Platelet-reinforced polymer matrix composites by combined gel-casting and hot-pressing. Part II: Thermoplastic polyurethane matrix composites

Abstract A combined gel-casting and hot-pressing method was used to fabricate platelet-reinforced polymer matrix composites. Submicrometer thin alumina platelets were dispersed in a highly diluted polymer solution. A thermoplastic polyurethane elastomer was used as matrix for its high elasticity and excellent adhesion to the platelets. After dissolution of the polymer and casting, quick evaporation of the solvent triggered the formation of a polymer gel trapping the platelets in their well dispersed positions. The polymer–platelet gel densified during drying and the platelets were oriented horizontally due to the capillary forces and the large decrease in the thickness of the gel. The dried composites were hot-pressed to further improve the platelet orientation along the shear flow and close potential pores in the polymer. While the ultimate tensile strength of the composites gradually decreased with increasing platelet volume fractions, the increase in the elastic modulus and the stress necessary to deform the composite 10% was more than 100 and 18 times higher than the respective values of the pure polymer. The use of alumina platelets with an aspect ratio below the critical value allowed for the ductile platelet pull-out fracture mode. Since the polymer had to deform more to achieve identical deformation of the composite at higher platelet volume fraction, the strain at rupture steadily decreased. The incorporation of voids towards high platelet concentrations and the thereby triggered crack initiation and growth during straining lead to an additional decrease in the elasticity of composites with increasing platelet volume fractions. However, the extremely high extensibility of a polymer matrix allowed for the fabrication of composites that still deformed up to 162 ± 19% at platelet volume fractions as high as 0.33. When compared to other platelet-reinforced elastomers, the achieved platelet volume fraction is much higher and the relative increase in elastic modulus and stress at low strains is therefore much larger at the expense of a decrease in the strain at rupture. The fabrication method and designing principles employed in this study are transferable to other types of polymers and platelets and potentially allow the creation of new composites with tailored properties.