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With economic development, environmental problems are becoming more and more prominent, and achieving green chemistry is an urgent task nowadays, which creates an opportunity for the development of supercritical foaming technology. The foaming agents used in supercritical foaming technology are usually supercritical carbon dioxide (ScCO2) and supercritical nitrogen (ScN2), both of which are used without environmental burden. This technology can reduce the environmental impact of polymer foam production. Although supercritical foaming technology is already in production in some fields, it has not been applied on a large scale. Here, we present a detailed analysis of the types of foaming agents currently used in supercritical foaming technology and their applications in various fields, summarizing the technological improvements that have been made to the technology. However, we have found that today’s supercritical technologies still need to address some additional challenges to achieve large-scale production.

The microcellular injection molding (MuCell®) process, which uses supercritical fluid (SCF) as a foaming agent, is considered an important green molding solution to reduce product weight, molding energy, and cycle time and to improve the foam quality. However, maximizing the foaming density while keeping size uniformity in the foaming cell requires further attention. In this study, H2O and the SCF N2 were employed as cofoaming agents in the MuCell® process of polypropylene (PP). Owing to the different critical points of N2 and H2O, bubble nucleation was expected to occur in interactive ways. Various process parameters were investigated, including the SCF N2 content, the moisture content adsorbed within the resin under targeted PP weight reductions of 30% and 40%, the melt and mold temperature conditions, and the gas counter pressure. The resulting foaming morphology was examined to evaluate the foam quality in terms of the foaming density and bubble size distribution. The bubble coalescence, particularly in the skin layer, was examined, and the associated gas permeability flow rate was measured. The results indicated that H2O-assisted foaming led to bubble coalescence and allowed for gas penetration in the direction of the part thickness direction, resulting in an overall increase in foaming density, particularly in the skin layer. Under high SCF N2 and H2O contents, the solid skin layer disappeared, regulating the gas permeability from one surface side to the other. Under the optimized process parameters, the gas permeability flow rate in the filter-like foaming PP material reached 300–450 mL/min. The application of gas counter pressure also helped increase the foam density and bubble coalescence, enhancing the gas permeability in the PP material to about 500 mL/min. These results demonstrate the potential application of microcellular injection molding using water as a cofoaming agent in moisture-release devices.

The study is focused on ultra-light foam concrete (FC) aimed as a thermal insulation material. Two important properties of such material were investigated: compressive strength and thermal conductivity. In the conducted tests, the influence of the air-dry density (200–500 kg/m3), type of foaming agent (synthetic and protein) and binder type (ordinary Portland cement—OPC; calcium sulphoaluminate cement—CSA; metakaolin; siliceous fly ash—SFA; calcareous fly ash—CFA) on the mentioned properties were examined. The results confirmed the dependence of compressive strength and thermal conductivity on the FC density but also indicated the important effect of the nature of the foaming agent and the binder type. The best thermo-mechanical properties were obtained for the foam concrete made of protein-based foaming agent, OPC and metakaolin. Simultaneously, the use of CSA mixed with metakaolin and foam based on the synthetic foaming agent also shows satisfactory properties.

During recent decades, rubber foams have found their way into several areas of the modern world because these materials have interesting properties such as high flexibility, elasticity, deformability (especially at low temperature), resistance to abrasion and energy absorption (damping properties). Therefore, they are widely used in automobiles, aeronautics, packaging, medicine, construction, etc. In general, the mechanical, physical and thermal properties are related to the foam’s structural features, including porosity, cell size, cell shape and cell density. To control these morphological properties, several parameters related to the formulation and processing conditions are important, including foaming agents, matrix, nanofillers, temperature and pressure. In this review, the morphological, physical and mechanical properties of rubber foams are discussed and compared based on recent studies to present a basic overview of these materials depending on their final application. Openings for future developments are also presented.

Various foaming agents can be used to achieve foaming of the precursors obtained by using the powder metallurgy method. However, the thermal behavior of pure aluminum precursors with different foaming agents has been studied very little in recent times. For the production of aluminum foams with closed cells, 1 wt.% of calcium carbonate (CaCO3), titanium hydride (TiH2), heat-treated TiH2 and zirconium hydride (ZrH2) were used. The foaming capability of the compacted precursors was investigated at temperatures 700, 720 and 750 °C. CaCO3 and TiH2 showed the best foamability at all considered temperatures, while ZrH2 achieved relatively good foaming only at the highest temperature, 750 °C. Due to their low onset temperature of the decomposition compared to the melting point of the unalloyed aluminum, in hydride-based foaming agents the drainage occurred at the bottom part of the foam samples. Among the investigated foaming agents, precursors with heat-treated TiH2 had the worst foaming properties, while CaCO3 showed the best foamability without the occurrence of drainage.

Poly(hydroxyalkanoates) (PHAs) are emerging as sustainable materials in packaging and medical device industries. Nevertheless, the high cost and the need to improve the mechanical properties have limited their widespread use. Blending with other bio-based polymers, such as poly(lactic acid) (PLA), has been proposed in previous studies. This study investigates the effects of temperature, azodicarbonamide (AZ, foaming agent), boron nitride (BN, filler), and multilayer film/foam coextrusion on the properties of a blend containing an amorphous PHA and PLA. The effect of twin-screw micro-compounder temperature (185 °C & 205 °C) and BN concentrations of 1, 2, 3, 5, and 10 wt% (185 °C) on the properties of the PHA/PLA blend were investigated using differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), and tensile testing. Design of experiments (DoE) was used to find the optimal concentrations of AZ and BN (205 °C) using JMP® software. The response surface analysis predicted an optimal design based on the target response levels (modulus, tensile strength, strain at break, and toughness). This formulation was prepared and characterized using DSC, TGA, tensile, and melt flow index (MFI) measurements. Finally, this formulation was processed via film/foam coextrusion and examined using scanning electron microscopy (SEM) and density measurements. This study demonstrated that AZ and BN can be used to manipulate the mechanical properties and crystallinity of PHA/PLA blends, while reducing the overall material cost via density reduction (20–21% for the optimal formulation). Furthermore, reducing the concentration of AZ using the I-optimal design in this study could alleviate the toxicity concerns for food packaging.

Vegetation concrete is one of the most widely used substrates in ecological slope protection, but its practical application often limits the growth and nutrient uptake of plant roots due to consolidation problems, which affects the effectiveness of slope protection. This paper proposed the use of a plant protein foaming agent as a porous modifier to create a porous, lightweight treatment for vegetation concrete. Physical performance tests, direct shear tests, plant growth tests, and scanning electron microscopy experiments were conducted to compare and analyze the physical, mechanical, microscopic characteristics, and phyto-capabilities of differently treated vegetation concrete. The results showed that the higher the foam content, the more significant the porous and lightweight properties of the vegetation concrete. When the foam volume was 50%, the porosity increased by 106.05% compared to the untreated sample, while the volume weight decreased by 20.53%. The shear strength, cohesion, and internal friction angle of vegetation concrete all showed a decreasing trend with increasing foaming agent content. Festuca arundinacea grew best under the 30% foaming agent treatment, with germinative energy, germinative percentage, plant height, root length, and underground biomass increasing by 6.31%, 13.22%, 8.57%, 18.71%, and 34.62%, respectively, compared to the untreated sample. The scanning electron microscope observation showed that the pore structure of vegetation concrete was optimized after foam incorporation. Adding plant protein foaming agents to modify the pore structure of vegetation concrete is appropriate, with an optimal foam volume ratio of 20–30%. This study provides new insights and references for slope ecological restoration engineering.

Incorporating CO 2 -philic functionalities into surfactant structure is proposed to address the drawbacks of conventional foaming agents such as premature rupture of lamellae in contact with oil, surfactant loss due to adsorption on rock or partitioning between oil and water, and salinity and temperature tolerance issues. Increased activity at the gas/water interface and less surfactant adsorption to the rock due to the presence of CO 2 -philic chains results in higher foam durability in the presence of oil. In the present paper, a comprehensive study on the adsorption of anionic CO 2 -philic surfactants onto sandstone rock surface is performed to understand adsorption mechanisms through the addition of CO 2 -philic tail groups in surfactant structure by observing the changes in concentration, static adsorption, and point of zero charge measurements. The static adsorption tests, Fourier Transform Infrared, and the X-ray Photoelectron Spectroscopy techniques were employed to investigate the interaction of surfactants with crushed Berea sandstone core sample at 90 °C. The static adsorption values of the S (single-tail), D (double-tail), and T (triple-tail) anionic surfactants were reported to be 0.53, 0.40, and 0.6 mg /g, respectively. The effect of alkali on the adsorption process of surfactants was also investigated and the adsorption of synthesized surfactants was found significantly low in alkaline conditions. A variety of analyses, including model fitting along with kinetics and thermodynamics studies at 30, 40, and 50 °C were performed to predict the adsorption behavior. The adsorption isotherm was found to best fit in Langmuir model. The process showed the best fit in the pseudo-second-order reaction kinetics model. The spontaneity of the adsorption process was verified by thermodynamic feasibility studies of the process.

Zinc oxide nanoparticles (ZnO NPs) were synthesized by a precipitation method, and a new charring–foaming agent (CFA) N-ethanolamine triazine-piperazine, melamine polymer (ETPMP) was synthesized via nucleophilic substitution reaction by using cyanuric chloride, ethanolamine, piperazine, and melamine as precursor molecules. FTIR and energy-dispersive X-ray spectroscopy (EDS) studies were employed to characterize and confirm the synthesized ETPMP structure. New intumescent flame retardant epoxy coating compositions were prepared by adding ammonium polyphosphate (APP), ETPMP, and ZnO NPs into an epoxy resin. APP and ETPMP were fixed in a 2:1 w/w ratio and used as an intumescent flame-retardant (IFR) system. ZnO NPs were loaded as a synergistic agent in different amounts into the IFR coating system. The synergistic effects of ZnO NPs on IFR coatings were systematically evaluated by limited oxygen index (LOI) tests, vertical burning tests (UL-94 V), TGA, cone calorimeter tests, and SEM. The obtained results revealed that a small amount of ZnO NPs significantly increased the LOI values of the IFR coating and these coatings had a V-0 ratings in UL-94 V tests. From the TGA data, it is clear that the addition of ZnO NPs could change the thermal degradation behaviors of coatings with increasing char residue percentage at high temperatures. Cone calorimeter data reported that ZnO NPs could decrease the combustion parameters including peak heat release rates (PHRRs), and total heat release (THR) rates. The SEM results showed that ZnO NPs could enhance the strength and the compactness of the intumescent char, which restricted the flow of heat and oxygen.

Lightweight geopolymers have the advantages of a wide source of raw materials, chemical corrosion resistance, high mechanical strength and excellent durability, and are expected to replace traditional building insulation materials. In this paper, a green bio-based foaming agent with a small 1 h settlement distance, high average foaming multiple and low bleeding ratio was obtained by a Cetyltrimethylammonium Bromide/yeast solution. When the amount of Cetyltrimethylammonium Bromide is 0.50 wt%, the foam prepared by the yeast and Cetyltrimethylammonium Bromide solution exhibits the improved 1 h settlement distance, the large average foaming multiple, the small bleeding ratio and uniform foam size. Subsequently, a lightweight geopolymer based on metakaolin and fly ash (or silica fume) was successfully prepared by the bio-based foaming agent, and the effects of different foam content on the properties of the geopolymer, such as dry density, water absorption, thermal conductivity, compressive strength and morphology, were studied. With an increase in foam content, the dry density, thermal conductivity and compressive strength of the geopolymer gradually decrease, the water absorption increases, regardless of whether silica fume or fly ash are added. Herein, it is confirmed that the foaming agent based on yeast can be effectively used to prepare lightweight geopolymers, which can provide vast opportunities to turn into candidates for novel inorganic thermal insulation materials.