Poly(methyl methacrylate) hybrid syntactic foams with hollow glass microspheres and polyhedral oligomeric silsesquioxanes

The study aims to produce poly(methyl methacrylate) (PMMA)-based lower density syntactic foams with hollow glass microspheres (HGMs) and to improve their mechanical properties by the addition of polyhedral oligomeric silsesquioxanes (POSSs) while maintaining the thermal properties of the neat polymer. First to understand the effect of POSS addition, PMMA–POSS composites with octaisobutyl and octaphenyl POSS were produced through extrusion. Higher relative flexural and impact strengths were obtained with POSS addition to PMMA. Obtaining more enhanced properties with octaphenyl POSS, PMMA-HGM-POSS hybrid syntactic foams were prepared with this additive. In general, the specific flexural strength and modulus of the PMMA syntactic foams were improved with the POSS loading, while the lower density and thermal properties of the PMMA syntactic foams were maintained. PMMA hybrid syntactic foams with 15 wt % HGMs and 0.25 wt % POSS exhibited 37.6% improvement in the specific flexural modulus with respect to the neat PMMA. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2020 , 137, 48368.     

Nanoclay‐reinforced syntactic foams: Flexure and thermal behavior

Syntactic foams containing 60 vol% of hollow glass microballoons in epoxy matrix are modified with untreated nanoclays using combined mechanical and ultrasonication methods. Effects of nanoclays on flexure and thermal behavior of syntactic foams are investigated by adding different amount of nanoclays in the range of 1–3% by weight. Microscopic examinations and physical property characterization are performed to determine the interactions among constituent materials and the void formation during fabrication. It is found that the syntactic foams with 2 wt% nanoclays show the highest improvement in flexural properties (∼42% strength and ∼18% modulus) and dynamic mechanical properties (∼30% storage modulus and ∼28% loss modulus) properties. Thermal decomposition temperature is found to be unaffected by the addition of nanoclays, whereas a continuous reduction in the coefficient of thermal expansion (CTE) is observed. An examination of failure surface indicates that the failure is initiated on the tension side of the flexure sample due to fracturing of microballoons. POLYM. COMPOS., 31:1332–1342, 2010. © 2009 Society of Plastics Engineers     

Mechanical and dynamic mechanical properties of epoxy syntactic foams reinforced by short carbon fiber

Epoxy syntactic foams were prepared with diglycidyl ether of bisphenol‐A (DGEBA) epoxy resin, 2.4.6‐tri(dimethylaminomethyl)phenol (DMP‐30), coupling treated microsphere and short carbon fiber. The density of the foam was maintained between 0.56 and 0.91 g/cm³ for all compositions. Compressive, flexural, tensile and dynamic mechanical properties of the foams were investigated with respect to hollow glass microsphere (HGM) and carbon fiber (CF) content. A considerable improvement in the mechanical properties viz. compressive, flexural and tensile strengths was observed for the foams on incorporation of a small quantity of CF. The storage modulus were higher for the foam composites containing CF. The presence of HGM has significant influence on T_g of the syntactic foams, spherical filler diminished the T_g of the syntactic foams due to the plasticizing effect of the coupling treatment of HGM, that is helpful for enhancing damping properties of syntactic foams. POLYM. COMPOS., 37:1960–1970, 2016. © 2015 Society of Plastics Engineers     

Compressive and thermal characterization of syntactic foams containing hollow silicon carbide particles with porous shell

Silicon carbide hollow particle (SiC_HS) reinforced vinyl ester matrix syntactic foams are prepared and characterized for compressive properties and coefficient of thermal expansion (CTE). Two types of SiC_HS were utilized in 60 vol % to prepare syntactic foams. These SiC_HS had ratio of inner to outer radius of 0.91 and 0.84 for the thin and thick walled particles. The specific compressive strength values were 33.4 and 38.8 kPa/kg/m³ and the specific compressive modulus values were 0.8 MPa/kg/m³ and 0.6 MPa/kg/m³ for the thin and thick walled SiC_HS‐filled syntactic foams, respectively. The shell of the hollow particles contained microporous voids, and the porosity was estimated as 16.6% and 24.8% in the walls of the thin and thick walled particles, respectively. The shell porosity adversely affected the specific compressive strength and the modulus of the syntactic foam. However, the SiC_HS‐filled syntactic foams exhibited low CTE values (26.7 and 15.9 × 10^?6/°C). These CTE values were 65.1% and 79.3% lower than the CTE of the neat resin. Such properties can be useful for applications where syntactic foams are exposed to high temperatures and dimensional stability is important. A theoretical model is used to estimate the porosity level in the SiC shells and estimate the effective mechanical properties of the porous SiC material that forms the particle shell. Such analysis can help in using the models as predictive tools to estimate the mechanical properties of syntactic foams. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40689.     

Study of mechanical and dynamic mechanical behavior of halloysite nanotube-reinforced multiscale syntactic foam

The present study deals with the development of novel cenosphere-epoxy multiscale syntactic foam (MSF) reinforced with halloysite nanotubes (HNTs). Cenospheres with different volume fractions (0, 20, 30, 40, 50 vol%) and HNTs (1 vol%) used in the fabrication of syntactic foams. The addition of HNTs increases the tensile modulus (42%) and flexural modulus (66%) compared with plain syntactic foam (PSF). Furthermore, FTIR studies reveal the strong hydrogen bonding interaction between HNTs and epoxy. Field emission scanning electron microscopy (FESEM) confirms the unique crack deflection phenomenon by HNT, which indicates the structure–property correlation. In addition, the storage and loss modulus of MSFs is 36 and 113%, respectively (at 30°C) higher than the neat epoxy. Improvement in the tensile and flexural properties along with excellent thermal stability at elevated temperature makes MSF a promising material for structural, weight-sensitive, and high-temperature applications.     

Elastic and plastic properties of epoxy resin syntactic foams filled with hollow glass microspheres and glass fibers

Representative volume elements of syntactic foams with a random filling of short glass fibers and hollow glass microspheres in epoxy resin were established by a random sequential adsorption method. The fiber volume fraction was set at 4%, and the microsphere volume fraction range was from 5 to 30%. This numerical simulation was studied with ANSYS software. The influence on the elastic and plastic mechanical properties of syntactic foams of the microsphere volume fraction and relative wall thickness were investigated, and the plastic strain evolution process in the composites was analyzed. The results show that the compressive yield limit and Young's modulus values of the syntactic foams decreased with increasing microsphere volume fraction when the microsphere relative wall thickness was 0.02, but these properties were enhanced with increasing microsphere volume fraction when the relative wall thickness exceeded 0.04. The specific strength and tangent modulus values of the composites increased with increasing microsphere volume fraction. In addition, we observed that the yield stress, Young's modulus, and tangent modulus values of the syntactic foams were obviously enhanced by the addition of glass fibers. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 44188.     

Electrospun Polyamide Nanofiber-Reinforced Hybrid Syntactic Foams

The potential of polyamide nanofibers towards improving the mechanical properties of syntactic foams is demonstrated. Nylon nanofibers were prepared by electrospinning, and the operating parameters, namely solution concentration and flow rate varied to obtain fibers of requisite dimensions. The fibrous mats were employed for reinforcing cenosphere-epoxy syntactic foams. The introduction of nanofibers (0.25% v/v), when placed perpendicularly to the direction of loading led to a marginal improvement (～7%) in the compressive strength. In comparison, the flexural properties of the reinforced foam was significantly higher, with 75 and 62% enhancement in the flexural strength and elongation, respectively.     

Effect of cenosphere surface treatment and blending method on the tensile properties of thermoplastic matrix syntactic foams

The influence of cenosphere surface treatment and blending method on the properties of injection molded high‐density polyethylene (HDPE) matrix syntactic foams is investigated. Cenospheres are treated with silane and HDPE is functionalized with dibutyl maleate. Tensile test specimens are cast with 20, 40, and 60 wt % of cenospheres using injection molding. Modulus and strength are found to increase with increasing cenosphere content for composites with treated constituents. Highest modulus and strength were observed for 40 and 60 wt % untreated mechanically mixed and treated brabender mixed cenospheres/HDPE blends, respectively. These values are 37 and 17% higher than those for virgin and functionalized HDPE. Theoretical models are used to assess the effect of particle properties and interfacial bonding on modulus and strength of syntactic foams. Brabender mixing method provided highest ultimate tensile and fracture strengths, which is attributed to the effectiveness of Brabender in breaking particle clusters and generating the higher particle–matrix surface area compared to that by mechanical mixing method. Theoretical trends show clear benefits of improved particle–matrix interfacial bonding in the strength results. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 43881.     

Effect of organoclay on the morphology,mechanical, and thermal properties of polyimide/organoclay nanocomposite foams

A series of polyimide (PI)/organoclay nanocomposite foams containing different contents of organoclay were prepared by the monomer in situ intercalative polymerization. The effect of organoclay on the chemical structure, morphology, mechanical, and thermal properties of the nanocomposite foams was studied. Fourier transform infrared spectra showed that the hydrogen bonds between organoclay and the polymer matrix were formed. X‐ray diffraction and transmission electron microscope results indicated that the organoclay were well dispersed in the PI matrix. The compressive strength and tensile strength of the nanocomposite foams enhanced significantly, especially for the nanocomposite foam containing 4 wt% organoclay, increasing by 15% and 9%, respectively, compared with these of the neat PI foam, and the presence of the organoclay in the PI foam improved apparently the cellular structure of the nanocomposite foams. Besides, thermogravimetric analysis revealed that the addition of organoclay improved the thermal stability of the nanocomposite foams strongly, and dynamic mechanical analysis indicated that the incorporation of organoclay significantly influenced the storage modulus of the nanocomposite foams. POLYM. COMPOS., 35:2311–2317, 2014. © 2014 Society of Plastics Engineers     

Flexible polyurethane foams reinforced with organic and inorganic nanofillers

The effect of three different types of cellulose nanofillers on the morphology, mechanical, and thermal properties of flexible polyurethane foam was studied. Cellulose nanocrystals (CNC), cellulose nanofibrils (CNF), and cellulose filaments (CelFil) were used as fillers at 0.1–0.8 wt% loading levels. The comparison of the results showed that smaller loading levels resulted in foams with better performance in almost all cases. In the next step, the properties of foams containing CNC, CNF, or CelFil at 0.025%–0.1% loading levels were compared with those made with inorganic nanofillers including nanosilica (nSi), reduced graphene oxide, and halloysite nanotubes (HNT). Among all the properties evaluated, the tensile modulus of the foams was improved up to 40% by adding HNT at 0.05 wt% loading level whereas the addition of CNF resulted in a 44% increase in the compressive modulus of the foams at 0.1 wt% loading level.     

Effect of composition on the fracture toughness and flexural strength of syntactic foams

Syntactic foams are strong, lightweight materials that can be useful in marine and aeronautical applications. However, these materials are brittle, which can limit their usefulness. The fracture toughness of several epoxy based syntactic foams, as affected by foam composition, was evaluated. The parameters of interest were the curing agent type (anhydride and amine) and elastomer type and level. For the anhydride curing agents studied, the addition of elastomer improved the fracture toughness, and no reduction in flexural strength was observed upon elastomer addition. Examination of the fracture surface showed that the failure mechanism varied with foam composition, from crack propagation around the microballoon filler to crack propagation through the filler, possibly explaining the strength results. For a syntactic foam cured with a cycloaliphatic amine curing agent, the addition of elastomer did not significantly affect the fracture toughness. Examination of the fracture surface showed that the failure mechanism for the syntactic foam compositions with and without added elastomer was crack propagation through the matrix rather than through the microballoon filler. Polym. Compos. 25:229–236, 2004. © 2004 Society of Plastics Engineers.     

Mechanical properties of polybenzoxazine syntactic foams

Syntactic foams of polybenzoxazine, containing moderately high volume percentage of glass microballoons, were prepared. The specific gravity decreased with increase in microballoon content. The disproportionate decrease in specific gravity was ascribed to entrapment of air voids during compaction. The high content of microballoon increased the possibility for air voids that tended to get accumulated. The effect of microballoon concentration on tensile, compressive, and flexural strengths of the foams was studied. Tensile and compressive properties were optimized at about 68% by volume of microballoon while flexural strength decreased marginally on increasing the microballoon content. Althought the specific tensile and compressive strength showed a maximum followed by a decrease, the specific flexural strength systematically increased with microballoon content. The increased packing density of syntactic foam of a given constituent composition increased the compressive strength. The property variation was corroborated by morphological features, as evidenced in scanning electron micrographs. The syntactic foams showed “multiple resin‐neck formation” and “disc‐shaped microballoon regions.” The crushing of microballoons during molding was inevitable when compaction was effected to achieve a density beyond the theoretical one. Low‐density syntactic foams tend to fail at lower loads because of fracturing of microballoons. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Estimation of mechanical properties for rigid polyurethane foams

Rigid plastic foams find application in construction mainly as core materials for loaded sandwich structures—in buildings, ground vehicles, and airplanes. This work provides an equation for the mechanical behavior of polyurethane foams as a function of foam density. Starting from a model conception and the qualitative microscopic consideration of the deformation and failure mechanism, simple relations are found for the tensile, compressive and shear strength and the elastic modulus, which sufficiently express the measured results.     

Enhancing specific strength and stiffness of phenolic microsphere syntactic foams through carbon fiber reinforcement

Composite syntactic foams with different densities were fabricated with hollow phenolic microspheres, a phenolic resin binder, and a small addition of chopped carbon fibers. Compressive, shear, and tensile properties were studied for the syntactic foams with and without carbon fibers. Two fiber layer orientations, either parallel (P‐type) or perpendicular (N‐type) to the loading direction, were considered in the mechanical testing. For N‐type foams, mechanical properties were weakly dependent on foam density. For P‐type foams, the mechanical properties of the foams were strongly dependent on the strength of the supporting matrix. The specific strength and specific stiffness of the P‐type foams were significantly enhanced compared with the neat foams. These findings indicate that fiber reinforcement is an effective way to enhance the mechanical performance of syntactic foams, and the enhanced performance should lead to applications as a foam core material for sandwich structures. POLYM. COMPOS., 2010. © 2009 Society of Plastics Engineers     

Mechanical properties of commingled plastic from recycled polyethylene and polystyrene

The mechanical properties of commingled plastic in the form of thick beams prepared by the ET-1 process have been examined in flexure and compression. The mechanical properties were evaluated in relationship to the hierarchical morphology described in a previous study. It was found that the flexural modulus was dominated by the properties of the skin and was satisfactorily modeled by approaches based on the observed micro-morphology, such as the Nielsen and Davis models. It was not necessary to consider the skin–core macromorphology because the flexural modulus was dominated by the void-free skin. The compressive modulus was lower than the flexural modulus and was strongly affected by the skin–core macro-morphology. From the differences between the flexural and compressive moduli, it was determined that the core was essentially nonload-bearing in compression. Flexural fracture initiated on the tension side of the beam and propagated rapidly through the thickness, whereas compressive failure occurred by longitudinal splitting of the skin. © 1994 John Wiley & Sons, Inc.     

Numerical simulation of the mechanical properties of a carbon-fiber-reinforced hollow glass microsphere–epoxy syntactic foam

The addition of carbon fibers has a great influence on the mechanical properties of hollow glass microsphere (HGM)–epoxy syntactic foam. Thus, to elucidate the reinforcement mechanism, the numerical simulation of HGM- and carbon-fiber-filled epoxy matrixes was carried out. The effect of the orientation of carbon fibers on the elastic modulus and stress distribution was studied. The effect of the elastic modulus of the matrix on the change of force was also studied. We noted that the orientation of carbon fibers affected the elastic modulus of the matrix, and when the carbon fibers were distributed in the direction of force, the elastic modulus of the matrix reached its maximum. The maximum stress of HGMs decreased with increasing matrix elastic modulus, and the mechanical properties of the syntactic foam increased with increasing elastic modulus of the matrix. When the carbon fibers were distributed in the direction of the force, the enhancement effect was the best. Because the carbon fibers had a higher elastic modulus than the matrix, the degree of compressive deformation of the carbon fibers was smaller than that of the matrix. During compression, carbon fibers were pulled out and consumed a lot of energy. Thus, the mechanical properties of the syntactic foam were improved. © 2018 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2019 , 136, 47083.     

Tensile properties of glass microballoon‐epoxy resin syntactic foams

The effect of hollow glass particle (microballoon) volume fraction in the range of 0.3–0.6 on the tensile properties and fracture mode of syntactic foams is characterized in the present research. Sixteen types of syntactic foams have been fabricated and tested. Four types of glass microballoons, having 220, 320, 380, and 460 kg/m³ density, are used with epoxy resin matrix for making the syntactic foam samples. These foams contain 30, 40, 50 and 60% microballoons by volume. All types of microballoons have the same size but different wall thickness, which reflects as a difference in their density. It is observed that the tensile strength increases with a decrease in the volume fraction of microballoons. All types of syntactic foams showed 60–80% decrease in the tensile strength compared with that of the neat resin. The foams containing low strength microballoons showed lower tensile modulus compared with that of the neat resin, but the presence of high strength microballoons led to an increase in the tensile modulus of the composites. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 102: 1254–1261, 2006     

Nano‐crystalline cellulose,chemical blowing agent,and mold temperature effect on morphological,physical/mechanical properties of polypropylene

Polypropylene (PP)/nano‐crystalline cellulose (NCC) composites and foams were produced through extrusion compounding combined with injection molding. From the samples produced, a complete morphological, physical, and mechanical analysis was performed to study the effect of NCC concentration (0–5wt %), foaming agent content (0 to 2wt %) and mold temperature (30°C and 80°C). NCC was very effective to reduce cell size (42–71%) and increase cell density (5–37 times) of the foams, while slightly increasing the overall density (2–7%). The results showed that NCC addition increased the specific tensile modulus (15–22%), specific tensile strength (1–14%) and specific flexural modulus (13–26%) of PP, but decreased specific impact strength (10–20%) and specific elongation at break (50–96%). © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42845.     

Investigation of mechanical properties of graphene decorated with graphene quantum dot-reinforced epoxy nanocomposite

In this investigation, the mechanical properties such as compression, impact, and flexural properties of graphene decorated with graphene quantum dots (GDGQD) epoxy composites with concentration of GDGQD ranging from 0.25 to 1 wt % were studied. Ideal mechanical properties are obtained by systematically varying the filler weight in the epoxy matrix. The morphological studies of GDGQD have been characterized using transmission electron microscope, X-ray diffraction, and Fourier transform infrared technique. The compression, impact, and flexural strengths were enhanced effectively by the GDGQD loading. With the addition of 0.75 wt % of GDGQD, the compressive strength, compressive modulus, flexural strength, and flexural modulus of the composites were improved by 22, 29, 31, and 63%, respectively. Also an improvement in impact strength of 102% for 0.75 wt % GDGQD epoxy sample was also obtained. Examination of fractured test specimens was performed with scanning electron microscope. The enhancement in the mechanical properties is due to the better stress transfer that is attributed by enhanced interfacial bonding between GDGQDs and the epoxy. Using the GDGQD aspect ratio in the two-dimensional randomly oriented filler modified Halpin–Tsai model, the theoretical flexural modulus for the GDGQD/epoxy composites has been established. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2019 , 137, 48680.     

Nanostructured rigid polyurethane foams with improved specific thermo-mechanical properties using bacterial nanocellulose as a hard segment

Rigid polyurethane foams (RPUFs) were synthesized with bacterial nanocellulose (BNC) at concentrations of up to 0.5 wt% using two insertion routes based on its reaction with the isocyanate precursor (ISO route) and the formation of a colloidal dispersion in the polyol precursor (POL route). The results indicated that, for BNC concentrations of only 0.1 wt%, drastic improvements of the specific elastic compressive modulus (+244.2%) and strength (+77.5%) were measured for foams with apparent density of 46.4^{+/− 4.7} Kg.m⁻³. The chemical reaction of BNC with the precursor was corroborated through the measurement of the isocyanate number and FTIR analysis. The BNC caused a significant nucleation effect, decreasing the cell size up to 39.7%. Differential scanning calorimetry analysis revealed that the BNC had a strong effect on post-cure enthalpy, particularly for the POL route. Dynamical mechanical thermal analysis under flexural conditions proved that, regardless of BNC concentration, the incorporation of BNC caused anisotropy and that the ISO route contributed to an enhanced damping factor at high temperatures. These results prove that the ISO route is a key aspect to achieve foamed nanocomposites with improved specific mechanical properties.