Fracture Toughening and Self-Healing of Composite Laminates by Nanofibrous Mats Interleaving

Composite laminates present important advantages compared to conventional monolithic materials, mainly because for equal stiffness and strength they have a weight up to four times lower. However, due to their ply-by-ply nature, they are susceptible to delamination, whose propagation can bring the structure to a rapid catastrophic failure. In this thesis, in order to increase the service life of composite materials, two different approaches were explored: increase the intrinsic resistance of the material or confer to them the capability of self-repair. The delamination has been hindered through interleaving the composite laminates with polymeric nanofibers, which completed the hierarchical reinforcement scale of the composite. The manufacturing process for the integration of the nanofibrous mat in the laminate was optimized, resulting in an enhancement of mode I fracture toughness up to 250%. The effect of the geometrical dimensions of the nano-reinforcement on the architecture of the micro one (UD and woven laminates) was studied on mode I and II. Moreover, different polymeric materials were employed as nanofibrous reinforcement (Nylon 66 and polyvinylidene fluoride). The nano toughening mechanism was studied by micrograph analysis of the crack path and SEM analysis of the fracture surface. The fatigue behavior to the onset of the delamination and the crack growth rate for woven laminates interleaved with Nylon 66 nanofibers was investigated. Furthermore, the impact behavior of GLARE aluminum-glass epoxy laminates, toughened with Nylon 66 nanofibers was investigated. Finally, the possibility of confer to the composite material the capability of self-repair was explored. An extrinsic self-healing-system, based on core-shell nanofibers filled with a two-component epoxy system, was developed by co-electrospinning technique. The healing potential of the nano vascular system has been proved by microscope electron observation of the healing agent release as result of the vessels rupture and the crosslinking reaction was verified by thermal analysis.

Novel bio-based amine curing agents for epoxy resins: the way towards fully bio-based composite materials

Epoxy resins are widely used in many applications, such as paints, adhesives and matrices for composites materials, since they present the possibility to be easily and conveniently tailored in order to display a unique combination of characteristics. In literature, various examples of bio-based epoxy resins produced from a wide range of renewable sources can be found. Nevertheless, the toxicity and safety of curing agents have not been deeply investigated and it was observed that all of them still present some environmental drawback. Therefore, the development of new environmentally friendly fully bio-based epoxy systems is of great importance for designing green and sustainable materials. In this context, the present project aims at further exploring the possibility of using bio-based compounds as curing agents for epoxy resin precursors. A preliminary evaluation of several amine-based compounds demonstrated the feasibility of using Adenine as epoxy resin hardener. In order to better understand the crosslinking mechanism, the reaction of Adenine with the mono-epoxy compound Glycidyl 2-methylphenyl ether (G2MPE), was study by 1H-NMR analysis. Then Adenine was investigated as hardener of Diglycidil ether of bisphenol A (DGEBA), which is the simplest epoxy resin based on bisphenol A, in order to determine the best hardener/resin stoichiometric ratio, and evaluate the crosslinking kinetics and conversion and the final mechanical properties of the cured resin. Then, Adenine was tested as hardener of commercial epoxy resins, in particular the infusion resin Elan-tron® EC 157 (Elantas), the impregnation resin EPON™ Resin 828 (Hexion) and the bio-based resin SUPER SAP® CLR (Entropyresins). Such systems were used for the production of composites materials reinforced with chopped recycled carbon fibers and natural fibers (flax and jute). The thermo-mechanical properties of these materials have been studied in comparison with those ones of composites obtained with the same thermosetting resin reinforced with chopped virgin carbon fibers.

Advanced electrospun nanofibrous mats for hindering delamination, improving damping and for sensing of composite laminates

Carbon Fiber Reinforced Polymers (CFRPs) display high specific mechanical properties, allowing the creation of lightweight components and products by metals replacement. To reach outstanding mechanical performances, the use of stiff thermoset matrices, like epoxy, is preferred. Laminated composites are commonly used for their ease of manipulation during object manufacturing. However, the natural anisotropic structure of laminates makes them vulnerable toward delamination. Moreover, epoxy-based CFRPs are very stiff materials, thus showing low damping capacity, which results in unwanted vibrations and structure-borne noise that may contribute to delamination triggering. Hence, searching for systems able to limit these drawbacks is of primary importance for safety reasons, as well as for economic ones. In this experimental thesis, the production and integration of innovative rubbery nanofibrous mats into CFRP laminates are presented. A smart approach, based on single-needle electrospinning of rubber-containing blends, is proposed for producing dimensionally stable rubbery nanofibers without the need for rubber crosslinking. Nano-modified laminates aim at obtaining structural composites with improved delamination resistance and enhanced damping capacity, without significantly lowering other relevant mechanical properties. The possibility of producing nanofibers nano-reinforced with graphene to be applied for reinforcing composite laminates is also investigated. Moreover, the use of piezoelectric nanofibrous mats in hybrid composite laminates for achieving self-sensing capability is presented too as a different approach to prevent the catastrophic consequences of possible structural laminate failure. Finally, an accurate, systematic, and critical study concerning tensile testing of nonwovens, using electrospun Nylon 66 random nanofibrous mats as a case study, is proposed. Nanofibers diameter and specimen geometry were investigated to thoroughly describe the nanomat tensile behaviour, also considering the polymer thermal properties, and the number of nanofibers crossings as a function of the nanofibers diameter. Stress-strain data were also analysed using a phenomenological data fitting model to interpret the tensile behaviour better.

Damping and Thermomechanical behaviour of CFRP laminates modified with rubbery nanofibers

Nanofibrous membranes are a promising material for tailoring the properties of laminated CFRP composites by embedding them into the structure. This project aimed to understand the effect of number, position and thickness of nanofibrous modifications specifically on the damping behaviour of the resulting nano-modified CFRP composite with an epoxy matrix. An improvement of damping capacity is expected to improve a composites lifetime and fatigue resistance by prohibiting the formation of microcracks and consequently hindering delamination, it also promises a rise in comfort for a range of final products by intermission of vibration propagation and therefore diminution of noise. Electrospinning was the technique employed to produce nanofibrous membranes from a blend of polymeric solutions. SEM, WAXS and DSC were utilised to evaluate the quality of the obtained membranes before they were introduced, following a specific stacking sequence, in the production process of the laminate. A suitable curing cycle in an autoclave was applied to mend the modifications together with the matrix material, ensuring full crosslinking of the matrix and therefore finalising the production process. DMA was exercised in order to gain an understanding about the effects of the different modifications on the properties of the composite. During this investigation it became apparent that a high number of modifications of laminate CFRP composites, with an epoxy matrix, with thick rubbery nanofibrous membranes has a positive effect on the damping capacity and the temperature range the effect applies in. A suggestion for subsequent studies as well as a recommendation for the production of nano-modified CFRP structures is included at the end of this document.

Natural Wax-Based Water Vapour Barrier Coatings on PLA for MAP Food Packaging

PLA is a bio-based polymer that is obtained from renewable resources and it is very promising for a sustainable packaging manufacturing. However, its gas and vapour barrier properties are not enough to comply with the requirements of MAP packaging of fresh foods, which need specific concentration of water and oxygen to avoid spoilage and to keep the organoleptic properties unaltered throughout their shelf-life. The use of waxes from natural renewable sources such as plants (e.g., candelilla wax, carnauba wax, rice bran wax, sunflower wax) or animals (e.g., beeswax) could tackle down the permeation of water vapour through the packaging without affecting its bio-based content. The core of this work is developing wax-based coatings with enhanced thermo-mechanical properties so that they can undergo thermoforming and a proper adhesion to the PLA substrate can be ensured. Chemical modifications and crosslinking of waxes are performed to produce wax-based alkyd resins. The synthesised materials are characterised both by DSC and FTIR. Films of the wax-based alkyds are produced in order to assess their water vapour permeability.

3D bioprinted organ models for drug screening

In recent years, 3D bioprinting has emerged as an innovative and versatile technology able to produce in vitro models that resemble the native spatial organization of organ tissues, by employing or more bioinks composed of various types of cells suspended in hydrogels. Natural and semi-synthetic hydrogels are extensively used for 3D bioprinting models since they can mimic the natural composition of the tissues, they are biocompatible and bioactive with customizable mechanical properties, allowing to support cell growth. The possibility to tailor hydrogels mechanical properties by modifying the chemical structures to obtain photo-crosslinkable materials, while maintaining their biocompatibility and biomimicry, make their use versatile and suitable to simulate a broad spectrum of physiological features. In this PhD Thesis, 3D bioprinted in vitro models with tailored mechanical properties and physiologically-like features were fabricated. AlgMa-based bioinks were employed to produce a living platform with gradient stiffness, with the aim to create an easy to handle and accessible biological tool to evaluate mechanobiology. In addition, GelMa, collagen and IPN of GelMa and collagen were used as bioinks to fabricate a proof-of-concept of 3D intestinal barrier, which include multiple cell components and multi-layered structure. A useful rheological guide to drive users to the selection of the suitable bioinks for 3D bioprinting and to correlate the model’s mechanical stability after crosslinking is proposed. In conclusion, a platform capable to reproduce models with physiological gradient stiffness was developed and the fabrication of 3D bioprinted intestinal models displaying a good hierarchical structure and cells composition was fully reported and successfully achieved. The good biological results obtained demonstrated that 3D bioprinting can be used for the fabrications of 3D models and that the mechanical properties of the external environment plays a key role on the cell pathways, viability and morphology.

Development of new collagen cross-linkers for adhesive bonding stabilization

Aims: This thesis aimed to investigate the influence of different collagen cross-linkers, as separate primers or contained within desensitizing agents, on the longevity of dental restorations and on the dentinal enzymatic activity immediately, or after aging in vitro. Methods: A series of studies was conducted using several different cross-linking molecules and several adhesive systems. Four studies investigated the longevity of the hybrid layer by means of microtensile bond strength test, and the enzymatic activity using gelatin and in situ zymography, immediately or after 1 year of aging in the artificial saliva. The first study tested samples bonded with or without a cross-linking agent, that were previously aged for 5 years. The degradation of the hybrid layer was observed using transmission electron microscopy, the enzymatic activity in the hybrid layer using in situ zymography. Raman spectroscopy was used to investigate whether the active substance was still within the hybrid layer after 5 years. Results: The results of the studies showed that collagen cross-linkers were efficient in preserving bond strength after aging in vitro when used as separate primers on demineralized or partially demineralized dentin. In the cases when the cross-linker was utilized on mineralized dentin, bond strength results were higher than in the control groups immediately and after aging, however, no difference in enzymatic activity was detected after aging. Conclusions: The tested cross-linker molecules used as separate primers in etch-and-rinse and self-etch adhesives seem to be clinically applicable, since the procedure is not overly time-consuming and seems to preserve the hybrid layer over time. As for the cross-linkers contained in the desensitizing agent, when utilized before the adhesive procedures, it has shown to increase the bond strength of self-etch adhesives, but further studies are needed to better understand its effect on the enzymatic activity and crosslinking effects on mineralized dentin.