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.

Development of numerical methodologies to predict the liquid fuel sprays - wall interaction to optimize the mixing process of direct injection spark ignition engines

Nowadays the development of new Internal Combustion Engines is mainly driven by the need to reduce tailpipe emissions of pollutants, Green-House Gases and avoid the fossil fuels wasting. The design of dimension and shape of the combustion chamber together with the implementation of different injection strategies e.g., injection timing, spray targeting, higher injection pressure, play a key role in the accomplishment of the aforementioned targets. As far as the match between the fuel injection and evaporation and the combustion chamber shape is concerned, the assessment of the interaction between the liquid fuel spray and the engine walls in gasoline direct injection engines is crucial. The use of numerical simulations is an acknowledged technique to support the study of new technological solutions such as the design of new gasoline blends and of tailored injection strategies to pursue the target mixture formation. The current simulation framework lacks a well-defined best practice for the liquid fuel spray interaction simulation, which is a complex multi-physics problem. This thesis deals with the development of robust methodologies to approach the numerical simulation of the liquid fuel spray interaction with walls and lubricants. The accomplishment of this task was divided into three tasks: i) setup and validation of spray-wall impingement three-dimensional CFD spray simulations; ii) development of a one-dimensional model describing the liquid fuel – lubricant oil interaction; iii) development of a machine learning based algorithm aimed to define which mixture of known pure components mimics the physical behaviour of the real gasoline for the simulation of the liquid fuel spray interaction.

Development and Characterization of Biopolymers

Development and characterization of biopolymers was done in AIJU’s laboratories. AIJU, Technological Institute for children’s products and leisure is based in Spain. The work has the aim to study qualities and characteristics of bioplastics’ blends, in order to design where improvements can be executed. Biopolymers represent a sector with great development possibilities because they combine high technical potential and eco-sustainability. Nowadays, plastic pollution has becoming increasingly concerning, particularly in terms of management of waste. Bioplastics provide an alternative for the disposal of products, reducing the volume of waste and enhancing the end of life recovery. Despite the growing interest in biopolymers there is some gaps that need be filled. The main objective on this work, is the optimization of bioplastics mechanical properties, to find suitable substitutes, as similar as possible to conventional plastics. Firstly, investigations on processability of biomaterials has been deepen since the project deals with toy manufacturing’s sector. Thus, starting from laboratory scale the work aspires to expand industrially. By working with traditional machines, it was notable that, with some limited modifications, the equipment can perform the same functions. Therefore, operational processes do not emerge as an obstacle to the production chain. Secondly, after processing bio-blends, they are characterized by thermal tests (melt flow index, differential scanning calorimetry-DSC, thermogravimetry-TGA) and mechanical tests (traction and flexural tests, Charpy impact, SHORE D hardness and density). While the compatibility does not show relevant results, mechanical improvements has been visualized with addition of more ductile materials. The study was developed by inclusion of sustainable additive VINNEX® to blends. The thesis has highlighted that integration of more flexible materials provides elasticity without compromising bioplastics’ properties.

Development and characterization of innovative graphene-based composites

Over the last decade, graphene and related materials (GRM) have drawn significant interest and resources for their development into the next generation of composite materials. This is because these nanoparticles have the ability to operate as reinforcing additives capable of imparting considerable mechanical property increases while also embedding multi-functional advantages on the host matrix. Because graphene and 2D materials are still in their early stages, the relative maturity of different types of composite systems varies. As a result, certain nanocomposite systems are currently commercially accessible, while others are not yet sufficiently developed to enter the market. A substantial emphasis has been placed on developing thermoplastic and thermosetting materials that combine a variety of mechanical and functional qualities. These include higher strength and stiffness, increased thermal and electrical conductivity, improved barrier properties, fire retardancy, and others, with the ultimate goal of providing multifunctionality to already employed composites. The work presented in this thesis investigates the use and benefits that GRM could bring to composites for a variety of applications, with the goal of realizing multifunctional components with improved properties that leads to lightweight and, as a result, energy and cost savings and pollution reduction in the environment. In particular, we worked on the following topics: • Benchmarking of commercial GRM-based master batches; • GRM-coatings for water uptake reduction; • GRM as thermo-electrical anti-icing /de-icing system; • GRM for Out of Oven curing of composites.

Innovative electrospun nanofibers for improving delamination resistance and damping of CFRP laminates

Carbon Fiber Reinforced Polymers (CFRPs) are well renowned for their excellent mechanical properties, superior strength-to-weight characteristics, low thermal expansion coefficient, and fatigue resistance over any conventional polymer or metal. Due to the high stiffness of carbon fibers and thermosetting matrix, CFRP laminates may display some drawbacks, limiting their use in specific applications. Indeed, the overall laminate stiffness may lead to structural problems arising from their laminar structure, which makes them susceptible to structural failure by delamination. Moreover, such stiffness given by the constituents makes them poor at damping vibration, making the component more sensitive to noise and leading, at times, to delamination triggering. Nanofibrous mat interleaving is a smart way to increase the interlaminar fracture toughness: the use of thermoplastic polymers, such as poly(ε- caprolactone) (PCL) and polyamides (Nylons), as nonwovens are common and well established. Here, in this PhD thesis, a new method for the production of rubber-rich nanofibrous mats is presented. The use of rubbery nanofibers blended with PCL, widely reported in the literature, was used as matrix tougheners, processing DCB test results by evaluating Acoustic Emissions (AE). Moreover, water-soluble electrospun polyethylene oxide (PEO) nanofibers were proposed as an innovative method for reinforcing layers and hindering delamination in epoxy-based CFRP laminates. A nano-modified CFRP was then aged in water for 1 month and its delamination behaviour compared with the ones of the commercial laminate. A comprehensive study on the use of nanofibers with high rubber content, blended with a crystalline counterpart, as enhancers of the interlaminar properties were then investigated. Finally, PEO, PCL, and Nylon 66 nanofibers, plain or reinforced with Graphene (G), were integrated into epoxy-matrix CFRP to evaluate the effect of polymers and polymers + G on the laminate mechanical properties.

Formulazione e caratterizzazione di idropitture con materie prime “Bio-Based”

The market for paint products with raw materials derived from renewable sources is growing rapidly in the building industry. When high performance in wet scrub resistance is required, “washable” paints are used. However, formulating products with Bio-Based raw materials generally results in a decrease in performances compared to similar products with raw materials from fossil sources. Therefore, a new formulation approach is needed to characterize polymeric binders from renewable sources and to consider the synergistic effects given by blends of polymeric binders of different origin and chemical structure. To date, the development of new formulations that imply less environmental impact is necessary if these products have to remain competitive in the marketplace. During the trainingship in IVAS S.p.A., washable paints with different PVC (Pigment Volume Concentration) were formulated and tested, evaluating whether the performance of paints with polymeric binders obtained from renewable sources was comparable to those with polymeric binders from fossil sources. The binders were chemically characterized by DSC, FT-IR and NMR analysis. Characterization tests of paints were focused on the evaluation of degree of whiteness, hiding power, dirt setting, and wet scrub resistance. Following the results obtained from the available binder combinations, it was possible to formulate two washable paints with comparable performances to those from fossil sources: paint A with 20 % of alkydic polymer and 80 % styrene/acrylic polymer and paint B with 40 % of alkydic polymer and 60 % styrene/acrylic polymer. Finally, the formulation was completed by adding the mainly Bio-Based derived additives generally used for this category of paints.