Siok Wei Tay

This research investigates a novel hybrid E-glass fiber coated with a thin amorphous carbon (coke) layer, referred to as GF@C, designed to enhance the affinity of fiber with a polymer matrix. Acrylonitrile butadiene styrene (ABS), an engineering thermoplastic, was selected as the matrix to form the composite. The carbon coating was produced by pyrolyzing a lubricant oil (Lo) layer applied to the glass fiber strands. To promote the formation of graphite crystallites during carbonization, a small amount (x wt.% of Lo) of coronene (Cor) was added to Lo as a dopant. The resulting doped fibers, denoted GF@C_Lo-Cor(x%), were embedded in ABS at 70 wt.%, leading to significant improvements in mechanical properties. At the optimal doping level (x = 5), the composite achieved a Young’s modulus of 1.02 GPa and a tensile strength of 6.96 MPa, substantially higher than the 0.4 GPa and 3.81 MPa observed for the composite with the pristine GF. This enhancement is attributed to a distribution of graphite crystallites and their graphitization extent in the carbon coating, which improves interfacial bonding and increases chain entanglement. Additionally, GF@C_Lo-Cor(x%)–ABS composites (x = 0 and 5) exhibit significantly higher dielectric constant–temperature profiles than GF–ABS, attributed to the formation of diverse chain adsorption states on the C-coating.

Carbon fiber-reinforced polymer (CFRP) composites are highly functional composites which comprise two major components: the polymer matrix and the carbon fiber. Lightweight and having high strength, CFRPs have been used heavily in various industries such as wind, aerospace and automobile. The increasing demand and extensive use led to a huge quantum of CFRP waste from both end-of-life and during manufacturing. Out of this waste, only 2% is recycled, the rest are disposed of via incineration and/or landfill. This has raised significant environmental and sustainability concerns. The current state-of-the-art way of recycling CFRPs is by pyrolysis. However, through the pyrolysis process, the polymer used in the CFRPs, which accounts for around 65–75 wt.%, cannot be recovered and reused. In most publications, the focus on CFRP recycling was on the recovering of the more valuable carbon fiber. The polymer matrix is mostly burnt off, in the case of pyrolysis, or disposed. To obtain full circularity, recovering and reusing both the carbon fiber and polymer is necessary. In this paper, we primarily focus on the recovered bisphenol-A type of epoxy polymer (REP) obtained from solvolysis digestion of CFRP and explore the feasibility of reusing this REP by blending it with pristine epoxy in various compositions to create new materials. The physical and mechanical properties, including decomposition temperatures (T_d), glass transition temperatures (T_g), storage modulus, loss modulus, flexural and tensile strength, were characterized using thermal gravity analyzer (TGA), differential scanning calorimetry (DSC), dynamic mechanical analyzer (DMA) and Instron universal tester. The results indicate a decrease in glass transition and decomposition temperature, and mechanical properties as the blending composition increases. This suggests that the total blending composition should not exceed 10 wt.%, with an optimal range potentially falling between 5 to 6 wt.%.

We created a coke-repellent inner surface in a stainless steel (SS-321) tube using an enhanced chemical etching tactic. A water-borne etching solution was formulated by combining an ion sequestering ligand (L), hydrogen peroxide (H), hydrochloric acid (C), and a stabilizing agent (E or N). Three etchants, LHC, LHC-E, and LHC-N, were therefore formulated, respectively. The coke-repellent metal surfaces achieved by these etchants all show a characteristic topographic pattern on a micron scale, specifically with grooved spherulite and ridge-like topographic patterns. Fundamentally, these two topographic patterns prompt overhead micro turbulence fields whose agitation mitigates the surface entrapment of aromatic hydrocarbon flocs generated from the overhead lubricant. The surface entrapment of flocs is the crucial step to trigger coke growth. The coke repellency was assessed by placing an SS-321 tube filled with a lubricant in a heat soak. It was found that the topographic pattern and its surface roughness level have opposite effects on coke development. Hence, the three etchants give rise to different coke-resilient surfaces. Moreover, the plug flow rate of the etchant also affects the anti-coking performance, exhibiting an optimal flow rate that offers the highest coke-proof efficacy.

Assimilating hydrophilic hollow polymer spheres (HPS) into Nafion matrix by a loading of 0.5 wt % led to a restructured hydrophilic channel, composed of the pendant sulfonic acid groups (–SO₃H) and the imbedded hydrophilic hollow spheres. The tiny hydrophilic hollow chamber was critical to retaining moisture and facilitating proton transfer in the composite membranes. To obtain such a tiny cavity structure, the synthesis included selective generation of a hydrophilic polymer shell on silica microsphere template and the subsequent removal of the template by etching. The hydrophilic HPS (100–200 nm) possessed two different spherical shells, the styrenic network with pendant sulfonic acid groups and with methacrylic acid groups, respectively. By behaving as microreservoirs of water, the hydrophilic HPS promoted the Grotthus mechanism and, hence, enhanced proton transport efficiency through the inter-sphere path. In addition, the HPS with the –SO₃H borne shell played a more effective role than those with the –CO₂H borne shell in augmenting proton transport, in particular under low humidity or at medium temperatures. Single H₂-PEMFC test at 70 °C using dry H₂/O₂ further verified the impactful role of hydrophilic HPS in sustaining higher proton flux as compared to pristine Nafion membrane.