This research aims to study the effects of the sintering mechanism on the crystallization kinetics when the geopolymer is sintered at different temperatures: 200 °C, 400 °C, 600 °C, 800 °C, 1000 °C, and 1200 °C for a 3 h soaking time with a heating rate of 5 °C/min. The geopolymer is made up of kaolin and sodium silicate as the precursor and an alkali activator, respectively. Characterization of the nepheline produced was carried out using XRF to observe the chemical composition of the geopolymer ceramics. The microstructures and the phase characterization were determined by using SEM and XRD, respectively. The SEM micrograph showed the microstructural development of the geopolymer ceramics as well as identifying reacted/unreacted regions, porosity, and cracks. The maximum flexural strength of 78.92 MPa was achieved by geopolymer sintered at 1200 °C while the minimum was at 200 °C; 7.18 MPa. The result indicates that the flexural strength increased alongside the increment in the sintering temperature of the geopolymer ceramics. This result is supported by the data from the SEM micrograph, where at the temperature of 1000 °C, the matrix structure of geopolymer-based ceramics starts to become dense with the appearance of pores.
In the pursuit of achieving zero emissions, exploring the concept of recycling metal waste from industries and workshops (i.e., waste-free) is essential. This is because metal recycling not only helps conserve natural resources but also requires less energy as compared to the production of new products from virgin raw materials. The use of metal scrap in rapid tooling (RT) for injection molding is an interesting and viable approach. Recycling methods enable the recovery of valuable metal powders from various sources, such as electronic, industrial, and automobile scrap. Mechanical alloying is a potential opportunity for sustainable powder production as it has the capability to convert various starting materials with different initial sizes into powder particles through the ball milling process. Nevertheless, parameter factors, such as the type of ball milling, ball-to-powder ratio (BPR), rotation speed, grinding period, size and shape of the milling media, and process control agent (PCA), can influence the quality and characteristics of the metal powders produced. Despite potential drawbacks and environmental impacts, this process can still be a valuable method for recycling metals into powders. Further research is required to optimize the process. Furthermore, ball milling has been widely used in various industries, including recycling and metal mold production, to improve product properties in an environmentally friendly way. This review found that ball milling is the best tool for reducing the particle size of recycled metal chips and creating new metal powders to enhance mechanical properties and novelty for mold additive manufacturing (MAM) applications. Therefore, it is necessary to conduct further research on various parameters associated with ball milling to optimize the process of converting recycled copper chips into powder. This research will assist in attaining the highest level of efficiency and effectiveness in particle size reduction and powder quality. Lastly, this review also presents potential avenues for future research by exploring the application of RT in the ball milling technique.
The growth and formation of primary intermetallics formed in Sn-3.5Ag soldered on copper organic solderability preservative (Cu-OSP) and electroless nickel immersion gold (ENIG) surface finish after multiple reflows were systematically investigated. Real-time synchrotron imaging was used to investigate the microstructure, focusing on the in situ growth behavior of primary intermetallics during the solid-liquid-solid interactions. The high-speed shear test was conducted to observe the correlation of microstructure formation to the solder joint strength. Subsequently, the experimental results were correlated with the numerical Finite Element (FE) modeling using ANSYS software to investigate the effects of primary intermetallics on the reliability of solder joints. In the Sn-3.5Ag/Cu-OSP solder joint, the well-known Cu6Sn5 interfacial intermetallic compounds (IMCs) layer was observed in each reflow, where the thickness of the IMC layer increases with an increasing number of reflows due to the Cu diffusion from the substrate. Meanwhile, for the Sn-3.5Ag/ENIG solder joints, the Ni3Sn4 interfacial IMC layer was formed first, followed by the (Cu, Ni)6Sn5 IMC layer, where the formation was detected after five cycles of reflow. The results obtained from real-time imaging prove that the Ni layer from the ENIG surface finish possessed an effective barrier to suppress and control the Cu dissolution from the substrates, as there is no sizeable primary phase observed up to four cycles of reflow. Thus, this resulted in a thinner IMC layer and smaller primary intermetallics, producing a stronger solder joint for Sn-3.5Ag/ENIG even after the repeated reflow process relative to the Sn-3.5Ag/Cu-OSP joints.
Globally, there is an increasing need for ceramic materials that have a variety of applications in the environment, for precision tools, and for the biomedical, electronics, and environmental industries. However, in order to obtain remarkable mechanical qualities, ceramics have to be manufactured at a high temperature of up to 1600 °C over a long heating period. Furthermore, the conventional approach presents issues with agglomeration, irregular grain growth, and furnace pollution. Many researchers have developed an interest in using geopolymer to produce ceramic materials, focusing on improving the performances of geopolymer ceramics. In addition to helping to lower the sintering temperature, it also improves the strength and other properties of the ceramics. Geopolymer is a product of polymerization involving aluminosilicate sources such as fly ash, metakaolin, kaolin, and slag through activation using an alkaline solution. The sources of the raw materials, the ratio of the alkaline solution, the sintering time, the calcining temperature, the mixing time, and the curing time may have significant impacts on the qualities. Therefore, this review aims to study the effects of sintering mechanisms on the crystallization of geopolymer ceramics, concerning the strength achieved. A future research opportunity is also presented in this review.
This paper presents an assessment of the effect of isothermal annealing of Sn whisker growth behavior on the surface of Sn0.7Cu0.05Ni solder joints using the hot-dip soldering technique. Sn0.7Cu and Sn0.7Cu0.05Ni solder joints with a similar solder coating thickness was aged up to 600 h in room temperature and annealed under 50 °C and 105 °C conditions. Through the observations, the significant outcome was the suppressing effect of Sn0.7Cu0.05Ni on Sn whisker growth in terms of density and length reduction. The fast atomic diffusion of isothermal annealing consequently reduced the stress gradient of Sn whisker growth on the Sn0.7Cu0.05Ni solder joint. It was also established that the smaller (Cu,Ni)6Sn5 grain size and stability characteristic of hexagonal η-Cu6Sn5 considerably contribute to the residual stress diminished in the (Cu,Ni)6Sn5 IMC interfacial layer and are able to suppress the growth of Sn whiskers on the Sn0.7Cu0.05Ni solder joint. The findings of this study provide environmental acceptance with the aim of suppressing Sn whisker growth and upsurging the reliability of the Sn0.7Cu0.05Ni solder joint at the electronic-device-operation temperature.
A molded expanded polystyrene (EPS) cushion is a flexible, closed-cell foam that can be molded to fit any packing application and is effective at absorbing shock. However, the packaging waste of EPS cushions causes pollution to landfills and the environment. Despite being known to cause pollution, this sustainable packaging actually has the potential to reduce this environmental pollution because of its reusability. Therefore, the objective of this study is to identify the accurate design parameter that can be emphasized in producing a sustainable design of EPS cushion packaging. An experimental method of drop testing and design simulation analysis was conducted. The effectiveness of the design parameters was also verified. Based on the results, there are four main elements that necessitate careful consideration: rib positioning, EPS cushion thickness, package layout, and packing size. These parameter findings make a significant contribution to sustainable design, where these elements were integrated directly to reduce and reuse packaging material. Thus, it has been concluded that 48 percent of the development cost of the cushion was decreased, 25 percent of mold modification time was significantly saved, and 27 percent of carbon dioxide (CO2) reduction was identified. The findings also aided in the development of productive packaging design, in which these design elements were beneficial to reduce environmental impact. These findings had a significant impact on the manufacturing industry in terms of the economics and time of the molded expanded polystyrene packaging development.
This paper elucidates the mechanical performance, microstructure, and porosity evolution of fly ash geopolymer after 10 years of curing age. Given their wide range of applications, understanding the microstructure of geopolymers is critical for their long-term use. The outcome of fly ash geopolymer on mechanical performance and microstructural characteristics was compared between 28 days of curing (FA28D) and after 10 years of curing age (FA10Y) at similar mixing designs. The results of this work reveal that the FA10Y has a beneficial effect on strength development and denser microstructure compared to FA28D. The total porosity of FA10Y was also lower than FA28D due to the anorthite formation resulting in the compacted matrix. After 10 years of curing age, the 3D pore distribution showed a considerable decrease in the range of 5-30 µm with the formation of isolated and intergranular holes.
This paper elucidates the influence of dimple-microtextured copper substrate on the performance of Sn-0.7Cu solder alloy. A dimple with a diameter of 50 µm was produced by varying the dimple depth using different laser scanning repetitions, while the dimple spacing was fixed for each sample at 100 µm. The dimple-microtextured copper substrate was joined with Sn-0.7Cu solder alloy using the reflow soldering process. The solder joints' wettability, microstructure, and growth of its intermetallic compound (IMC) layer were analysed to determine the influence of the dimple-microtextured copper substrate on the performance of the Sn-0.7Cu solder alloy. It was observed that increasing laser scan repetitions increased the dimples' depth, resulting in higher surface roughness. In terms of soldering performance, it was seen that the solder joints' average contact angle decreased with increasing dimple depth, while the average IMC thickness increased as the dimple depth increased. The copper element was more evenly distributed for the dimple-micro-textured copper substrate than its non-textured counterpart.
Foamed concrete is considered a green building material, which is porous in nature. As a result, it poses benefits such as being light in self-weight, and also has excellent thermal insulation properties, environmental safeguards, good fire resistance performance, and low cost. Nevertheless, foamed concrete has several disadvantages such as low strength, a large amount of entrained air, poor toughness, and being a brittle material, all of which has restricted its usage in engineering and building construction. Hence, this study intends to assess the potential utilization of polypropylene fibrillated fiber (PFF) in foamed concrete to enhance its engineering properties. A total of 10 mixes of 600 and 1200 kg/m3 densities were produced by the insertion of four varying percentages of PFF (1%, 2%, 3%, and 4%). The properties assessed were splitting tensile, compressive and flexural strengths, workability, porosity, water absorption, and density. Furthermore, the correlations between the properties considered were also evaluated. The outcomes reveal that the foamed concrete mix with 4% PFF attained the highest porosity, with approximately 13.9% and 15.9% for 600 and 1200 kg/m3 densities in comparison to the control specimen. Besides, the mechanical properties (splitting tensile, compressive and flexural strengths) increased steadily with the increase in the PFF percentages up to the optimum level of 3%. Beyond 3%, the strengths reduced significantly due to poor PFF dispersal in the matrix, leading to a balling effect which causes a degraded impact of scattering the stress from the foamed concrete vicinity to another area of the PFF surface. This exploratory investigation will result in a greater comprehension of the possible applications of PFF in LFC. It is crucial to promote the sustainable development and implementation of LFC materials and infrastructures.
Geopolymers, or also known as alkali-activated binders, have recently emerged as a viable alternative to conventional binders (cement) for soil stabilization. Geopolymers employ alkaline activation of industrial waste to create cementitious products inside treated soils, increasing the clayey soils' mechanical and physical qualities. This paper aims to review the utilization of fly ash and ground granulated blast furnace slag (GGBFS)-based geopolymers for soil stabilization by enhancing strength. Previous research only used one type of precursor: fly ash or GGBFS, but the strength value obtained did not meet the ASTM D 4609 (<0.8 Mpa) standard required for soil-stabilizing criteria of road construction applications. This current research focused on the combination of two types of precursors, which are fly ash and GGBFS. The findings of an unconfined compressive strength (UCS) test on stabilized soil samples were discussed. Finally, the paper concludes that GGBFS and fly-ash-based geo-polymers for soil stabilization techniques can be successfully used as a binder for soil stabilization. However, additional research is required to meet the requirement of ASTM D 4609 standard in road construction applications, particularly in subgrade layers.
There is nothing more fundamental than clean potable water for living beings next to air. On the other hand, wastewater management is cropping up as a challenging task day-by-day due to lots of new additions of novel pollutants as well as the development of infrastructures and regulations that could not maintain its pace with the burgeoning escalation of populace and urbanizations. Therefore, momentous approaches must be sought-after to reclaim fresh water from wastewaters in order to address this great societal challenge. One of the routes is to clean wastewater through treatment processes using diverse adsorbents. However, most of them are unsustainable and quite costly e.g. activated carbon adsorbents, etc. Quite recently, innovative, sustainable, durable, affordable, user and eco-benevolent Geopolymer composites have been brought into play to serve the purpose as a pretty novel subject matter since they can be manufactured by a simple process of Geopolymerization at low temperature, lower energy with mitigated carbon footprints and marvellously, exhibit outstanding properties of physical and chemical stability, ion-exchange, dielectric characteristics, etc., with a porous structure and of course lucrative too because of the incorporation of wastes with them, which is in harmony with the goal to transit from linear to circular economy, i.e., "one's waste is the treasure for another". For these reasons, nowadays, this ground-breaking inorganic class of amorphous alumina-silicate materials are drawing the attention of the world researchers for designing them as adsorbents for water and wastewater treatment where the chemical nature and structure of the materials have a great impact on their adsorption competence. The aim of the current most recent state-of-the-art and scientometric review is to comprehend and assess thoroughly the advancements in geo-synthesis, properties and applications of geopolymer composites designed for the elimination of hazardous contaminants viz., heavy metal ions, dyes, etc. The adsorption mechanisms and effects of various environmental conditions on adsorption efficiency are also taken into account for review of the importance of Geopolymers as most recent adsorbents to get rid of the death-defying and toxic pollutants from wastewater with a view to obtaining reclaimed potable and sparkling water for reuse offering to trim down the massive crisis of scarcity of water promoting sustainable water and wastewater treatment for greener environments. The appraisal is made on the performance estimation of Geopolymers for water and wastewater treatment along with the three-dimensional printed components are characterized for mechanical, physical and chemical attributes, permeability and Ammonium (NH4+) ion removal competence of Geopolymer composites as alternative adsorbents for sequestration of an assortment of contaminants during wastewater treatment.
Underwater concrete is a cohesive self-consolidated concrete used for concreting underwater structures such as bridge piers. Conventional concrete used anti-washout admixture (AWA) to form a high-viscosity underwater concrete to minimise the dispersion of concrete material into the surrounding water. The reduction of quality for conventional concrete is mainly due to the washing out of cement and fine particles upon casting in the water. This research focused on the detailed investigations into the setting time, washout effect, compressive strength, and chemical composition analysis of alkali-activated fly ash (AAFA) paste through underwater placement in seawater and freshwater. Class C fly ash as source materials, sodium silicate, and sodium hydroxide solution as alkaline activator were used for this study. Specimens produced through underwater placement in seawater showed impressive performance with strength 71.10 MPa on 28 days. According to the Standard of the Japan Society of Civil Engineers (JSCE), the strength of specimens for underwater placement must not be lower than 80% of the specimen's strength prepared in dry conditions. As result, the AAFA specimens only showed 12.11% reduction in strength compared to the specimen prepared in dry conditions, thus proving that AAFA paste has high potential to be applied in seawater and freshwater applications.
This manuscript reports the isothermal annealing effect on the mechanical and microstructure characteristics of Sn-0.7Cu-1.5Bi solder joints. A detailed microstructure observation was carried out, including measuring the activation energy of the intermetallic compound (IMC) layer of the solder joints. Additionally, the synchrotron µX-ray fluorescence (XRF) method was adopted to precisely explore the elemental distribution in the joints. Results indicated that the Cu6Sn5 and Cu3Sn intermetallic layers thickness at the solder/Cu interface rises with annealing time at a rate of 0.042 µm/h for Sn-0.7Cu and 0.037 µm/h for Sn-0.7Cu-1.5Bi. The IMC growth's activation energy during annealing is 48.96 kJ mol-1 for Sn-0.7Cu, while adding Bi into Sn-0.7Cu solder increased the activation energy to 55.76 kJ mol-1. The µ-XRF shows a lower Cu concentration level in Sn-0.7Cu-1.5Bi, where the Bi element was well dispersed in the β-Sn area as a result of the solid solution mechanism. The shape of the IMC layer also reconstructs from a scallop shape to a planar shape after the annealing process. The Sn-0.7Cu hardness and shear strength increased significantly with 1.5 wt.% Bi addition in reflowed and after isothermal annealing conditions.
Modification has been made to TiO2 thin film to improve the wettability and the absorption of light. The sol-gel spin coating method was successfully used to synthesize GO/TiO2 thin films using a titanium (IV) isopropoxide (TTIP) as a precursor. Different amounts of polyethylene glycol (PEG) (20 to 100 mg) were added into the parent sol solution to improve the optical properties and wettability of the GO/TiO2 thin film. The effect of different amounts of PEG was characterized using X-ray diffraction (XRD) for the phase composition, scanning electron microscopy (SEM) for microstructure observation, atomic force microscopy (AFM) for the surface topography, ultraviolet-visible spectrophotometry (UV-VIS) for the optical properties and wettability of the thin films by measuring the water contact angle. The XRD analysis showed the amorphous phase. The SEM and AFM images revealed that the particles were less agglomerated and surface roughness increases from 1.21 × 102 to 2.63 × 102 nm when the amount of PEG increased. The wettability analysis results show that the water contact angle of the thin film decreased to 27.52° with the increase of PEG to 80 mg which indicated that the thin film has hydrophilic properties. The optical properties also improved significantly, where the light absorbance wavelength became wider and the band gap was reduced from 3.31 to 2.82 eV with the presence of PEG.
The present work investigates the effect of freeze-thaw cycles on the porosity of three mixtures of road concrete containing blast furnace slag in comparison with two mixtures made with conventional materials. The main technique used in our investigations is nuclear magnetic resonance (NMR) relaxometry. This permitted the extraction of information with respect to the freeze-thaw effect on pore-size distribution, which influences both the mechanical strength and the molecular transport through the material. Moreover, by using this technique, the structure of the air voids was analyzed for the entire pore system in the cement paste and the aggregate particles. The samples under study were first dried in a vacuum oven and then saturated with water or cyclohexane where the distribution of the transverse relaxation times of the protons was recorded. The NMR relaxation measurements were performed on samples extracted from specimens maintained at 300 freeze-thaw cycles and on control samples extracted from specimens kept in water during the freeze-thaw period. Scanning Electron Microscopy (SEM) was used to analyze the microstructure of concrete samples in order to obtain information about the pore sizes and the distance between them. The results from the NMR relaxation measurements were consistent with those obtained by using standard techniques for determining the porosity and the freeze-thaw resistances. The investigations made it possible to establish the optimal composition of blast furnace slag that can be incorporated into road concrete compositions. This non-invasive technique can also complete standard techniques for assessing the porosity and the progress of internal cracks during the freeze-thaw test.
This study aims to obtain the relationship between density and compressive strength of foamed concrete. Foamed concrete is a preferred building material due to the low density of its concrete. In foamed concrete, the compressive strength reduces with decreasing density. Generally, a denser foamed concrete produces higher compressive strength and lower volume of voids. In the present study, the tests were carried out in stages in order to investigate the effect of sand-cement ratio, water to cement ratio, foam dosage, and dilution ratio on workability, density, and compressive strength of the control foamed concrete specimen. Next, the test obtained the optimum content of processed spent bleaching earth (PSBE) as partial cement replacement in the foamed concrete. Based on the experimental results, the use of 1:1.5 cement to sand ratio for the mortar mix specified the best performance for density, workability, and 28-day compressive strength. Increasing the sand to cement ratio increased the density and compressive strength of the mortar specimen. In addition, in the production of control foamed concrete, increasing the foam dosage reduced the density and compressive strength of the control specimen. Similarly with the dilution ratio, the compressive strength of the control foamed concrete decreased with an increasing dilution ratio. The employment of PSBE significantly influenced the density and compressive strength of the foamed concrete. An increase in the percentage of PSBE reduced the density of the foamed concrete. The compressive strength of the foamed concrete that incorporated PSBE increased with increasing PSBE content up to 30% PSBE. In conclusion, the compressive strength of foamed concrete depends on its density. It was revealed that the use of 30% PSBE as a replacement for cement meets the desired density of 1600 kg/m3, with stability and consistency in workability, and it increases the compressive strength dramatically from 10 to 23 MPa as compared to the control specimen. Thus, it demonstrated that the positive effect of incorporation of PSBE in foamed concrete is linked to the pozzolanic effect whereby more calcium silicate hydrate (CSH) produces denser foamed concrete, which leads to higher strength, and it is less pore connected. In addition, the regression analysis shows strong correlation between density and compressive strength of the foamed concrete due to the R2 being closer to one. Thus, production of foamed concrete incorporating 30% PSBE might have potential for sustainable building materials.
The demand for natural fiber hybrid composites for various applications has increased, which is leading to more research being conducted on natural fiber hybrid composites due to their promising mechanical properties. However, the incompatibility of natural fiber with polymer matrix limits the performance of the natural fiber hybrid composite. In this research work, the mechanical properties and fiber-to-matrix interfacial adhesion were investigated. The efficiency of methyl methacrylate (MMA)-esterification treatments on composites' final product performance was determined. The composite was prepared using the hand lay-up method with varying kenaf bast fiber (KBF) contents of 10, 15, 20, 25, 30, 35 (weight%) and hybridized with glass fiber (GF) at 5 and 10 (weight%). Unsaturated polyester (UPE) resin and methyl ethyl ketone peroxide (MEKP) were used as binders and catalysts, respectively. Scanning electron microscopy (SEM) and Fourier-transform infrared spectroscopy (FTIR) were used to examine the effects of MMA-esterification treatment on tensile strength and morphology (tensile fracture and characterization of MMA-esterification treatment) of the composite fabricated. The tensile strength of MMA-treated reinforced UPE and hybrid composites are higher than that of untreated composites. As for MMA treatment, 90 min of treatment showed the highest weight percent gain (WPG) and tensile strength of KBF-reinforced UPE composites. It can be concluded that the esterification of MMA on the KBF can lead to better mechanical properties and adhesion between the KFB and the UPE matrix. This research provides a clear reference for developing hybrid natural fibers, thus contributing to the current field of knowledge related to GF composites, specifically in transportation diligences due to their properties of being lightweight, superior, and involving low production cost.
Concrete mix design and the determination of concrete performance are not merely engineering studies, but also mathematical and statistical endeavors. The study of concrete mechanical properties involves a myriad of factors, including, but not limited to, the amount of each constituent material and its proportion, the type and dosage of chemical additives, and the inclusion of different waste materials. The number of factors and combinations make it difficult, or outright impossible, to formulate an expression of concrete performance through sheer experimentation. Hence, design of experiment has become a part of studies, involving concrete with material addition or replacement. This paper reviewed common design of experimental methods, implemented by past studies, which looked into the analysis of concrete performance. Several analysis methods were employed to optimize data collection and data analysis, such as analysis of variance (ANOVA), regression, Taguchi method, Response Surface Methodology, and Artificial Neural Network. It can be concluded that the use of statistical analysis is helpful for concrete material research, and all the reviewed designs of experimental methods are helpful in simplifying the work and saving time, while providing accurate prediction of concrete mechanical performance.
Image analysis techniques are gaining popularity in the studies of civil engineering materials. However, the current established image analysis methods often require advanced machinery and strict image acquisition procedures which may be challenging in actual construction practices. In this study, we develop a simplified image analysis technique that uses images with only a digital camera and does not have a strict image acquisition regime. Mortar with 10%, 20%, 30%, and 40% pozzolanic material as cement replacement are prepared for the study. The properties of mortar are evaluated with flow table test, compressive strength test, water absorption test, and surface porosity based on the proposed image analysis technique. The experimental results show that mortar specimens with 20% processed spent bleaching earth (PSBE) achieve the highest 28-day compressive strength and lowest water absorption. The quantified image analysis results show accurate representation of mortar quality with 20% PSBE mortar having the lowest porosity. The regression analysis found strong correlations between all experimental data and the compressive strength. Hence, the developed technique is verified to be feasible as supplementary mortar properties for the study of mortar with pozzolanic material.
This paper reports on the potential use of geopolymer in the drilling process, with respect to tool wear and surface roughness. The objectives of this research are to analyze the tool life of three different economy-grade drill bit uncoated; high-speed steel (HSS), HSS coated with TiN (HSS-TiN), and HSS-cobalt (HSS-Co) in the drilling of geopolymer and to investigate the effect of spindle speed towards the tool life and surface roughness. It was found that, based on the range of parameters set in this experiment, the spindle speed is directly proportional to the tool wear and inversely proportional to surface roughness. It was also observed that HSS-Co produced the lowest value of surface roughness compared to HSS-TiN and uncoated HSS and therefore is the most favorable tool to be used for drilling the material. For HSS, HSS coated with TiN, and HSS-Co, only the drilling with the spindle speed of 100 rpm was able to drill 15 holes without surpassing the maximum tool wear of 0.10 mm. HSS-Co exhibits the greatest tool life by showing the lowest value of flank wear and produce a better surface finish to the sample by a low value of surface roughness value (Ra). This finding explains that geopolymer is possible to be drilled, and therefore, ranges of cutting tools and parameters suggested can be a guideline for researchers and manufacturers to drill geopolymer for further applications.