Process-Structure-Property Relationship in Polymer Nanocomposites
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2018 Elsevier Inc. All rights reserved. The focus of this chapter is to provide understanding of the process-structure-property relationship in polymer nanocomposites, reveal the reinforcing mechanisms, and investigate possible synergistic phenomena at nano- and microscale. Such understanding can provide a roadmap for design and manufacture of polymer nanocomposites with tailored properties using minimum number of iterations instead of the time- and cost-inefficient "trial-error" approach currently used. Processes that will be considered in terms of mixing the nanomaterials with the polymer resins are: in situ polymerization, polymer solution, solid-state compounding, spray/coating, and melt compounding. The processes related to fabrication, once compounding is completed, that will be considered are injection molding, extrusion, compression molding, and selective laser sintering. The effect of each manufacturing process on the structure/morphology and the properties of the polymer nanocomposites will be determined for a given material system. The properties of interest are mechanical (tensile modulus and strength, flexural modulus and strength and impact) electrical (conductivity, percolation threshold), and thermal (conductivity). In addition, the effects of the processing conditions for a given manufacturing method and given material system on the composite properties will also be addressed. The term material system is used to describe the basic two constituents of the nanocomposites, i.e., the polymer matrix and the nanomaterials. The process-structure-property of nanocomposites with either thermoset or thermoplastic polymer matrix reinforced with either inorganic (clays), organic (graphite nanoplatelets, carbon nanofibers, and carbon nanotubes) or ceramic nanomaterials will be investigated. Major characteristics of the nanomaterials including aspect ratio, shape, surface chemistry/functionalization and of the polymer including viscosity, crystallization behavior, in case of thermoplastics, or degree of cure, in case of thermosets, that are affected by the manufacturing method and processing conditions employed will be identified and discussed in detail in terms of the effect that these characteristics have on the properties of the composites. Features that are commonly used to describe the structure/morphology of nanocomposites will also be identified. Case studies for specific material systems will be presented in detail and a roadmap that covers a wide range of processes, materials, and nanocomposite properties will be provided.
