The high performance multi-walled carbon nanotubes (MWNTs) reinforced epoxy polymer nanocomposites (PNCs) have been synthesized at different MWNT loading levels. The surface functionalization of MWNTs with conductive PANI was achieved by using a facile surface initiated polymerization method with the aid of the oxidations of CNTs and subsequent anilines by hexavalent chromium (Cr(VI)) oxidant. The effects of MWNT loading, surface functionalization and temperature on the rheological behaviors of liquid epoxy resin nanosuspensions and on the physicochemical properties of cured solid PNCs were systematically investigated. The glass transition temperature (T g ) of the cured epoxy PNCs filled with functionalized MWNTs obtained from the dynamic mechanical analysis (DMA)test was increased about 6-25 C than that of cured pure epoxy. The PNCs reinforced with functionalized MWNTs demonstrated an enhanced tensile strength than either cured pure epoxy or its PNCs filled with the as-received MWNTs. The electrical conductivity of cured epoxy PNCs with functionalized MWNTs was improved by 5.5 orders of magnitude compared with cured pure epoxy.Thermogravimetric analysis (TGA) revealed an enhanced thermo-stability in the cured epoxy PNCs filled with functionalized MWNTs than that of cured pure epoxy and its PNCs filled with the as-received MWNTs. The observed strong interfacial interaction between MWNTs and the epoxy resin matrix was responsible for the enhanced mechanical tensile strength. The nanocomposite formation mechanism is proposed based on the analysis from Fourier transform infrared (FT-IR), thermogravimetric analysis (TGA), Raman and differential scanning calorimetry (DSC) tests.

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Both fibril and spherical polyaniline (PANI) nanostructures have successfully served as nanofillers for obtaining epoxy resin polymer nanocomposites (PNCs). The effects of nanofiller morphology and loading level on the mechanical properties, rheological behaviors, thermal stability, flame retardancy, electrical conductivity, and dielectric properties were systematically studied. The introduction of the PANI nanofillers was found to reduce the heat-release rate and to increase the char residue of epoxy resin. A reduced viscosity was observed in both types of PANI-epoxy resin liquid nanosuspension samples at lower loadings (1.0 wt % for PANI nanospheres; 1.0 and 3.0 wt % for PANI nanofibers), the viscosity was increased with further increases in the PANI loading for both morphologies. The dynamic storage and loss modulii were studied, together with the glass-transition temperature (T(g)) being obtained from the peak of tan δ. The critical PANI nanofiller loading for the modulus and T(g) was different, i.e., 1.0 wt % for the nanofibers and 5.0 wt % for the nanospheres. The percolation thresholds of the PANI nanostructures were identified with the dynamic mechanical property and electrical conductivity, and, because of the higher aspect ratio, nanofibers reached the percolation threshold at a lower loading (3.0 wt %) than the PANI nanospheres (5.0 wt %). The PANI nanofillers could increase the electrical conductivity, and, at the same loading, the epoxy nanocomposites with the PANI nanofibers showed lower volume resistivity than the nanocomposites with the PANI nanospheres, which were discussed with the contact resistance and percolation threshold. The tensile test indicated an improved tensile strength of the epoxy matrix with the introduction of the PANI nanospheres at a lower loading (1.0 wt %). Compared with pure epoxy, the elasticity modulus was increased for all the PNC samples. Moreover, further studies on the fracture surface revealed an enhanced toughness. Finally, the real permittivity was observed to increase with increasing the PANI loading, and the enhanced permittivity was analyzed by the interfacial polarization.

Magnetic epoxy polymer nanocomposites (PNCs) reinforced with magnetite (Fe(3)O(4)) nanoparticles (NPs) have been prepared at different particle loading levels. The particle surface functionality tuned by conductive polyaniline (PANI) is achieved via a surface initiated polymerization (SIP) approach. The effects of nanoparticle loading, surface functionality, and temperature on both the viscosity and storage/loss modulus of liquid epoxy resin suspensions and the physicochemical properties of the cured solid PNCs are systematically investigated. The glass transition temperature (T(g)) of the cured epoxy filled with the functionalized NPs has shifted to the higher temperature in the dynamic mechanical analysis (DMA) compared with that of the cured pure epoxy. Enhanced mechanical properties of the cured epoxy PNCs filled with the functionalized NPs are observed in the tensile test compared with that of the cured pure epoxy and cured epoxy PNCs filled with as-received NPs. The uniform NP distribution in the cured epoxy PNCs filled with functionalized NPs is observed by scanning electron microscope (SEM). These magnetic epoxy PNCs show the good magnetic properties and can be attached by a permanent magnet. Enhanced interfacial interaction between NPs and epoxy is revealed in the fracture surface analysis. The PNCs formation mechanism is also interpreted from the comprehensive analysis based on the TGA, DSC, and FTIR in this work.

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Epoxy resin nanocomposites reinforced with silica nanoparticles have been prepared at different nanoparticle loading levels. The surface functionality of the silica nanoparticles is manipulated by the phosphoric acid (H3PO4)-doped conductive polyaniline (PANI) via a surface initiated polymerization (SIP) method. The improved glass transition temperature (T g) and enhanced mechanical properties of the cured epoxy resin nanocomposites filled with the functionalized silica nanoparticles are observed compared with those of the cured pure epoxy resin. The flammability and thermal stability behaviors of these nanocomposites are evaluated using microscale combustion calorimeter (MCC) and thermogravimetric analysis (TGA). The heat release rate (HRR) peak of the epoxy filled with functionalized silica nanoparticles is observed to decrease dramatically with increasing functionalized silica particle loadings, indicating a flame-retardant performance from the phosphoric acid-doped PANI.

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