Syntactic foams formulations, production techniques, and industry applications: a review

Afolabi, Lukmon Owolabi; Ariff, Zulkifli Mohamad; Hashim, Syed Fuad Saiyid; Alomayri, Thamer; Mahzan, Shahruddin; Kamarudin, Kamarul-Azhar; Muhammad, Ibrahim Dauda

doi:10.1016/j.jmrt.2020.07.074

Cited by 60 publications

(25 citation statements)

References 81 publications

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“…Matrix materials can be polymeric, ceramic, or metallic. Polymeric matrices are the most diffused due to their low density, low cost, and easy processability while metallic and ceramic foams are employed in niche applications requiring exceptional resistance to high temperatures or harsh environment [ 8 ]. Hollow particles can be made of various materials, such as glass, boron carbide, silica, and other ceramics; and with different shapes, such as spherical, cubic, cuboid, and cylindric [ 4 ].…”

Section: Introductionmentioning

confidence: 99%

Thermophysical Properties of Multifunctional Syntactic Foams Containing Phase Change Microcapsules for Thermal Energy Storage

Galvagnini¹,

Dorigato²,

Fambri³

et al. 2021

Polymers

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Syntactic foams (SFs) combining an epoxy resin and hollow glass microspheres (HGM) feature a unique combination of low density, high mechanical properties, and low thermal conductivity which can be tuned according to specific applications. In this work, the versatility of epoxy/HGM SFs was further expanded by adding a microencapsulated phase change material (PCM) providing thermal energy storage (TES) ability at a phase change temperature of 43 °C. At this aim, fifteen epoxy (HGM/PCM) compositions with a total filler content (HGM + PCM) of up to 40 vol% were prepared and characterized. The experimental results were fitted with statistical models, which resulted in ternary diagrams that visually represented the properties of the ternary systems and simplified trend identification. Dynamic rheological tests showed that the PCM increased the viscosity of the epoxy resin more than HGM due to the smaller average size (20 µm vs. 60 µm) and that the systems containing both HGM and PCM showed lower viscosity than those containing only one filler type, due to the higher packing efficiency of bimodal filler distributions. HGM strongly reduced the gravimetric density and the thermal insulation properties. In fact, the sample with 40 vol% of HGM showed a density of 0.735 g/cm3 (−35% than neat epoxy) and a thermal conductivity of 0.12 W/(m∙K) (−40% than neat epoxy). Moreover, the increase in the PCM content increased the specific phase change enthalpy, which was up to 68 J/g for the sample with 40 vol% of PCM, with a consequent improvement in the thermal management ability that was also evidenced by temperature profiling tests in transient heating and cooling regimes. Finally, dynamical mechanical thermal analysis (DMTA) showed that both fillers decreased the storage modulus but generally increased the storage modulus normalized by density (E′/ρ) up to 2440 MPa/(g/cm3) at 25 °C with 40 vol% of HGM (+48% than neat epoxy). These results confirmed that the main asset of these ternary multifunctional syntactic foams is their versatility, as the composition can be tuned to reach the property set that best matches the application requirements in terms of TES ability, thermal insulation, and low density.

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Section: Introductionmentioning

confidence: 99%

Thermophysical Properties of Multifunctional Syntactic Foams Containing Phase Change Microcapsules for Thermal Energy Storage

Galvagnini¹,

Dorigato²,

Fambri³

et al. 2021

Polymers

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“…Therefore, when such materials are used, there is a large CTE mismatch with other materials. Especially after many thermal cycles, the two materials generate greater stress at the contact surfaces, which can cause the instability of device performance [ 69 ].…”

Section: Modification Of Thermal Characteristics Of Epoxy Resin Composite Foam Insulation Materialsmentioning

confidence: 99%

Current Status of Research on the Modification of Thermal Properties of Epoxy Resin-Based Syntactic Foam Insulation Materials

Zhang

Dai

et al. 2021

Polymers

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As a lightweight and highly insulating composite material, epoxy resin syntactic foam is increasingly widely used for insulation filling in electrical equipment. To avoid core burning and cracking, which are prone to occur during the casting process, the epoxy resin-based syntactic foam insulation materials with high thermal conductivity and low coefficient of thermal expansion are required for composite insulation equipment. The review is divided into three sections concentrating on the two main aspects of modifying the thermal properties of syntactic foam. The mechanism and models, from the aspects of thermal conductivity and coefficient of thermal expansion, are presented in the first part. The second part aims to better understand the methods for modifying the thermal properties of syntactic foam by adding functional fillers, including the addition of thermally conductive particles, hollow glass microspheres, negative thermal expansion filler and fibers, etc. The third part concludes by describing the existing challenges in this research field and expanding the applicable areas of epoxy resin-based syntactic foam insulation materials, especially cross-arm composite insulation.

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“…Therefore, such studies give no direct answer to how the deformation of the internal structure and its changes are related to its mechanical response. With the advancements achieved in the field of porous solids for structural applications [ 26 , 27 , 28 , 29 , 30 , 31 , 32 ] and deformation energy absorption [ 33 , 34 , 35 , 36 , 37 ], advanced XCT imaging methodologies have been sought to reveal the deformation processes in the microstructure driving the overall mechanical response of the developed materials [ 38 , 39 , 40 , 41 ]. In particular, time-resolved XCT (4D XCT) experiments allowing for the characterisation of porous solids in response to mechanical loading has been extensively used, as it enables one to capture the deforming microstructure during the in-situ experiment performed in the XCT scanner either in discrete load steps or continuously throughout the loading procedure (so-called on-the-fly XCT) [ 42 , 43 ].…”

Section: Introductionmentioning

confidence: 99%

Analysis of Advanced Pore Morphology (APM) Foam Elements Using Compressive Testing and Time-Lapse Computed Microtomography

et al. 2021

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Advanced pore morphology (APM) foam elements are almost spherical foam elements with a solid outer shell and a porous internal structure mainly used in applications with compressive loading. To determine how the deformation of the internal structure and its changes during compression are related to its mechanical response, in-situ time-resolved X-ray computed microtomography experiments were performed, where the APM foam elements were 3D scanned during a loading procedure. Simultaneously applying mechanical loading and radiographical imaging enabled new insights into the deformation behaviour of the APM foam samples when the mechanical response was correlated with the internal deformation of the samples. It was found that the highest stiffness of the APM elements is reached before the appearance of the first shear band. After this point, the stiffness of the APM element reduces up to the point of the first self-contact between the internal pore walls, increasing the sample stiffness towards the densification region.

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Syntactic foams formulations, production techniques, and industry applications: a review

Cited by 60 publications

References 81 publications

Thermophysical Properties of Multifunctional Syntactic Foams Containing Phase Change Microcapsules for Thermal Energy Storage

Thermophysical Properties of Multifunctional Syntactic Foams Containing Phase Change Microcapsules for Thermal Energy Storage

Current Status of Research on the Modification of Thermal Properties of Epoxy Resin-Based Syntactic Foam Insulation Materials

Analysis of Advanced Pore Morphology (APM) Foam Elements Using Compressive Testing and Time-Lapse Computed Microtomography

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