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With regard to upcoming regulations of common chemical blowing agents for epoxy foams, carbamates provide suitable alternatives. They act as blowing agents releasing CO2 and cure epoxy resins after...

Composites based on fully bio-based epoxy-amine resins reinforced with recycled carbon fibers were obtained and compared to petro- and partially bio-based benchmark materials. Rheology measurements...

Machine learning (ML) based fatigue damage detection from thermal imaging in glass-epoxy composites is an important component of remote structural health monitoring used for safety assessment and optimization of composite structures and components. However, accurate characterization of fatigue damage hotspots in terms of size, shape, location, hysteretic heat, and local temperature deep inside the material using surface thermal images remains a challenge to date. This work aims at evaluating the theoretical accuracy level of hotspot characterization by training a ML model with artificially generated thermal images from 3D finite element models with increasing complexity. Modelling the fatigue damage as an intrinsic heat source allowed to significantly reduce the influence of thermal image noise and other uncertainties related to heat transfer. It is shown that ML can indeed accurately recover the heat influx, depth, and geometry of the heat source from the original thermal images of the composite materials with prediction accuracies in the range 85%–99%. The effect of training set size and image resolution on the prediction error is also presented. The findings reported in this work contribute to the advancement of accurate and efficient remote fatigue damage detection methods for fibre composite materials.

In this study, an empirical correlation between the tack of phenolic prepregs and the rheological state of the base resin was established. Multivariable analyses were carried out to investigate the determining mechanisms of the prepreg tack along with the temperature- and time-dependent state of the resin. The material storage stability in terms of the degree of cure (DoC) was monitored within 150 days. Furthermore, the DoC at gelation was determined so discussion could be made over the morphological state of the base resin. Rheological properties of the resin such as storage and loss moduli were evaluated as a function of the DoC and temperature, thus describing the flow and cohesive behaviour towards the final prepreg tackiness. A maximum tack plateau was found when conditions of ageing and temperature were balanced within a suitable viscosity and DoC range. Indicators suggest that the interaction between resin and filler effectively changes the resin viscosity, therefore regulating the prepreg tackiness level. For the first time, inherent phenolic resin properties were thoroughly determined by systematically varying the conversion state and operating temperature, in order to gain an in-depth understanding of the effects on the final composite tack property.

The aging behavior of a fast-curing epoxy resin (EP) was examined over three months in unidirectional carbon fiber prepregs for the first time. The semi-latent, 120 °C curing one-pot formulation was developed based on industry-grade diglycidyl ether of bisphenol A (DGEBA) resins without the necessity of B-staging, to fully monitor the property change by aging without any post-processing influence. To extend the shelf-life compared to standard wet EP systems, the latent dicyandiamide (DICY) and a semi-latent urea-based catalyst were used, leading to full conversion within 15 min. The conversion was monitored by increasing Tg0 and rheology. High quality unidirectional carbon prepregs were manufactured and then investigated over three months regarding tackiness and resin flow. In parallel, laminates were autoclave-manufactured to evaluate the aging influence on the interlaminar properties. Thus, a correlation between decreasing gel-time, interlaminar adhesion and resulting multiple crack growth was observed via GIC and interlaminar shear strength (ILSS) testing. The investigations show a clear influence of the consolidation quality of the prepregs based on ILSS values and GIC values. A decrease of 19% in ILSS and combined with an erroneous increase of 63% of the GIC due to multiple delamination was observed in the worst case.

Multi-wall carbon nanotubes were dispersed homogeneously throughout a poly(ether ether ketone) matrix by melt processing. The influence of nanotube content on both rheological and electrical properties was analysed. The dynamic storage modulus, G ′ , shows a characteristic solid-like behavior above 1 wt% nanotubes. A sharp transition from an electrically insulating to a conductive composite was observed between 1 and 1.5 wt%. By applying a power-law relation, the rheological and electrical percolation thresholds were found to be 0.9 wt%, and 1.3 wt%, respectively. Considering this data, Guth’s filler reinforcement theory provides a valuable estimation of the aspect ratio of the nanotubes after processing and indicates substantial length degradation during the dispersion process.

Immiscible blends of poly(2,6-dimethyl-1,4-phenylene ether)/poly(styrene-co-acrylonitrile) (PPE/SAN) were batch-foamed using CO2 as a blowing agent as a function of foaming temperature, foaming time, and blend composition. Evaluation of the resulting cellular morphology revealed an enhanced foamability of SAN with PPE contents up to 20 wt% as indicated by a similar volume expansion but a significantly reduced mean cell size. This behavior is related to a heterogeneous nucleation activity by the dispersed PPE phase. A further increasing PPE content, however, leads to increasing foam densities as well as nonuniform foam morphologies. The changes in the foaming behavior can be correlated with the melt rheological properties and the corresponding blend morphology. Shear-rheological investigations revealed an onset of percolation of the dispersed PPE phase between 20 and 40 wt%, and a transition towards cocontinuity at 60 wt%. The materials response under uniaxial elongational flow, as assessed by Rheotens measurements, revealed an increase in elongational viscosity scaling with the PPE content, similar to the shear data. However, the strain hardening behavior was reduced by increasing PPE contents and, at 20 wt%, the drawability revealed a significant drop-both phenomena limiting the foamability of polymers. In summary, the present study discusses fundamental aspects of foaming immiscible PPE/SAN blends. POLYM. ENG. SCI., 48:2111–2125, 2008. © 2008 Society of Plastics Engineers

The potential of fatigue crack growth experiments to sensitively analyze the anisotropic mechanical behavior of injection-molded, multiphase polymer blends is presented. The properties of immiscible blends based on poly(2,6-dimethyl-1,4-phenylene ether) (PPE) and poly(styrene-co-acrylonitrile) is investigated, both in perpendicular and in parallel to the injection-direction. As a result of the limited interfacial adhesion and the orientation of the blend phases, the direction in parallel to flow revealed to be the weaker link. In order to enhance the toughness behavior, the PPE/SAN blends were systematically modified by the addition of different polystyrene-b-polybutadiene-b-poly(methyl methacrylate) triblock terpolymers (SBM), potentially acting as a compatibilizing and toughening agent. Such a compatibilization step of PPE/SAN blend leads to the formation of nanostructured morphologies. Depending on the composition of the triblock terpolymer, the resistance to crack growth was either further degraded or, in the case of high interfacial presence and compatibilization efficiency, significantly improved. The results were correlated to the fracture mechanisms of the blends as analyzed by scanning electron microscopy of the fracture surfaces. In contrast to poorly-compatibilized blends, a significant plastic deformation, an enhanced phase adhesion and a strongly reduced anisotropy could be detected in case of well-compatibilized blends. In summary, the presented study of the fatigue crack growth behavior revealed a detailed insight into the mechanical property profile of the selected multiphase blends and, moreover, demonstrated the potential of this method to sensitively analyze the anisotropy of such materials.

The mechanical performance of immiscible blends of poly(2,6-dimethyl-1,4-phenylene ether) (PPE) and poly(styrene-co-acrylonitrile) (SAN) and the subsequent influence of compatibilisation by tailored polystyrene-block-polybutadiene-block-poly(methyl methacrylate) triblock terpolymers (SBM) on the mechanical performance under static and dynamic loads is analysed in detail. A PPE/SAN 60/40 blend was selected as a base system for the compatibilisation experiments. The observed static tensile behaviour is described by micromechanical models and correlated to the blend microstructures as observed by transmission electron microscopy. In most cases, the addition of the SBM triblock terpolymers further enhances the ductility of the blend while only leading to a minor reduction of modulus and strength. Triblock terpolymers with symmetric end blocks, mainly located at the interface between PPE and SAN, led to nearly isotropic specimens. In contrast, SBM materials with a longer polystyrene block predominantly formed micelles in the PPE phase and the blends revealed a highly anisotropic morphology. Comparative investigations of the fatigue crack growth behaviour parallel to the direction of injection also reflected this variation in mechanical anisotropy of the compatibilised blends. A poor toughness and a predominant interfacial failure were observed in the case of the SBM with a long polystyrene block. In contrast, a considerable improvement in properties as a result of pronounced plastic deformations was observed for blends compatibilised by triblock terpolymers with symmetric end blocks. The systematic correlation between morphology and mechanical performance of compatibilised PPE/SAN blends established in this study provides an efficient way for the desired selection of suitable and effective compatibilising agents, ensuring both a superior multiaxial toughness as well as a high strength and modulus of the overall system.

There is enormous scientific and economic interest in the development and evaluation of polymer nanocomposites due to the fact that the properties of a material become increasingly insensitive to flaws at the nanoscale, enabling the exploitation of the unique physical and mechanical properties of very small objects in large-scale components. However, the successful industrial implementation of such novel materials poses unique challenges which are not only related to the small size of the reinforcements. Decades of intensive research have shown that polymer nanocomposites differ from their counterparts based on traditional reinforcements in many ways and a fundamental understanding of the structure-propertyrelationships of such novel materials is only slowly emerging. Although issues such as the intrinsic properties of the nanoscale constituent as well as the degree of dispersion and orientation of individual filler particles clearly appear to be important factors, molecular interactions between the filler and the matrix during processing can lead to pronounced variations in the matrix microstructure. These variations in themselves lead to pronounced changes in the micro- and macromechanical deformation behaviour of the nanocomposites. A detailed investigation of fatigue crack growth behaviour of such novel materials for example is essential in order to understand the fracture mechanical performance and the transition from a ductile to a brittle behaviour which is often observed experimentally, especially in the case of amorphous matrices. However, as the size of the filler particles approaches the molecular level, the novel interactions at the interface or even in the interphase can lead to significant changes in the micromechanical deformation behaviour. Significant work has been carried out regarding the fracture mechanical investigation of polymer blends with both micro- and nanoscale morphologies and much can be learned by comparing the results of polymer nanocomposites to these more established polymer blends.

Carbon nanofibre (CNF)-reinforced ultrahigh molecular weight polyethylene (UHMWPE) nanocomposites containing up to 10 wt % of nanofibres were prepared by a novel solvent-assisted extrusion process using short chain oligomers to tailor the melt viscosity of the UHMWPE matrix. A detailed investigation of the resulting nanocomposite microstructure and of the static mechanical properties revealed that the carbon nanofibres lead to improved mechanical properties of the UHMWPE related to the wear performance of such systems. Unidirectional sliding tests against a 100Cr6 steel under dry conditions verified the significant potential of dispersed carbon nanofibres to reduce the wear rate of this polymer. In light of the promising results, a further optimization of the processing conditions of such UHMWPE nanocomposites is expected to yield interesting future nanocomposite materials even for demanding applications such as artificial knee implants. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 104: 4173–4181, 2007

Immiscible blends of poly(2,6-dimethyl-1,4-phenylene ether) (PPE) and poly(styrene-co-acrylonitrile) (SAN) with a weight composition of 60/40 were compatibilised by polystyrene-block-polybutadiene-block-poly(methyl methacrylate) triblock terpolymers (SBM) using a two-stage melt-processing approach. In order to investigate the influence of the SBM composition on the compatibilisation efficiency, the block lengths of the triblock terpolymers were systematically varied. The resulting morphological features of the blend systems as function of SBM composition and processing parameters are correlated with the resulting thermal and thermo-mechanical properties. In the ideal case, SBM should be located at the interface as PS is miscible with PPE while PMMA is miscible with SAN. The elastomeric middle block as an immiscible component should remain at the interface. This particular morphological arrangement is known as the ‘raspberry morphology’. A detailed TEM analysis of the blend morphologies following initial extrusion-compounding revealed a high compatibilisation efficiency of the SBM types with equal lengths of the end blocks and, furthermore, the desired raspberry morphology was achieved. In contrast, high PS contents in comparison to the other blocks led to a pronounced micelle formation in the PPE phase. Further evaluation of the blend structures following injection-moulding indicated that the morphologies remain relatively stable during this second melt-processing step. A detailed thermal analysis of all blend systems supports the interpretation of the observed morphological features. The fundamental correlation between SBM composition and blend morphology established in this study opens the door for the controlled development of interfacial properties of such compatibilised PPE/SAN blends during melt-processing.

In the context of establishing novel polymer nanocomposites for successful industrial use, this chapter is aimed at providing a fundamental overview of comprehensive research regarding carbon nanofiber (CNF)-reinforced poly(ether ether ketone) (PEEK) composites for demanding tribological applications. Following a summary overview describing the potential of nanoscale additives for tribological systems in general, the intrinsic structure–property relationships of CNFs are discussed in order to set the frame for the subsequent experimental results regarding their use in PEEK. As demonstrated, successful PEEK–nanofiber composites have been developed, showing a clear enhancement in mechanical properties while minimizing other detrimental effects commonly observed with such nanocomposites. These nanocomposites also reveal a significant beneficial effect on the wear behavior of PEEK under dry sliding conditions. In addition to relating the observed enhancements in the tribological performance to the underlying microstructures and properties of the nanocomposites, evidence for a further optimization of such systems by combining the nanoscale filler with conventional tribological additives and reinforcements such as carbon fibers is provided. Lastly, based on the promising results regarding the wear behavior of such hybrid systems, the performance of advanced nanocomposite hybrid materials for an intended industrial tribological application is introduced and discussed.

Foaming of multiphase blend systems can be identified as a promising approach to satisfy the steadily growing demand for cellular materials with enhanced properties. However, combining the sophisticated fields of polymer blends and polymer foams not only offers great chances, but also poses a significant challenge, as the multiphase characteristics of blends and the complexity of foam processing need to be taken into account. Therefore, the foaming behavior of polymer blends is systematically analyzed, correlating the blend structure and the physical characteristics of reference systems to their foam processability and resulting foam morphology. The cellular materials are prepared via batch-foam processing, using carbon dioxide as a blowing agent. Starting with an immiscible poly(2,6-dimethyl-1,4-phenylene ether)/poly(styrene-co-acrylonitrile) blend, pathways to tailor the foaming behavior via controlling the micro- and nanostructure of such blends are developed; strategies aiming at reducing the cell size, enhancing the foam homogeneity, and improving the density reduction. As a result of adjusting the blend structure over multiple length scales, cooperative foaming of all blend phases and cell sizes down to several hundred nanometers can be achieved. In the light of the results presented, a general understanding of foaming multiphase blends is developed and guidelines for the selection of blend systems suitable for foaming can be deduced.

The microstructure of melt-processed, immiscible poly(2,6-dimethyl-1,4- phenylene ether)/poly(styrene-co-acrylonitrile) blends (PPE/SAN) was controlled by systematically adjusting the viscosity ratio between both phases. For this purpose, low-viscous polystyrene (PS) was added as a third component, as it shows selective miscibility with PPE and thus allows the varying of the shear viscosity of PPE over a broad range. In order to theoretically predict the phase morphology, a model following Utracki was applied taking into account the viscosity ratio and the respective volume contents of each phase. Detailed transmission electron microscopic investigations of the blend morphologies demonstrated excellent agreement with theory. Moreover, quantitative evaluation of the observed microstructures allowed further description of the degree of blend co-continuity. Thus, desirable compositions of the ternary blend systems could be identified which potentially show enhanced properties such as a high heat deflection temperature, an elevated strength, stiffness, and ease of processing. Finally, a optimum (PPE/PS)/SAN blend system that has been optimised regarding the aforementioned properties was compatibilized by polystyrene-b-poly(1,4-butadiene)-b-poly(methyl methacrylate) triblock terpolymers. Due to the interfacial enrichment of the block copolymer, nanostructured blend morphologies were observed. In the view of these results, pathways to control both the micro- and the nanostructure of PPE/SAN blends are derived, potentially useful to enhance the mechanical as well as thermomechanical property profile.

The foaming behaviour of polymer blends was systematically investigated using carbon dioxide as a blowing agent. Two batch-processing techniques were used to prepare specimens of different size. Various binary mixtures over a wide compositional range were selected as reference materials, in particular including immiscible (poly(2,6-dimethyl-1,4-phenylene ether)/poly(styrene-co-acrylonitrile) (PPE/SAN) blends. Moreover, the influence of a compatibilization with block copolymers was investigated for PPE/SAN blends. The resulting foam morphology was characterised by evaluating the density, the cell size distribution, the cell wall morphology and the compression behaviour. Besides the commonly accepted key criteria for foaming neat polymers, our study identified significant factors determining the foamability of blends such as the blend morphology, the rheological and the thermal properties. Interestingly, the compatibilization of these PPE/SAN blends by block copolymers was identified as a technique to establish micro- and submicrocellular foam morphologies with nanostructured cell walls. In view of these results, new pathways for the tailoring of cellular materials are derived.