Self-Healing Fiber-Reinforced Composites with Tailored Supramolecular Matrices

Fiber Reinforced Composites (FRCs), due to their intrinsic heterogeneity, are generally affected by complex multi-scale failure mechanisms leading to the formation of matrix cracks that are difficult to detect and repair. FRCs with the ability to heal and recover at least part of their initial properties after damage could present a solution to extend their lifetime and reliability. A possible approach is to introduce external healing agents in the matrix of the composite, through capsules or micro-channels, but this is often difficult to achieve in a high volume fraction reinforcement composite. An alternative approach is to rely on intrinsic self-healing polymers as matrices, which alleviates the need for additional phases beyond matrix and reinforcement. The present work investigated this second approach, by exploring for the first time the feasibility of processing glass fabric reinforced composites based on supramolecular hybrid network self-healing matrices and analysing their resulting properties and transfer of the self-healing ability to the composite. Hybrid networks based on epoxy chemistry, combining covalent cross-links and cooperative reversible hydrogen bonds, were selected as benchmark materials. These systems were charac- terized, in particular in terms of processing parameters and self-healing ability, and showed to be a-priori compatible with FRCs manufacturing techniques and demonstrated higher healing efficiency by increasing the H-bonds content in the polymer network, from none to 50%. On the other hand, networks characterized by large number of physical cross-links exhibited limited solvent and creep resistance, hindering their potential application. These issues were addressed by modifying the average functionality of the monomers through the combination of bifunctional and tetrafunctional epoxy resins in the compositions while keeping the use of a catalyst, leading to better controlled networks, both in terms of kinetics and final structure, and to propose a range of materials with several levels of compromise between self-healing efficiency, mechanical strength, creep resistance, and damping properties. In particular, 50% to 100% self-healing recovery of tensile properties were observed after one day, depending on the tetraepoxide content. In parallel, since the Tg of benchmark supramolecular hybrid net- works was in the range from 11-16 âŠC, an aliphatic diepoxide was introduced in the synthetic procedure to propose materials with a Tg down to -10 âŠC, to reach applications closer to those of elastomers. In view of FRCs development, the ability of partially supramolecular self-healing polymers to bond to inorganic reinforcements and to heal interfacial failure was then investigated: two dedicated butt joint-like and tack-like test methods were developed. Adhesion strength of the polymers cured on glass substrates decreased with increasing H-bonds content in the polymer networks (from 0 to 50 %) as the mechanical strength of the polymer also decreased, while the failure mechanism shifted from adhesive to cohesive due to the possibility to form hydrogen bonds with the glass substrates. Interface restoration through healing of the polymer matrices however increased from none to a strength recovery up to 70 % after 1 h healing time for the 50% H-bond polymer...

Shape memory polymers with controlled time-dependent shape recovery

Charly David Azra

The aim of this thesis has been to investigate the use of heat-activated shape memory polymers (SMPs) as novel smart actuators for the controlled delivery of fluids and their suitability for applications such as low-cost drug delivery. On heating to temperatures in the vicinity of their glass transition temperature, Tg, amorphous SMPs are able to recover their equilibrium shape from a “programmed” temporary shape generated by mechanical deformation, and fixed by cooling to below Tg. This phenomenon is linked to the substantial increase in molecular mobility on heating through the glass transition, and the memory of an equilibrium shape associated a crosslinking network. While SMPs have received considerable attention in the literature, there has to date been relatively little focus on the time-dependence of shape recovery in these materials. There are nevertheless many potential biomedical applications, for example, in which it is necessary to control the actuation rate in SMP-based devices activated by natural heat sources such as the human body, whose temperature may be subject to significant fluctuations. The present work has therefore focused on the time-dependent shape memory effect under isothermal conditions and its sensitivity to temperature variations. The first part of the study involved commercial thermoplastic (physically cross-linked) and thermoset (chemically cross-linked) shape memory polyurethanes (SMPUs). This provided insight into the physical mechanisms underlying the time-dependence of the shape memory effect, which was found to correlate strongly with the viscoelastic behaviour of a given material and the thermomechanical variables associated with the shape memory cycle. It also revealed the importance of the width of the α-transition, ∆Tα , as determined by dynamic mechanical analysis (DMA), and its position on the temperature axis relative to the recovery temperature, Tr. In particular, it was shown that controlled recovery rates could be obtained if Tr corresponded to the onset of the α-transition, and a broad transition led to a reduction in the sensitivity of the shape recovery rate to thermal fluctuations about a given Tr. The next part of the study was devoted to the development of materials optimized for controlled shape recovery under well-defined conditions. The commercial formulations were found to be unsuitable for this purpose, because they offered relatively limited possibilities for tailoring Tg and ∆Tα . Thermoset SMPUs with tunable Tg and ∆Tα were therefore produced in house, based on polytetrahudrofuran (PTHF), 4,4’-diphenylmethane diisocyanate (MDI) and 1,1,1-trimethylolpropane (TMP). The starting point was a literature formulation, which was used to optimize a reactive injection molding (RIM) set-up designed to produce void-free parts with a molding time of less than 3 minutes. These SMPUs were characterized by a PTHF network linked by rigid domains made up of crosslinked MDI and TMP. This made it possible to vary Tg from -60 to 80 °C and ∆Tα from 35 to 100 °C, by varying the molecular weight of the PTHF from 2000 to 650 g/mol, and hence the cross-link density for a given stoichiometric ratio PTHF:MDI:TMP. In order to adjust ∆Tα independently of Tg, flexible segments were introduced to the rigid domains and to the junctions between the rigid domains and the PTHF, using a fourth component, 1,4-butanediol (BDO), or by replacing the TMP with ethoxylated TMP (eTMP). This provided a highly flexible platform for optimizing the shape memory performance. Moreover, the resulting SMPUs showed equilibrium moduli, Ee, of up to 13 MPa, which is relatively high for unreinforced thermosets, and clearly beneficial for fluid displacement where high recovery stresses may be important. To increase Ee further, alumina nanoparticles were dispersed in the SMPUs. This was achieved through ultrasonic, solvent-assisted dispersion of the alumina in PTHF and subsequent curing with the MDI and TMP. Reproducible, void-free, SMPU nanocomposite sheets with alumina contents as high as 15 wt% could be produced in this way within the 3 minute pot-life of the reactive mixtures. These showed a homogeneous dispersion of the alumina (aggregates less than 50 nm in diameter), as confirmed by transmission electron microscopy, leading to a modest increase in Ee to about 21 MPa. This indicated reinforcement to be essentially a geometrical effect (strain amplification), suggesting relatively limited matrix/filler interactions. On the other hand, Rr remained high in these nanocomposites (a decrease of only 5 % on addition of 15 wt% alumina), in contrast with reports in the literature of a significant degradation in shape memory performance for SMPUs containing highly interacting fillers. A linear thermo-viscoelastic model was used to simulate the small strain shape memory effect. Continuous relaxation and retardation spectra, H(τ) and L(τ) respectively, were used to model the time-dependence, and a shift factor, aT(T), was used to model the temperature dependence. To streamline the procedure, a novel characterization method was developed for the determination of aT (T ) from a constant frequency DMA temperature sweep, based on the establishment of an approximate relationship between the storage modulus, the loss modulus and aT (T ). It was hence possible to generate continuous data for aT (T ) from a single DMA run, avoiding the time-consuming and operator-dependent construction of a mastercurve from multiple experiments. Using the Havriliak-Negami parametric functions, H(τ) and L(τ) could be subsequently obtained over a large number of decades of time from the modulus and compliance data. Comparison with results from experimental shape memory data for different model SMPUs, showed this approach to provide a reliable indication of the long-term shape recovery rate. Moreover, this method has great potential for providing rapid insight into the temperature-dependent viscoelastic properties of thermorheologically simple polymers in general, regardless of whether they are being considered specifically for shape memory applications. In the final part of the study, a tailored SMPU nanocomposite formulation was used to produce demonstrators in the form of active shape memory reservoirs, capable of expelling a liquid content under isothermal conditions. The reservoirs consisted of circular membranes (the equilibrium shape), inflated at elevated temperature to form 5 ml blisters and subsequently stabilized in this form by cooling (the programmed shape), using a biaxial deformation set-up incorporating temperature control. This innovative programming procedure made it possible to generate active SMPU reservoirs that could be activated at the skin temperature (32 °C), resulting in low average flow rates ranging between 1 and 5 μL/min over several hours. Such as a device has important potential applications, e.g. skin-temperature activated, low-cost transdermal drug delivery patches.

EPFL2013

Tailored Capsule Based Self-Healing for Epoxy Matrix Composites

Sam Neuser

Self-healing materials are a novel class of materials able to repair structural or, more generally, functional damage to a part. They hence have the potential to improve reliability and cost effectiveness, because failure or loss of functionality may be postponed or completely avoided. This concept has been applied to all classes of materials, but is particularly suited to polymers and their composites. Indeed, it was first demonstrated for epoxies containing capsules of dicyclopentadiene and dispersed Grubbs’ catalyst. However, the high cost of the catalyst precludes commercial use of this self-healing system. In the present thesis, two alternative approaches to self-healing of an epoxy matrix were investigated: (1) a solvent based self-healing epoxy; (2) a two-component epoxy/amine self-healing system using a novel encapsulation technique. The solvent-based system showed efficient healing in an under-cured epoxy matrix. The solvent in question was ethyl phenylacetate (EPA) encapsulated with urea-formaldehyde (UF) or UF-polyurethane. It was demonstrated that during a crack event, the solvent diffused into the epoxy matrix following a non-Fickian case II profile, with a geometrical swelling of the surface layer of the crack. For a healing time of 24h, a critical crack gap of 30μm was identified, beyond which the swelling was insufficient to bridge the crack faces and the healing efficiency was limited to around 25%. For smaller crack gaps, solvent swelling led to intimate contact of the crack faces and reaction of residual functional groups through a reduction of the glass transition temperature Tg of the epoxy, resulting in improved healing efficiency. The use of shape memory alloys (SMA) that are strained during the fracture event and subsequently heated to reduce the crack opening was also investigated. High healing efficiencies were observed and it was found that longer SMA wire activation times further improved the healing efficiency up to almost 80% through improved crack closure and an increased degree of polymerization. The behavior of this material during aging was then investigated in partially cracked samples, guaranteeing small crack gaps. It was found that the premature diffusion of the solvent through the microcapsule membrane into the epoxy matrix led to a decrease in healing efficiency from around 75% in fresh samples, to about 15% in samples aged for 75 days. Increasing the thickness of the polymeric shell of the capsules did not significantly improve performance. Moreover, moisture uptake by the epoxy also contributed to the reduced healing efficiency. Because the healing agent is hydrophobic, a higher water content in the epoxy matrix limited solvent diffusion into the epoxy and hence the extent of healing. A potential solution to the problem of premature diffusion of solvent into the epoxy is suggested to be the use of other shell materials or additional coatings on the capsules. The response of the solvent based self-healing system to dynamic fatigue was also studied. While in static testing, matrix swelling governs crack healing, a different mechanism was observed in the case of dynamic loading. In contrast to the unmodified epoxy, which showed rapid crack propagation under all the conditions investigated, in the presence of the solvent, crack arrest was observed for stress intensities of up to 0.48 MPam1/2. This phenomenon was attributed to crack pinning owing to diffusion of the solvent into the matrix surrounding the crack tip. The elongation at break of the solvated epoxy increased threefold, and the Young’s modulus decreased by more than 50%. Using finite element analysis (FEM) to model the stress distribution around the solvent-infused crack tip, it was shown that the local crack tip stress was reduced by 43%, accounting for this novel toughening effect. While solvent healing performed well in an under-cured matrix and interesting phenomena were observed, a fully cured matrix with a two-component self-healing system may be preferable for real applications because it avoids issues pertaining to premature solvent diffusion. The possibility of encapsulating an amine curing agent in a core-shell structure was therefore investigated as an alternative. A microfluidic glass chip was used to encapsulate a hydrophilic amine/water based curing agent in an acrylate resin shell using ex-situ exposure to UV light. Low viscosity epoxy was encapsulated with UF using a modified agitated emulsion encapsulation technique. Successful self-healing was demonstrated for epoxy specimens containing these microcapsules, along with embedded SMA wires, with healing efficiencies of up to 100% and 40% for low and high temperature curing epoxy, respectively. Overall, this work represents a significant step towards affordable epoxy self-healing materials, the feasibility of solvent and epoxy/amine healing having been successfully demonstrated for an epoxy matrix. The epoxy/amine self-healing system is thought to be particularly promising, considering the early stage of development. Furthermore, the integration of SMA wires proved to improve healing efficiencies dramatically, especially with the epoxy/amine microcapsules. With further optimization and scale-up of the microfluidic encapsulation method, a new low cost self-healing system, and hence potentially compatible with a wide range of polymeric materials, including composites, is therefore within reach because it is based on a commonly used epoxy/amine adhesive.

EPFL2013

Shape memory polymers with controlled time-dependent shape recovery

Charly David Azra

EPFL2013

Tailored Capsule Based Self-Healing for Epoxy Matrix Composites

Sam Neuser

EPFL2013