This document discusses novel applications of nano-composites and multiscale composites through five case studies. It summarizes the nanostructuring of Kevlar fibers through surface chemical modification for better composite properties. It also discusses multiscale dental composites and novel nano-steel and nano cast iron containing carbon nano phases. Additionally, it outlines glass fabric/epoxy composites containing carbon nanotubes for electronic and structural applications. Finally, the synthesis of a bio-resin nano-composite containing nano-silica and carbon black for electronics is described.

1. 11
Novel Applications of Nano-
composites and Multiscale Composites
Through Case Studies
Dr. K. PadmanabhanDr. K. Padmanabhan
Asst. Director and ProfessorAsst. Director and Professor
School of Mechanical EngineeringSchool of Mechanical Engineering
VIT-University, Vellore-632014VIT-University, Vellore-632014
Email: padmanabhan.k@vit.ac.inEmail: padmanabhan.k@vit.ac.in

2. 22
HistoryHistory

3. 33
Indus Valley and NaturalIndus Valley and Natural
CompositesComposites
Mud Composite Figurines and Sun Baked Mud Composite
Bricks Were Produced by The Indus Valley People from
5000 BC
It was not the Egyptians first- A myth !

4. 44
Kajal or Mai- the home madeKajal or Mai- the home made
nanocarbon from castor oil !nanocarbon from castor oil !
Nanocarbon structures are present in the soot !

5. 55
Nanotechnology of Delhi Iron PillarNanotechnology of Delhi Iron Pillar
The external rust layer on the
fracture surface of the pillar iron
was heavily cracked. The flowery
needle-like nano rust can also be
seen in the upper right portion of
the figure.
Microstructure of the pillar iron
showing the presence of a
larger fraction of miniscule
pearlite near some slag
particles.
-Prof. R Balasubramaniam, IITK

6. 66
Samurai SwordSamurai Sword
Microstructure showing nanocarbon
and nanoparticles in the sword.

7. 77
Sword of DamascusSword of Damascus
The sword of Damascus that can slice
through falling silk and cut stones
with out dulling contains carbon
nanotubes and nanophases

8. Novel Applications of Nano-
composites and Multiscale
Composites Through Case
Studies
88

9. 99
Abstract
Nanocomposites and multiscale composites find wide
applications in structures, electronics, biomedical fields,
automobiles and aviation. This invited lecture illustrates
some of these applications through five case studies that the
investigator has carried out.
1. Nanostructuring of Kevlar fibres through chemical
modification of the surface for better interfacial properties
with epoxy matrices in composite applications.

10. 1010
2. Multiscale composites for manufacturing
restoratives for dental applications.
3. Novel fabrication methods and uses of nano-steel
and nano cast iron containing nano phases of carbon.
4. Novel applications of a glass fabric /epoxy
composite containing a centroidal layer of multiwalled
carbon nanotubes, in electronic circuit boards,
packaging, cladding and structural applications .

11. 1111
5. The synthesis and characterization of a bio-resin
based nano-composite containing nano-silica and
carbon black is vividly described. Here, the Cashew
Nut Shell Oil (CNSL) is converted in to a usable plastic
matrix with which a nano-composite is synthesized
and characterized for applications in electronic
packaging.
The lecture concludes by summing up some novel
applications of nano-composites and multi-scale
composites

12. 1212
1. Nano Structuring of Kevlar1. Nano Structuring of Kevlar

13. 0.51 nm
Schematic diagram of Kevlar® 49 fiber
showing the radially arranged
pleated sheets
Microstructure of aramid fiber
Kevlar fibers

14. Kevlar-49 Structure

15. 1515
Kevlar Fibre Nano StructuringKevlar Fibre Nano Structuring

16. 1616
Kevlar Fibre Nano StructuringKevlar Fibre Nano Structuring
10 Min Methanol
And water Washing

17. 1717
XPS of Treated KevlarXPS of Treated Kevlar
SurfacesSurfaces

18. 1818
SEM of Treated Kevlar SurfacesSEM of Treated Kevlar Surfaces

19. 1919
Multiple Fibre Pullout TestsMultiple Fibre Pullout Tests
Ref: K. Padmanabhan , Composites B, 30(1999) p205 ( Citation
ssic )
Ref: K. Padmanabhan , Toyobo Confidentiality Report, 2002

20. 2020
Kevlar Fibre/ Epoxy CompositesKevlar Fibre/ Epoxy Composites
- Interfacial Results- Interfacial Results

21. 2121
2. Multiscale Composites in2. Multiscale Composites in
DentistryDentistry

22. 2222
Composites in DentistryComposites in Dentistry
Acrylics, Acrylic esters, Bis-
GMA, PMMA derivatives,
Ceramic filled composites
Can you make out the
difference ?
Ref: K. Padmanabhan , Comment on 'standards on restoratives'
2009 , Volume : 20 , Issue : 4 , Page : 516, 1000 + downloads

23. 2323
Composites in ProsthodonticsComposites in Prosthodontics
Tooth is a functionally graded
composite material with enamel
and dentin. In the third maxillary
molar the occlusal stress can
be 2-3 MPa.
The masticatory heavy chewing
stress will be around 193 MPa.
A composite restorative must with
stand this with an FOS and with
constant hygrothermal attack.

24. 2424
Multi Scale Composites forMulti Scale Composites for
DentistryDentistry
 Bis GMA, UDMA, Methacrylic Esters containBis GMA, UDMA, Methacrylic Esters contain
glassy particles that are mostly less than 1glassy particles that are mostly less than 1
micron in sizemicron in size
 Esters and acrylates/ceramic filler (bariumEsters and acrylates/ceramic filler (barium
alumina silica glass, glassy microfillers, 0.1 toalumina silica glass, glassy microfillers, 0.1 to
10 microns size) restorative composites.10 microns size) restorative composites.
 Multi scale composites are also useful asMulti scale composites are also useful as
luting cements, crown and bridge materialsluting cements, crown and bridge materials
and cements and veneer materialsand cements and veneer materials..

25. 2525
Wear Data for RestorativesWear Data for Restoratives
 Aesthetics, Shade, ReliabilityAesthetics, Shade, Reliability
 Most of the composites show a logarithmic wearMost of the composites show a logarithmic wear
rate, linear wear rate is unwelcome !rate, linear wear rate is unwelcome !
 Wear of less than 200 microns in 10 years isWear of less than 200 microns in 10 years is
acceptable.acceptable.
 Wear volume will be 0.5 to 0.8 cu. mm perWear volume will be 0.5 to 0.8 cu. mm per
annum, enamelannum, enamel vsvs restoratives.restoratives.
 Coeff of Friction is ~ 0.1 to 0.35.Coeff of Friction is ~ 0.1 to 0.35.

26. Hygrothermal BehaviourHygrothermal Behaviour
Fibre reinforced plastics are known forFibre reinforced plastics are known for
environmental attacks that reduce their function.environmental attacks that reduce their function.
Mechanical properties degrade over time !Mechanical properties degrade over time !
Moisture plays havoc at elevated temperatures,Moisture plays havoc at elevated temperatures,
in the presence of voids, defects and in low Tin the presence of voids, defects and in low Tgg
plastics .plastics .
Diffusion and osmotic pressure are the drivingDiffusion and osmotic pressure are the driving
mechanisms for hygrothermal attackmechanisms for hygrothermal attack
Evaluation methods and surface preservationEvaluation methods and surface preservation
Important in marine, biomedical, aeronautical,Important in marine, biomedical, aeronautical,
electronic and automobile applicationselectronic and automobile applications

27. 27
Variation of strength with temperature
Glass Transition Temperature

28. ASTM STP D 5229 M RuleASTM STP D 5229 M Rule
The MOT( Maximum Operating Temperature)The MOT( Maximum Operating Temperature)
of the material, device/component should beof the material, device/component should be
at leastat least 25 º Celsius lower than the lowest Tg
(normally wet) of the material attained after
hygrothermal equillibration. All the polymeric. All the polymeric
materials and their composites must satisfymaterials and their composites must satisfy
this rule in order to qualify for certification forthis rule in order to qualify for certification for
reliability and durability.reliability and durability.

29. The need to revise standardsThe need to revise standards
2929
K. Padmanbhan,

30. 3030
Nano Cast Iron and Nano SteelNano Cast Iron and Nano Steel

31. 3131
Iron-iron carbide phase diagramIron-iron carbide phase diagram

32. 3232
AFM of MWCNTAFM of MWCNT
K. Padmanabhan & Sai Sirisha, Procedia Engineering , 97 ( 2014 ) 1422 – 1433.

33. 3333
XRD of As Cast Nano Cast IronXRD of As Cast Nano Cast Iron

34. XRD DiscussionXRD Discussion
3434
Figure reveals that the 1.57116, 2.27751 and the 2.89858 d spacing
MWCNT peaks were seen in the as cast nano cast iron. However, a
very minor shift was also recorded in these peaks which could be
attributed to the copper coating on the MWCNTs prior to stir casting
and the mild solubility of the same in cast iron. It is clear from the x-
ray of the as cast nano iron that the MWCNT d spacing peaks appear at
1.58433, 2.26832 and 2.87563 values among the other peaks that are
typically representative of a grey cast iron. The 2.26832 peak is
common to both the Quantum MWCNT and a conventional unfilled
grey cast iron as it is most likely that it is Fe5C2 phase which is
present as an impurity in both.

35. 3535
XRD of Heat Treated NCCIXRD of Heat Treated NCCI

36. XRD DiscussionXRD Discussion
3636
Small amounts of impurities present seem to dissolve in the NCCI due to
heat treating thereby suppressing the impurity peaks. However, the two
α-ferrite peaks at a 2θ value of 44.981 º and 65 º in Figure show that
the phase evolved is a (110) ferrite . Heat treatment at 550 º C appears to
improve , solid solubility. Copper found in trace amounts ( because of
coating the MWCNT) naturally leads to better corrosion resistance and
strength in the NCCI in addition to protecting the MWCNT in the as cast
NCCI. However, solid solubility of copper and MWCNT in the NCCI
appear to take place as a result of heat treatment which is evident from
Figure . This ferritizing anneal reduces the hardness of the NCCI as seen
later.

37. 3737
Micrograph of NCCIMicrograph of NCCI

38. 3838
Micrograph of HTNCCIMicrograph of HTNCCI

39. MWCNT/ Glass Fabric /EpoxyMWCNT/ Glass Fabric /Epoxy
Multiscale CompositesMultiscale Composites
3939

40. 40
Glass/ Epoxy MWCNT
Multiscale Composites
These sandwich structures find wide applications in
electronic packaging, thermal insulation, structural members
and products with cladding.

41. Specimen and Testing
AA Ravindra, Razim Refai, Aman Nigam, Siddarth Kumar, Padmanabhan. K, Procedia
Engineering 97 ( 2014 ) 449 – 458, About 200 downloads !

42. Parameters for Evaluation
• ILSS- Interlaminar Shear Strength
• Mode II Strain Energy Release Rate
• Russell’s Theory
• Direct Beam Theory
42

43. Micrographs of
Fracture
43

44. 4444
Nano Bio Composites inNano Bio Composites in
Microsystems andMicrosystems and
Nanosystems PackagingNanosystems Packaging

45. 4545
Microsystems and NanosystemsMicrosystems and Nanosystems
Packaging RoadmapPackaging Roadmap

46. 4646
AnalysisAnalysis
 Electric-Thermal AnalysisElectric-Thermal Analysis
 Thermal – Structural AnalysisThermal – Structural Analysis
– Materials usedMaterials used
 Lead Frame and LeadsLead Frame and Leads - Copper- Copper
 Wire bondingWire bonding - Gold- Gold
 DieDie - Silicon- Silicon
 Adhesive for lead frameAdhesive for lead frame
and dieand die - Silver Epoxy- Silver Epoxy
 EncapsulationEncapsulation - Carbon black and fused silica- Carbon black and fused silica
particles filled epoxy andparticles filled epoxy and
phenolic resin –a multiscalephenolic resin –a multiscale
composite !composite !
K. Padmanabhan, D. Sanjay and S. Subeesh, International Jl. of Micro
and Nano Electronics , Circuits and Systems, 1(2), 2009, pp 67-76

47. 47
FUNCTIONS OF PACKAGES
1. Shut out environmental
influences
2. Enable electrical connectivity
3. Dissipate heat
4. Improve handling
& assembly

48. Applications of IC
Packages
• Mobile Phones
• PDA s
• Automotive Electronics
• Digital Cameras and Camcorders
• TVs and Monitors
• Signal Transmission and
Reception ICs
• Aviation, Marine and
Biotechnology 48

49. 49
Electric and Thermal Results
Electric plot Temperature distribution
Ref: K. Padmanbhan, A multiphysics based finite element approach to evaluate
the reliability of IC packages, Book chapter in IGI Global Handbook, USA, 2016.

50. 12/11/15 50
Cashew Nut Shell Oil as
Composite Matrix Material
• Cashew nut shell
oil can be
polymerized using
acids, toluene as
inhibitor and
formaldehyde at
120 celsius.
• A tough and strong
maroon coloured
matrix !

51. 12/11/15 51
Composition of CNSL

52. 12/11/15 52
CNSL Matrix Material
Hygrothermally Very Stable and Termite Resistant

53. 53
• Dielectric Constant
• Coefficient of Thermal expansion
• Thermal conductivity
• Specific Heat Capacity
• Vibration tests

54. 1) Carbon Black powder under an SEM VS Nanosilica powder
under SEM
2) EDS of carbon black powder VS EDS of nanosilica powder
3) Formaldehyde phenol curedCNSL and the nanocomposite
4) Microstructure of Nanocomposite
5) EDS of nanocomposite
6) DSC/TGA plot of CNSL resin VS DSC/TGA plot of
nanocomposite
7) The Dielectric Permittivity

55. 12/11/15 55
CNSL COMPOSITES
AND THEIR DYNAMIC APPLICATIONS
CNSL MATRIX/ GLASS FABRIC LAMINATE. FRF and FFT of CNSL a Composite

56. 5656
Cosmic CreationCosmic Creation
The most elegant and
sublime of creation is a
representation of the
creation of the universe
at the beginning of each
cosmic cycle, a motif
known as the cosmic
dance of Lord Shiva. In
the upper right hand is
a drum whose sound is
the sound of creation -
Thank You All