Residual Strain Development in Rapid Frontally Curing Polymers.

Frontal polymerization (FP) has emerged as a rapid and energy-efficient process for fabricating thermoset polymers and composites. In this process, a self-propagating reaction front cures the polymer rapidly by the exothermic heat of polymerization reaction instead of an external heat source. Design for FP-based manufacturing in commercial applications requires more comprehensive characterization and prediction of material evolution and residual deformation throughout the process.

Controlled patterning of crystalline domains by frontal polymerization.

Materials with hierarchical architectures that combine soft and hard material domains with coalesced interfaces possess superior properties compared with their homogeneous counterparts. These architectures in synthetic materials have been achieved through deterministic manufacturing strategies such as 3D printing, which require an a priori design and active intervention throughout the process to achieve architectures spanning multiple length scales. Here we harness frontal polymerization spin mode dynamics to autonomously fabricate patterned crystalline domains in poly(cyclooctadiene) with multiscale organization.

A Mechanism-Based Reaction-Diffusion Model for Accelerated Discovery of Thermoset Resins Frontally Polymerized by Olefin Metathesis.

Frontal ring-opening metathesis polymerization (FROMP) involves a self-perpetuating exothermic reaction, which enables the rapid and energy-efficient manufacturing of thermoset polymers and composites. Current state-of-the-art reaction-diffusion FROMP models rely on a phenomenological description of the olefin metathesis kinetics, limiting their ability to model the governing thermo-chemical FROMP processes. Furthermore, the existing models are unable to predict the variations in FROMP kinetics with changes in the resin composition and as a result are of limited utility toward accelerated discovery of new resin formulations.

Adaptive Data-Driven Deep-Learning Surrogate Model for Frontal Polymerization in Dicyclopentadiene.

Frontal polymerization (FP) is a self-sustaining curing process that enables rapid and energy-efficient manufacturing of thermoset polymers and composites. Computational methods conventionally used to simulate the FP process are time-consuming, and repeating simulations are required for sensitivity analysis, uncertainty quantification, or optimization of the manufacturing process. In this work, we develop an adaptive surrogate deep-learning model for FP of dicyclopentadiene (DCPD), which predicts the evolution of temperature and degree of cure orders of magnitude faster than the finite-element method (FEM).

Frontal Polymerizations: From Chemical Perspectives to Macroscopic Properties and Applications.

The synthesis and processing of most thermoplastics and thermoset polymeric materials rely on energy-inefficient and environmentally burdensome manufacturing methods. Frontal polymerization is an attractive, scalable alternative due to its exploitation of polymerization heat that is generally wasted and unutilized. The only external energy needed for frontal polymerization is an initial thermal (or photo) stimulus that locally ignites the reaction.

Anisotropic frontal polymerization in a model resin-copper composite.

This work investigates experimentally and numerically frontal polymerization in a thermally anisotropic system with parallel copper strips embedded in 1,6-hexanediol diacrylate resin. Both experiments and multiphysics finite element analyses reveal that the front propagation in the thermally anisotropic system is orientation-dependent, leading to variations in the front shape and the front velocity due to the different front-metal strip interaction mechanisms along and across the metal strips. The parameters entering the cure kinetics model used in this work are chosen to capture the key characteristics of the polymerization front, i.

Controllable Frontal Polymerization and Spontaneous Patterning Enabled by Phase-Changing Particles.

Frontal polymerization provides a rapid, economic, and environmentally friendly methodology to manufacture thermoset polymers and composites. Despite its efficiency and reduced environmental impact, the manufacturing method is underutilized due to the limited fundamental understanding of its dynamic control. This work reports the control and patterning of the front propagation in a dicyclopentadiene resin by immersion of phase-changing polycaprolactone particles.

Rapid frontal polymerization achieved with thermally conductive metal strips.

Frontal polymerization, which involves a self-propagating polymerizing reaction front, has been considered as a rapid, energy-efficient, and environmentally friendly methodology to manufacture lightweight, high-performance thermoset polymers, and composites. Previous work has reported that the introduction of thermally conductive elements can enhance the front velocity. As follow-up research, the present work investigates this problem more systemically using both numerical and experimental approaches by investigating the front shape, front width, and heat exchange when aluminum and cooper metal strips are embedded in the resin.

Manipulating Frontal Polymerization and Instabilities with Phase-Changing Microparticles.

Recently presented as a rapid and eco-friendly manufacturing method for thermoset polymers and composites, frontal polymerization (FP) experiences thermo-chemical instabilities under certain conditions, leading to visible patterns and spatially dependent material properties. Through numerical analyses and experiments, we demonstrate how the front velocity, temperature, and instability in the frontal polymerization of cyclooctadiene are affected by the presence of poly(caprolactone) microparticles homogeneously mixed with the resin. The phase transformation associated with the melting of the microparticles absorbs some of the exothermic reaction energy generated by the FP, reduces the amplitude and order of the thermal instabilities, and suppresses the front velocity and temperatures.

Spontaneous Patterning during Frontal Polymerization.

Complex patterns integral to the structure and function of biological materials arise spontaneously during morphogenesis. In contrast, functional patterns in synthetic materials are typically created through multistep manufacturing processes, limiting accessibility to spatially varying materials systems. Here, we harness rapid reaction-thermal transport during frontal polymerization to drive the emergence of spatially varying patterns during the synthesis of engineering polymers.

Rapid synchronized fabrication of vascularized thermosets and composites.

Bioinspired vascular networks transport heat and mass in hydrogels, microfluidic devices, self-healing and self-cooling structures, filters, and flow batteries. Lengthy, multistep fabrication processes involving solvents, external heat, and vacuum hinder large-scale application of vascular networks in structural materials. Here, we report the rapid (seconds to minutes), scalable, and synchronized fabrication of vascular thermosets and fiber-reinforced composites under ambient conditions.

ChemNet: A Deep Neural Network for Advanced Composites Manufacturing.

Among advanced manufacturing techniques for fiber-reinforced polymer-matrix composites (FRPCs) which are critical for aerospace, marine, automotive, and energy industries, frontal polymerization (FP) has been recently proposed to save orders of magnitude of time and energy. However, the cure kinetics of the matrix phase, usually a thermosetting polymer, brings difficulty to the design and control of the process. Here, we develop a deep learning model, ChemNet, to solve an inverse problem for predicting and optimizing the cure kinetics parameters of the thermosetting FRPCs for a desired fabrication strategy.

Rapid energy-efficient manufacturing of polymers and composites via frontal polymerization.

Thermoset polymers and composite materials are integral to today's aerospace, automotive, marine and energy industries and will be vital to the next generation of lightweight, energy-efficient structures in these enterprises, owing to their excellent specific stiffness and strength, thermal stability and chemical resistance. The manufacture of high-performance thermoset components requires the monomer to be cured at high temperatures (around 180 °C) for several hours, under a combined external pressure and internal vacuum . Curing is generally accomplished using large autoclaves or ovens that scale in size with the component.

Frontal Polymerization of Dicyclopentadiene: A Numerical Study.

As frontal polymerization is being considered as a faster and more energy efficient manufacturing technique for polymer-matrix fiber-reinforced composites, we perform a finite-element-based numerical study of the initiation and propagation of a polymerization front in dicyclopentadiene (DCPD). The transient thermochemical simulations are complemented by an analytical study of the steady-state propagation of the polymerization front, allowing to draw a direct link between the cure kinetics model and the key characteristics of the front, i.e.

Interplay between Process Zone and Material Heterogeneities for Dynamic Cracks.

Using an elastodynamic boundary integral formulation coupled with a cohesive model, we study the problem of a dynamic rupture front propagating along an heterogeneous plane. We show that small-scale heterogeneities facilitate the supershear transition of a mode-II crack. The elastic pulses radiated during front accelerations explain how microscopic variations of fracture toughness change the macroscopic rupture dynamics.

Wave tailoring by precompression in confined granular systems.

We present a granular system whose response under an impact load can be varied from rapidly decaying to almost constant amplitude waves by an external regulator. The system consists of a granular chain of larger spheres surrounded by small spheres, confined in a hollow cylindrical tube and supporting wave propagation along the axis of the cylinder. We demonstrate using numerical simulations that the response can be controlled by applying radial precompression.

Family of plane solitary waves in dimer granular crystals.

Uniform planar impact on a two-dimensional square packing of spheres with intruders at interstitial locations is investigated. An equivalent one-dimensional granular chain model is proposed with appropriate scaling and is verified numerically. Numerical observations demonstrate the existence of a new family of plane solitary waves with different profiles at unique combinations of material properties.

Molecular tailoring of interfacial failure.

Self-assembled monolayers (SAMs) provide an enabling platform for molecular tailoring of the chemical and physical properties of an interface. In this work, we systematically vary SAM end-group functionality and quantify the corresponding effect on interfacial failure between a transfer printed gold (Au) film and a fused silica substrate. SAMs with four different end groups are investigated: 11-amino-undecyltriethoxysilane (ATES), dodecyltriethoxysilane (DTES), 11-bromo-undecyltrimethoxysilane (BrUTMS), and 11-mercapto-undecyltrimethoxysilane (MUTMS).

Characterization of wave propagation in elastic and elastoplastic granular chains.

For short duration impulse loadings, elastic granular chains are known to support solitary waves, while elastoplastic chains have recently been shown to exhibit two force decay regimes [ Pal, Awasthi and Geubelle Granular Matter 15 747 (2013)]. In this work, the dynamics of monodisperse elastic and elastoplastic granular chains under a wide range of loading conditions is studied, and two distinct response regimes are identified in each of them. In elastic chains, a short loading duration leads to a single solitary wave propagating down the chain, while a long loading duration leads to the formation of a train of solitary waves.

Interfacial adhesive properties between a rigid-rod pyromellitimide molecular layer and a covalent semiconductor via atomistic simulations.

We conducted a comprehensive atomistic simulation study of the adhesive properties of aromatic rigid-rod poly-[(4,4'diphenylene) pyromellitimide] on a dimer-reconstructed silicon surface. We describe the structural developments within the adherent's interfacial region at the atomistic scale, and evaluate the energetics of the adhesive interactions between bimaterial constituents. In particular, we observe a transition between noncontact and contact adhesion regimes as a function of the interfacial bonding strength between the polyimide repeat units and the silicon substrate.

Wave propagation in random granular chains.

The influence of randomness on wave propagation in one-dimensional chains of spherical granular media is investigated. The interaction between the elastic spheres is modeled using the classical Hertzian contact law. Randomness is introduced in the discrete model using random distributions of particle mass, Young's modulus, or radius.