Radio frequency heating and material processing using carbon susceptors.

Carbon nanomaterials have been shown to rapidly evolve heat in response to electromagnetic fields. Initial studies focused on the use of microwaves, but more recently, it was discovered that carbon nanomaterial systems heat in response to electric fields in the radio frequency range (RF, 1-200 MHz). This is an exciting development because this range of radio frequencies is safe and versatile compared to microwaves. Additional RF susceptor materials include other carbonaceous materials such as carbon black, graphite, graphene oxide, laser-induced graphene, and carbon fibers. Such conductive fillers can be dispersed in matrices such as polymer or ceramics; these composites heat rapidly when stimulated by electromagnetic waves. These findings are valuable for materials processing, where volumetric and/or targeted heating are needed, such as curing composites, bonding multi-material surfaces, additive manufacturing, chemical reactions, actuation, and medical ablation. By changing the loading of these conductive RF susceptors in the embedding medium, material properties can be customized to achieve different heating rates, with possible other benefits in thermo-mechanical properties. Compared to traditional heating and processing methods, RF heating provides faster heating rates with lower infrastructure requirements and better energy efficiency; non-contact RF applicators or capacitors can be used for out-of-oven processing, allowing for distributed manufacturing.

Rapid Heating of Silicon Carbide Fibers under Radio Frequency Fields and Application in Curing Preceramic Polymer Composites.

Silicon carbide (SiC) fibers are widely used as a reinforcement in ceramic matrix composites due to their high mechanical strength and superior thermal resistance. Here, we investigate the rapid radio frequency (RF) heating response of two types of SiC fibers (Hi-Nicalon and Sylramic) in the 1-200 MHz frequency range. Hi-Nicalon fibers exhibit a surprisingly rapid RF heating response of 240 °C/s in the perpendicular orientation, and this property could be exploited for oven-free and noncontact processing of composites with SiC fibers. The presence of excess carbon on the surface of Hi-Nicalon fibers is most likely responsible for the RF heating response and significantly higher temperatures in the parallel as compared to perpendicular alignment of fibers to the electric field. The RF heating response of Hi-Nicalon SiC fibers was utilized to heat preceramic polymers (polycarbosilanes) infiltrated in SiC fibers and cure them to ceramic matrix composites (CMCs) using RF applicators. A noncontact RF heating setup to pyrolyze the precursor polymers under inert conditions and make SiC/SiC composites is also developed.

Heating of Ti3C2Tx MXene/polymer composites in response to Radio Frequency fields.

Here we report for the first time that Ti3C2Tx/polymer composite films rapidly heat when exposed to low-power radio frequency fields. Ti3C2Tx MXenes possess a high dielectric loss tangent, which is correlated with this rapid heating under electromagnetic fields. Thermal imaging confirms that these structures are capable of extraordinary heating rates (as high as 303 K/s) that are frequency- and concentration-dependent. At high loading (and high conductivity), Ti3C2Tx MXene composites do not heat under RF fields due to reflection of electromagnetic waves, whereas composites with low conductivity do not heat due to the lack of an electrical percolating network. Composites with an intermediate loading and a conductivity between 10-1000 S m-1 rapidly generate heat under RF fields. This finding unlocks a new property of Ti3C2Tx MXenes and a new material for potential RF-based applications.