An open carbon-phenolic ablator for scientific exploration.

Space exploration missions rely on ablative heat shields for the thermal protection of spacecraft during atmospheric entry flights. While dedicated research is needed for future missions, the scientific community has limited access to ablative materials typically used in aerospace. In this paper, we report the development of the HEFDiG Ablation-Research Laboratory Experiment Material (HARLEM), a carbon-phenolic ablator designed to supply the need for ablative materials in laboratory experiments. HARLEM is manufactured using polyacrylonitrile-based carbon fiber preforms and a simplified processing route for phenolic impregnation. We characterized the thermal protection performance of HARLEM in arcjet experiments conducted in the plasma wind tunnel PWK1 of the Institute of Space Systems at the University of Stuttgart. We assessed the performance of the new material by measuring surface recession rate and temperature using photogrammetry and thermography setups during the experiments, respectively. Our results show that HARLEM's thermal protection performance is comparable to legacy carbon-phenolic ablators that have been validated in different arcjet facilities or in-flight, as demonstrated by calculations of the effective heat of ablation and scanning electron microscopy of as-produced samples. In-house manufacturing of carbon-phenolic ablators enables the addition of embedded diagnostics to ablators, allowing for the acquisition of data on internal pressure and more sophisticated pyrolysis analysis techniques.

Nacre-like composites with superior specific damping performance.

Biological materials such as nacre have evolved microstructural design principles that result in outstanding mechanical properties. While nacre's design concepts have led to bio-inspired materials with enhanced fracture toughness, the microstructural features underlying the remarkable damping properties of this biological material have not yet been fully explored in synthetic composites. Here, we study the damping behavior of nacre-like composites containing mineral bridges and platelet asperities as nanoscale structural features within its brick-and-mortar architecture. Dynamic mechanical analysis was performed to experimentally elucidate the role of these features on the damping response of the nacre-like composites. By enhancing stress transfer between platelets and at the brick/mortar interface, mineral bridges and nano-asperities were found to improve the damping performance of the composite to levels that surpass many biological and man-made materials. Surprisingly, the improved properties are achieved without reaching the perfect organization of the biological counterparts. Our nacre-like composites display a loss modulus 2.4-fold higher than natural nacre and 1.4-fold more than highly dissipative natural fiber composites. These findings shed light on the role of nanoscale structural features on the dynamic mechanical properties of nacre and offer design concepts for the manufacturing of bio-inspired composites for high-performance damping applications.

Three-dimensional printing of photonic colloidal glasses into objects with isotropic structural color.

Structural color is frequently exploited by living organisms for biological functions and has also been translated into synthetic materials as a more durable and less hazardous alternative to conventional pigments. Additive manufacturing approaches were recently exploited for the fabrication of exquisite photonic objects, but the angle-dependence observed limits a broader application of structural color in synthetic systems. Here, we propose a manufacturing platform for the 3D printing of complex-shaped objects that display isotropic structural color generated from photonic colloidal glasses. Structurally colored objects are printed from aqueous colloidal inks containing monodisperse silica particles, carbon black, and a gel-forming copolymer. Rheology and Small-Angle-X-Ray-Scattering measurements are performed to identify the processing conditions leading to printed objects with tunable structural colors. Multimaterial printing is eventually used to create complex-shaped objects with multiple structural colors using silica and carbon as abundant and sustainable building blocks.

Sustainable wood electronics by iron-catalyzed laser-induced graphitization for large-scale applications.

Ecologically friendly wood electronics will help alleviating the shortcomings of state-of-art cellulose-based "green electronics". Here we introduce iron-catalyzed laser-induced graphitization (IC-LIG) as an innovative approach for engraving large-scale electrically conductive structures on wood with very high quality and efficiency, overcoming the limitations of conventional LIG including high ablation, thermal damages, need for multiple lasing steps, use of fire retardants and inert atmospheres. An aqueous bio-based coating, inspired by historical iron-gall ink, protects wood from laser ablation and thermal damage while promoting efficient graphitization and smoothening substrate irregularities. Large-scale (100 cm2), highly conductive (≥2500 S m-1) and homogeneous surface areas are engraved single-step in ambient atmosphere with a conventional CO2 laser, even on very thin (∼450 µm) wood veneers. We demonstrate the validity of our approach by turning wood into highly durable strain sensors, flexible electrodes, capacitive touch panels and an electroluminescent LIG-based device.

Stretchable Soft Composites with Strain-Induced Architectured Color.

Colors enable interaction and communication between living species in a myriad of biological and artificial environments. While living organisms feature low-power mechanisms to dynamically control color in soft tissues, man-made color-changing devices remain predominantly rigid and energy intensive. Here, architectured composites that display striking color changes when stretched in selective directions under ambient light with minimum power input are reported. The orientation-dependent color change results from the rotation of reflective coated platelets that are embedded in a soft polymer matrix and pre-aligned in a well-defined architecture. The light reflected by the platelets generates structural color defined by the oxide coating on the platelet surface. By magnetically programming the initial orientation and spatial distribution of selected platelets within the soft matrix, composites with strain-modulated color-changing effects that cannot be achieved using state-of-the-art technologies are created. The proposed concept of strain-induced architectured color can be harnessed to develop low-power smart stretchable displays, tactile synthetic skins, and autonomous soft robotic devices that undergo fast and reversible color changes through the mechano-optic coupling programmed within their soft composite architecture.

Magnetic Manipulation of Nanowires for Engineered Stretchable Electronics.

Nanowires are often key ingredients of high-tech composite materials. The properties and performance of devices created using these, depend heavily on the structure and density of the embedded nanowires. Despite significant efforts, a process that can be adapted to different materials, compatible with current nanowire deposition methods, and that is able to control both variables simultaneously has not been achieved yet. In this work, we show that we can use low magnetic fields (80 mT) to manipulate nanowires by electrostatically coating them with superparamagnetic iron oxide nanoparticles in an aqueous solution. Monolayers, multilayers, and hierarchical structures of oriented nanowires were achieved in a highly ordered manner using vacuum filtration for two types of nanowires: silver and gold-coated titanium dioxide nanowires. The produced films were embedded in an elastomer, and the strain-dependent electrical properties of the resulting composites were investigated. The orientation of the assembly with respect to the tensile strain heavily impacts the performance of the composites. Composites containing nanowires perpendicular to the strain direction exhibit an extremely low gauge factor. On the other hand, when nanowires are arranged parallel to the strain direction, the composites have a high gauge factor. The possibility to orient nanowires during the processing steps is not only interesting for the shown strain sensing application but also expected to be useful in many other areas of material science.

Photonic response and temperature evolution of SiO2/TiO2 multilayers.

The microstructural and optical reflectivity response of photonic SiO2/TiO2 nanomultilayers have been investigated as a function of temperature and up to the material system's melting point. The nanomultilayers exhibit high, broadband reflectivities up to 1350 °C with values that exceed 75% for a 1 µm broad wavelength range (600-1600 nm). The optimized nanometer sized, dielectric multilayers undergo phase transformations from anatase TiO2 and amorphous SiO2 to the thermodynamically stable phases, rutile and cristobalite, respectively, that alter their structural morphology from the initial multilayers to that of a scatterer. Nonetheless, they retain their photonic characteristics, when characterized on top of selected substrate foils. The thermal behavior of the nanometer sized multilayers has been investigated by differential thermal analysis (DTA) and compared to that of commercially available, mm-sized, annealed powders. The same melting reactions were observed, but the temperatures were lower for the nm-sized samples. The samples were characterized using X-ray powder diffraction before DTA and after annealing at temperatures of 1350 and 1700 °C. The microstructural evolution and phase compositions were investigated by scanning electron microscopy and energy-dispersive X-ray spectroscopy measurements. The limited mutual solubility of one material to another, in combination with the preservation of their optical reflectivity response even after annealing, makes them an interesting material system for high-temperature, photonic coatings, such as photovoltaics, aerospace re-entry and gas turbines, where ultra-high temperatures and intense thermal radiation are present. SUPPLEMENTARY INFORMATION: The online version contains supplementary material available at 10.1007/s10853-021-06557-y.

Programmable droplet manipulation and wetting with soft magnetic carpets.

The ability to regulate interfacial and wetting properties is highly demanded in anti-icing, anti-biofouling, and medical and energy applications. Recent work on liquid-infused systems achieved switching wetting properties, which allow us to turn between slip and pin states. However, patterning the wetting of surfaces in a dynamic fashion still remains a challenge. In this work, we use programmable wetting to activate and propel droplets over large distances. We achieve this with liquid-infused soft magnetic carpets (SMCs) that consist of pillars that are responsive to external magnetic stimuli. Liquid-infused SMCs, which are sticky for a water droplet, become slippery upon application of a magnetic field. Application of a patterned magnetic field results in a patterned wetting on the SMC. A traveling magnetic field wave translates the patterned wetting on the substrate, which allows droplet manipulation. The droplet speed increases with an increased contact angle and with the droplet size, which offers a potential method to sort and separate droplets with respect to their contact angle or size. Furthermore, programmable control of the droplet allows us to conduct reactions by combining droplets loaded with reagents. Such an ability of conducting small-scale reactions on SMCs has the potential to be used for automated analytical testing, diagnostics, and screening, with a potential to reduce the chemical waste.

Amphibious Transport of Fluids and Solids by Soft Magnetic Carpets.

One of the major challenges in modern robotics is controlling micromanipulation by active and adaptive materials. In the respiratory system, such actuation enables pathogen clearance by means of motile cilia. While various types of artificial cilia have been engineered recently, they often involve complex manufacturing protocols and focus on transporting liquids only. Here, soft magnetic carpets are created via an easy self-assembly route based on the Rosensweig instability. These carpets can transport not only liquids but also solid objects that are larger and heavier than the artificial cilia, using a crowd-surfing effect.This amphibious transportation is locally and reconfigurably tunable by simple micromagnets or advanced programmable magnetic fields with a high degree of spatial resolution. Two surprising cargo reversal effects are identified and modeled due to collective ciliary motion and nontrivial elastohydrodynamics. While the active carpets are generally applicable to integrated control systems for transport, mixing, and sorting, these effects can also be exploited for microfluidic viscosimetry and elastometry.

Tough metal-ceramic composites with multifunctional nacre-like architecture.

The brick-and-mortar architecture of biological nacre has inspired the development of synthetic composites with enhanced fracture toughness and multiple functionalities. While the use of metals as the "mortar" phase is an attractive option to maximize fracture toughness of bulk composites, non-mechanical functionalities potentially enabled by the presence of a metal in the structure remain relatively limited and unexplored. Using iron as the mortar phase, we develop and investigate nacre-like composites with high fracture toughness and stiffness combined with unique magnetic, electrical and thermal functionalities. Such metal-ceramic composites are prepared through the sol-gel deposition of iron-based coatings on alumina platelets and the magnetically-driven assembly of the pre-coated platelets into nacre-like architectures, followed by pressure-assisted densification at 1450 °C. With the help of state-of-the-art characterization techniques, we show that this processing route leads to lightweight inorganic structures that display outstanding fracture resistance, show noticeable magnetization and are amenable to fast induction heating. Materials with this set of properties might find use in transport, aerospace and robotic applications that require weight minimization combined with magnetic, electrical or thermal functionalities.

Broadband, High-Temperature Stable Reflector for Aerospace Thermal Radiation Protection.

A simple and thermally stable photonic heterostructure exhibiting high average reflectivity (⟨R⟩ ≈ 88.8%) across a broad wavelength range (920-1450 nm) is presented. The design combines a thin, highly reflective and broadband metallic substrate (Ta) with an optimized dielectric coating (10 layers) to create an enhanced reflector with improved optical and thermal properties compared to its constituents. The heterostructure exhibits temperature-reversible reflective properties up to 1000 °C. In order to take advantage of the high reflectivity and temperature stable properties of this coating, in a wide range of non-photonic composite materials, we have fabricated heterostructure platelets as additives. By impregnating these additives into other types of materials, their response can be photonically enhanced.  Platelets of such a heterostructure have been introduced inside an organic matrix to increase its broadband reflection performance. The platelet-impregnated matrix displays an average reflectivity improvement from 5% to an average of 55% over a 1000 nm range, making it a suitable additive for next generation thermal protection systems (TPS).

Active cargo transport with Janus colloidal shuttles using electric and magnetic fields.

Active colloids show non-equilibrium behavior that departs from classical Brownian motion, thus providing a platform for novel fundamental phenomena and for enticing possible applications ranging from water treatment to medicine and microrobotics. Although the physics, motion mechanisms and guidance have been extensively investigated, active colloids are rarely exploited to simultaneously guide and transport micron-sized objects in a controllable and reversible manner. Here, we use autonomous active Janus particles as colloidal shuttles to controllably transport cargo at the microscale using external electric and magnetic fields. The active motion arises from the metallodielectric characteristics of the Janus particles, which allows them to also trap, transport and release cargo particles through dielectrophoretic interactions induced by an AC electric field. The ferromagnetic nature of the nickel layer that forms the metallic hemisphere of the Janus colloids provides an additional mechanism to direct the motion of the shuttle using an external magnetic field. With this highly programmable colloidal system, we are able to harness active colloid motion and use it to transport cargo particles to specific destinations through a pre-defined route. A simple analytical model is derived to successfully describe the motion of the shuttle-cargo assembly in response to the applied electrical field. The high level of control on cargo pick-up, transport and release leads to a powerful delivery tool, which could eventually be used in microactuators, microfluidics or for controlled delivery within organ-on-a-chip devices.