The Different Properties of Geopolymer Composites Reinforced with Flax Fibers and Carbon Fibers.

The main motivation for this research was to improve the properties of geopolymers by reinforcement using synthetic and natural fibers, and to gain new knowledge regarding how the nature and/or the quantity of reinforcement fibers influences the properties of the final geopolymers. The main objective was to investigate the effects of different types of reinforcement fibers on the properties of the geopolymers. These reinforcement fibers were mainly environmentally friendly materials that can be used as alternatives to ordinary Portland cement. The authors used fly ash and river sand as the raw materials for the matrix, and added carbon fibers (CF), flax fibers (FF), or a hybrid of both (CFM) as reinforcements. The samples were prepared by mixing, casting, and curing, and then subjected to various tests. The main research methods used were compressive strength (CS), flexural strength (FS), water absorption (WA), abrasion resistance (Böhme's disk method), microstructure analysis (SEM), chemical composition (XRF), and crystal structure analysis (XRD). The results showed that the addition of fibers partially improved the mechanical properties of the geopolymers, as well as reducing microcracks. The CF-reinforced geopolymers exhibited the highest compressive strength, while the FF-reinforced geopolymers showed the lowest water absorption. The authors, based on previous research, also discussed the factors that influence fiber-matrix adhesion, and the optimal fiber content for geopolymers.

Influence of Alumina Grade on Sintering Properties and Possible Application in Binder Jetting Additive Technology.

Alumina is one of the most popular ceramic materials widely used in both tooling and construction applications due to its low production cost, and high properties. However, the final properties of the product depend not only on the purity of the powder, but also, e.g., on its particle size, specific surface area, and the production technology used. These parameters are particularly important in the case of choosing additive techniques for the production of details. Therefore, the article presents the results of comparing five grades of Al2O3 ceramic powder. Their specific surface area (via Brunauer-Emmett-Teller (BET) and Barrett-Joyner-Halenda (BJH) methods), particle size distribution, and phase composition by X-ray diffraction (XRD) were determined. Moreover, the surface morphology was characterized by the scanning electron microscopy (SEM) technique. The discrepancy between generally available data and the results obtained from measurements has been indicated. Moreover, the method of spark plasma sintering (SPS), equipped with the registration system of the position of the pressing punch during the process, was used to determine the sinterability curves of each of the tested grades of Al2O3 powder. Based on the obtained results, a significant influence of the specific surface area, particle size, and the width of their distribution at the beginning of the Al2O3 powder sintering process was confirmed. Furthermore, the possibility of using the analyzed variants of powders for binder jetting technology was assessed. The dependence of the particle size of the powder used on the quality of the printed parts was demonstrated. The procedure presented in this paper, which involves analyzing the properties of alumina varieties, was used to optimize the Al2O3 powder material for binder jetting printing. The selection of the best powder in terms of technological properties and good sinterability makes it possible to reduce the number of 3D printing processes, which makes it more economical and less time-consuming.

Properties of 3D Printed Concrete-Geopolymer Hybrids Reinforced with Aramid Roving.

Three-dimensional concrete printing (3DCP) is an innovative technology that can lead to breakthrough modifications of production processes in the construction industry. The paper presents for the first time the possibility of 3D printing concrete-geopolymer hybrids reinforced with aramid roving. Reference concrete samples and concrete-geopolymer hybrids composed of 95% concrete and 5% geopolymer based on fly ash or metakaolin were produced. The properties of the samples without reinforcement and samples with 0.5% (wt.) aramid roving were compared. The frost resistance tests, UV radiation resistance, and thermal conductivity were evaluated for samples that were 3D-printed or produced by the conventional casting method. Compressive strength tests were carried out for each sample exposed to freeze-thaw cycles and UV radiation. It was observed that after the frost resistance test, the samples produced by the 3D printing technology had a minor decrease in strength properties compared to the samples made by casting. Moreover, the thermal conductivity coefficient was higher for concrete-geopolymer hybrids than concrete reinforced with aramid roving.

Optimizing the L/S Ratio in Geopolymers for the Production of Large-Size Elements with 3D Printing Technology.

Geopolymer concretes can be a viable alternative to conventional Portland cement-based materials. In their design, it is important to maintain an appropriate liquid-to-solid ratio (L/S), which affects several properties, such as the compressive strength, water absorption, and frost resistance. The objective of this paper is to analyze the influence of the fly-ash and metakaolin precursor types for three different L/S ratios: 0.30, 0.35, and 0.45. The results of the physical and mechanical properties, including the apparent density and compressive strength, as well the durability parameters, including frost resistance and water penetration depth, are presented in this paper. It was found that as the L/S ratio decreased, the average compressive strength increased for all materials. After freeze-thaw cycles, decreases in the compressive strength properties were observed for all types of materials-metakaolin- and fly ash-based-irrespective of the L/S ratio. Moreover, the frost resistance of geopolymers increased with the increase in the L/S ratio. The printability of the mixes was also verified in order to confirm the application of the developed materials to additive manufacturing processes.

3D Printing of Concrete-Geopolymer Hybrids.

In recent years, 3D concrete printing technology has been developing dynamically. Intensive research is still being carried out on the composition of the materials dedicated to innovative 3D printing solutions. Here, for the first time, concrete-geopolymer hybrids produced with 3D printing technology and dedicated environmentally friendly building construction are presented. The concrete-geopolymer hybrids consisting of 95% concrete and 5% geopolymer based on fly ash or metakaolin were compared to standard concrete. Moreover, 3D printed samples were compared with the samples of the same composition but prepared by the conventional method of casting into molds. The phase composition, water leachability, compressive, and flexural strength in the parallel and perpendicular directions to the printing direction, and fire resistance followed by compressive strength were evaluated. Concrete-geopolymer hybrids were shown to contain a lower content of hazardous compounds in leaches than concrete samples. The concentration of toxic metals did not exceed the limit values indicated in the Council Decision 2003/33/EC; therefore, the materials were classified as environmentally neutral. The different forms of Si/Al in fly ash and metakaolin resulted in the various potentials for geopolymerization processes, and finally influenced the densification of the hybrids and the potential for immobilization of toxic elements. Although the compressive strength of concrete was approximately 40% higher for cast samples than for 3D printed ones, for the hybrids, the trend was the opposite. The addition of fly ash to concrete resulted in a 20% higher compressive strength compared to an analogous hybrid containing the addition of metakaolin. The compressive strength was 7-10% higher provided the samples were tested in the parallel direction to the Z-axis of the printout. The sample compressive strength of 24-43 MPa decreased to 8-19 MPa after the fire resistance tests as a result of moisture evaporation, weight loss, thermal deformation, and crack development. Importantly, the residual compressive strength of the hybrid samples was 1.5- to 2- fold higher than the concrete samples. Therefore, it can be concluded that the addition of geopolymer to the concrete improved the fire resistance of the samples.

Fracture Behavior of Long Fiber Reinforced Geopolymer Composites at Different Operating Temperatures.

The aim of this article was to analyze the fracture behavior of geopolymer composites based on fly ash or metakaolin with fine aggregate and river sand, with three types of reinforcement: glass, carbon, and aramid fiber, at three different temperatures, approximately: 3 °C, 20 °C, and 50 °C. The temperatures were selected as a future work temperature for composites designed for additive manufacturing technology. The main research method used was bending strength tests in accordance with European standard EN 12390-5. The results showed that the addition of fibers significantly improved the bending strength of all composites. The best results at room temperature were achieved for the metakaolin-based composites and sand reinforced with 2% wt. aramid fiber-17 MPa. The results at 50 °C showed a significant decrease in the bending strength for almost all compositions, which are unexpected results, taking into account the fact that geopolymers are described as materials dedicated to working at high temperatures. The test at low temperature (ca. 3 °C) showed an increase in the bending strength for almost all compositions. The grounds of this type of behavior have not been clearly stated; however, the likely causes of this are discussed.

Hybrid Materials Based on Fly Ash, Metakaolin, and Cement for 3D Printing.

Nowadays, one very dynamic development of 3D printing technology is required in the construction industry. However, the full implementation of this technology requires the optimization of the entire process, starting from the design of printing ideas, and ending with the development and implementation of new materials. The article presents, for the first time, the development of hybrid materials based on a geopolymer or ordinary Portland cement matrix that can be used for various 3D concrete-printing methods. Raw materials used in the research were defined by particle size distribution, specific surface area, morphology by scanning electron microscopy, X-ray diffraction, thermal analysis, radioactivity tests, X-ray fluorescence, Fourier transform infrared spectroscopy and leaching. The geopolymers, concrete, and hybrid samples were described according to compressive strength, flexural strength, and abrasion resistance. The study also evaluates the influence of the liquid-to-solid ratio on the properties of geopolymers, based on fly ash (FA) and metakaolin (MK). Printing tests of the analyzed mixtures were also carried out and their suitability for various applications related to 3D printing technology was assessed. Geopolymers and hybrids based on a geopolymer matrix with the addition of 5% cement resulted in the final materials behaving similarly to a non-Newtonian fluid. Without additional treatments, this type of material can be successfully used to fill the molds. The hybrid materials based on cement with a 5% addition of geopolymer, based on both FA and MK, enabled precise detail printing.

Mechanical and Fracture Properties of Long Fiber Reinforced Geopolymer Composites.

The aim of the article is to analyze the structure and mechanical properties in terms of the cracking mechanics of geopolymer composites based on fly ash and river sand, as well as metakaolin and river sand with three types of reinforcement material: glass fiber, carbon fiber, and aramid fiber, in terms of their use in additive manufacturing. Geopolymer composites were reinforced with fibers in a volume ratio of 0.5%, 1.0%, and 2.0%. Subsequently, these samples were subjected to bending strength tests in accordance with the European standard EN 12390-3. The addition of fibers significantly improved the bending strength of all composites made of metakaolin and sand. The reinforcement with aramid fiber in the amount of 2.0% resulted in more than a 3-fold increase in strength compared to the reinforcement-free composites. An analysis of the morphology of the fibers was carried out on the basis of photos taken from an electron microscope. The correct addition of fibers changes the nature of the fracture from brittle to more ductile and reduces the number of cracks in the material.

Process Design for a Production of Sustainable Materials from Post-Production Clay.

Alkali activated cement (AAC) can be manufactured from industrial by-products to achieve goals of "zero-waste" production. We discuss in detail the AAC production process from (waste) post-production clay, which serves as the calcium-rich material. The effect of different parameters on the changes in properties of the final product, including morphology, phase formation, compressive strength, resistance to the high temperature, and long-term curing is presented. The drying and grinding of clay are required, even if both processes are energy-intensive; the reduction of particle size and the increase of specific surface area is crucial. Furthermore, calcination at 750 °C ensure approximately 20% higher compressive strength of final AAC in comparison to calcination performed at 700 °C. It resulted from the different ratio of phases: Calcite, mullite, quartz, gehlenite, and wollastonite in the final AAC. The type of activators (NaOH, NaOH:KOH mixtures, KOH) affected AAC mechanical properties, significantly. Sodium activators enabled obtaining higher values of strength. However, if KOH is required, the supplementation of initial materials with fly ash or metakaolin could improve the mechanical properties and durability of AAC, even c.a. 28%. The presented results confirm the possibility of recycling post-production clay from the Raciszyn II Jurassic limestone deposit.

Optimal Design of Ph-Neutral Geopolymer Foams for Their Use in Ecological Plant Cultivation Systems.

We have calculated that with the world population projected to increase from 7.5 billion in 2017 to 9.8 in 2050, the next generation (within 33 years) will produce 12,000-13,000 Mt of plastic, and that the yearly consumption will reach 37-40 kilos of plastic per person worldwide. One of the branches of the plastics industry is the production of plastics for agriculture e.g., seed trays and pots. In this paper, novel metakaolin-based geopolymer composites reinforced with cellulosic fibres are presented as an alternative to plastic pots. Materials can be dedicated to agricultural applications, provided they have neutral properties, however, geopolymer paste and its final products have high pH. Therefore, a two-step protocol of neutralisation of the geopolymer foam pots was optimised and implemented. The strength of the geopolymer samples was lower when foams were neutralised. The reinforcement of geopolymers with cellulose clearly prevented the reduction of mechanical properties after neutralisation, which was correlated with the lower volume of pores in the foam and with the cellulose chemical properties. Both, neutralisation and reinforcement with cellulose can also eliminate an efflorescence. Significantly increased plant growth was found in geopolymer pots in comparison to plastic pots. The cellulose in geopolymers resulted in better adsorption and slower desorption of minerals during fertilisation. This effect could also be associated with a lower number of large pores in the presence of cellulose fibres in pots, and thus more stable pore filling and better protection of internal surface interactions.