers of CFRP strips (MBrace-230). Rubber modified epoxy will be used for carbon fibre external attachment using wet lay-up method. Loading frame of 500 kN capacity will be used for beams testing. While for applying uniformly distributed load on the slabs a purpose built attachment will be used. The experimental results will report on the ultimate load, failure mode, mid-span deflection, strains readings in different locations and the ductility for both groups of strengthened beams and slabs. A mathematical model will be developed to predict the behavior of RC beams and two-way slabs.

Bond properties of rubber modified epoxy

In this paper, the bond integrity of unmodified and rubber-modified epoxy used for bonding the carbon fibre sheets to the hosting steel surface was investigated. The rigidity of the bonding agent is one of the factors that have a significant role in the premature failure (debonding) of this application. In order to overcome this issue, a series of experiments were conducted on the steel plates using the epoxy resin modified by CTBN and ATBN reactive liquid polymers, in addition to the unmodified epoxy resin. The interface between the carbon fibre matrix and the hosting surface is subjected to a longitudinal shear force for which the corresponding displacement is recorded. The shear stress-strain relationship for the tested specimen is plotted. The result shows that, the bond behaviour of modified epoxy using CTBN and ATBN reactive liquid polymers was improved in terms of ductility and toughness.

Effect of surface functionality of PAN-based carbon fibres on the mechanical performance of carbon/epoxy composites

The performance of composite laminates depends on the adhesion between the fibre reinforcement and matrix, with the surface properties of the fibres playing a key role in determining the level of adhesion achieved. For this reason it is important to develop an in-depth understanding of the surface functionalities on the reinforcement fibres. In this work, multi-scale surface analysis of carbon fibre during the three stages of manufacture; carbonisation, electrolytic oxidation, and epoxy sizing was carried out. The surface topography was examined using scanning electron microscopy (SEM), which revealed longitudinal ridges and striations along the fibre-axis for all fibre types. A small difference in surface roughness was observed by scanning probe microscopy (SPM), while the coefficient of friction measured by an automated single fibre tester showed 51% and 98% increase for the oxidised and sized fibres, respectively. The fibres were found to exhibit heterogeneity in surface energy as evidenced from SPM force measurements. The unsized fibres were much more energetically heterogeneous than the sized fibre. A good correlation was found between fibre properties (both physical and chemical) and interlaminar shear strength (ILSS) of composites made from all three fibre types. © 2014 Elsevier Ltd.

Epoxy nanocomposites containing magnetite-carbon nanofibers aligned using a weak magnetic field

Abstract Novel magnetite-carbon nanofiber hybrids (denoted by Fe3O4@CNFs) have been developed by coating carbon nanofibers (CNFs) with magnetite nanoparticles in order to align CNFs in epoxy using a relatively weak magnetic field. Experimental results have shown that a weak magnetic field (∼mT) can align these newly-developed nanofiber hybrids to form a chain-like structure in the epoxy resin. Upon curing, the epoxy nanocomposites containing the aligned Fe3O4@CNFs show (i) greatly improved electrical conductivity in the alignment direction and (ii) significantly higher fracture toughness when the Fe3O4@CNFs are aligned normal to the crack surface, compared to the nanocomposites containing randomly-oriented Fe3O4@CNFs. The mechanisms underpinning the significant improvements in the fracture toughness have been identified, including interfacial debonding, pull-out, crack bridging and rupture of the Fe3O4@CNFs, and plastic void growth in the polymer matrix.