Shrinking down into nanoscale, materials exhibit huge property advantages over their bulk form. New forms of carbon at nanoscale have occupied the prominent position in modern materials research. With a very long history accompanying our human civilisation, carbon as a wonder material has once again contributed to our technological advances, as evidenced by the discoveries and research attractions in the last a few decades. Research into fullerenes (C60, C70, etc.), carbon nanotubes (CNTs) and graphene has been continued raising, because of the numerous novel properties associated with these new carbon forms1-3. On top of their excellent electronical, physical and chemical properties, CNTs and graphene also exhibit excellent mechanical properties including ultra-high tensile strength, Young’s Modulus, as well as high thermal conductivities. Research into carbon has also promoted the flourish of many new non-carbon nanomaterials, and typical examples include the inorganic fullerene-like tungsten disulphide (IF-WS2) nanoparticles (NPs), numerous oxide NPs and nanowires that also exhibit various remarkable properties, such as high hardness and anti-oxidation stability. To combine the outstanding performances of both carbon and non-carbon nanomaterials by marrying nanoscale carbon with various metal oxide particles, which forms the backbone of my thesis by carrying out the intensive investigations. In my project it have further validated the advantages of the resulting new carbon-coated NPs in different polymeric matrix composites. The main findings are as follows: 1. A home-made rotary chemical vapour deposit (RCVD) system has been modified and this versatile facility has been applied successfully to produce different types of graphitic carbon-coated nanocomposite particles, from micro- down to nano-scale, including IF-WS2, TiO2, ZnO, Y2O3, Cr2O3, CeO2 and ZrO2 etc. The production can be up to 30 g/per batch, which is 10s times more than using a traditional static furnace, by avoiding severe agglomeration. 2. The resulting coating consists of a few layered graphitic carbon with lattice space 0.34 nm. The thickness of the coating is simply controllable between 1-5 nm, depending on the deposition time (10~60 min), precursor injection flow rate (1.2~2.4 ml/L) and heating temperature (700~900 oC). Furthermore, the oxide core of ZnO@C was removed by heating under the H2/Ar atmosphere, and have successfully generated nano- to micro-scale, hollow, closed, and all-carbon structures. 3. The commercial Nylon 12 is applied to fabricate the metal oxide polymer composite. Using ZnO@C-Nylon 12 composite as an example, at 2 wt% content, the composites have achieved with the ultimate tensile strength increased by 27% (from 47.9 to 59.6 MPa), In particular, at 4 wt% content, the ZnO@C showed an impressive improvement in thermal conductivity of nearly 50% (From 0.21 t0 0.31 W∙m-1∙K-1), comparing 16% improvement for ZnO-Nylon 12 composite. 4. Apart from investigations of nylon composite, intensive studies of the Poly ether ether ketone (PEEK), an important high performance engineering thermoplastics polymer, and its nanocomposites reinforced by IF-WS2 and IF-WS2@C have been carried out in this thesis. The IF-WS2/PEEK composites exhibited not only an improvements of 24% (From 77.6 to 96.7 MPa) in the tensile strength (2 wt%), but also showed an extraordinary increase in thermal conductivity by 190%, from 0.248 to 0.719 W∙m-1∙K-1 at 8 wt%, higher onset decomposing temperatures (54 oC) against the plain PEEK. 5. Moreover, owing to the better dispersal capacity of IF-WS2@C NPs, the ternary IF-WS2@C-PEEK nanocomposites produced in this thesis displayed impressive mechanical properties, increased by 51% (From 77.6 to 120.9 MPa, at 2 wt%), and extremely greater thermal conductivity, with 235% (From 0.248 to 0.831 W∙m-1∙K-1 at 8 wt%), and better stability than the comparison IF-WS2-PEEK composites. The parameters influencing the coating quality and thickness have also been investigated. Further, their interface studies based on the FTIR and XPS techniques have verified the formation of chemical bonding (C=S bonding and carbon π-π bonding), rather than physically bonded together. The successful application of the generic RCVD process can be further extended to the processing of many new particles for an ultrathin carbon coating. Considering the vast amount of literature focusing on carbon, the project further processing of carbon-coated materials in composites could easily be tailored to achieve desired surface contacts with different matrices and leading to the better desired performance, as verified in this thesis for the advanced binary and ternary composites. Finally, this research is expecting to expand the application potentials of PEEK-based nanocomposites in critical areas where thermal conductivity and thermal stability are important.

Polymer nanocomposite foams have attracted tremendous interests due to their multifunctional properties in addition to the inherited lightweight benefit of being foamed materials. Polymer nanocomposite foams using high performance polymer and bio-degradable polymer with carbon nanotubes were fabricated, and the effects of foam density and pore size on properties were characterized. Electrical conductivity modeling of polymer nanocomposite foams was conducted to investigate the effects of density and pore size. High performance polymer Polyetherimide (PEI) and multi-walled carbon nanotube (MWCNT) nanocomposites and their foams were fabricated using solvent-casting and solid-state foaming under different foaming conditions. Addition of MWCNTs has little effect on the storage modulus of the nanocomposites. High glass transition temperature of PEI matrix was maintained in the PEI/MWCNT nanocomposites and foams. Volume electrical conductivities of the nanocomposite foams beyond the percolation threshold were within the range of electro-dissipative materials according to the ANSI/ESD standard, which indicates that these lightweight materials could be suitable for electro-static dissipation applications with high temperature requirements. Biodegradable Polylactic acid (PLA) and MWCNT nanocomposites and their foams were fabricated using melt-blending and solid-state foaming under different foaming conditions. Addition of MWCNTs increased the storage modulus of PLA/MWCNT composites. By foaming, the glass transition temperature increased. Volume electrical conductivities of foams with MWCNT contents beyond the percolation threshold were again within the range of electro-dissipative materials according to the ANSI/ESD standard. The foams with a saturation pressure of 2 MPa and foaming temperature of 100 °C showed a weight reduction of 90% without the sacrifice of electrical conductivity. This result is promising in terms of multi-functionality and material saving. At a given CNT loading expressed as volume percent, the electrical conductivity increased significantly as porosity increased. A Monte-Carlo simulation model was developed to understand and predict the electrical conductivity of polymer/MWCNT nanocomposite foams. Two different foam morphologies were considered, designated as Case 1: volume expansion without nanotube rearrangement, and Case 2: nanotube aggregation in cell walls. Simulation results from unfoamed nanocomposites and the Case 1 model were validated with experimental data. The results were in good agreement with those from PEI/MWCNT nanocomposites and their foams, which had a similar microstructure as modeled in Case 1. Porosity effects on electrical conductivity were investigated for both Case 1 and Case 2 models. There was no porosity effect on electrical conductivity at a given volume percent CNT loading for Case 1. However, for Case 2 the electrical conductivity increased as porosity increased. Pore size effect was investigated using the Case 2 model. As pore size increased, the electrical conductivity also increased. Electrical conductivity prediction of foamed polymer nanocomposites using FEM was performed. The results obtained from FEM were compared with those from the Monte-Carlo simulation method. Feasibility of using FEM to predict the electrical conductivity of foamed polymer nanocomposites was discussed. FEM was able to predict the electrical conductivity of polymer nanocomposite foams represented by the Case 2 model with various porosities. However, it could not capture the pore size effect in the electrical conductivity prediction. The FEM simulation can be utilized to predict the electrical conductivity of Case 2 foams when the percolation threshold is determined by Monte-Carlo simulation to save the computational time. This has only been verified when the pore size is small in the range of a few micrometers. / text

This work investigates the feasibility of the use of plasma spray deposition as a method of producing high performance polymer coatings. The work concentrates on the understanding of the processing of the plasma spraying of polymers, the behaviour of polymeric materials during deposition, and the study of process-structure-properties relationships. Processing modelling for the three stages of the evolution of a polymer deposit (droplet-splat-coating) has been carried out using heat transfer theory. A theoretical model is proposed which consists of three parts: the first part predicts the temperature profile of in-flight particles within plasma jet, the second part predicts the cooling of isolated splats impacting on a substrate and the third part, the heat transfer through the coating thickness. The heat transfer analysis predicts that the development of large temperature gradients within the particle is a general characteristics of polymers during plasma spraying. This causes difficulties for polymer particles to be effectively molten within the plasma jet without decomposition. The theoretical calculations have predicted the effect of processing parameters on the temperature, the degree of melting and decomposition of in-flight polymer particles. With the aid of the model, the conditions for the preparation of high integrity thermoplastic deposits have been established by the control of the plasma arc power, plasma spraying distance, feedstock powder injection, torch traverse speed and feedstock particle size. The optimal deposition conditions are designed to produce effective particle melting in the plasma, extensive flow on impact, and minimal thermal degradation. The experimental work on optimizing processing parameters has confirmed the theoretical predictions. Examination of polymer coating structures reveals that the major defects are unmelted particles, cracks and pores. Five major categories of pores have been classified. It also revealed a significant loss in crystallinity and the presence of a minor metastable phase in the plasma deposited polyamide coatings due to rapid solidification. The study has indicated that the molecular weight of a polymer plays an important role on the splat flow and coating structure. Under non-optimal deposition condition, substantial thermal degradation occurred for which a chain scission mechanism is proposed for plasma deposited polyamide coatings. There are difficulties in achieving cross-linking during plasma spray deposition of thermosets. The theoretical calculations predict that adequate cross-linking is unlikely in a coating deposited under normal conditions, but preheating the substrate to above the cross-linking temperature improves the degree of cross-linking of the coatings substantially. In addition, the coating thickness has a major effect on the degree of cross-linking of thermosets. The calculations also predict that lowering the thermal conductivity by applying a thermal barrier undercoat and using a faster curing agent to reduce time required for the cross-linking reaction can improve the degree of cross-linking of thermoset deposits. The experimental results for the degree of cross-linking and wear resistance confirmed these predictions.

High molecular weight poly(phenylene sulfide sulfone) (PPSS) homo- and statistical copolymers have been reproducably synthesized using a known, but complex procedure utilizing 4,4'-dichlorodiphenyl sulfone (DCDPS), sodium hydrosulfide, sodium hydroxide, sodium acetate, and deionized water, in NMP at elevated reaction temperatures and pressure. The effect of these variations, e.g., reaction temperatures and times, molar ratios of H2O-to-NaSH, NMP-to-H2O, etc. were investigated. Optimized conditions were defined, which produced Tg as high as 222°C, very high refractive index (1.70), and tough/solvent resistant films could be prepared by melt fabrication. A two-stage decomposition mechanism in air was demonstrated by dynamic thermal gravimetric analysis. The melt stability of PPSS was improved by incorporating thermally stable endgroups, such as diphenyl sulfone, 4-chlorophenylphenyl sulfone, and t-butylphenoxide. The chemical structures of the endgroups were confirmed by 13C and 1H NMR spectra. Compared with mercaptide endcapped PPSS, the new systems showed higher initial degradation temperatures (2% and 5% weight loss), higher char yield at 650°C in air and a more stable melt viscosity at 300°C. A greatly simplified synthesis of both homo and copolymers has been successfully developed using the new A-A or A-B type thiol-functional monomers, such as bis-(4-mercaptophenyl) sulfone, 4-chloro-4'-mercaptodiphenyl sulfone and 4-chloro-4'-mercapto benzophenone, instead of sodium hydrosulfide. A series of high molecular weight triphenyl phosphine oxide and/or diphenyl ketone containing PPSS copolymers were subsequently synthesized from the bis-(4-mercaptophenyl) sulfone by reaction with 4,4'-dichlorodiphenyl sulfone, bis-(4-fluorophenyl) phenyl phosphine oxide, and 4,4'-difluorobenzophenone in DMAc in the presence of K2CO3 at 160°C. The new phosphine oxide containing PPSS copolymers were completely amorphous, showed improved solubility in common organic solvents and exhibited very high char yields in air at 750°C. Surface (XPS) analysis results suggested that the phosphorus moieties in the polymer backbone can form phosphate-like layers on the polymer surface which protects the inner materials from further decomposition in air at high temperatures. The diphenyl ketone containing PPSS copolymers showed very high char yields at 750°C in a nitrogen atmosphere, compared to sulfide sulfone homopolymer and phosphine oxide containing copolymers, possibly because of higher bond energies. Semi-crystalline poly(phenylene sulfide ketone) homopolymers and sulfone containing copolymers with sulfone/ketone mole ratio (S : K) < 25 : 75 were synthesized by a novel base catalyzed self-polycondensation of 4-chloro-4'-mercaptodiphenyl sulfone and/or 4-chloro-4'-mercapto benzophenone in N-cyclohexyl-2-pyrrolidinone (CHP) at 290°C. Amorphous copolymers with S : K ratios > 25 : 75 were prepared in DMAc at 160°C. These materials exhibited an increase in glass transition temperature with increasing sulfone content. TGA and micro cone calorimetry analyses showed that the semi-crystalline materials with high ketone content had much higher char yields and significantly lower heat release rate and total heat release, compared to the poly(phenylene sulfide sulfone) and poly(pheylene sulfide) controls. / Ph. D.

This work is concerned with the production of high performance polymer foams via a benign foaming process. The first goal of this project was to develop a process and the conditions necessary to produce a low density (>80% density reduction) foam from poly(arylene ether sulfone) (PAES). Water and supercritical carbon dioxide (scCO2) were used as the blowing agents in a one-step batch foaming process. Both water and scCO2 plasticize the PAES, allowing for precise control on both the foam morphology and the foam density. To optimize the foaming conditions, both thermogravimetric analysis and differential scanning calorimetery (DSC) were used to determine the solubility and the reduced glass transition temperature (Tg) due to plasticization of the polymer. It was determined that 2 hours was sufficient time to saturate the PAES with water and scCO2 when subjected to a temperature of 220 oC and 10.3 MPa of pressure. Under these conditions, a combination of 7.5% of water and scCO2 were able to diffuse into the PAES specimen, correlating to ~60 oC reduction in the Tg of the PAES. The combination of water and scCO2 produced foam with up to an 80% reduction in density. The compressive properties, tensile modulus, and impact strength of the foam were measured. The relative compressive properties were slightly lower than the commercially available structural foam made of poly(methacrylimide). The second objective of the dissertation was to enhance the compressive properties of the PAES foam, without concern for the foam density. Foam was produced over a range of density, by controlling the cell size, in order to optimize the compressive properties. Carbon nanofibers (CNFs) were also added to the PAES matrix prior to foaming to both induce heterogeneous nucleation, which leads to smaller cell size, and to reinforce the cell walls. Dynamic mechanical thermal analysis (DMTA), on saturated CNF-PAES, was used to determine the reduced Tg due to plasticization and establish the temperature for pressure release during foaming. DMTA proved to be more effective than DSC in establishing quantitative results on the reduction in the Tg. The CNF-PAES foam produced had compressive properties up to 1.5 times the compressive properties of the PAES foam. / Ph. D.

Polymers, among metals and ceramics, are major solid materials which are widely used in all kinds of applications. Polymers are of particular interest because they can be tailored with desirable properties. Polymer-based complexes and composites, which contain both the polymers and other components such as metal oxide/salts, are playing a more and more important role in the material fields. Such complexes and composites may display the benefits of both the polymer and other materials, endowing them with excellent functionalities for targeted applications. In this dissertation, a great deal of research was conducted to synthesize novel polymers and build polymeric complexes and composites for biomedical and aerospace applications. In chapter 3, two methods were developed and optimized to fabricate sub-micron high-performance polymer particles which were subsequently used to coat onto functional carbon fibers via electrostatic interactions, for the purpose of fabricating carbon fiber reinforced polymer composites. In chapter 4, a novel Pluronic® P85-bearing penta-block copolymer was synthesized and formed complexes with magnetite. The complexes displayed non-toxicity to cells normally but were able to selectively kill cancer cells without killing normal cells when subjected to a low-frequency alternating current magnetic field. Such results demonstrated the potential of such polymeric complexes in cancer treatment. Chapter 5 described the synthesis of several ionic graft copolymers primarily bisphosphonate-containing polymers, and the fabrication of polymer-magnetite complexes. The in-depth investigation results indicated the capability of the complexes for potential drug delivery, imaging, and other biomedical applications. Chapter 6 described additional polymer synthesis and particle or complex fabrication for potential drug delivery and imaging, as well as radiation shielding. / PHD / Polymers, metals, and ceramics are three major classes of solid materials that are used every day and everywhere. Polymers are of particular significance because they can be tailored to possess certain desirable properties, and, hence, they are playing a more and more important role as substitutes for metals and ceramics in a wide array of applications. Engineering and high-performance polymers were synthesized with excellent properties for biomedical and aerospace applications. Polymers can be fabricated into composites and complexes which contain not only polymers but also other materials, such as metal oxides/salts, carbon fibers, glass fibers, etc. When composites and complexes are made with sufficient stability, the materials may display the advantages of each component, making them more promising for specific applications. In this dissertation, effort was focused on developing versatile polymer-based complexes and composites for aerospace and biomedical applications. Chapter 3 describes the fabrication of sub-micron high-performance polymer particles by two methods and they were subsequently coated onto functional carbon fibers for making composites. Chapter 4 describes the synthesis of a novel copolymer that formed complexes with magnetite nanoparticles. The complexes were able to selectively kill cancerous cells without killing normal cells when exposed to an external magnetic field, and thus these materials have potential for cancer treatment. Chapter 5 describes the fabrication of phosphonate-bearing ionic copolymer-magnetite complexes and their potential applications in drug delivery, imaging, and other biomedical applications. Chapter 6 describes the synthesis of polymers and their corresponding complexes for potential drug delivery and imaging, as well as potential radiation shielding applications.

L'objectif de cette thèse est de créer de nouveaux mélanges thermoplastiques présentant une processabilité accrue comparée à des matrices thermoplastiques hautes performances utilisées dans l'industrie aéronautique. Ces matériaux ont vocation à être intégrés en atmosphère avionique pressurisée. Afin de combler le cahier des charges imposé par le domaine aéronautique, le choix des matériaux s'est porté sur un mélange incompatible de polyétheréthercétone PEEK et de polymères à cristaux liquides LCP présentant une morphologie fibrillaire développée grâce à des conditions particulières d'écoulement lors de la mise en oeuvre.Dans un premier temps, les propriétés rhéologiques des matériaux sont caractérisées de manière à confirmer le respect des spécifications relatives à leur processabilité. La compréhension des phénomènes régissant la baisse de viscosité du mélange permet d'assurer la répétabilité et la reproductibilité des performances rhéologiques en vue d'un transfert industriel. L'étude se concentre ensuite sur les propriétés de cristallinité des mélanges, qui permettent de déterminer que la présence de deux matériaux semi-cristallins au sein d'une même structure ne perturbe pas leurs propriétés de cristallinité garantes de leurs performances thermomécaniques.Enfin, une campagne de caractérisation complète est effectuée afin de dresser une fiche matière et de la comparer aux spécifications exigées par l'industrie aéronautique. / The aim of this thesis is to create new thermoplastic blends exhibiting improved processability incomparison with high performance aeronautical thermoplastics. These materials are dedicated tointegrating pressurized avionic structures.To reach the specific aeronautical specifications, an incompatible polymer blend made ofpolyetheretherketone PEEK and liquid crystalline polymers LCP is chosen. The particular flow conditionsset for the compounding ensure the blend a fibrillar morphology.First, the material rheological properties are characterized so as to confirm that the processabilityspecifications are met. The viscosity drop causes are explained and grant the maintaining of therheological performances in any processing configuration.The study then focuses on the blend crystallinity properties in order to determine whether two interlinkedsemi-crystalline structures do not impede the thermomechanical performances.At last, a characterization campaign is led to compare the blend performances with the demandedaeronautical specifications.

Syfte Syftet med föreliggande studie är att genom en systematisk översikt identifiera skillnaderna i de kemiska och mekaniska egenskaperna hos materialen PEEK och PEKK och till vilka dentala applikationer materialen kan användas.  Material och metod Materialens kemiska och mekaniska egenskaper identifierades genom litteratursökning med PRISMA och PICO-systemet. Databaserna som användes var PubMed, Scopus samt Web of Science. Granskning gjordes på titel-, abstrakt- och fulltextnivå, baserat på inklusions- och exklusionskriterier. Resultat Sökningen resulterade i totalt 226 artiklar varav 210 artiklar i PubMed, nio artiklar i Scopus och sju artiklar i Web of Science. Efter kontroll av dubbletter och bedömning utifrån inklusions- och exklusionskriterier var det totalt sju artiklar som analyserades på fulltextnivå. Av dessa sju artiklarna utvärderades olika materialegenskaper där de använda materialtesterna skiljde sig åt. I fem artiklar utvärderades bindningsstyrkan mellan fasadmaterial och PEEK och/eller PEKK. En artikel undersökte ytan hos materialen beroende på ytbehandling och en artikel testade tryckhållfasthet på tre-ledsbroar av PEEK och PEKK. Båda materialen uppvisade liknande mekaniska och kemiska egenskaper vid jämförelse mot varandra.  Slutsats PEEK och PEKKs mekaniska och kemiska egenskaper skiljer sig inte åt. Mer forskning och kliniska data behövs om materialens dentala applikationer. Nyckelord: Avtagbar protetik, fast protetik, högpresterande polymer, PAEK, tandvård / Purpose The purpose of the present study is to carry out a systematic review to identify the differences in mechanical and chemical properties of the materials PEEK and PEKK, as well as which  dental applications the materials can be used for.  Material and method The materials’ mechanical and chemical properties were identified using PRISMA and PICO system through a literature search. The databases used were PubMed, Scopus and Web of Science. Screening and assessing were done at title, abstract and full text level, based on the inclusion and exclusion criteria. Results The search resulted in a total of 226 articles, whereon 210 articles in PubMed, nine articles in Scopus and seven articles in Web of Science. After removal of duplicates and assessment of the studies according to the inclusion and exclusion criteria, the total amount of studies reviewed was seven. In these seven articles, different properties were evaluated, and the tests used differed. In five articles, the shear bond strength between veneering materials and PEEK and/or PEKK was tested. In one article the surface roughness depending on surface treatment was tested and in another, the strength of three-unit fixed dental prostheses made of PEEK and PEKK was tested. PEEK and PEKK showed similar mechanical and chemical properties in comparison to each other.  Conclusion The mechanical and chemical properties of PEEK and PEKK do not differ. More research and clinical data are needed on the dental applications of the materials.Keywords: Dentistry, fixed dental prosthesis, high-performance polymer, removable dental prothesis, PAEK.

With industries aiming at higher efficiencies, lightweight parts, and easier manufacturability there has been a recent trend of replacing the metallic materials with polymeric materials and its composites. Particularly in the automotive industry, there is a demand of replacing metallic material of bushes and bearings with polymer based materials (PBM). For these heavy performance requirements (as in automobiles), the commonly used industrial polymers like Acetal and Nylon fail to provide good mechanical and tribological performance. High-performance polymer like Polyphenylene Sulfide (PPS) is a relatively newer material and shows a potential of being a PBM alternative for metallic bearings in automobiles if their tribological performance can be improved.  One of the ways of improving the tribological performance of the polymer is by the addition of filler material, hence making a polymer composite. In this study, we used Short Carbon Fibre as micro-reinforcement material and Nano-diamonds and Graphene Oxide as nano-reinforcement material to make PPS composites. The varying mechanical and tribological behaviour of PPS composites with different weight percentage of reinforcement materials was investigated. The optimum composition of the reinforcement materials was identified, which resulted in significant improvement in mechanical and tribological properties of the base material.