During the past decade, polymer nanocomposites have emerged as a novel and rapidly developing class of materials and attracted considerable investment in research and development worldwide. However, there is currently a lack of information available in the literature on the nano and ultrafine particle emission rates from these materials. In this paper, influence of nanoclay on mechanical drilling of PA6 composites, in terms of dust generation, has been reported. With the help of real-time characterization, submicrometer-sized particles (5.6–512 nm), size distribution, and number concentration emitted from polyamide 6/nanoclay composites during mechanical drilling are studied. Total particle concentration for the PA6/nanoclay composites was 20,000 cm−3, while unreinforced panel measured a total concentration of approximately 400,000 cm−3. While the airborne particle concentration for the PA6/nanoclay composites was 20 times lower than for the PA6 matrix, the concentration of deposited nanoparticles doubled for the nanocomposite. The results clearly show that more particles in the size range between 175 and 350 nm are generated, during drilling of the nanocomposites, and these particles deposit in a shorter time. It is likely that the presence of nanoclay in some way retains the formation of high quantity of airborne particles and promotes particle deposition.

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The risk assessment, exposure and understanding of the release of embedded carbon nanotubes (CNTs) and carbon nanofibers (CNFs) from commercial high performance composites during machining processes are yet to be fully evaluated and quantified. In this study, CNTs and CNFs were dispersed in epoxy matrix through calendaring process to form nanocomposites. The automated drilling was carried out in a specially designed drilling chamber that allowed elimination of background noise from the measurements. Emission measurements were taken using condensed particle counter (CPC), scanning mobility particle sizer (SMPS) and DMS50 Fast Particulate Size Spectrometer. In comparison to the neat epoxy, the study results revealed that the nano-filled samples produced an increase of 102% and 227% for the EP/CNF and EP/CNT sample respectively in average particle number concentration emission. The particle mass concentration indicated that the EP/CNT and EP/CNF samples released demands a vital new perspective on CNTs and CNFs embedded within nanocomposite materials to be considered and evaluated for occupational exposure assessment. Importantly, the increased concentration observed at 10nm aerosol particle sizes measurements strongly suggest that there are independent CNTs being released at this range.

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