Galvanic Corrosion of High-Temperature Low-Sag (HTLS) High Voltage Conductors: New Materials - New Challenges

High-Temperature Low-Sag (HTLS) high voltage overhead conductors offer higher operating temperatures, reduced resistance and less sag than conventional designs. With up to twice the current capacity for the same diameter conductor, they may help ease the power shortage in the constantly increasing electricity demand, but there might be some concerns about their corrosion resistance. These new conductors use materials relatively new to the power industry, such as advanced carbon fiber polymer matrix composites and unique metal matrix composites/nano-composites predominantly used in aerospace industries. This study has made an initial assessment of potential galvanic corrosion problems in three very different HTLS designs: ACCC (Aluminum Conductor Composite Core), ACCR (Aluminum Conductor Composite Reinforced) and ACSS (Aluminum Conductor Steel Supported). In particular the ACCC design was evaluated for its resistance to corrosion and compared to the other designs. The study concludes that all three designs can develop galvanic corrosion under certain circumstances. While the results are not sufficient to make service life predictions of any of the tested conductors, they point out the necessity of thorough corrosion testing of all new conductor designs.

Predictions of J integral and tensile strength of clay/epoxy nanocomposites material using phase field model

We predict macroscopic fracture related material parameters of fully exfoliated clay/epoxy nano- composites based on their fine scale features. Fracture is modeled by a phase field approach which is implemented as user subroutines UEL and UMAT in the commercial finite element software Abaqus. The phase field model replaces the sharp discontinuities with a scalar damage field representing the diffuse crack topology through controlling the amount of diffusion by a regularization parameter. Two different constitutive models for the matrix and the clay platelets are used; the nonlinear coupled system con- sisting of the equilibrium equation and a diffusion-type equation governing the phase field evolution are solved via a NewtoneRaphson approach. In order to predict the tensile strength and fracture toughness of the clay/epoxy composites we evaluated the J integral for different specimens with varying cracks. The effect of different geometry and material parameters, such as the clay weight ratio (wt.%) and the aspect ratio of clay platelets are studied.

Mechanical, electrical and electro-mechanical properties of thermoplastic elastomer styrene–butadiene–styrene/multiwal carbon nanotubes composites

Composites of styrene–butadiene–styrene (SBS) block copolymer with multiwall carbon nanotubes were processed by solution casting to investigate the influence of filler content, the different ratios of styrene/butadiene in the copolymer and the architecture of the SBS matrix on the electrical, mechanical and electro-mechanical properties of the composites. It was found that filler content and elastomer matrix architecture influence the percolation threshold and consequently the overall composite electrical conductivity. Themechanical properties aremainly affected by the styrene and filler content. Hopping between nearest fillers is proposed as the main mechanism for the composite conduction. The variation of the electrical resistivity is linear with the deformation. This fact, together with the gauge factor values in the range of 2–18, results in appropriate composites to be used as (large) deformation sensors.

Mechanical, electrical and electro-mechanical properties of thermoplastic elastomer styrene–butadiene–styrene/multiwall carbon nanotubes composites

Composites of styrene–butadiene–styrene (SBS) block copolymer with multiwall carbon nanotubes were processed by solution casting to investigate the influence of filler content, the different ratios of styrene/butadiene in the copolymer and the architecture of the SBS matrix on the electrical, mechanical and electro-mechanical properties of the composites. It was found that filler content and elastomer matrix architecture influence the percolation threshold and consequently the overall composite electrical conductivity. The mechanical properties are mainly affected by the styrene and filler content. Hopping between nearest fillers is proposed as the main mechanism for the composite conduction. The variation of the electrical resistivity is linear with the deformation. This fact, together with the gauge factor values in the range of 2–18, results in appropriate composites to be used as (large) deformation sensors.

Preparation and characterization of micro and nano fiber reinforced natural rubber composites by latex stage processing

Use of short fibers as reinforcing fillers in rubber composites is on an increasing trend. They are popular due to the possibility of obtaining anisotropic properties, ease of processing and economy. In the preparation of these composites short fibers are incorporated on two roll mixing mills or in internal mixers. This is a high energy intensive time consuming process. This calls for developing less energy intensive and less time consuming processes for incorporation and distribution of short fibers in the rubber matrix. One method for this is to incorporate fibers in the latex stage. The present study is primarily to optimize the preparation of short fiber- natural rubber composite by latex stage compounding and to evaluate the resulting composites in terms of mechanical, dynamic mechanical and thermal properties. A synthetic fiber (Nylon) and a natural fiber (Coir) are used to evaluate the advantages of the processing through latex stage. To extract the full reinforcing potential of the coir fibers the macro fibers are converted to micro fibers through chemical and mechanical means. The thesis is presented in 7 chapters

Free-standing urethane/urea elastomer films undoped and doped with ferro-nano-particles

We report on an experimental study of the structures presented by urethane/urea elastomeric films without and with ferromagnetic nanoparticles incorporated. The study is made by using the X-ray diffraction, nuclear magnetic resonance (NMR), optical, atomic and magnetic force (MFM) microscopy techniques, and mechanical assays. The structure of the elastomeric matrix is characterized by a distance of 0.46 nm between neighboring molecular segments, almost independent on the stretching applied. The shear casting performed in order to obtain the elastomeric films tends to orient the molecules parallel to the flow direction thus introducing anisotropy in the molecular network which is reflected on the values obtained for the orientational order parameter and its increase for the stretched films. In the case of nanoparticles-doped samples, the structure remains nearly unchanged although the local order parameter is clearly larger for the undoped films. NMR experiments evidence modifications in the molecular network local ordering. Micrometer size clusters were observed by MFM for even small concentration of magnetic particles.

Electro-mechanical properties of triblock copolymer styrene-butadiene-styrene / carbon nanotube composites for large deformation sensor applications

Thermoplastic elastomer/carbon nanotube composites are studied for sensor applications due to their excellent mechanical and electrical properties. Piezoresisitive properties of tri-block copolymer styrene-butadiene-styrene (SBS)/ carbon nanotubes (CNT) prepared by solution casting have been investigated. Young modulus of the SBS/CNT composites increases with the amount of CNT filler content present in the samples, without losing the high strain deformation on the polymer matrix (~1500 %). Further, above the percolation threshold these materials are unique for the development of large deformation sensors due to the strong piezoresistive response. Piezoresistive properties evaluated by uniaxial stretching in tensile mode and 4-point bending showed a Gauge Factors up to 120. The excellent linearity obtained between strain and electrical resistance makes these composites interesting for large strain piezoresistive sensors applications.

Polyaniline Coated Short Nylon Fiber/Elastomer Composites: Electrical and Microwave Characteristics

Department of Polymer Science and Rubber Technology, Cochin University of Science and Technology

Studies on short nylon fiber - reclaimed rubber/elastomer composites

The thesis deals with the development of short nylon fiber-reclaimed rubber/elastomer composites. Three rubbers viz, natural rubber, acrylonitrile butadiene rubber and styrene butadiene rubber were selected and were partially replaced with reclaimed rubber. The blend ratio was optimized with respect to cure characteristics and mechanical properties. Reclaimed rubber replaced 40 parts of NR and SBR and 20 parts of NBR without much affecting the properties. These blends were then reinforced with short nylon fibers. The mechanical properties of the composites were studied in detail. In all the cases the tensile strength, tear strength and the abrasion resistance increased with increase in fiber content. In the case of NRlreclaimed rubber blends, the tensile strength-fiberloading relationship was non-linear where as in the case of NBRlreclaimed rubber blends and SBRlreclaimed rubber blends the tensile strength-fiber loading relationship was linear. All the composites showed anisotropy in mechanical properties. The effect of bonding system on the composite properties was also studied with respect to cure characteristics and mechanical properties. For this, a 20 phr fiber loaded reclaimed rubber/elastomer composites were selected and the effect of MDI/PEG resin system was studied. The resin used was 5 phr and the resin ratios used were 0.67: I, 1:1, 1.5:1 and 2:1. The bonding system improved the tensile strength, tear strength and abrasion resistance. The best results are with SBRlreclaimed rubber-short nylon fiber composites. The optimized resin ratio was 1:1 MDI/PEG for all the composites.

Studies on short Nylon-6 fiber - elastomer composites with epoxy resin as bonding agent

The thesis describes the development and evaluation of epoxy resin as interfacial bonding agent for short Nylon-6 fiber elastomer composites. Epoxy resin is well known for its adhesive property. The potential use of it as interfacial bonding agent in short fiber composite is not explored yet. Three rubbers viz., acrylonitrile butadiene rubber (NBR), Neoprene rubber (CR) and styrene butadiene rubber (SBR) were selected and different fiber loading were tried. The resin concentration was optimized for each fiber loading with respect to cure characteristics and mechanical properties. Rheological characteristics and thermal degradation of the composites containing different fiber loading and different resin concentrations were studied in detail to find the effect of epoxy resin bonding system. The mechanical properties were studied in detail. The short Nylon -6 fiber improved most of the mechanical properties of all the three rubbers. Tensile strength showed a dip at 10 phr fiber loading in the case of CR while it was continuously increased with fiber loading in the case of NBR and SBR. All the composites showed anisotropy in mechanical properties. The epoxy resin is an effective bonding agent for short Nylon -6 fiber reinforced NBR and CR composites. Epoxy resin improved tensile strength, abrasion resistance and modulus of these composites. SEM studies confirmed the improved bonding of fiber and matrix in the presence of epoxy bonding agent. Epoxy resin was not effective as bonding agent in the case of short Nylon fiber- SBR composite. From the rheological studies of the composites with and without bonding agent it was observed that all the composite exhibited pseudoplasticity, which decreased with temperature. At higher shear rates all the mixes showed plug flow. SEM pictures showed that maximum orientation of fibers occured at a shear rate, just before the onset of plug flow. The presence of fiber reduced the temperature sensitivity of the flow at a given shear rate. Die swell was reduced in the presence of fiber. Shear viscosity of the composite was increased in the presence of resin. Die swell was increased in the presence of epoxy resin for composites at all shear rates. The thermal degradation of NBR and SBR composites with and without bonding agent followed single step degradation pattern. Thermal stability of the composites was improved in the presence of bonding agent. The degradation of virgin elastomer and the composites followed first order kinetics.

Studies on Conducting Polymers and Conductive Elastomer Composites

The primary aim of this work has been to develop conductive silicone and nitrile rubbers, which are extensively used for making conductive pads in telephone sets, calculators and other applications. Another objective of the work has been to synthesise and characterize novel conducting polymers based on glyoxal and paraphenylenediamine- poly(p-phenylenediazomethine. Conducting polymer matrices were developed from polymer blends such as poly(pphenylenediazomethine), polyethylene, PVC and silica and their properties were studied.

Investigations on The Finite Size Effects of Some Inverse Spinels and Studies on Their Composites Based on Nitrile Rubber

Magnetism and magnetic materials have been an ever-attractive subject area for engineers and scientists alike because of its versatility in finding applications in useful devices. They find applications in a host of devices ranging from rudimentary devices like loud speakers to sophisticated gadgets like waveguides and Magnetic Random Access Memories (MRAM).The one and only material in the realm of magnetism that has been at the centre stage of applications is ferrites and in that spinel ferrites received the lions share as far as practical applications are concerned.It has been the endeavour of scientists and engineers to remove obsolescence and improve upon the existing so as to save energy and integrate in to various other systems. This has been the hallmark of material scientists and this has led to new materials and new technologies.In the field of ferrites too there has been considerable interest to devise new materials based on iron oxides and other compounds. This means synthesising ultra fine particles and tuning its properties to device new materials. There are various preparation techniques ranging from top- down to bottom-up approaches. This includes synthesising at molecular level, self assembling,gas based condensation. Iow temperature eo-precipitation, solgel process and high energy ball milling. Among these methods sol-gel process allows good control of the properties of ceramic materials. The advantage of this method includes processing at low temperature. mixing at the molecular level and fabrication of novel materials for various devices.Composites are materials. which combine the good qualities of one or more components. They can be prepared in situ or by mechanical means by the incorporation of fine particles in appropriate matrixes. The size of the magnetic powders as well as the nature of matrix affect the processability and other physical properties of the final product. These plastic/rubber magnets can in turn be useful for various applications in different devices. In applications involving ferrites at high frequencies, it is essential that the material possesses an appropriate dielectric permittivity and suitable magnetic permeability. This can be achieved by synthesizing rubber ferrite composites (RFC's). RFCs are very useful materials for microwave absorptions. Hence the synthesis of ferrites in the nanoregirne.investigations on their size effects on the structural, magnetic, and electrical properties and the incorporation of these ferrites into polymer matrixes assume significance.In the present study, nano particles of NiFe204, Li(!5Fe2S04 and Col-e-O, are prepared by sol gel method. By appropriate heat treatments, particles of different grain sizes are obtained. The structural, magnetic and electrical measurements are evaluated as a function of grain size and temperature. NiFel04 prepared in the ultrafine regime are then incorporated in nitrile rubber matrix. The incorporation was carried out according to a specific recipe and for various loadings of magnetic fillers. The cure characteristics, magnetic properties, electrical properties and mechanical properties of these elastomer blends are carried out. The electrical permittivity of all the rubber samples in the X - band are also conducted.

”Investigations on The Finite Size Effects of Some Inverse Spinels and Studies on Their Composites Based on Nitrile Rubber”

In the present study, nano particles of NiFe3O4, I_.l()5Feg5O4 and CoFegO4 are prepared by sol gel method. By appropriate heat treatments, particles of different grain sizes are obtained. The structural, magnetic and electrical measurements are evaluated as a function of grain size and temperature. NiFe3O4 prepared in the ultrafine regime are then incorporated in nitrile rubber matrix. The incorporation was carried out according to a specific recipe and for various loadings of magnetic fillers. The cure characteristics, magnetic properties, electrical properties and mechanical properties of these elastomer blends are carried out. The electrical permittivity of all the rubber samples in the X — band are also conducted

Cure Characteristics and Mechanical Properties of Rubber Ferrite Composites Based on Nano-Nickel Ferrites

Ultra fine nickel ferrite have been synthesized by the sol-gel method. By heat treating different portions of the prepared powder separately at different temperatures, nano-sized particles of nickel ferrite with varying particle sizes were obtained. These powders were characterised by the X-ray diffraction and then incorporated in the nitrile rubber matrix according to a specific recipe for various loadings. The cure characteristics and the mechanical properties of these rubber ferrite composites (RFCs) were evaluated. The effect of loading and the grain size of the filler on the cure characteristics and tensile properties were also evaluated. It is found that the grain size and porosity of the filler plays a vital role in determining the mechanical properties of the RFCs

Studies on betanin natural dye incorporated ZnO composites at nano and micro scale for photonic device applications

Green energy and Green technology are the most of the quoted terms in the context of modern science and technology. Technology which is close to nature is the necessity of the modern world which is haunted by global warming and climatic alterations. Proper utilization of solar energy is one of the goals of Green Energy Movement. The present thesis deals with the work carried out in the eld of nanotechnology and its possible use in various applications (employing natural dyes) like solar cells. Unlike arti cial dyes, the natural dyes are available, easy to prepare, low in cost, non-toxic, environmentally friendly and fully biodegradable. Looking to the 21st century, the nano/micro sciences will be a chief contributor to scienti c and technological developments. As nanotechnology progresses and complex nanosystems are fabricated, a growing impetus is being given to the development of multi-functional and size-dependent materials. The control of the morphology, from the nano to the micrometer scales, associated with the incorporation of several functionalities can yield entirely new smart hybrid materials. They are special class of materials which provide a new method for the improvement of the environmental stability of the material with interesting optical properties and opening a land of opportunities for applications in the eld of photonics. Zinc oxide (ZnO) is one such multipurpose material that has been explored for applications in sensing, environmental monitoring, and bio-medical systems and communications technology. Understanding the growth mechanism and tailoring their morphology is essential for the use of ZnO crystals as nano/micro electromechanical systems and also as building blocks of other nanosystems.