Search Results (84)

Microwave-assisted heating (MWH) has established itself as a transformative and energy-efficient paradigm for advanced materials processing. This review provides a comprehensive overview of the advances achieved at the CNR-SCITEC laboratories in Genoa. In this context, a customized microwave platform has been strategically employed for the synthesis, sintering, foaming, and melting of diverse inorganic, organic, and hybrid systems. The spectrum of materials investigated includes superconducting magnesium diboride (MgB₂), hydroxyapatite-based scaffolds, polyethylene components obtained via microwave-assisted rotational molding, cork-based sound-adsorbing composites, recycled expanded polystyrene (rEPS) panels, and polyvinylidene fluoride (PVDF) piezoelectric films. Across the case studies, MWH demonstrated a superior capacity for reducing energy consumption and processing times while maintaining—or even enhancing—the target functional properties. Furthermore, this work evaluates the technological maturity and emerging market opportunities of microwave-based processing, positioning it as a key and sustainable platform for next-generation materials development. Full article

Selenium nanoparticles (SeNPs) present a promising alternative to toxic inorganic selenium salts, yet the differential bioactivity between their allotropic forms—amorphous red (RSeNPs) and crystalline grey (GSeNPs)—is not fully determined. This study investigated the allotropic status and concentration-dependent effects of RSeNPs and GSeNPs (0.5, 5, and 50 mg·L⁻¹) on Saccharomyces cerevisiae growth, monitored via foam expansion distance, calculated growth rate, and the normal logarithm of the samples’ optical densities at 600 nm. The results revealed that the allotropic form was the dominant factor influencing yeast performance. Specifically, RSeNPs exhibited superior biocompatibility; the 0.5 mg·L⁻¹ dose (RSe0.5) yielded the highest overall growth rate, suggesting a potential growth-promoting effect. Conversely, GSeNPs demonstrated concentration-dependent toxicity, with the 50 mg·L⁻¹ dose (GSe50) causing a statistically significant inhibition compared to the control. Moreover, optical density measurements confirmed that both red and grey SeNPs enhanced the maximum specific growth rate (µmax) compared to the control, demonstrating a stimulatory effect on yeast growth kinetics. These findings confirm that amorphous RSeNPs are less inhibitory and potentially more beneficial than their crystalline grey counterparts, underscoring the critical importance of nanoparticle morphology in determining biological outcomes. Full article

Rigid polyurethane foams (RPUFs) are essential polymeric materials, prized for their low density, high mechanical strength, and superior thermal insulation, making them indispensable in construction, refrigeration, and transportation. Despite these advantages, their highly porous, carbon-rich structure renders them intrinsically flammable, promoting rapid flame spread, intense heat release, and the generation of toxic smoke. Traditional strategies to reduce flammability have primarily focused on incorporating additive or reactive flame retardants into the foam matrix, which can effectively suppress combustion but often compromise mechanical integrity, suffer from migration or compatibility issues, and involve complex synthesis routes. Despite recent progress, the long-term stability, scalability, and durability of surface flame-retardant coatings for RPUFs remain underexplored, limiting their practical application in industrial environments. Recent advances have emphasized the development of surface-engineered flame-retardant coatings, including intumescent systems, inorganic–organic hybrids, bio-inspired materials, and nanostructured composites. These coatings form protective interfaces that inhibit ignition, restrict heat and mass transfer, promote char formation, and suppress smoke without altering the intrinsic properties of RPUFs. Emerging deposition methods, such as layer-by-layer assembly, spray coating, ultraviolet (UV) curing, and brush application, enable precise control over thickness, uniformity, and adhesion, enhancing durability and multifunctionality. Integrating bio-based and hybrid approaches further offers environmentally friendly and sustainable solutions. Collectively, these developments demonstrate the potential of surface-engineered coatings to achieve high-efficiency flame retardancy while preserving thermal and mechanical performance, providing a pathway for safe, multifunctional, and industrially viable RPUFs. Full article

Polypropylene (PP) exhibits high flammability (LOI ≈ 17.5%), which limits its industrial applications. Previous studies have primarily focused on the flame-retardant mechanisms of intumescent flame-retardant (IFR) systems, while less attention has been given to the role of inorganic synergistic additives in balancing flame retardancy with mechanical performance—an aspect crucial for commercial applications This study investigated the effect of small additions of zinc oxide (ZnO) and manganese oxide (MnO) on the flame-retardant, mechanical, and thermal properties of PP/IFR (APP + PER) composites. The oxide content was varied between 0 and 2 wt.%. LOI and UL-94 tests showed that as little as 0.25 wt.% increased LOI to 30% and enabled all materials to achieve a UL-94 V-0 classification. The highest performance was observed for ZnO (LOI = 43.7% at 1.5 wt.%), while MnO induced a linear increase up to 38.6% at 2 wt.%. SEM analysis confirmed the formation of a compact, foamed char layer. Mechanical testing revealed improved stiffness (~15%) and flexural strength (~20%), with unchanged tensile strength but reduced impact strength (−50% for ZnO, −30% for MnO). The HDT increased from 55 °C to 65 °C. These findings demonstrate that small amounts of ZnO and MnO act as effective and economically viable IFR synergists in PP composites. Full article

New energy vehicles face a critical challenge in balancing the thermal safety management of high-specific-energy battery systems with the simultaneous improvement of energy density. With the large-scale application of high-energy-density systems such as silicon-based anodes and solid-state batteries, their inherent thermal runaway risks pose severe challenges to battery thermal management systems (BTMS). Currently, the thermal insulation performance, temperature resistance, and fire protection capabilities of flame-retardant materials (e.g., foam cotton, fiber felts) used in automotive batteries are inadequate to meet the demands of intense combustion and high temperatures generated during thermal failure in high-energy-density batteries. Against this backdrop, thermal insulation and fireproof aerogel materials are emerging as a revolutionary solution for the next generation of power battery thermal protection systems. Leveraging their nanoporous structure’s exceptional thermal insulation properties (thermal conductivity of 0.013–0.018 W/(m·K) at room temperature) and extreme fire resistance (temperature resistance > 1100 °C/UL94 V-0 flame retardancy), aerogels are gaining prominence. This article provides a systematic review of thermal runaway phenomena in automotive batteries and corresponding protective measures. It highlights recent breakthroughs in the selection of material systems, optimization of preparation processes, and fiber–matrix composite technologies for automotive fireproof aerogel composites. The core engineering values of these materials, such as blocking thermal runaway propagation, reducing system weight, and improving volumetric efficiency, are quantitatively validated. Furthermore, the paper explores future research directions, including the development of low-cost aerogel composites and the design of organic–inorganic hybrid composite structures, aiming to provide a foundation and industrial pathway for the research and development of next-generation high-performance battery thermal management systems. Full article

Waste glass recycling generates waste streams such as fine glass fraction, waste ceramics containing fine glass, and waste polyethylene plastics. All of the aforementioned streams contain contaminants of organic and inorganic origin that are difficult to remove. This research was conducted to determine technological processes aimed at achieving a circular economy (CE) in the recycling of waste glass. Foam glass was made from the fine-grained, multicolored fraction of contaminated glass, an effective method for recycling glass waste at a low cost. A frothing system based on manganese oxide (MnO₂) and silicon carbide (SiC) was proposed, and an optimum weight ratio of MnO₂/SiC equal to 1.0 was determined. The possibility of controlling the process to achieve the desired foam glass densities was demonstrated. Statistical analysis was used to determine the effect of the MnO₂/SiC ratio and MnO₂ content on the density of the resulting foam glass products. Waste ceramics contaminated with different-colored glass were transformed into ceramic–glass granules. The characteristic temperature curve of the technological process was determined. The metal content in water extracts from ceramic–glass granules and pH value indicate their potential use for alkalizing areas degraded by industry and agriculture. Waste polyethylene-based plastics were converted into polyethylene waxes by thermal treatment carried out in two temperature ranges: low temperature (155–175 °C) and high temperature (optimum in 395 °C). The melting temperature range of the obtained waxes (95–105 °C) and their FTIR spectral characteristics indicate the potential application of these materials in the plastics and rubber industries. The integrated management of all material streams generated in the glass recycling process allowed for the development of a CE model for the glass recycling plant. Full article

Cellulose aerogel is a promising thermal insulation material with terrific thermal insulation and environmental friendliness. However, the intrinsic flammability of polysaccharide molecules and dependence on freeze-drying have limited its application in flame-retardant and thermal management systems. Here, we develop a flame-retardant biomass aerogel based on a dual-network matrix of bacterial cellulose and sodium alginate. This innovative material enables high-efficiency and low-cost preparation via ambient pressure drying technology (only ~3.5% volume shrinkage), while achieving flame retardancy by introducing an inorganic nanosheet microstructure within a polymer matrix. The resulting dual-network flame-retardant cellulose aerogel demonstrates thermal performance superior to that of most polymer foams and conventional cellulose aerogels, featuring an ultra-low thermal conductivity of ~0.04 W m⁻¹ K⁻¹ and a high limiting oxygen index (LOI) of ~69%. This research provides a novel strategy for simultaneous flame-retardant modification and energy-efficient manufacturing of biomass-derived aerogels. Full article

With increasing natural gas processing demands, triethylene glycol (TEG) in dehydration systems becomes contaminated by gas-carried impurities, leading to problematic foaming, degradation, and significant glycol losses that compromise operational economics, pipeline integrity, and product quality. To systematically investigate impurity effects, we conducted comprehensive single-factor TEG regeneration experiments simulating field conditions. Through precise measurements of foaming height, defoaming time, and interfacial tension, we established clear correlations between impurity types and TEG foaming characteristics. Our results demonstrate a distinct hierarchy of foaming influence: chemical additives > solid impurities > water-soluble inorganic salts > MDEA > hydrogen sulfide > hydrocarbons. Chemical additives showed the most pronounced effect on surface tension, reducing it to 31.1 mN/m at 1500 mg/L. Water-soluble inorganic salts affected foaming through combined decomposition and crystalline morphology effects, ranked as MgCl₂ > NaHCO₃ > KCl > NaCl > Na₂SO₄ > CaCl₂ (MgCl₂ achieving 33.8 mN/m at 2000 mg/L). Solid impurity impacts correlated strongly with particle morphology (CaCO₃ > Fe₂O₃ > CaSO₄ > ZnO > CuO > Al₂O₃ > FeS), stabilizing at 1.5 mg/L. Hydrocarbons showed negligible influence, while hydrogen sulfide and MDEA caused only minor surface tension reductions with limited foaming effects. Based on these findings, we propose targeted mitigation strategies for industrial implementation. Full article

In recent years, the increasing frequency of building fires has highlighted the limitations of traditional polymeric materials due to their inadequate fireproof performance. Ceramifiable polymer composites have emerged as a promising alternative by incorporating ceramic-forming fillers that create rigid ceramic-like structures through high-temperature eutectic reactions, offering exceptional thermal insulation and fireproof properties. These composites maintain structural integrity under fire exposure through sufficient mechanical strength retention. The effects of several ceramifiable inorganic fillers (CIFs) on the properties of polydimethylsiloxane (PDMS) foams were systematically investigated in this study. The research demonstrated that fillers with better matrix compatibility significantly enhance the foaming quality, mechanical performance, and fireproof capabilities. Notably, the CaCO₃-filled PDMS foam composite (CPF-Ca) demonstrates exceptional foaming characteristics with 84% porosity and a remarkably low density of 0.36 g/cm³. The material achieves tensile and compressive strengths of 0.22 MPa and 0.84 MPa, representing 22% and 127% enhancements, respectively, compared to pure PDMS foam (PPF). Regarding the ceramic conversion capability, the sintered residue of CPF-Ca maintains a compressive strength of 4.39 MPa under high-temperature conditions. This composite material exhibited superior fireproof performance, successfully withstanding a butane torch for 300 s without penetration while maintaining a remarkably low backside temperature of merely 83.6 °C. Full article

In sustainable construction and packaging, the development of novel bio-based materials is crucial, driving a re-evaluation of traditional components. Lightweight, biodegradable materials, including xerogels, have great potential in architectural and packaging applications. However, reinforcing these materials to improve their mechanical strength remains a challenge. Alginate is a promising matrix material that may be compatible with inorganic fibrous or particulate materials. In this study, biocomposite xerogel-structured foam materials based on an alginate matrix with expanded perlite reinforcement are improved using certain additives in different weight ratios. The plasticizers used include glycerol and gum arabic, while chitosan was added as an additional reinforcement, and iota carrageenan was added as a stabilizer. The tested specimens, with varying weight ratios of the added components, showed good mechanical behavior that highlights their potential use as packaging and/or architectural materials. The influence of the presence of different components in the composite material specimens on the modulus of elasticity was investigated using SEM images and FTIR analyses of the specimens. The results show that the specimen with the largest improvement in the elastic modulus contained a combination of chitosan and glycerol at a lower percentage (1.96 MPa), and the specimen with the largest improvement in tensile strength was the specimen containing chitosan with no plasticizers (120 kPa), compared to cases where combinations of other materials are present. Full article

Bubble coalescence plays a critical role in optimizing biological and industrial processes, impacting efficiency in areas such as fermentation, wastewater treatment, and foaming control. While the relationship between chemical structure and bubble coalescence has been thoroughly explored for inorganic ions, limited data exist on organic ions and surfactants, despite their widespread use in these industries. This study addresses this gap by investigating the effects of surfactant hydrophobicity and bubble size on coalescence behavior at a flat air–liquid interface and within a bubble column. Surface tension measurements were employed to assess surfactant hydrophobicity, while bubble size and coalescence time were analyzed to determine their respective influences. The results reveal a novel quantitative relationship between surfactant hydrophobicity and the half-coalescence inhibition concentration (HCIC), a new variable introduced in this study. This relationship demonstrates that as hydrophobicity increases, the HCIC also rises, providing a new relationship between surfactant hydrophobicity and bubble coalescence. While it is well-known that more hydrophobic molecules delay coalescence, this is the first time a direct, proportional relationship has been established with HCIC, offering a new parameter for predicting and controlling coalescence phenomena. Full article

Can the foamability of surfactant aqueous solutions be controlled chemically? Well-known antifoams can prevent foaming by inducing the coalescence of the bubbles, but can the surfactants be deactivated chemically? If yes, how does this affect the surface tension of their aqueous solutions and their foaming capacity? To shed a light on these fundamental questions, we chose a well-known surfactant containing in its molecule a sulfate group (Sodium dodecyl sulfate, SDS) and mixed it with BaCl₂, (the solubility of BaSO₄ is 0.245 mg/100 mL water, T = 20 °C), Pb(NO₃)₂ (the solubility of PbSO₄ is 40.4 mg/100 mL water, T = 25 °C) and FeCl₃ (the solubility of Fe₂(SO₄)₃ is 25.6 g/100 mL water, T = 20 °C) at different molar ratios (MX_n/SDS): 1/2, 1/1, 2/1, 4/1. The results were surprising: in the case of BaCl₂, despite being in stoichiometric molar ratio with SDS (BaCl₂ + 2SDS -> Ba(DS)₂ + 2 NaCl), or in excess of BaCl₂, which should convert the whole amount of SDS into a sediment, the surface tension value remained significantly lower than that of the single surfactant. At the same time, foamability was either low or absent. It therefore appears that all of the surfactants should be converted into a sediment with very small solubility, but the low surface tension indicates the opposite. The lack of foamability indicated the opposite of that opposite. With Pb(NO₃)₂ and FeCl₃, the results are even stranger. The surface tension values are substantially smaller than those of the single surfactants, and at the same time, low foamability or lack of foamability was observed. It appears that the surfactant exists and at the same time does not exist in the aqueous solution. Where is the truth? Future studies will shed a light. Full article

The sol–gel process is a green method used in the last few decades to synthesize new organic–inorganic phosphorus-containing hybrid materials. The sol–gel synthesis is a green method because it takes place in mild conditions, mostly by using water or alcohol as solvents, at room temperature. Therefore, the sol–gel method is, among others, a promising route for obtaining metal-phosphonate networks. In addition to phosphorus, the obtained hybrid materials could also contain titanium, zirconium, boron, and other elements, which influence their properties. The sol–gel process has two steps: first, the sol formation, and second, the transition to the gel phase. In other words, the sol–gel process converts the precursors into a colloidal solution (sol), followed by obtaining a network (gel). By using the sol–gel method, different organic moieties could be introduced into an inorganic matrix, resulting in organic–inorganic hybrid structures (sometimes they are also referred as organic–inorganic copolymers). Full article

The purpose of this study was to analyze the effects of phase-change components on the properties of geopolymer foams. Geopolymer foams are lightweight foamed geopolymers that are characterized by a high degree of porosity. Phase change materials, on the other hand, are compounds that, when added to a material, allow it to absorb, store, and then release large amounts of energy. Three types of PCMs, i.e., MikroCaps, GR42, and PX25, were introduced at 15% by weight. Geopolymer materials were produced based on silica fly ash, and hydrogen peroxide H₂O₂ was used to foam the geopolymer structure. The PCM geopolymer composites were cured at 60 °C. The produced materials were tested for physical, chemical, and thermal properties. The tests included oxide and mineral composition analysis of the base material, PCM particle size analysis, apparent density and porosity tests on the foams, water leachability tests, thermal tests (λ, Cv, Cp, α), and structural and textural analysis. The most relevant tests to confirm the performance of the phase-change materials were thermal tests. With the introduction of PCMs, volumetric heat capacity increased by as much as 41% and specific heat by 45%, and thermal diffusivity decreased by 23%. The results confirm the great potential of geopolymer composites as modern insulation materials for buildings and structures. Full article

This study investigates the effects of inorganic flame retardants, zinc borate, and magnesium hydroxide, on the thermal, morphological, flame retardancy, and mechanical properties of polypropylene (PP)/calcium carbonate composites for potential construction industry applications. Polypropylene/calcium carbonate (50 wt.%) composites containing 5 and 10 wt.% flame retardants were prepared using a batch mixer, followed by compression moulding. The results demonstrated enhanced thermal stability, with the highest char residue reaching 47.2% for polypropylene/calcium carbonate/zinc borate (10 wt.%)/magnesium hydroxide (10 wt.%) composite, a notably strong outcome. Additionally, the composite exhibited an elevated limited oxygen index (LOI) of 29.4%, indicating a synergistic effect between zinc borate and magnesium hydroxide. The proposed flame retardancy mechanism suggests that the flammability performance is driven by the interaction between the flame retardants within the polypropylene/calcium carbonate matrix. Magnesium hydroxide contributes to smoke suppression by releasing water, while zinc borate forms a protective glassy foam that covers the burning surface, promoting char formation and acting as a physical barrier to heat transmission and fire spread. Scanning electron microscopy confirmed good dispersion of the additives alongside calcium carbonate within the polymer matrix. Despite the addition of up to 10 wt.% flame retardants, the composites maintained high-notched impact strength. Full article