The Tensile, Thermal and Flame-Retardant Properties of Polyetherimide and Polyetherketoneketone Processed via Fused Filament Fabrication.

Polymer materials are increasingly widely used in high-fire-risk applications, such as aviation interior components. This study aimed to compare the tensile, thermal, and flame-retardant properties of test samples made from ultra-performance materials, polyetherimide (PEI) and polyetherketoneketone (PEKK), using the fused filament fabrication process (FFF). The tensile tests were performed for these materials at different raster angles (0, 45, and 90°). The thermomechanical tests were done in the axial, perpendicular, and through-thickness directions to the extruded filaments. The impact of printing parameters on the flame retardancy of 3D-printed samples was investigated in vertical burn tests with varying specimen thicknesses and printing directions. Experimentally, it was testified that PEKK had better isotropic behaviour than PEI for mechanical performance, thermal expansion, and fire-resistant properties, which are essential in fabricating intricately shaped products.

Electrical Resistivity of 3D-Printed Polymer Elements.

During this study, the resistivity of electrically conductive structures 3D-printed via fused filament fabrication (FFF) was investigated. Electrical resistivity characterisation was performed on various structural levels of the whole 3D-printed body, starting from the single traxel (3D-printed single track element), continuing with monolayer and multilayer formation, finalising with hybrid structures of a basic nonconductive polymer and an electrically conductive one. Two commercial conductive materials were studied: Proto-Pasta and Koltron G1. It was determined that the geometry and resistivity of a single traxel influenced the resistivity of all subsequent structural elements of the printed body and affected its electrical anisotropy. In addition, the results showed that thermal postprocessing (annealing) affected the resistivity of a standalone extruded fibre (extruded filament through a printer nozzle in freefall) and traxel. The effect of Joule heating and piezoresistive properties of hybrid structures with imprinted conductive elements made from Koltron G1 were investigated. Results revealed good thermal stability within 70 °C and considerable piezoresistive response with a gauge factor of 15-25 at both low 0.1% and medium 1.5% elongations, indicating the potential of such structures for use as a heat element and strain gauge sensor in applications involving stiff materials and low elongations.

Moisture Sorption and Degradation of Polymer Filaments Used in 3D Printing.

Experimental research of the moisture sorption process of 12 typical filaments used for FFF was performed in atmospheres with a relative humidity from 16 to 97% at room temperature. Materials with high moisture sorption capacity were revealed. Fick's diffusion model was applied to all tested materials, and a set of sorption parameters was found. The solution of Fick's second equation for the two-dimensional cylinder was obtained in series form. Moisture sorption isotherms were obtained and classified. Moisture diffusivity dependence on relative humidity was evaluated. The diffusion coefficient was independent of the relative humidity of the atmosphere for six materials. It essentially decreased for four materials and grew for the other two. Swelling strain changed linearly with the moisture content of the materials and reached up to 0.5% for some of them. The degree of degradation of the elastic modulus and the strength of the filaments due to moisture absorption were estimated. All tested materials were classified as having a low (changes ca. 2-4% or less), moderate (5-9%), or high sensitivity to water (more than 10%) by their reduction in mechanical properties. This reduction in stiffness and strength with absorbed moisture should be considered for responsible applications.

Effect of Post-Printing Cooling Conditions on the Properties of ULTEM Printed Parts.

This paper aimed to estimate the effect of post-printing cooling conditions on the tensile and thermophysical properties of ULTEM® 9085 printed parts processed by fused deposition modeling (FDM). Three different cooling conditions were applied after printing Ultem samples: from 180 °C to room temperature (RT) for 4 h in the printer (P), rapid removal from the printer and cooling from 200 °C to RT for 4 h in the oven (O), and cooling at RT (R). Tensile tests and dynamic mechanical thermal analysis (DMTA) were carried out on samples printed in three orthogonal planes to investigate the effect of the post-printing cooling conditions on their mechanical and thermophysical properties. Optical microscopy was employed to relate the corresponding macrostructure to the mechanical performance of the material. The results obtained showed almost no difference between samples cooled either in the printer or oven and a notable difference for samples cooled at room temperature. Moreover, the lowest mechanical performance and sensitivity to the thermal cooling conditions were defined for the Z printing direction due to anisotropic nature of FDM and debonding among layers.

Effect of Core-Shell Rubber Nanoparticles on the Mechanical Properties of Epoxy and Epoxy-Based CFRP.

The aim of the research was to estimate the effect of core-shell rubber (CSR) nanoparticles on the tensile properties, fracture toughness, and glass transition temperature of the epoxy and epoxy-based carbon fiber reinforced polymer (CFRP). Three additives containing CSR nanoparticles were used for the research resulting in a filler fraction of 2-6 wt.% in the epoxy resin. It was experimentally confirmed that the effect of the CSR nanoparticles on the tensile properties of the epoxy resin was notable, leading to a reduction of 10-20% in the tensile strength and elastic modulus and an increase of 60-108% in the fracture toughness for the highest filler fraction. The interlaminar fracture toughness of CFRP was maximally improved by 53% for ACE MX 960 at CSR content 4 wt.%. The glass transition temperature of the epoxy was gradually improved by 10-20 °C with the increase of CSR nanoparticles for all of the additives. A combination of rigid and soft particles could simultaneously enhance both the tensile properties and the fracture toughness, which cannot be achieved by the single-phase particles independently.

Scalable MXene and PEDOT-CNT Nanocoatings for Fibre-Reinforced Composite De-Icing.

In this study, the de-icing performance is investigated between traditional carbon fibre-based coatings and novel MXene and poly(3,4-ethylenedioxythiophene)-coated single-walled carbon nanotube (PEDOT-CNT) nanocoatings, based on simple and scalable coating application. The thickness and morphology of the coatings are investigated using atomic force microscopy and scanning electron microscopy. Adhesion strength, as well as electrical properties, are evaluated on rough and glossy surfaces of the composite. The flexibility and electrical sensitivity of the coatings are studied under three-point bending. Additionally, the influence of ambient temperature on coating's electrical resistance is investigated. Finally, thermal imaging and Joule heating are analysed with high-accuracy infrared cameras. Under the same power density, the increase in average temperature is 84% higher for MXenes and 117% for PEDOT-CNT, when compared with fibre-based coatings. Furthermore, both nanocoatings result in up to three times faster de-icing. These easily processable nanocoatings offer fast and efficient de-icing for large composite structures such as wind turbine blades without adding any significant weight.

In Situ Deformation Monitoring of 3D Woven Composite T-Profile Using MXene Nanoparticles.

The aim of this study was to develop a process-efficient smart three-dimensional (3D) woven composite T-profile by depositing MXene nanoparticles at the junction for sensing damage and deformation at the junction. Such smart composites could find application in the online health monitoring of complex-shaped parts. The composites were manufactured by infusing epoxy resin in a single-layer fabric T-profile preform, woven in folded form on a dobby shuttle loom using 300 tex glass roving. The chemically etched Ti3C2Tz MXene nanoparticles were dispersed in deionised water and 10 layers were sprayed at the junction of the composite to form a conductive coating. The MXene-coated composite T-profile specimens were subjected to tensile and fatigue loading to study the electromechanical response of the MXene coating to applied displacement. The results showed that the MXene coating was able to sense the sample deformation till ultimate failure of the composite. The MXene coating was also able to effectively sense the tensile-tensile fatigue loading, carried out at 2000 cycles and 4000 cycles for a 50 N-0.5 Hz and a 100 N-1 Hz load-frequency combination, respectively, while being sensitive to the overall deformation of the composite. The smart complex-shaped composites developed in this work were capable of monitoring their health under tensile and fatigue loading in real time.

Electrical Conductivity of Glass Fiber-Reinforced Plastic with Nanomodified Matrix for Damage Diagnostic.

The electrical conductivity of glass fiber-reinforced plastic (GFRP) with epoxy matrix modified by multiwall carbon nanotubes (MWCNT) was studied. The electrical conductivity of nanomodified lamina and multi-layered GFRP was investigated on several levels using a structural approach. Components of the electrical conductivity tensor for unidirectional-reinforced monolayer were calculated similarly as in micromechanics using the conductivity of the nanomodified matrix. The electrical conductivity of multilayer composite was calculated using laminate theory and compared with values measured experimentally for various fiber orientation angles. Calculated and experimental data were in good agreement. The voltage distribution measured throughout the laminate allowed detecting the damage in its volume. The electrode network located on the laminate surface could determine the location, quantification, and geometry of the damage in the GFRP lamina modified with MWCNT. Experimental and calculated electrical resistance data for GFRP double-cantilever beam specimens were investigated in Mode I interlaminar fracture toughness test. Results demonstrate that electrical resistance could be successfully used for the diagnostic of the crack propagation during interlaminar fracture of the MWCNT-modified GFRP.

Strain Sensing Coatings for Large Composite Structures Based on 2D MXene Nanoparticles.

Real-time strain monitoring of large composite structures such as wind turbine blades requires scalable, easily processable and lightweight sensors. In this study, a new type of strain-sensing coating based on 2D MXene nanoparticles was developed. A Ti3C2Tz MXene was prepared from Ti3AlC2 MAX phase using hydrochloric acid and lithium fluoride etching. Epoxy and glass fibre-reinforced composites were spray-coated using an MXene water solution. The morphology of the MXenes and the roughness of the substrate were characterised using optical microscopy and scanning electron microscopy. MXene coatings were first investigated under various ambient conditions. The coating experienced no significant change in electrical resistance due to temperature variation but was responsive to the 301-365 nm UV spectrum. In addition, the coating adhesion properties, electrical resistance stability over time and sensitivity to roughness were also analysed in this study. The electromechanical response of the MXene coating was investigated under tensile loading and cyclic loading conditions. The gauge factor at a strain of 4% was 10.88. After 21,650 loading cycles, the MXene coating experienced a 16.25% increase in permanent resistance, but the response to loading was more stable. This work provides novel findings on electrical resistance sensitivity to roughness and electromechanical behaviour under cyclic loading, necessary for further development of MXene-based nanocoatings. The advantages of MXene coatings for large composite structures are processability, scalability, lightweight and adhesion properties.

Novel Hybrid Polymer Composites with Graphene and MXene Nano-Reinforcements: Computational Analysis.

This paper presents a computational analysis on the mechanical and damage behavior of novel hybrid polymer composites with graphene and MXene nano-reinforcements targeted for flexible electronics and advanced high-strength structural applications with additional functions, such as real-time monitoring of structural integrity. Geometrical models of three-dimensional representative volume elements of various configurations were generated, and a computational model based on the micromechanical finite element method was developed and solved using an explicit dynamic solver. The influence of the geometrical orientation, aspect ratio, and volume fractions of the inclusions, as well as the interface properties between the nano-reinforcements and the matrix on the mechanical behavior, was determined. The results of the presented research give initial insights about the mechanical and damage behavior of the proposed composites and provide insight for future design iterations of similar multifunctional materials.

Prompt Determination of the Mechanical Properties of Industrial Polypropylene Sandwich Pipes.

A simple and prompt method to determine the mechanical properties of industrial multilayer extrusion polypropylene pipes for a gravity sewer network is suggested. The engineering formulas included for calculating the permissible thickness and relative position of a foam core in the pipes are based on a linear-elastic approximation and the rule of mixtures. The applicability of the approximation was justified experimentally during investigation of the effective tensile characteristics of single- and multilayer pipes and each layer specimen by using traditional tests and finite-element calculations. The results obtained were used to formulate engineering recommendations for calculations of this type.

Basalt Fibre Composite with Carbon Nanomodified Epoxy Matrix under Hydrothermal Ageing.

This work aimed to investigate the effect of hybrid carbon nanofillers (e.g., carbon nanotubes/carbon nanofibers in the ratio 1:1 by mass) over the electrical and flexural properties for an epoxy matrix and corresponding basalt fibre reinforcing composite (BFRC) subjected to full-year seasonal water absorption. Hydrothermal ageing was performed by full immersion of the tested materials into distilled water according to the following model conditions (seasons). The mechanical properties were measured in three-point bending mode before environmental ageing and after each season. Upon environmental ageing, the relative change of flexural strength and elastic modulus of the epoxy and NC was within 10-15%. For nanomodified BFRCs, the slightly higher effect (approx. by 10%) of absorbed moisture on flexural characteristics was found and likely attributed to higher defectiveness (e.g., porosity, the formation of agglomerates etc.). During flexural tests, electrical resistance of the nanocomposites (NC) and BFRC/NC samples was evaluated. The electrical conductivity for UD BFRC/NC, before and after hydrothermal ageing, was by 2 and 3 times higher than for the NC, accordingly, revealing the orientation of electrically conductive nanoparticles and/or their agglomerates during lay-up manufacturing which was evaluated by the rules of the mixture. Based on all results obtained it can be concluded that the most potentially applicable for damage indication was UD BFRC/NC along fibres since full-year hydrothermal ageing improved its electrical conductivity by approx. 98% and, consequently, the ability to monitor damages was also enhanced.

Hydrothermal Aging of an Epoxy Resin Filled with Carbon Nanofillers.

The effects of temperature and moisture on flexural and thermomechanical properties of neat and filled epoxy with both multiwall carbon nanotubes (CNT), carbon nanofibers (CNF), and their hybrid components were investigated. Two regimes of environmental aging were applied: Water absorption at 70 °C until equilibrium moisture content and thermal heating at 70 °C for the same time period. Three-point bending and dynamic mechanical tests were carried out for all samples before and after conditioning. The property prediction model (PPM) was successfully applied for the prediction of the modulus of elasticity in bending of manufactured specimens subjected to both water absorption and thermal aging. It was experimentally confirmed that, due to addition of carbon nanofillers to the epoxy resin, the sorption, flexural, and thermomechanical characteristics were slightly improved compared to the neat system. Considering experimental and theoretical results, most of the epoxy composites filled with hybrid carbon nanofiller revealed the lowest effect of temperature and moisture on material properties, along with the lowest sorption characteristics.

Deformation and Failure of MXene Nanosheets.

This work is aimed at the development of finite element models and prediction of the mechanical behavior of MXene nanosheets. Using LS-Dyna Explicit software, a finite element model was designed to simulate the nanoindentation process of a two-dimensional MXene Ti3C2Tz monolayer flake and to validate the material model. For the evaluation of the adhesive strength of the free-standing Ti3C2Tz-based film, the model comprised single-layered MXene nanosheets with a specific number of individual flakes, and the reverse engineering method with a curve fitting approach was used. The interlaminar shear strength, in-plane stiffness, and shear energy release rate of MXene film were predicted using this approach. The results of the sensitivity analysis showed that interlaminar shear strength and in-plane stiffness have the largest influence on the mechanical behavior of MXene film under tension, while the shear energy release rate mainly affects the interlaminar damage properties of nanosheets.

Cyclic Moisture Sorption and its Effects on the Thermomechanical Properties of Epoxy and Epoxy/MWCNT Nanocomposite.

The aim of this work was to reveal the moisture absorption-desorption-resorption characteristics of epoxy and epoxy-based nanocomposites filled with different multiwall carbon nanotubes (MWCNTs) by investigating the reversibility of the moisture effect on their thermomechanical properties. Two types of MWCNTs with average diameters of 9.5 and 140 nm were used. For the neat epoxy and nanocomposite samples, the moisture absorption and resorption tests were performed in atmospheres with 47%, 73%, and 91% relative humidity at room temperature. Dynamic mechanical analysis was employed to evaluate the hygrothermal ageing effect for unconditioned and environmentally "aged" samples. It was found that moisture sorption was not fully reversible, and the extent of the irreversibility on thermomechanical properties was different for the epoxy and the nanocomposite. The addition of both types of MWCNTs to the epoxy resin reduced sorption characteristics for all sorption tests, improved the hygrothermal and reduced the swelling rate after the moisture absorption-desorption.