Myungsoo Kim

Design, manufacturing, and characterization of high-performance lightweight bipolar plates based on carbon nanotube-exfoliated graphite nanoplatelet hybrid nanocomposites

We report a study on manufacturing and characterization of a platform material for high-performance lightweight bipolar plates for fuel cells based on nanocomposites consisting of carbon nanotubes (CNTs) and exfoliated graphite nanoplatelets (xGnPs). The experiments were designed and performed in three steps. In the preexperimental stage, xGnP-epoxy composite samples were prepared at various xGnP weight percentages to determine the maximum processable nanofiller concentration. The main part of the experiment employed the statistics-based design of experiments (DOE) methodology to identify improved processing conditions and CNT: xGnP ratio for minimized electrical resistivity. In the postexperimental stage, optimized combinations of material and processing parameters were investigated. With the aid of a reactive diluent, 20wt.% was determined to the be maximum processable carbon nanomaterial content in the epoxy. The DOE analyses revealed that the CNT: xGnP ratio is the most dominant factor that governs the electrical properties, and its implications in relation to CNT-xGnP interactions and microstructure are elucidated. In addition, samples fabricated near the optimized condition revealed that there exists an optimal CNT: xGnP ratio at which the electrical performance can be maximized. The electrical and mechanical properties of optimal samples suggest that CNT-xGnP hybrid nanocomposites can serve as an alternative material platform for affordable, lightweight bipolar plates.

Characterisation and modelling of CNT-epoxy and CNT-fibre-epoxy composites

Abstract This research presents an experimental and theoretical investigation on the effects of carbon nanotube (CNT) integration within neat epoxy resin (nanocomposites) and a carbon fabric–epoxy composite (multiscale composites). An approach is presented for the prediction of mechanical properties of multiscale composites. This approach combines woven fibre micromechanics (MESOTEX) with the Mori-Tanaka model which was used for the prediction of mechanical properties of nanocomposites in this research. Nanocomposite and multiscale composite samples were manufactured using cast moulding, resin infusion, and hand lay-up process. The CNT concentrations in the composite samples were from 0 to 5 wt-%. The samples were characterised using tensile, shear and flexural tests. The discrepancy between the theoretical predictions and the experimental observations was hypothesised to be due to dispersion and bonding issues and SEM images are presented in support of the hypothesis.

Manufacturing process improvement and mechanical modelling of multiwalled carbon nanotube/epoxy composites

Abstract Multiwalled carbon nanotube (MWNT) reinforced epoxy resin composites were fabricated and characterised. Several process variables were investigated using design of experiments. The MWNTs (0·5 wt-%) were dispersed in Epon 862 epoxy resin under various sonication conditions. Young’s modulus, energy to failure, glass transition temperature Tg and storage modulus E′ were assessed. The first three were selected in a design of experiment optimisation study. The results indicated that as the sonication intensity and the duration of sonication were increased, the material response of the MWNT/epoxy composite, specifically Young’s modulus, energy and Tg, was enhanced. The fracture surfaces of the composites were examined using scanning electron microscopy. Improved dispersion was observed in samples fabricated with increased sonication intensities. The Mori–Tanaka model was used to predict the mechanical properties of the MWNT/epoxy composites and was found to be in reasonable agreement with experimental data. Nonetheless, the experimental results yielded slightly inferior properties to those from the model prediction.

Predicting mechanical properties of multiscale composites

Abstract The effect of carbon nanotube (CNT) integration in polymer matrixes (two-phase) and fibre reinforced composites (three-phase) was studied. Simulations for CNT/polymer composites (nanocomposites) and CNT/fibre/polymer composites (multiscale) were carried out by combining micromechanical theories applied to nanoscale and woven fibre micromechanic theories. The mechanical properties (Young’s modulus, Poisson’s ratio and shear modulus) of a multiscale composite were predicted. The relationships between the mechanical properties of nano- and multiscale composite systems for various CNT aspect ratios were studied. A comparison was made between a multiscale system with CNTs infused throughout and one with nanotubes excluded from the fabric tows. The mechanical properties of the composites improved with increased CNT loading. The influence of CNT aspect ratio on the mechanical properties was more pronounced in the nanocomposites than in the multiscale composites. Composites with CNTs in the fibre strands generated more desirable mechanical properties than those with no CNTs in the fibre strands.