Low-cycle fatigue behavior of flexible 3D printed thermoplastic polyurethane blends for thermal energy storage/release applications

Thermal energy storage (TES) materials constituted by a microencapsulated paraffin having a melting temperature of 6°C and a thermoplastic polyurethane (TPU) matrix were prepared through fused deposition modeling. Scanning electron microscope (SEM) micrographs demonstrated that the microcapsules were homogeneously distributed within the matrix, with a rather good adhesion within the layers of 3D printed specimens, even at elevated concentrations of microcapsules. The presence of paraffin capsules having a rigid polymer shell lead to a stiffness increase, associated to a decrease in the stress and in the strain at break. Tensile and compressive low-cycles fatigue tests showed that the presence of microcapsules negatively affected the fatigue resistance of the samples, and that the main part of the damage occurred in the first fatigue cycles. After the first 10 loading cycles at 50% of the stress at break, a decrease in the elastic modulus ranging from 60% for neat TPU to 80% for composite materials was detected. This decrease reached 40% of the original value at 90% of the stress at break after 10 cycles. Differential scanning calorimetry tests on specimens after fatigue loading highlighted a substantial retention of the original TES capability, in the range of 80%–90% of the pristine value, even after 1000 cycles, indicating that the integrity of the capsules was maintained and that the propagation of damage during fatigue tests took probably place within the surrounding polymer matrix. It could be therefore concluded that it is possible to apply the developed blends in applications where the materials are subjected to cyclic stresses, both in tensile and compressive mode.