Advancing composite materials: Exploring thermomechanical properties of Aerosil/polycarbonate composites via additive manufacturing

This study presents a new class of composite materials developed through additive manufacturing, combining ceramic nanofillers with a polymer matrix, polycarbonate (PC). We used Aerosil 300 as a nanometric reinforcement at concentrations of 1 %, 2 %, and 4 % by weight to enhance the mechanical properties of the material. This work is distinguished by an in-depth analysis of the behavior of the composites under extreme thermal conditions, with static compression tests performed on samples at temperatures ranging from −90 °C to 80 °C. The results show that the incorporation of Aerosil 300 significantly improves the elasticity of the composite, particularly at low temperatures, where elasticity reaches its maximum at −90 °C, indicating optimal resilience. At high temperatures (80 °C), a decrease in elasticity is observed, reducing the material's flexibility. The densification modulus also varies with temperature and nanofiller concentration, reaching its maximum at 4 % reinforcement and its minimum without nanofillers. In addition to experimental tests, a numerical modeling was carried out using Digimat software to homogenize the composite and analyze the impact of the nanofillers on the mechanical properties. This approach also provides a better understanding of the distribution of nanofillers, porosity, and potential material defects, thereby offering valuable insights for demanding applications such as aerospace.