Projects

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Preparation, structure and properties of polymer-graphene nanocomposites
Supervisor: B Chen
Brief Description (no more than 200 words):
Polymer nanocomposites are promising materials for a wide variety of applications including aerospace,
automotive, packaging, healthcare and energy sectors because additions of a small amount of nanoparticles
may provide substantial enhancements on the mechanical, thermal and barrier properties of polymer matrices.
Graphene, an atom-thick layer of carbon atoms, has recently been a rising star as a reinforcing filler in
composites, due to its extraordinary physiochemical properties. This project aims to investigate the effects of
graphene on the mechanical, thermal and electrical properties of polymers. It will involve the preparation of
graphene nanosheets, processing of polymer nanocomposites, structural characterisation, and mechanical,
thermal and electrical testing.
Assessor: J Foreman
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Project Title: Tailoring the Natural Toughness in Epoxy Resins
Supervisor: Dr Joel Foreman
This project is suitable for up to 3 students.
Strategies for improving the existing toughness in thermosetting polymers such as epoxy resins include the
addition of rubber particles and dissolved/phase separated thermoplastic polymers. Whilst using these
approaches will increase the toughness it is often difficult to correspondingly maintain the strength and
stiffness of the material. However, high performance epoxy resins invariably have some natural (built-in)
toughness courtesy of the reacted epoxy ring or cooperative rotation of the backbone phenylene rings. This
provides a mechanism to dissipate energy and therefore improves the toughness of the material. As part of a
wider research effort into this phenomenon, this project will investigate the effect of systematically altering
the chemical structure in a model epoxy resin and observing the effect this has on the properties.
The project will involve epoxy resin manufacture (mixing, degassing, casting, cutting and grinding),
characterisation (dynamic mechanical thermal analysis, differential scanning calorimetry and others) and
analysis of the results in terms of the energy disspation mechanisms present due to the chemical structure.
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Project Title: Quantifying plasma etching of polymer blends for organic (plastic) solar cell engineering
Supervisor: C. Rodenburg
Brief Description: :
In this project you will be contributing to the ongoing research in the engineering of organic solar cells. The
latter can potentially manufactured very cheaply and cover large areas such as car roofs etc., due to their
flexibility. However, currently limited lifetime and inconsistent efficiency have prevent this technology to fulfil
its potential. One of the key obstacles is the fast, 3D characterisation of these materials/devices. You will be
contributing to solve this challenge by establishing a method to gain reliable 3D access through serial material
removal using a plasma. You will be involved in the preparation of polymer blends, carry out plasma etching
experiments (adjusting gas, power, time) in conjunction with optical spectroscopy and image processing of
scanning electron microscopy (SEM) data with the goal to determine etch rates and detect/identify any
potential damage caused by the plasma. You results are expected to be used for developing an SEM based
tomography method for fast 3D characterisation of these materials/devices.

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Project Title: Developing New Particulate Reinforced Composites
Supervisor: Dr Joel Foreman
This project is suitable for 1 student.
Polymer composites traditionally fall into two categories depending on the type of reinforcement, fibre or
particulate. In particulate composites, mineral fillers (such as talc or mica) are used to either extend the
polymer (replace volume with cheaper component) or enhance its properties (reinforcement). Gypsum
(calcium sulphate) is a naturally occurring mineral (also produced as a by-product in fossil fuel power stations)
that has many uses including plaster and plasterboard. However, its effectiveness as a filler in particulate

composites is less well understood. It will extend a polymer such as polypropylene, but whether it can enhance
useful properties such as strength or stiffness is essentially unknown. The interface between the gypsum
particles and the polymer is one of several important factors which affect the properties of the composite.
Treatment of the gypsum with a suitable coupling agent is likely to improve this interface. The aim of this
project is to assess how effective gypsum is in enhancing the properties of polypropylene. This will be done by
making gypsum reinforced polypropylene with varying compositions using a twin-screw extruder which will be
formed into a suitable sample geometry using an injection moulder. The samples will be mechanically tested
and the results analysed in terms of the type of gypsum filler, the load level and the coupling agent. This
project is supported by H.J. Enthoven.
Recent work on this project has revealed how effective the gypsum is as a flame retardant in the gypsumpolypropylene composite. This aspect will be investigated next.
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Optical self-sensing in composite materials
Supervisor S A Hayes
This project will extend work in to the development of novel glass reinforcing fibres that can be used as an
optical sensing element for smart materials. So called self-sensing uses the reinforcing fibres to determine the
state of the composite either during manufacture (cure monitoring) or through its life (condition monitoring),
allowing the operator to investigate if problems arise. High refractive index glass, specifically tailored toward
self-sensing using evanescent wave spectroscopy (for cure monitoring and chemical monitoring), and also as
intensity-based sensors (for damage detection), have been developed at the University of Sheffield. In the
project self-sensing composite materials will be produced and tested under varying conditions to determine
the state of the composite, with a view to maximising the dimensions of the panels, while maintaining the
sensitivity of the system. Production of glass fibres for the project will be undertaken, before panels are
produced using vacuum assisted resin transfer moulding. The panels will then be tested using impact and
mechanical testing methods.
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Electrical self-sensing in composite materials
Supervisor S A Hayes
This project will extend work in to the use of carbon reinforcing fibres as electrical sensing elements in smart
materials. So called self-sensing uses the reinforcing fibres to determine the state of the composite either
during manufacture (cure monitoring) or through its life (condition monitoring), allowing the operator to
investigate if problems arise. By monitoring resistance changes in carbon fibre composite materials during
manufacture and service, it is possible to monitor either cure state of the panel or damage occurring within
the panel. Two projects are available, one will examine cure using changes in electrical resistance to indicate
the end of the cure process, while the second will monitor the development of damage within the structure.
Both projects will seek create practical implementations of the sensors than have the potential for commercial
application, while maximising the monitored area without loss of accuracy. They will involve the manufacture
of carbon fibre composites using autoclave and vacuum bagging techniques, followed by testing using
appropriate chemical or mechanical methods.
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Direct electrical cure of carbon fibre composites
Supervisor S A Hayes
The application of electric current to a carbon fibre panel has recently been shown to be capable of curing it,
with properties that match or exceed those specified by the manufacturer. At present, panels cured in this
way are flat and relatively small, measuring 30 cm by 20 cm. This project seeks to increase the panel area,
while maintaining the mechanical properties. It will also investigate the production of more complex parts
such as L-shaped and top-hat stiffeners. One key aspect of the project will be the investigation of
consolidation and void content in panels cured using directly applied electric current, as void content and fibre
volume fraction are critical to the mechanical properties of component. Comparison will be made to
conventionally cured parts, and the electrical approach optimised to maximise the mechanical properties.
Finally, comparison of the energy requirement for conventional cure and direct electrical cure will be
considered to determine the viability of the process as a commercial manufacturing route.