Synthesis of KOH-based geopolymers for innovative applications

This study presents an evaluation on compressive strength of metakaolin-based geopolymers synthetized by using different activators, KOH and NaOH. The influence of NaOH/KOH concentration ratio together with curing temperature and time were investigated to find the best results from the compressive strength tests of metakaolin-based geopolymers, synthesized with a commercial metakaolin. Aggregates of small grain size referred as fillers, were added to reduce brittleness, and minimize the pore size and shrinkage of the final mixture creating a stronger network. In this work, silt recovered from industrial processes of wash water used for aggregates production was used as a filler in the production of KOH-based geopolymers, examining the possible influence on the mechanical strength of the final product. The curing temperatures chosen for the synthesis were 85°C, 60°C and 40°C. The samples were tested after 7 days and 28 days, according to the UNI EN 1015-11:2019 applied on Ca-based cements, analyzing the differences in mechanical strength comparing samples with similar and different compositions. The study presented in total 72 synthetized geopolymer specimens that were analyzed with unconfined compression test (UCT). The characterization of the starting materials metakaolin and silt was carried out using X- ray diffraction analysis (XRD). Whereas, the formed geopolymers were analyzed using X- ray diffraction (XRD), and scanning electron microscopy (SEM) with energy dispersive X- ray spectroscopy (EDS).

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.