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Rapid innovations in 3-D printing technology have created a demand for multifunctional composites. Advanced polymers like amorphous thermoplastic polyetherimide (PEI) can create robust, lightweight, and efficient structures while providing high-temperature stability. This work manufactured ULTEM, a PEI-based polymer, and carbon-fiber-infused ULTEM multi-material composites with varying layering patterns (e.g., AAABBB vs. ABABAB) using fused filament fabrication (FFF). The microstructure of fractured surfaces and polished cross-sections determined that the print quality of layers printed closer to the heated bed was higher than layers closer to the top surface, primarily due to the thermal insulating properties of the material itself. Mechanical properties of the multi-material parts were between those of the single-material parts: an ultimate tensile strength and elastic modulus of 59 MPa and 3.005 GPa, respectively. Multi-material parts from the same filaments but with different layering patterns showed different mechanical responses. Prints were of higher quality and demonstrated a higher elastic modulus (3.080 GPa) when consecutive layers were printed from the same filament (AAABBB) versus parts with printed layers of alternating filaments (ABABAB), which showed a higher ultimate strength (62.04 MPa). These results demonstrate the potential for creatively designing multi-material printed parts that may enhance mechanical properties.

Additive manufacturing (AM), commonly known as 3D printing, has gained significant popularity for its ability to produce intricate parts with high precision. However, the presence of residual stresses and warpage deformation are common issues affecting the quality and functionality of 3D-printed parts. This study conducts a comprehensive finite element analysis (FEA) to investigate the material-dependent impact of key printing parameters on residual stress and warpage deformation in 3D printing. The research focuses on three distinct materials: polyetherimide (PEI), acrylonitrile butadiene styrene (ABS), and polyamide 6 (PA6). Various printing parameters are systematically varied, including printing temperature, printing speed, bed temperature, infill density, layer thickness, and infill pattern. The study employs the Taguchi L27 orthogonal array and employs the analysis of variance (ANOVA) statistical technique to assess the significance of the input parameters. The obtained results reveal that certain parameters exhibit a greater sensitivity to material differences, whereas the layer thickness parameter demonstrates a relatively lower sensitivity. Notably, infill density and printing temperature play a crucial role in reducing residual stress for PA6, while the infill pattern parameter proves to be a significant contributor to minimizing warpage deformation across all three materials. These findings underscore the importance of conducting material-specific analyses to optimize 3D printing parameters and achieve the desired quality outcomes while mitigating residual stress and warpage deformation.

The continuous advancement of materials science has highlighted the ongoing need for additional studies on the main composite materials topics, particularly in the field of multifunctional nano-composites, towards improving their capability to meet multifaceted requirements in order to stimulate both scientific and technological development. In this study, we report the preparation and characterization of polyetherimides (PEIs) derived from 4,4′-(4,4′-isopropylidenediphenoxy) bis (phthalic anhydride) following a two-step polycondensation reaction using either 4,4′-(1,3-phenylenedioxy) dianiline, or Jeffamine ED-600 as comonomers, or a mixture of the two diamines. Based on the PEI containing flexible Jeffamine segments, polymer composite films were developed by incorporating BaTiO[sub.3] particles. The chemical structure and morphology of the composite films were investigated by FTIR spectroscopy and scanning electron microscopy. Thermal properties were determined by thermogravimetric analysis and differential scanning calorimetry. The influence of Jeffamine segments on the thermal decomposition process was investigated by TG/MS/FTIR measurements under air and nitrogen atmospheres. Based on the obtained data, the thermal decomposition mechanism was established and is discussed in accordance with the chemical structures of the polymers. The surface properties of the PEI and PEI-composite films were characterized by performing contact angle measurements. The addition of BaTiO[sub.3] increased the wettability of the surfaces. The dielectric characteristics of polymer composite films were investigated by broad band dielectric spectroscopy measurements. It was noticed that the addition of BaTiO[sub.3] nanoparticles to the copolymer matrix gradually enhanced the dielectric constant of the composites.

This paper deals with the design of novel epoxy adhesives by incorporating thermoplastic polymers such as polyetherimide (PEI) and poly(ε-caprolactone) (PCL) into a bio-based and recyclable epoxy resin, known as Polar Bear. The adhesives were characterized by their mechanical (quasi-static and dynamic) and rheological properties, thermal stability, and adhesion properties in single-lap joints tested at three different temperatures (i.e., −55 °C, 23 °C, 80 °C). The experimental results indicated that low PEI content substantially improved the mechanical performance and toughness of the adhesive, while preserving good processability. Nonetheless, exceeding 3% weight percentage adversely affected the adhesives’ mechanical resistance and workability. Conversely, while PCL addition enhanced the adhesives’ viscosity, it also decreased mechanical performance. However, its eco-friendliness offers potential for sustainable adhesive applications. It is worth noting that regardless of temperature, the modified adhesives consistently outperformed the commercial epoxy adhesive (DP-460), used as reference, in single-lap shear joint tests. Additionally, both PEI- and PCL-modified epoxy adhesives have demonstrated recyclability through a simple acid-based process, enabling joint disassembly and recycling of the adhesive into a thermoplastic polymer. Overall, the modified adhesives represent a promising eco-friendly, high-performance alternative for structural applications, aligning with sustainable and circular practices.

Blend membranes consisting of two polymer pairs improve gas separation, but compromise mechanical and thermal properties. To address this, incorporating titanium dioxide (TiO[sub.2]) nanoparticles has been suggested, to enhance interactions between polymer phases. Therefore, the objective of this study was to investigate the impact of TiO[sub.2] as a filler on the thermal, surface mechanical, as well as gas separation properties of blend membranes. Blend polymeric membranes consisting of polyetherimide (PEI) and polyvinyl acetate (PVAc) with blend ratios of (99:1) and (98:2) were developed via a wet-phase inversion technique. In the latter, TiO[sub.2] was incorporated in ratios of 1 and 2 wt.% while maintaining a blend ratio of (98:2). TGA and DSC analyses were used to examine thermal properties, and nano-indentation tests were carried out to ascertain surface mechanical characteristics. On the other hand, a gas permeation set-up was used to determine gas separation performance. TGA tests showed that blend membranes containing TiO[sub.2] had better thermal characteristics. Indentation tests showed that TiO[sub.2]-containing membranes exhibited greater surface hardness compared to other membranes. The results of gas permeation experiments showed that TiO[sub.2]-containing membranes had better separation characteristics. PEI–PVAc blend membranes with 2 wt.% TiO[sub.2] as filler displayed superior separation performance for both gas pairs (CO[sub.2]/CH[sub.4] and CO[sub.2]/N[sub.2]). The compatibility between the rubbery and glassy phases of blend membranes was improved as a result of the inclusion of TiO[sub.2], which further benefited their thermal, surface mechanical, and gas separation performances.

As high brittleness limits the application of all epoxy resins (EP), here, it can be modified by high-performance thermoplastic poly(ether nitrile ketone) containing phthalazinone structures (PPENK). Therefore, the influence of different PPENK contents on the mechanical, thermal, and low-temperature properties of EP was comprehensively investigated in this paper. The binary blend of PPENK/EP exhibited excellent properties due to homogeneous mixing and good interaction. The presence of PPENK significantly improved the mechanical properties of EP, showing 131.0%, 14.2%, and 10.0% increases in impact, tensile, and flexural strength, respectively. Morphological studies revealed that the crack deflection and bridging in PPENK were the main toughening mechanism in the blend systems. In addition, the PPENK/EP blends showed excellent thermal and low-temperature properties (−183 °C). The glass transition temperatures of the PPENK/EP blends were enhanced by approximately 50 °C. The 15 phr of the PPENK/EP blends had a low-temperature flexural strength of up to 230 MPa, which was 46.5% higher than EP. Furthermore, all blends exhibited better thermal stability.

The urgent demand for capacitive energy storage at elevated temperatures is limited by significant leakage currents in existing polymer dielectrics, which lead to excessive heat generation and increase the risk of thermal runaway. Here we demonstrate a strategy to mitigate conduction loss by modulating energetic disorder within the polymer matrix. Incorporation of high-polarity organic molecules into polyetherimide enhances dipole-dipole interactions, increasing energetic disorder and thereby decreasing charge carrier mobility. Experimental measurements and computational simulations reveal that disorder-induced energy fluctuations broaden the energy separation between transport states, effectively suppressing charge transport. The resulting composite delivers an energy density of 6.45 J cm −3 with a charge-discharge efficiency of 90% at 200 °C, and exhibits stable performance over 100,000 cycles under an applied field of 400 MV m −1 . The observed uniformity and quality of the all-organic composite films address the challenges of scalable manufacturing for dielectric films, offering a practical pathway for the development of high-temperature dielectric materials. Suppressing charge transport and reducing conduction loss at high temperatures and electric fields is crucial in high-temperature dielectric materials. Here, the authors incorporate high-polarity small molecules into polyetherimide to increase its energetic disorder and reduce charge transport, enabling an energy density of 6.45 J cm-3 with an efficiency of 90%.

The electrical properties of nanocomposites based on polyetherimide (PEI) filled with reduced graphene oxide (rGO) and a graphene oxide hybrid material obtained from graphene oxide grafted with poly(monomethyl itaconate) (PMMI) modified with barium titanate nanoparticles (BTN) getting (GO-g-PMMI/BTN) were studied. The results indicated that the nanocomposite filled with GO-g-PMMI/BTN had almost the same electrical conductivity as PEI (1 × 10−11 S/cm). However, the nanocomposite containing 10 wt.% rGO and 10 wt.% GO-g-PMMI/BTN as fillers showed an electrical conductivity in the order of 1 × 10−7 S/cm. This electrical conductivity is higher than that obtained for nanocomposites filled with 10% rGO (1 × 10−8 S/cm). The combination of rGO and GO-g-PMMI/BTN as filler materials generates a synergistic effect within the polymeric matrix of the nanocomposite favoring the increase in the electrical conductivity of the system.

Film capacitor technology has been under development for over half a century to meet various applications such as direct-current link capacitors for transportation, converters/inverters for power electronics, controls for deep well drilling of oil and gas, direct energy weapons for military use, and high-frequency coupling circuitry. The biaxially oriented polypropylene film capacitor remains the state-of-the-art technology; however, it is not able to meet increasing demand for high-temperature (>125°C) applications. A number of dielectric materials capable of operating at high temperatures (>140°C) have attracted investigation, and their modifications are being pursued to achieve higher volumetric efficiency as well. This paper highlights the status of polymer dielectric film development and its feasibility for capacitor applications. High-temperature polymers such as polyetherimide (PEI), polyimide, and polyetheretherketone were the focus of our studies. PEI film was found to be the preferred choice for high-temperature film capacitor development due to its thermal stability, dielectric properties, and scalability.

Polymer dielectric materials are widely used in electrical and electronic systems, and there have been increasing demands on their dielectric properties at high temperatures. Incorporating inorganic nanoparticles into polymers is an effective approach to improving their dielectric properties. However, the agglomeration of inorganic nanoparticles and the destabilization of the organic-inorganic interface at high temperatures have limited the development of nanocomposites toward large-scale industrial production. In this work, we synthesize metal-organic cage crosslinked nanocomposites by incorporating self-assembled metal-organic cages with amino reaction sites into the polyetherimide matrix. The in-situ crosslinking by self-assembled metal-organic cages not only achieves a homogeneous distribution of inorganic components, but also constructs robust organic-inorganic interfaces, which avoids the interfacial losses of conventional nanocomposites and improves the breakdown strength at elevated temperatures. Ultimately, the developed nanocomposites exhibit exceptionally high energy densities of 7.53 J cm −3 (150 °C) and 4.55 J cm −3 (200 °C) with charge-discharge efficiency of 90%. The authors synthesize metal-organic cage crosslinked nanocomposites by incorporating self-assembled metal-organic cages with amino reaction sites into the polyetherimide matrix. The in-situ crosslinking achieves a homogeneous distribution of inorganic components, constructing robust organic-inorganic interfaces.