Nanoclay and long-fiber-reinforced composites based on epoxy and phenolic resins

In this study, high-performance thermoset polymer composites are synthesized by using both long fibers and nanoclays. Epoxy and phenolic resins, the two most important thermoset polymers, are used as the polymer matrix. The hydrophobic epoxy resin is mixed with surface modified nanoclay, while the hydrophilic phenolic resin is mixed with unmodified raw nanoclay to form nanocomposites. Long carbon fibers are also added into the nanocomposites to produce hybrid composites. Mechanical and thermal properties of synthesized composites are compared with both long-fiber-reinforced composites and polymer- layered silicate composites. The optimal conditions of sample preparation and processing are also investigated to achieve the best properties of the hybrid composites. It is found that mechanical and thermal properties of epoxy and phenolic nanocomposites can be substantially improved. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Microstructural and chemical effects of wet/dry cycling on pulp fiber-cement composites

The microstructural and chemical mechanisms responsible for pulp fiber-cement composite degradation during wet/dry cycling are being investigated through environmental scanning electron microscopy (ESEM), energy dispersive spectroscopy (EDS), and mechanical testing. Based on these results, a three-part progressive degradation mechanism for cast-in-place kraft pulp fiber-cement composites is proposed, which involves: (1) initial fiber-cement or fiber interlayer debonding, (2) reprecipitation of needle-like or sheath-like ettringite within the void space at the former fiber-cement interface or between the S1 and S2 fiber layers, and (3) fiber mineralization due to reprecipitation of calcium hydroxide filling the spaces within the fiber cell wall structure. This investigation also revealed that kraft pulp fibers exhibit poor resistance to degradation due to their inferior dimensional stability, as compared to thermomechanical pulp (TMP) fibers. TMP fibers contain significant amounts of lignin, which is alkali sensitive. Despite this, TMP fiber-cement composite exhibit improved resistance to degradation during wet/dry cycling. It is proposed that this improvement in durability may be attributed to the presence of lignin in the cell wall restricting fiber dimensional changes during wetting and drying, and hence, minimizing fiber-cement debonding. Additionally, it is proposed that lignin acts as physical barrier to calcium hydroxide formation within the fiber cell wall, minimizing fiber mineralization of TMP fibers.     

Composites based on jute fibers and phenolic matrices: Properties of fibers and composites

Composites based on phenolic matrices and both untreated and alkali and ionized air–treated jute fibers were prepared. Different fiber lengths and fiber content were used to reinforce the phenolic matrices. The jute fibers were characterized with respect to lignin, holocellulose, ash, and humidity contents and also to the crystallinity index. The mechanical properties of fibers were investigated by means of tensile analysis and the morphology by SEM. The untreated and treated jute fiber–reinforced composites were characterized as to water absorption. The mechanical property and morphological aspects of the composites were evaluated by impact strength and photomicrographs obtained from SEM. Among the jute fiber treatments considered in the present work, the treatment with a solution of 5% NaOH presented the best results because: (1) the fiber presented a higher tensile strength, and a larger percentage of elongation at break; (2) the composite reinforced with this fiber presented the highest impact strength results when this was the unique treatment (20% of fiber), as well as when it was combined with ionized air (30% of fiber); and (3) the composite that presented the lowest water uptake was that reinforced with this fiber. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 91: 1077–1085, 2004     

Flammability testing of flame-retarded epoxy composites and phenolic composites

Flame-retarded epoxy composites and phenolic composites containing fiberglass, aramid (Kevlar® 49), and graphite fiber-reinforcements were tested using the NASA upward flame propagation test, the controlled-atmosphere cone calorimeter test, and the liquid oxygen (LOX) mechanical impact test. The upward flame propagation test showed that phenolic/graphite had the highest flame resistance and epoxy/graphite had the lowest flame resistance. The controlled-atmosphere cone calorimeter was used to investigate the effect of oxygen concentration and fiber reinforcement on the burning behavior of composites. The LOX mechanical impact test showed that epoxy/fiberglass had the lowest ignition resistance and phenolic/aramid had the highest ignition resistance in LOX. The composites containing epoxy resin and/or aramid fiber reinforcement reacted very violently in LOX upon mechanical impact. © 1997 by John Wiley & Sons, Ltd.     

Accelerated durability test of DMFC electrodes by electrochemical potential cycling

Durability of direct methanol fuel cell electrodes was evaluated by electrochemical potential cycling and we observed the degradation phenomena during the performance decay. An individual potential measurement of anode and cathode with built-in reversible hydrogen electrode revealed that the anode and cathode performance contributions are almost of the same order of magnitude to the entire performance loss, although the anode degradation is relatively bigger, due to the dominating effect of ruthenium dissolution, corresponding loss of electrocatalytic activity. On the contrary, it was apparent that the electrochemical active surface area of Pt cathode decreased significantly with potential cycling under methanol crossover condition, which is not clearly reflected on the performance loss due to the initial decrease of interfacial resistance between membrane and cathode catalyst layer. Impedance studies could reinforce the current–voltage polarization by more comprehensive information.     

Effect of several solid lubricants on the mechanical and tribological properties of phenolic resin‐based composites

The flake graphite, polytetrafluoroethylene, and molybdenum disulfide (MoS₂) filled phenolic resin‐based composites were prepared by hot press molding. The thermal, mechanical, and tribological properties of composites were studied systematically. The morphologies of the worn surfaces and the change of chemical compositions during the sliding process of the composites were analyzed by scanning electron microscopy and X‐ray photoelectron spectroscopy, respectively. It was found that the heat‐resisting performance and the hardness of the composites are less affected by solid lubricants, while the solid lubricants did harm to the flexural strength of the composites. The friction and wear behaviors of composites highly depended on the volume fractions of solid lubricants and the sliding conditions. The wear resistance increases and the coefficient of friction decreases when the filler load increases. In addition, the appropriate content of solid lubricants is beneficial to reducing the sensitivities of the composites to load and sliding speed. POLYM. COMPOS., 36:2203–2211, 2015. © 2014 Society of Plastics Engineers     

The effects of phenolic resin-derived PyC interlayers on microstructure and mechanical properties of Cf/SiC composites

A novel, easy and cost-effective way, infiltration and pyrolysis of phenolic resin solution, was exploited to prepare pyrolytic carbon (PyC) interlayers for carbon fiber/silicon carbide (Cf/SiC) mini-composites. X-ray photoelectron spectroscopy, dynamic contact angle measurement and scanning electron microscope were carried out to characterize chemical structure of carbon fibers (CFs), wetting properties between CFs and phenolic resin solution and microstructure of CFs and their composites, respectively. Remarkably, SEM results showed regulation of uniformity and thicknesses of PyC interlayer could be achieved through controlling the concentration of phenolic resin solution and oxidation condition of CFs. When CFs were treated by 10?min' oxidation with 40?mg/L ozone followed by dip-coating with 4?wt% phenolic solution, uniform PyC interlayer with approximately 120?nm were prepared on CFs. The corresponding Cf/SiC specimens had the largest increase in tensile strength and work of fracture with the improvement of 26.2% and 71.6% from the PyC-free case.     

Effect of organic acids on the mechanical properties of phenolic resin composites

The effect of salicylic acid and its derivatives on the properties of phenolic resin composites was evaluated. The composites were reinforced with aluminum oxide particles in both solid and hollow forms. Differential scanning calorimetry studies have shown that the reaction rate of phenolic resin was accelerated by salicylic acid, but was not affected by the other compounds. Salicylic acid also reduced the flexural strengths of the phenolic resin composites. The strength was decreased by more than 30% in comparison to that with no acid added. In contrast, two derivatives of this acid—sodium salicylate and 4‐hydroxybenzoic acid—have minimal impact on the flexural strengths of the composites. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 76: 642–647, 2000     

Influence of carbon nanotube dispersion on the mechanical properties of phenolic resin composites

Despite the much touted mechanical properties of carbon nanotubes, composites reinforced with nanotubes have failed to achieve mechanical properties which rival those present in conventional fiber reinforced polymer composites. This article describes an attempt to bridge this gap. Multi‐walled carbon nanotubes (MWCNT) were synthesized using a chemical vapor deposition method and were dispersed in phenolic resin by both the wet and dry dispersion techniques before molding into composite bars (50 × 5 × 3 mm³). Although no improvement in the mechanical properties of the MWCNT/phenolic composites was observed over the neat resin value when wet mixing dispersion was employed, an improvement of nearly 158% (160 MPa as compared with 62 MPa for neat resin) was achieved in 5 vol% MWCNT containing phenolic resin prepared by the dry mixing. POLYM. COMPOS., 2010. © 2009 Society of Plastics Engineers     

Impact performance of phenolic composites following thermal exposure

The notched and unnotched Izod impact properties of a series of phenolic-glass composites following thermal exposure at 180°C, 300°C, and 800°C have been investigated. Four phenolic resins; a resol, a novolac, a resol/novolac blend, and a furan-novolac/resol copolymer were used to prepare the composites. The notched and unnotched impact properties of all S-glass composites improved following thermal exposure at 180°C for times up to 28 days. The best results at 180°C were obtained for the copolymer-based composite. However, thermal exposure at 300°C for times greater than 1 day led to significant reduction in the performance of this composite. The best retention of impact properties folowing exposure at 300°C and 800°C was found for the composite made with the resol/novolac blend. The results indicate that the impact properties of phenolic composites made with modified resins, that is, a blended resol/novolac or a furan-novolac/resol copolymer resin, improve significantly. © 1998 John Wiley & Sons, Inc. J Appl Polym Sci 67: 349–361, 1998     

Effects of ion‐exchange fillers on durability of the polymer matrix of composites

Glass fiber composites are susceptible to alkali attack on both glass fibers and the polymer matrix. Cation‐exchange fillers were introduced into the polymer matrix of composites to neutralize the alkaline solutions diffusing through the polymer system, and thus enhance the chemical resistance of composites. Experiments were conducted on isophthalic polyester and vinylester polymer systems incorporating different dosages of ion‐exchange fillers. Accelerated aging effects on these polymer systems validated the positive effects of ion exchangers on durability characteristics. POLYM. COMPOS. 26:679–683, 2005. © 2005 Society of Plastics Engineers     

Acid rain effects on the exterior durability of architectural coatings on wood

Acid rain is an important consequence of pollutants generated by modern industrial societies and is known to cause damage to ecological systems, construction materials and cultural artifacts. The assessment of the damage caused to paint films has included laboratory, exposure chamber, and exterior weathering experiments. This study uses visual assessment of paints applied directly to southern yellow pine and exposed at 30° south to either natural acid rain or deionized water spray sites in North Carolina and Ohio to determine damage by acid rain. An acrylic latex paint with a pigment volume concentration (PVC) of 52 and a volume solids (VS) of 35% was formulated with calcium carbonate or sodium potassium alumino-silicate extenders. This high PVC paint formulation is one known to stress the binding capacity of the latex and thus produce early grain cracking failures over bare wood. Major effects observed include severe yellowing and increased mildewing of the carbonate containing paints exposed to acid rain. While acid rain can damage exterior paints, much of the damage can be minimized by careful selection of the polymers and pigments used in the formulation.     

Effect of thermal exposure on the properties of phenolic composites: Dynamic mechanical analysis

Changes in the dynamic response of glass‐reinforced phenolic composites following thermal exposure at 180^oC for periods of time up to 28 days were monitored using dynamic mechanical analysis. Four phenolic resins were investigated: a resol/novolac blend, a phenolic–furan novolac/resol graft copolymer, a novolac, and a resol. Reactive blending and copolymerization of phenolic resins are currently being investigated to determine if these techniques will produce phenolic resins (and composites) that have improved impact properties and retain the excellent high‐temperature properties of resol and novolac phenolic resins. The results indicate that thermal aging at 180^oC for 1 day led to a more complete cure of all four phenolic resins as indicated by an increase in the temperature of the maximum of plots of both loss modulus (E″) and tan δ versus temperature. The storage modulus (E′) of the composites at 40^oC varied little following thermal aging at 180^oC for 1 day but decreased with increasing exposure time for samples aged 2, 7, and 28 days. Thermal aging led to an increase in E′ at higher temperatures and the magnitude of E′ at a given temperature decreased with increasing exposure time. The magnitude of E″ and tan δ decreased with aging time for all resins, although E″ and tan δ were larger for the blend and copolymer composites than for the novolac and resol composites. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 79: 385–395, 2001     

Effects of graphite filler loading and heat treatment temperature on the properties of phenolic resin based carbon–carbon composites

Carbon/carbon composites (C/Cs) were prepared through polymer pyrolysis using PAN based carbon fabric (Panex^(R) 35) and resol type phenolic resin having 0, 10, 20, 30, and 40 wt% of graphite fillers. These precursor composites were heat treated at 600, 900, and 1200°C. The effects of filler loading on the precursor composites and their C/Cs were investigated through density, microstructure, and mechanical properties. Since, the precursor composites were prepared under similar processing conditions and technique, at any particular filler loading when the heat treatment temperature increases, the bulk density of the samples decreases. The filler addition accelerates the formation of the carbon basal planes in the matrix supported by X‐ray diffraction studies. The properties such as tensile strength and strain decrease continuously mainly due to change in the matrix structure and decrease of density, whereas, the interlaminar shear strength (ILSS) and interlaminar fracture toughness (ILFT) increase mainly because of improvement in the modulus of matrix. At any particular heat treatment temperature, depending on the filler content and matrix type, the density, tensile properties, ILSS, and ILFT of the samples show different trends. POLYM. COMPOS., 2011. © 2011 Society of Plastics Engineers     

Effect of boron carbide nanoparticles on the thermal stability of carbon/phenolic composites

In this work, the use of nano‐boron carbide as a nanomodifier of phenolic matrix was envisioned. Particularly, nano‐boron carbide/phenolic‐based nanocomposites were produced and investigated. The obtained nanostructured matrices were also used to produce carbon fiber‐based bulk molding compounds (BMC). The thermal stability of nanocomposites and BMCs was investigated by thermogravimetric analysis both in nitrogen and in air atmospheres. The good dispersion and distribution of the nanosized particles in the matrix was confirmed by transmission electron microscopy while the post‐burning appearance of the BMCs was investigated by visual inspection and scanning electron microscopy. The experimental data highlighted the remarkable effects of nano‐boron carbide on the thermal stability and oxidation resistance of the carbon fiber‐based BMCs. Moreover, the boron oxide produced by the conversion of boron carbide allowed a substantial improvement of the dimensional stability of the BMC which also exhibited considerable residual structural integrity after burning. POLYM. COMPOS., 38:1819–1827, 2017. © 2015 Society of Plastics Engineers     

Hydration properties of vermiculite in phenolic resin friction composites

The dehydration and rehydration properties of the Mg-vermiculite are strongly affected by their crystal structure. Changes in the structure of Mg-vermiculite after dehydration and rehydration were used for evaluation of dehydration properties of composite materials containing vermiculite and phenol formaldehyde resin during friction process and for estimation of temperature on the surface of composite. From XRD patterns follows that d-spacing of the first basal diffraction varies as a function of applied annealing temperature and Mg-vermiculite alone rehydrates if the heating temperature does not exceed 700 °C. If embedded in a phenolic resin matrix, rehydration ability of vermiculite is limited and depends on vermiculite/resin content ratio. The maximum detected temperature on the friction surface of investigated composite samples after friction test was 900 °C.     

Moldability and properties of phenolic/artificial zeolite composites

The purpose of this study is to improve the several properties of composites consisting of a phenolic and fly ash or artificial Zeolite such as sodium type Zeolite (Na? Ze) or calcium type Zeolite(Ca? Ze). And it also includes the improvement in the flowability of molding compounds. The molding compounds were prepared from a phenol novolac, a curing agent, and several fillers. The flowability of the compounds containing fly ash and artificial Zeolite as a filler, mentioned above, was superior to that of the compounds containing glass fiber (GF), calcium carbonate (CaCO₃), or talc as a filler. The phenolic composites were prepared from the above molding compounds by transfer molding. The phenolic composite containing Ca? Ze had most superior heat resistance, electrical insulation, and flexural strength, though in the lastly listed property it ranked next to the GF‐filled composite. The linear expansion coefficient of the composite containing Ca? Ze was as low as almost isotropic. The reasons of obtaining these excellent properties were thought to be as follows: (1) Ca? Ze could finely be dispersed in the phenolic resin to bring good impregnation. (2) The surface chemical and physical interaction between the resin and Ca? Ze was higher than that between the resin and the other fillers. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 2007     

Enhancing the durability of poly(lactic acid) composites by nucleated modification

Biodegradable poly(lactic acid) (PLA) composites were prepared using an innovative combination of wood fiber (WF) and 1,3,2,4‐bis(3,4‐dimethylobenzylideno)sorbitol (DMDBS). DMDBS acted as an effective nucleating agent, which improved the mechanical properties and slowed down the degradation of the WF/PLA composites. The enzymatic degradation of the composites was examined by immersing in proteinase K or cellulase buffer. The presence of DMDBS resulted in a 26.7% increase of the crystallinity compared to the WF/PLA composites. The increase in crystallinity enhanced the thermal stability and tensile strength of the WF/DMDBS/PLA composites by 8.5%. The durability of the WF/DMDBS/PLA composites after nucleated modification was enhanced after enzymolysis. After nucleated modification, the surface of the WF/PLA composites showed clear cracks due to degradation, while these appeared about 2 weeks later in the case of the WF/DMDBS/PLA composites. The results revealed that the introduction of cellulase degraded WF in the composites, which increased hydrolysis or enzymolysis sites. The combination of nucleated modification and enzyme buffer gave an expanded downstream application of WF/PLA composites in packaging and agricultural materials. © 2019 Society of Chemical Industry     

改性纳米结晶纤维素/酚醛树脂复合材料的弯曲强度研究

以MPS(3-甲基丙烯酰氧基丙基三甲氧基硅烷)作为NCC(纳米结晶纤维素)颗粒的表面处理剂、MPS改性NCC作为增强填料和PF(酚醛树脂)作为基体,制备了改性NCC/PF复合材料,并对其结构和弯曲强度进行了表征。研究结果表明:当φ(MPS)=8.0%(相对于MPS-乙醇溶液的体积而言)时,PF基体的左、右侧接触角分别降低了19.2%、19.0%;当w(MPS改性NCC)=0.5%~1.0%(相对于PF基体质量而言)时,改性NCC在PF基体中分散良好,改性NCC/PF复合材料的结晶结构中位于22.1°、32.5°处的特征衍射峰显著增强;与对照样相比,1.5%MPS改性NCC可使PF复合材料的弯曲强度(达到98.6 MPa)提高15.7%。