ABSTRACT
Activated Carbon (AC) is widely available at a relatively low cost, has a high porosity and is commonly used as a filter material for a range of applications. However, it is a brittle and friable material. Ultra-High Molecular Weight Polyethylene (UHMWPE) polymer is a tough engineering plastic that has been used as a binder. The traditional method used in manufacturing AC/UHMWPE filters involves compressing AC/UHMWPE composite powder during heating in a mould. This process compresses the particles together and the materials undergo sintering. This process results in a low pore interconnectivity, which has a considerable impact on the filter's efficiency. Selective Laser Sintering is a laser powder bed fusion additive manufacturing technique for polymers. This has a number of advantages compared to the conventional technique and produces a porous structure with improved filtration efficiency. We propose that this is due to the greater pore interconnectivity. In this work, AC/UHMWPE powdered composites were prepared with different AC and UHMWPE ratios. The structure and properties of the AC/UHMWPE composite were investigated and characterised to assess their suitability for selective laser sintering. Particle size and morphology analysis were conducted, as well as density measurements, powder flow, thermal analysis, and crystallinity measurements. The results reveal that the addition of AC improves the UHMWPE flow. The thermal analysis results show that the intrinsic thermal properties of UHMWPE powder are not significantly affected by the introduction of activated carbon. However, thermal gravimetric analysis revealed that the onset of mass loss is considerably shifted (20 °C) to higher temperatures for the AC/UHMWPE composites, which is favourable for laser sintering. Additionally, the change in the composition ratio of untreated composite does not have a significant effect on the degree of crystallinity. Laser-sintered AC/UHMWPE parts were successfully manufactured using a commercial laser-sintering machine.
ABSTRACT
1,8-Diiodooctane (DIO) is an additive used in the processing of organic photovoltaics and has previously been reported, on the basis of small-angle X-ray scattering (SAXS) measurements, to deflocculate nano-aggregates of [6,6]-phenyl-C71-butyric acid methyl ester (PC71BM) in chlorobenzene. We have critically re-examined this finding in a series of scattering measurements using both X-rays and neutrons. With SAXS, we find that the form of the background solvent scattering is influenced by the presence of DIO, that there is substantial attenuation of the X-rays by the background solvent and that there appears to be beam-induced aggregation. All three factors call into question the suitability of SAXS for measurements on these samples. By contrast, small-angle neutron scattering (SANS) measurements, performed at concentrations of 15 mg ml-1 up to and including 40 mg ml-1, show no difference in the aggregation state for PC71BM in chlorobenzene with and without 3% DIO; we find PC71BM to be molecularly dissolved in all solvent cases. In situ film thinning measurements of spin-coated PC71BM solution with the DIO additive dry much slower. Optical imaging shows that the fullerene films possess enhanced molecular mobility in the presence of DIO and it is this which, we conclude, improves the nanomorphology and consequently solar cell performance. We propose that any compatible high boiling solvent would be expected to show the same behaviour.
