As an attempt to improve the overall cost-effectiveness and ease of structural electronics manufacturing, this study characterizes the mechanical and electrical responses of structures which are fabricated from a novel metallopolymer composite material by fused deposition modeling as they are subjected to quasi-static, uniaxial mechanical tension. Baseline values of tensile properties and electrical resistivity were first obtained via ASTM D638-22 standard testing procedures and linear sweep voltammetry (LSV), respectively. A hybrid procedure to measure in-situ mechanically dependent electrical behavior was subsequently developed and implemented. The mechanical and electromechanical testing was followed by the derivation of stochastic values for several mechanical and electrical properties of the printed structures. The mean values of a three-specimen sample’s ultimate tensile strength and tensile modulus were 8.76 and 244.5 megapascals, respectively, and the sample exhibited significant ductility through an average tensile elongation of 70.4 percent at fracture. The electrical resistance of test specimens appeared to be positively correlated to their mechanical strain. Correlation coefficients exceeding 0.95 were obtained for simple linear regression models of the resistance-strain curves for their two distinct regimes of strain sensitivity. The uncoupled mechanical and electrical performance of the printed structures were, however, significantly below what the nominal material properties suggested. Thus, it was concluded that the process of component manufacturing should be further improved, and that the structures’ mechanical and electromechanical behaviors should be more rigorously characterized, before attempting to use such components in applications of structural electronics.

The process, structure, and property relationship of PAN fiber as a precursor to carbon fiber was studied. The limitations of stable spinning and property improvement associated with hot draw in solution spinning were found and quantified. Conditions were varied to generated precursor fiber up to the limit of draw, from which actual samples were collected for thermal conversion to carbon fiber. Samples of PAN and subsequent carbon fiber were characterized using tensile testing and x-ray analysis. The effects of draw on modulus and break stress, as well as the orientation of the crystalline structure of both parent precursor and resultant carbon fiber were found and related back to the quantified draw limit.

This dissertation addresses the synthesis mechanism of mesoporous titania thin films with 2D Hexagonal Close Packed (HCP) cylindrical nanopores by an evaporation-induced self-assembly (EISA) method with Pluronic surfactants P123 and F127 as structure directing agents, and their applications in photovoltaics and lithium ion batteries. To provide orthogonal alignment of the pores, surface modification of substrates with crosslinked surfactant has been used to provide a chemically neutral surface. GISAXS studies show not only that aging at 4°C facilitates ordered mesostructure development, but also that aging at this temperature helps to provide orthogonal orientation of the cylindrical micelles which assemble into an ordered mesophase directly by a disorder-order transition. These films provide pores with 8-9 nm diameter, which is precisely the structure expected to provide short carrier diffusion length and high hole conductivity required for efficient bulk heterojunction solar cells. In addition, anatase titania is a n-type semiconductor with a band gap of +3.2 eV. Therefore, titania readily absorbs UV light with a wavelength below 387 nm. Because of this, these titania films can be used as window layers with a p-type semiconductor incorporated into the pores and at the top surface of the device to synthesize a photovoltaic cell. The pores provide opportunities to increase the surface area for contact between the two semiconductors, to align a p-type semiconductor at the junction, and to induce quantum confinement effects. These titania films with hexagonal phase are infiltrated with a hole conducting polymer, poly(3-hexylthiophene) (P3HT), in order to create a p-n junctions for organic-inorganic hybrid solar cells, by spin coating followed by thermal annealing. This assembly is hypothesized to give better photovoltaic performance compared to disordered or bicontinuous cubic nanopore arrangements; confinement in cylindrical nanopores is expected to provide isolated, regioregular “wires” of conjugated polymers with tunable optoelectronic properties, such as improved hole conductivity over that in bicontinuous cubic structure. The kinetics of infiltration into the pores show that maximum infiltration occurs within less than one hour in these films, and give materials with improved photovoltaic performance relative to planar TiO2/P3HT assemblies. These oriented mesoporous titania films are also used to develop an inorganic solar cell by depositing CdTe at the top using the Close Spaced Sublimation (CSS) technique. A power conversion efficiency of 5.53% is measured for heterostructures built using mesoporous titania films, which is significantly enhanced relative to planar TiO2/CdTe devices and prior reports in the literature. These mesoporous titania films have a great potential in inorganic solar cell development and can potentially replace CdS window layers which are conventionally used in inorganic CdS-CdTe solar cells. The last part of the dissertation addresses layer-by-layer synthesis to increase the thickness of mesoporous titania films with vertically oriented 2D-HCP nanopores, and their use in lithium ion batteries as negative electrodes because of advantages such as good cycling stability, small volume expansion (~3%) during intercalation/extraction and high discharge voltage plateau. The high surface area and small wall thickness of these titania films provide excellent lithium ion insertion and reduced Li-ion diffusion length, resulting in stable capacities as high as 200-250 mAh/g over 200 cycles.

Design and synthesis of porous organic polymers have attracted considerable attentions during the past decade due to their wide range of applications in gas storage, gas separation, energy conversion, and catalysis. Porous organic polymers can be pre-synthetically and post-synthetically functionalized with a wide variety of functionalities for desirable applications. Along these pursuits, we introduced new synthetic strategies for preparation of porous organic polymers for selective CO2 capture. Porous azo-linked polymers (ALPs) were synthesized by an oxidative reaction of amine-based monomers using copper(I) as a catalyst which leads to azo-linkage formation. ALPs exhibit high surface areas of up to 1200 m2 g-1 and have high chemical and thermal stabilities. The nitrogen atoms of the azo group can act as Lewis bases and the carbon atom of CO2 can act as a Lewis acid. Therefore, ALPs show high CO2 uptake capacities due to this Lewis acid-based interaction. The potential applications of ALPs for selective CO2 capture from flue gas, natural gas, and landfill gas under pressure-swing and vacuum swing separation settings were studied. Due to their high CO2 uptake capacity, selectivity, regenerability, and working capacity, ALPs are among the best porous organic frameworks for selective CO2 capture. In our second project, a new bis(imino)pyridine-linked porous polymer (BIPLP-1) was synthesized and post-synthetically functionalized with Cu(BF4)2 for highly selective CO2 capture. BIPLP-1 was synthesized via a condensation reaction between 2,6-pyridinedicarboxaldehyde and 1,3,5-tris(4-aminophenyl)benzene, wherein the bis(imino)pyridine linkages are formed in-situ during polymerization. The functionalization of the polymer with Cu(BF4)2 was achieved by treatment of the polymer with a solution of Cu(BF4)2 via complexation of copper cations with bis(imino)pyridine moieties of the polymer. BF4- ions can act Lewis base and CO2 can act as a Lewis acid; and therefore, the functionalized polymer shows high binding affinity for CO2 due to this Lewis acid-based interaction. The functionalization of the pores with Cu(BF4)2 resulted in a significant enhancement in CO2 binding energy, CO2 uptake capacity, and CO2 selectivity values. Due to high reactivity of bis(imino)pyridines toward transitions metals, BIPLP-1 can be post-synthetically functionalized with a wide variety of inorganic species for CO2 separation and catalytic applications.

Organic semiconductors have wide applications in organic-based light-emitting diodes, field-effect transistors, and thermoelectrics due to the easily modified electrical and optical properties, excellent mechanical flexibility, and solution processability. To fabricate high performance devices, it is important to understand charge transport mechanisms, which are mainly affected by material energetics and material morphology. Currently it is difficult to control the charge transport properties of new organic semiconductors and organic-inorganic nanocomposites due to our incomplete understanding of the large number of influential variables. Molecular doping of π-conjugated polymers and surface modification of nanowires are two means through which charge transport can be manipulated. In molecular doping, both the energetics and microstructures of polymer films can be changed by controlling the degree of oxidation of the conjugated polymer backbone. For surface modification of inorganic nanowires, the energetics and morphology can be influenced by the properties of the surface modifiers. Meanwhile, the energy band alignment, which can be controlled by surface modification and molecular doping, may also alter the charge transport due to the variation in energetic barriers between the transport states in the organic and inorganic components. To reveal the effects of morphology and energetics on charge transport in conjugated polymers and organic-inorganic nanocomposites, the influence of surface modifier on the electrical and morphological properties of nanocomposites was first probed. Silver nanowires modified with different thiols were blended with poly (3,4-ethylenedioxythiophene)-poly(styrenesulfonate)(PEDOT:PSS) to fabricate thin films. The modified nanowires provided a means of controllably altering the nanowire dispersability and compatibility with solvents and polymers. The results also demonstrated that charge transport between the nanowires was facilitated due to low wire-to-wire junction resistance. To further figure out the charge transport mechanism in organic-inorganic nanocomposites and the potential applications, tellurium nanowires and ferric chloride doped poly (3-hexylthiophene-2,5-diyl)(P3HT) were used to characterize energy band alignment effects on charge transport, electrical conductivity, and thermoelectric properties. The results showed that charge transfer between nanowires can be mediated by the polymer and may potentially increase the electrical conductivity as compared to the pure polymer or pure nanowires; while the observed enhancement of power factor (equal to electrical conductivity times the square of Seebeck coefficient) may not be affected by the energy band alignment. It is important to investigate the change of polymer morphology caused by molecular doping and processing method to determine how the morphology will influence the electrical and thermoelectric properties. Various p-type dopants, including ferric chloride and molybdenum tris(1,2-bis(trifluoromethyl)ethane-1,2-dithiolene) (Motfd3), were examined for us in P3HT and other polymers. The results showed that: i) At light doping levels, the electrical conductivity and power factor of polymers doped with the large electron affinity (EA) dopants were larger than small EA dopants; ii) At heavy doping levels, the large size dopants cannot effectively dope polymers even for the dopants with large EAs; iii) For the same dopant, as the IE of the polymer increased, the doping efficiency gradually decreased.

Understanding how different processing variables influence wood welded bonds is vital if the technique will ever be used to create engineered lumber without using adhesives. A variation of vibration welding, wood welding uses pressure and friction to bond materials together. During welding, heat causes a softening in the wood, a naturally occurring composite material. This softening leads to fiber entanglement and a bond forms upon cooling. The goal of this research was to investigate several processing aspects of the wood welding procedure. A prototype wood welding machine, designed and fabricated from the ground up, was used to investigate the effects of various welding parameters using birch wood. Wood welds were evaluated on the basis of bond coverage and ultimate shear strength. Four experiments were performed: welding frequency and duration interaction, grain orientation effects, alternative welding completion metrics, and strength development over time. During the wood welding process, three distinct phenomena were repeatedly observed: smoke creation, welding residue formation, and an audible pitch change. The presence of each was recorded for every wood welded specimen and used later in additional data analysis. Investigating each of the welding phenomena was done in an attempt to better characterize when fusion was achieved at the weld interface. ImageTool, an image analysis software package, was used to investigate and quantify the often irregular bonds exposed after shear fracture. The results of the various welding variables were analyzed on the basis of shear strength and bond uniformity. From the birch samples, it was shown that better bonds result from lower welding frequencies and longer welding durations. The grain orientation analysis demonstrated that welding orientation marginally affects the average shear strength of the wood weld. The data from the alternative welding metrics suggests that welding time is not a quality indicator of welding completion (bond coverage). The strength development trials confirmed previous research; wood welds obtain most of their strength in a relatively short period of time. Douglas fir and poplar both proved to be weldable for the first time, but they were sufficiently weaker than birch. When welding was attempted with Douglas fir under similar pressures used for birch, Douglas fir samples would commonly “washboard.” With reduced welding pressure, Douglas fir formed wood welds more easily.

Ultrathin film nanocomposites are becoming increasingly important for specialized performance of commercial coatings. Critical challenges for ultrathin film nanocomposites include their synthesis and characterization as well as their performance properties, including surface roughness, optical properties (haze, refractive index as examples), and mechanical properties. The objective of this work is to control the surface roughness of ultrathin film nanocomposites by changing the average particle size and the particle volume fraction (loading) of monomodal particle size distributions. This work evaluated one-layer and two-layer films for their surface properties. Monodispersed colloidal silica nanoparticles were incorporated into an acrylate-based monomer system as the model system. Ultrathin nanocomposites were prepared with three different size colloidal silica (13, 45, and 120 nm nominal diameters) at three different particle loadings (20, 40, and 50 vol. % inorganic solids). Silica particles were characterized using DLS and TEM. AFM was used to measure the root mean square roughness (Rq), ΔZ, and location-to-location uniformity of one-layer and two-layer nanocomposite coatings. Developing an understanding about the properties affected by the type and amount of particles used in a nanocomposite can be used as a tool with nanocharacterization techniques to quickly modify and synthesize desired ultrathin film coatings.

Multifunctional materials both with damping properties and strain sensing properties are very important. They promise to be more weight-efficient, and provide volume-efficient performance, flexibility and potentially, less maintenance than traditional multi-component brass-board systems. The goal of this dissertation work was to design, synthesize, investigate and apply polyaniline/Multiwall carbon nanotube (PANI/MWCNT) and polyurethane (PU) /MWCNT composites films for structural vibration control and strain sensors using free layer damping methods and static and dynamic strain sensing test methods. The PANI/MWCNT was made by in situ polymerization of PANI in the presence of MWCNT, then frit compression was used to make circular and rectangular PANI/MWCNT composite films. PU/MWCNT composites were made by the layer-by-layer method. Free end vibration test results showed both of PANI/MWCNT and PU/MWCNT have better damping ratios than each of their components. Static sensing test indicated that though there appears to be residual strain in both composite sensors after the load is removed, both the sensor and the foil strain gage react linearly when re-engaged. A drift test of the sensor showed that it is stable. The dynamic sensing test results showed that over the range of 10-1000 Hz, the PANI/MWCNT composite sensor was consistently superior to foil strain gage for sensing purposes since the highest peak consistently corresponded to the input frequency and was much higher, for example, at 20 Hz, 820 times higher than those of the strain gage. Using the same criterion, the PU/Buckypaper composite sensor was comparable to or superior to the foil strain gage for sensing purposes over the range of 10 Hz to 200 Hz. The relationship of loss factor, η, and beam coverage length, L1/L, is discussed for single sided and double sided attachment. For both PANI/MWCNT and PU/MWCNT, the loss factor, η, was found to increase as coverage length, L1/L, increases. The loss factor, η, was found to have a maximum as with coverage length, L1/L, as the coverage length continues to increase. The trend for double sided attachment was found to follow the trends discussed by Rao (2004) and Levy and Chen (1994) for viscoelastic material constrained damping.

Durable, cheap, and lightweight polymer based solar cells are needed, if simply to meet the demand for decentralized electrical power production in traditionally “off-grid” areas. Using a blend of Poly(3-hexylthiophene-2,5-diyl) (P3HT), Phenyl-C61-butyric acid methyl ester (PCBM), and the low band-gap polymer Poly[2,6-(4,4-bis-(2- ethylhexyl)-4H-cyclopenta [2,1-b;3,4-b′]dithiophene)-alt-4,7(2,1,3-benzothiadiazole)] (PCPDTBT), we have fabricated devices with a wide spectral response and 3% power conversion efficiency in AM 1.5 conditions; however, this thin film system exhibits only 0.43 optical density at 500 nm. To improve the performance of this polymer blend photovoltaic, we aim to increase absorption by adding CdSe(ZnS) core (shell) quantum dots. Four groups of devices are fabricated: a control group with an active polymer layer of 16 mg/mL P3HT, 16 mg/mL PCBM, and 4 mg/mL PCPDTBT; and three groups with dispersed quantum dots at 4 mg/ml, 1 mg/mL, and 0.25 mg/mL. The (CdSe)ZnS quantum dots are coated with octadecylamine ligands and have a peak absorbance at 560 nm and peak emission at 577 nm. The active layer was dissolved in chlorobenzene solvent and spun on glass substrates, patterned with indium tin oxide. The devices were then annealed for fifteen minutes at 110° C, 140° C, and 170° C. Current-voltage characteristic curves v and optical density data were taken before and after the anneal step. Finally, surface characterization was conducted with atomic force microscopy and electrostatic force microscopy. When compared to the control, the sensitized devices exhibited increased absorption and depressed electrical performance with increasing quantum dot loading. The surface morphology, both electrical and physical, showed deviation from the typical values and patterns shown by the control that increased with quantum dot loading. When the degrading electrical characteristics, increasing optical absorbance, and surface changes, are considered together, it becomes likely that the quantum dots interact in a significant manner with the morphology of the P3HT phase, which leads to an overall decrease in performance.

Composite materials offer a high strength-to-weight ratio and directional load bearing capabilities. Compression molding of composite materials yields a superior surface finish and good dimensional stability between component lots with faster processing compared to traditional manufacturing methods. This experimental compression molding capability was developed for the ME composites lab using unidirectional carbon fiber prepreg composites. A direct comparison was drawn between autoclave and compression molding methods to validate compression molding as an alternative manufacturing method in that lab. A method of manufacturing chopped fiber from existing unidirectional prepreg materials was developed and evaluated using destructive testing methods. The results from testing both the continuous and chopped fiber were incorporated into the design of a functionally graded hybrid continuous and chopped carbon fiber component, the manufacture of which resulted in zero waste prepreg material.