Carbon-Fiber-Recycling Strategies: A Secondary Waste Stream Used for PA6,6 Thermoplastic Composite Applications.

With a view to achieving sustainable development and a circular economy, this work focused on the possibility to valorize a secondary waste stream of recycled carbon fiber (rCF) to produce a 3D printing usable material with a PA6,6 polymer matrix. The reinforcing fibers implemented in the research are the result of a double-recovery action: starting with pyrolysis, long fibers are obtained, which are used to produce non-woven fabrics, and subsequently, fiber agglomerate wastes obtained from this last process are ground in a ball mill. The effect of different amounts of reinforcement at 5% and 10% by weight on the mechanical properties of 3D-printed thermoplastic composites was investigated. Although the recycled fraction was successfully integrated in the production of filaments for 3D printing and therefore in the production of specimens via the fused deposition modeling technique, the results showed that fibers did not improve the mechanical properties as expected, due to an unsuitable average size distribution and the presence of a predominant dusty fraction ascribed to the non-optimized ball milling process. PA6,6 + 10 wt.% rCF composites exhibited a tensile strength of 59.53 MPa and a tensile modulus of 2.24 GPa, which correspond to an improvement in mechanical behavior of 5% and 21% compared to the neat PA6,6 specimens, respectively. The printed composite specimens loaded with the lowest content of rCF provided the greatest improvement in strength (+9% over the neat sample). Next, a prediction of the "optimum" critical length of carbon fibers was proposed that could be used for future optimization of recycled fiber processing.

MWCNTs-TiO2 Incorporated-Mg Composites to Improve the Mechanical, Corrosion and Biological Characteristics for Use in Biomedical Fields.

This study attempts to synthesize MgZn/TiO2-MWCNTs composites with varying TiO2-MWCNT concentrations using mechanical alloying and a semi-powder metallurgy process coupled with spark plasma sintering. It also aims to investigate the mechanical, corrosion, and antibacterial properties of these composites. When compared to the MgZn composite, the microhardness and compressive strength of the MgZn/TiO2-MWCNTs composites were enhanced to 79 HV and 269 MPa, respectively. The results of cell culture and viability experiments revealed that incorporating TiO2-MWCNTs increased osteoblast proliferation and attachment and enhanced the biocompatibility of the TiO2-MWCNTs nanocomposite. It was observed that the corrosion resistance of the Mg-based composite was improved and the corrosion rate was reduced to about 2.1 mm/y with the addition of 10 wt% TiO2-1 wt% MWCNTs. In vitro testing for up to 14 days revealed a reduced degradation rate following the incorporation of TiO2-MWCNTs reinforcement into a MgZn matrix alloy. Antibacterial evaluations revealed that the composite had antibacterial activity, with an inhibition zone of 3.7 mm against Staphylococcus aureus. The MgZn/TiO2-MWCNTs composite structure has great potential for use in orthopedic fracture fixation devices.

Upscaling of Electrospinning Technology and the Application of Functionalized PVDF-HFP@TiO2 Electrospun Nanofibers for the Rapid Photocatalytic Deactivation of Bacteria on Advanced Face Masks.

In recent years, Electrospinning (ES) has been revealed to be a straightforward and innovative approach to manufacture functionalized nanofiber-based membranes with high filtering performance against fine Particulate Matter (PM) and proper bioactive properties. These qualities are useful for tackling current issues from bacterial contamination on Personal Protective Equipment (PPE) surfaces to the reusability of both disposable single-use face masks and respirator filters. Despite the fact that the conventional ES process can be upscaled to promote a high-rate nanofiber production, the number of research works on the design of hybrid materials embedded in electrospun membranes for face mask application is still low and has mainly been carried out at the laboratory scale. In this work, a multi-needle ES was employed in a continuous processing for the manufacturing of both pristine Poly (Vinylidene Fluoride-co-Hexafluoropropylene) (PVDF-HFP) nanofibers and functionalized membrane ones embedded with TiO2 Nanoparticles (NPs) (PVDF-HFP@TiO2). The nanofibers were collected on Polyethylene Terephthalate (PET) nonwoven spunbond fabric and characterized by using Scanning Electron Microscopy and Energy Dispersive X-ray (SEM-EDX), Raman spectroscopy, and Atomic Force Microscopy (AFM) analysis. The photocatalytic study performed on the electrospun membranes proved that the PVDF-HFP@TiO2 nanofibers provide a significant antibacterial activity for both Staphylococcus aureus (~94%) and Pseudomonas aeruginosa (~85%), after only 5 min of exposure to a UV-A light source. In addition, the PVDF-HFP@TiO2 nanofibers exhibit high filtration efficiency against submicron particles (~99%) and a low pressure drop (~3 mbar), in accordance with the standard required for Filtering Face Piece masks (FFPs). Therefore, these results aim to provide a real perspective on producing electrospun polymer-based nanotextiles with self-sterilizing properties for the implementation of advanced face masks on a large scale.

Low Molecular Weight Bio-Polyamide 11 Composites Reinforced with Flax and Intraply Flax/Basalt Hybrid Fabrics for Eco-Friendlier Transportation Components.

The transportation sector is striving to meet the more severe European legislation which encourages all industrial fields to embrace more eco-friendly policies by exploiting constituents from renewable resources. In this framework, the present work assessed the potential of a bio-based, low molecular weight PA11 matrix reinforced with flax and intraply flax/basalt hybrid fabrics. To this aim, both quasi-static and impact performance were addressed through three-point bending and low-velocity impact tests, respectively. For hybrid composites, the effect of stacking sequence, i.e., [0/0] and [0/90], and fiber orientation were considered, while the effect of temperature, i.e., -40 °C, room temperature and +45 °C, was investigated for laminates' impact response. The mechanical experimental campaign was supported by thermal and morphological analyses. The results disclosed an improved processability of the low molecular weight PA11, which ensured a manufacturing temperature of 200 °C, which is fundamental to minimize flax fibers' thermal degradation. Both quasi-static and impact properties demonstrated that hybridization is a good solution for obtaining good mechanical properties while preserving laminates' lightness and biodegradability. The [0/90] configuration proved to be the best solution, providing satisfying flexural performance, with an increase between 62% and 83% in stiffness and between 19.6% and 37.6% in strength compared to flax-based laminates, and the best impact performance, with a reduction in permanent indentation and back crack extent.

Recycled Multi-Material Packaging Reinforced with Flax Fibres: Thermal and Mechanical Behaviour.

In this work, the use of a recycled mix stemming from the treatment of multilayer aseptic packaging used in the food and beverage industry is proposed as the matrix for short fibre composites reinforced with flax fibres, to generate value-added materials in contrast to the more common end-of-life scenario including energy recovery. This is expected to be a preferred choice in the waste hierarchy at the European level. A commercially available material (EcoAllene) obtained from multilayer packaging recycling was compounded with short flax fibres up to 30 wt.% by twin screw extrusion, with a view to enhancing its poor mechanical profile and broadening its applications. Composites were in depth analyzed by thermogravimetric analysis and differential scanning calorimetry, which highlighted the complex nature of this recycled product, a limited nucleation ability of flax fibres and a lower thermal stability due to the premature degradation of natural hemicellulose and cellulose, though featuring in any case onset degradation temperatures higher than 300 °C. Composites' mechanical properties were assessed in tension, bending and impact conditions, with remarkable improvements over the neat matrix in terms of stiffness and strength. In particular, at 30 wt.% fibre content and with 5 wt.% of maleated coupling agent, an increase in tensile and flexural strength values by 92% and 138% was achieved, respectively, without compromising the impact strength. The effectiveness of flax fibres confirmed by dynamo-mechanical analysis is beneficial to the exploitation of these composites in automotive interiors and outdoor decking applications.

Fused Deposition Modeling Parameter Optimization for Cost-Effective Metal Part Printing.

Metal 3D-printed parts are critical in industries such as biomedical, surgery, and prosthetics to create tailored components for patients, but the costs associated with traditional metal additive manufacturing (AM) techniques are typically prohibitive. To overcome this disadvantage, more cost-effective manufacturing processes are needed, and a good approach is to combine fused deposition modeling (FDM) with debinding-sintering processes. Furthermore, optimizing the printing parameters is required to improve material density and mechanical performance. The design of experiment (DoE) technique was used to evaluate the impact of three printing factors, namely nozzle temperature, layer thickness, and flow rate, on the tensile and bending properties of sintered 316L stainless steel in this study. Green and sintered samples were morphologically and physically characterized after printing, and the optimal printing settings were determined by statistical analysis, which included the surface response technique. The mechanical properties of the specimens increased as the flow rate and layer thickness increased and the nozzle temperature decreased. The optimized printing parameters for the ranges used in this study include 110% flow rate, 140 µm layer thickness, and 240 °C nozzle temperature, which resulted in sintered parts with a tensile strength of 513 MPa and an elongation at break of about 60%.

Solvent Casting and UV Photocuring for Easy and Safe Fabrication of Nanocomposite Film Dressings.

The aim of this work was to optimize and characterize nanocomposite films based on gellan gum methacrylate (GG-MA) and silver nanoparticles (AgNPs) for application in the field of wound dressing. The films were produced using the solvent casting technique coupled with a photocuring process. The UV irradiation of GG-MA solutions containing glycerol as a plasticizer and different amounts of silver nitrate resulted in the concurrent crosslinking of the photocurable polymer and a reduction of Ag ions with consequent in situ generation of AgNPs. In the first part of the work, the composition of the films was optimized, varying the concentration of the different components, the GG-MA/glycerol and GG-MA/silver nitrate weight ratios as well as the volume of the film-forming mixture. Rheological analyses were performed on the starting solutions, whereas the obtained films were characterized for their mechanical properties. Colorimetric analyses and swelling studies were also performed in order to determine the AgNPs release and the water uptake capacity of the films. Finally, microbiological tests were carried out to evaluate the antimicrobial efficacy of the optimized films, in order to demonstrate their possible application as dressings for the treatment of infected hard-to-heal wounds, which is a demanding task for public healthcare.

Multi-Excitation Infrared Fusion for Impact Evaluation of Aluminium-BFRP/GFRP Hybrid Composites.

Fibre metal laminates are widely implemented in the aerospace industry owing to the merits of fatigue resistance and plastic properties. An effective defect assessment technique needs to be investigated for this type of composite materials. In order to achieve accurate impact-induced damage evaluation, a multi-excitation infrared fusion method is introduced in this study. Optical excitation thermography with high performance on revealing surface and subsurface defects is combined with vibro-thermography to improve the capability of detection on defects. Quantitative analysis is carried out on the temperature curve to assess the impact-induced deformation. A new image fusion framework including feature extraction, feature selection and fusion steps is proposed to fully utilize the information from two excitation modalities. Six fibre metal laminates which contain aluminium-basalt fibre reinforced plastic and aluminium-glass fibre reinforced plastic are investigated. Features from different perspectives are compared and selected via intensity contrast on deformation area for fusion imaging. Both types of defects (i.e., surface and sub-surface) and the internal deformation situation of these six samples are characterized clearly and intuitively.

The Compressive Behavior and Crashworthiness of Cork: A Review.

Cork, a natural material from renewable resources, is currently attracting increasing interest in different industrial fields because of its cellular structure and the presence of the flexible suberin as its main chemical component. In an agglomerated form, it proved to be a compelling product not only as a thermal and acoustic insulator, but also as core material in sandwich structures and as a liner or padding in energy absorbing equipment. From this perspective, the assessment of its compressive response is fundamental to ensure the right out-of-plane stiffness required to a core material and the proper crashworthiness in the safety devices. Considering the complex nature of cork and the resulting peculiar compressive response, the present review article provides an overview of this paramount property, assessing the main parameters (anisotropy, temperature, strain rate, etc.) and the peculiar features (near-zero Poisson's ratio and unique dimensional recovery) that characterize it in its natural state. Furthermore, considering its massive exploitation in the agglomerated form, the design parameters that allow its compressive behavior to be tailored and the operating parameters that can affect its crashworthiness were assessed, reporting some potential industrial applications.

Enhanced Infrared Sparse Pattern Extraction and Usage for Impact Evaluation of Basalt-Carbon Hybrid Composites by Pulsed Thermography.

Nowadays, infrared thermography, as a widely used non-destructive testing method, is increasingly studied for impact evaluation of composite structures. Sparse pattern extraction is attracting increasing attention as an advanced post-processing method. In this paper, an enhanced sparse pattern extraction framework is presented for thermographic sequence processing and defect detection. This framework adapts cropping operator and typical component extraction as a preprocessing step to reduce the dimensions of raw data and applies sparse pattern extraction algorithms to enhance the contrast on the defect area. Different cases are studied involving several defects in four basalt-carbon hybrid fiber-reinforced polymer composite laminates. Finally, comparative analysis with intensity distribution is carried out to verify the effectiveness of contrast enhancement using this framework.

Hybrid Cellulose-Basalt Polypropylene Composites with Enhanced Compatibility: The Role of Coupling Agent.

This study deals with the development and optimization of hybrid composites integrating microcrystalline cellulose and short basalt fibers in a polypropylene (PP) matrix to maximize the mechanical properties of resulting composites. To this aim, the effects of two different coupling agents, endowed with maleic anhydride (MA-g(grafted)-PP) and acrylic acid (AA-g-PP) functionalities, on the composite properties were investigated as a function of their amount. Tensile, flexural, impact and heat deflection temperature tests highlighted the lower reactivity and effectiveness of AA-g-PP, regardless of reinforcement type. Hybrid formulations with basalt/cellulose (15/15) and with 5 wt. % of MA-g-PP displayed remarkable increases in tensile strength and modulus, flexural strength and modulus, and notched Charpy impact strength, of 45% and 284%, 97% and 263%, and 13%, in comparison with neat PP, respectively. At the same time, the thermo-mechanical stability was enhanced by 65% compared to neat PP. The results of this study, if compared with the ones available in the literature, reveal the ability of such a combination of reinforcements to provide materials suitable for automotive applications with environmental benefits.

The Potential of Agglomerated Cork for Sandwich Structures: A Systematic Investigation of Physical, Thermal, and Mechanical Properties.

Considering the major role played by sandwich structures in many fields where high stiffness-to-weight ratio is required, the selection of a suitable core material is of paramount importance. In order to face the environmental problems related to waste disposal, the selection of an eco-friendly core material is now included in the design criteria of sandwich structures. Agglomerated cork is recognized as a good solution that combines satisfactory mechanical performances and eco-sustainability. Many research studies individually addressed cork's morphological, thermal, and mechanical features without providing a comprehensive overview of the relationships that exist between them. In this work, the investigation of the peculiar cork morphology allowed learning more about its good insulation capacity and its impressive recovery capability. The use of dynamic mechanical analysis (DMA) and thermogravimetric analysis (TGA) clarified the influence of temperature on both flexural and compressive performances. The effect of testing parameters such as temperature and speed on agglomerated cork properties was validated through statistical analysis. Moreover, to highlight agglomerated cork advantages and drawbacks, the work provides also a comparison with more traditional polyvinylchloride (PVC) foams commonly used in industrial applications.

Durability of Basalt/Hemp Hybrid Thermoplastic Composites.

The Achilles heel of thermoplastic natural fibre composites is their limited durability. The environmental degradation of the mechanical properties of hemp and hemp/basalt hybrid-reinforced high-density polyethylene (HDPE) composites has been investigated with a special focus on the effects of water ageing and accelerated ageing, including hygrothermal and UV radiation. Modification of the matrix was carried out using a maleic anhydride high-density polyethylene copolymer (MAPE) as a compatibilizer. Hybridization of hemp fibres with basalt fibres and the incorporation of MAPE were found to significantly decrease the water uptake (up to 75%) and increase the retention of mechanical properties after accelerated ageing. Secondary crystallization phenomena occurring in the composites, as confirmed by differential scanning calorimetry (DSC) analysis, were able to counteract the severe combined effects of hygrothermal stress and UV radiation, with the exception of hemp-fibre composites where permanent damage to the fibres occurred, with 2% and 20% reduction in tensile strength and modulus, respectively, for a 30 wt % hemp fibre-reinforced HDPE.