Thermal Frontal Polymerization in Polymer Composites: Numerical Simulation and the Role of Fe3O4 Nanoparticle Fillers

Abstract Recently Thermal Frontal Polymerization (TFP) has emerged as a low-energy alternative, that enables rapid and energy-efficient manufacturing of composites. Thus, compared to conventional processes, this innovative curing and polymerization process exhibits improved efficiency and reduced environmental impact and provides a promising strategy to address sustainability challenges. However, successful TFP requires a delicate balance of reaction rates, exothermicity, and efficient heat transport into unpolymerized media while minimizing heat losses to the surroundings. In this context, sustaining TFP of polymers reinforced with highly conductive fillers is challenging due to the increased energy dissipation and reduced availability of exothermic energy as the filler content increases at the cost of resin volume. In this work, a numerical study of the TFP based manufacturing of Bisphenol A Diglycidyl Ether (BADGE) filled with Fe 3 O 4 nanoparticles is presented. The simulation provides insight into the thermo-chemical process and into the impact of different particle filling degrees on the key characteristics of TFP, i.e., maximum attainable degree of cure, maximum temperature, front shape, and front speed.