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Novel multifunctional construction materials are needed to promote resilient infrastructure in the face of climate change and extreme weather. Nanostructured materials such as geopolymer reinforced with carbon-based nanomaterials are a promising way to reach that goal. In recent years, several studies have investigated the influence of nanomaterials on the physical properties of geopolymer composites such as compressive strength and fracture toughness. Yet, a fundamental understanding of the influence of nanomaterials on the nanoscale and micron-scale structure has been elusive so far. Our research objective is to understand how multiwalled carbon nanotubes (MWCNT) can help tailor the microstructure of geopolymers to yield architected multifunctional nanocomposites. We synthesized geopolymer nanocomposites reinforced with 50-nm thick multiwalled carbon nanotubes with mass fractions in the range of 0.1 wt%, 0.2 wt%, and 0.5 wt%. Our major finding is that MWCNTs act as hard templates that promote geopolymer formation via self-assembly. Geopolymer nanoparticle growth is observed along the walls of MWCNTs. A refinement in grain size is observed: increasing the fraction of MWCNTs by 0.5 wt% leads to a reduction in grain size by 54%. Similarly, increasing the mass fraction of MWCNTs leads to a densification of the geopolymer matrix as demonstrated by the Fourier transform infrared spectroscopy results and the statistical deconvolution analysis. Mercury intrusion porosimetry shows a nanoscale tailoring of the pore size distribution: a 26% decrease in porosity is observed as the fraction of MWCNTs is increased to 0.5 wt%. As a result of these nanoscale structural changes, a greater resistance to long-term deformation is observed for MWCNT-reinforced geopolymers, as the creep modulus increases both locally and macroscopically. At the macroscopic level, a 42% increase in the macroscopic logarithmic creep modulus is observed as the fraction of MWCNTs is increased to 0.5 wt%. These findings and the supporting methodology are important to understand how to manipulate matter below 100 nm. This research also paves the way for the design of resilient infrastructure materials with tailored microstructure and mechanical properties. 

Fiber-reinforced composites have provided tremendous opportunities in advanced engineering materials, but the fiber generation and spatial distribution are the most challenging aspects. This paper proposes a novel fabrication approach for fiber-reinforced composites with spatially resolved fiber distribution by combining immersion and near-field electrospinning. The new Immersed Electrohydrodynamic Direct-writing (I-EHD) process makes use of an electrostatic force to draw ultrafine fibers and allows the freestanding of electrospun fibers all inside a liquid matrix. This novel approach enables the dynamic control of fiber morphology and 3D spatial distribution inside the composites, which may lead to future scalable 3D printing of multifunctional composites. 

Electrospinning is a versatile approach to generate nanofibers in situ. Yet, recently, wet electrospinning has been introduced as a more efficient way to deposit isolated fibers inside bulk materials. In wet electrospinning, a liquid bath is adopted, instead of a solid collector, for fiber collection. However, despite several studies focused on wet electrospinning to yield polymer composites, few studies have investigated wet electrospinning to yield ceramic composites. In this paper, we propose a novel in-situ fabrication approach for nanofiber-reinforced ceramic composites based on an enhanced wet-electrospinning method. Our method uses electrospinning to draw polymer nanofibers directly into a reactive pre-ceramic gel, which is later activated to yield advanced nanofiber-reinforced ceramic composites. We demonstrate our method by investigating wet electrospun Polyacrylonitrile and Poly(ethylene oxide) fiber-reinforced geopolymer composites, with fiber weight fractions in the range 0.1–1.0 wt%. Wet electrospinning preserves the amorphous structure of geopolymer while changing the molecular arrangement. Wet electrospinning leads to an increase in both the fraction of mesopores and the overall porosity of geopolymer composites. The indentation modulus is in the range 6.76–8.90 GPa and the fracture toughness is in the range 0.49–0.76 MPam with a clear stiffening and toughening effect observed for Poly(ethylene oxide)-reinforced geopolymer composites. This work demonstrates the viability of wet electrospinning to fabricate multifunctional nanofiber-reinforced composites.