Metal Mimics: Lightweight, Strong, and Tough Nanocomposites and Nanomaterial Assemblies.

The ideal structural material would have high strength and stiffness with a tough ductile failure, all with a low density. Historically, no such material exists, and materials engineers have had to sacrifice a desired property during materials selection, with metals (high density), fiber composites (brittle failure), and polymers (low stiffness) having fundamental limitations on at least one front. The ongoing revolution of nanomaterials provides a potential route to build on the potential of fiber-reinforced composites, matching their strength while integrating toughening behaviors akin to metal deformations, all while using low-weight constituents. Here, the challenges, approaches, and recent developments of nanomaterials for structural applications are discussed, with an emphasis on improving toughening mechanisms, which is often the neglected factor in a field that chases strength and stiffness.

"Brick-and-Mortar" Nanostructured Interphase for Glass-Fiber-Reinforced Polymer Composites.

The fiber-matrix interface plays a critical role in determining composite mechanical properties. While a strong interface tends to provide high strength, a weak interface enables extensive debonding, leading to a high degree of energy absorption. Balancing these conflicting requirements by engineering composite interfaces to improve strength and toughness simultaneously still remains a great challenge. Here, a nanostructured fiber coating was realized to manifest the critical characteristics of natural nacre, at a reduced length scale, consistent with the surface curvature of fibers. The new interphase contains a high proportion (∼90 wt %) of well-aligned inorganic platelets embedded in a polymer; the window of suitable platelet dimensions is very narrow, with an optimized platelet width and thickness of about 130 and 13 nm, respectively. An anisotropic, nanostructured coating was uniformly and conformally deposited onto a large number of 9 µm diameter glass fibers, simultaneously, using self-limiting layer-by-layer assembly (LbL); this parallel approach demonstrates a promising strategy to exploit LbL methods at scale. The resulting nanocomposite interphase, primarily loaded in shear, provides new mechanisms for stress dissipation and plastic deformation. The energy released by fiber breakage in tension appear to spread and dissipate within the nanostructured interphase, accompanied by stable fiber slippage, while the interfacial strength was improved up to 30%.

High-Surface-Area, Emulsion-Templated Carbon Foams by Activation of polyHIPEs Derived from Pickering Emulsions.

Carbon foams displaying hierarchical porosity and excellent surface areas of >1400 m²/g can be produced by the activation of macroporous poly(divinylbenzene). Poly(divinylbenzene) was synthesized from the polymerization of the continuous, but minority, phase of a simple high internal phase Pickering emulsion. By the addition of KOH, chemical activation of the materials is induced during carbonization, producing Pickering-emulsion-templated carbon foams, or carboHIPEs, with tailorable macropore diameters and surface areas almost triple that of those previously reported. The retention of the customizable, macroporous open-cell structure of the poly(divinylbenzene) precursor and the production of a large degree of microporosity during activation leads to tailorable carboHIPEs with excellent surface areas.

Nacre-nanomimetics: Strong, Stiff, and Plastic.

The bricks and mortar in the classic structure of nacre have characteristic geometry, aspect ratios and relative proportions; these key parameters can be retained while scaling down the absolute length scale by more than 1 order of magnitude. The results shed light on fundamental scaling behavior and provide new opportunities for high performance, yet ductile, lightweight nanocomposites. Reproducing the toughening mechanisms of nacre at smaller length scales allows a greater volume of interface per unit volume while simultaneously increasing the intrinsic properties of the inorganic constituents. Layer-by-layer (LbL) assembly of poly(sodium 4-styrenesulfonate) (PSS) polyelectrolyte and well-defined [Mg2Al(OH)6]CO3.nH2O layered double hydroxide (LDH) platelets produces a dense, oriented, high inorganic content (∼90 wt %) nanostructure resembling natural nacre, but at a shorter length scale. The smaller building blocks enable the (self-) assembly of a higher quality nanostructure than conventional mimics, leading to improved mechanical properties, matching those of natural nacre, while allowing for substantial plastic deformation. Both strain hardening and crack deflection mechanisms were observed in situ by scanning electron microscopy (SEM) during nanoindentation. The best properties emerge from an ordered nanostructure, generated using regular platelets, with narrow size dispersion.