The Effect of Rubber-Metal Interactions on the Mechanical, Magneto-Mechanical, and Electrical Properties of Iron, Aluminum, and Hybrid Filler-Based Styrene-Butadiene Rubber Composites.

Multifunctional stretchable rubber composites are gaining attention due to their unique electrical, mechanical, and magnetic properties. However, their high production costs pose economic challenges. This study explores the use of cost-effective metal powders-iron, aluminum, and their 1:1 (vol/vol) hybrid filler-in styrene-butadiene rubber composites, varying from 10 to 20 vol%. The effects of these metal particles on the mechanical, electrical, morphological, and swelling properties were investigated. Metal particles generally act as non-reinforcing fillers but can significantly enhance the mechanical modulus, electrical, and magnetic properties based on the filler structure and the filler-rubber interactions. Iron-based composites exhibit significant electrical conductivity and excellent magnetic properties. Aluminum enhances the modulus, while the combination yields average mechanical properties with added magnetic characteristics. Iron demonstrates higher reactivity with sulfur-based crosslinking ingredients, adversely affecting the rubber matrix's crosslinks, as shown by swelling tests. This reactivity is attributed to iron's transition metal characteristics. At 20 vol%, iron-filled composites display the highest magnetic anisotropic effect on toughness (~25%) under a magnetic field by permanent magnets and excellent electrical conductivity (1.5 × 10-2 S/m). While iron significantly boosts the electrical and magnetic properties, higher filler amounts degrade the mechanical properties. These composites are currently suitable for electrical and smart mechanical applications, but incorporating reinforcing fillers could enhance their robustness for broader applications.

Enhancing Rubber Vulcanization Cure Kinetics: Lowering Vulcanization Temperature by Addition of MgO as Co-Cure Activator in ZnO-Based Cure Activator Systems.

Vulcanization is a chemical modification of rubber that requires a considerable amount of thermal energy. To save thermal energy, the kinetics of rubber vulcanization should be improved. In this article, the curing properties of rubber vulcanization are thoroughly investigated using the moving die rheometer (MDR) technique. To enhance the kinetics in different stages of ZnO-based sulfur vulcanization systems, small amounts of MgO were added. The results revealed that the small amount of 1 to 2 phr (per hundred grams of rubber) of MgO in the controlled 5 phr ZnO-based curing systems can significantly improve the curing kinetics. For example, the optimum curing time of 1 phr MgO added to the 5 phr ZnO-containing semi-efficient vulcanization system at different temperatures was more than half that of the controlled 5 phr ZnO-only compound. While maintaining a similar rate of vulcanization, the vulcanization temperature can be reduced by up to 20 °C by using MgO as a co-cure activator, which exhibits similar or better rheometric mechanical properties compared to the controlled compounds. With the addition of MgO as a co-cure activator, the vulcanization reactions become very fast, enabling vulcanization to be completed, even at the boiling point of water (100 °C) with an affordable curing time (<1 h). By reducing the vulcanization temperature, the scorch safety time can be enhanced in the ZnO/MgO-based binary cure activator-containing vulcanizates. Overall, MgO could be a potential candidate as a co-cure activator with ZnO for the vulcanization of rubber, offering better economical and eco-friendly methods.