Composites Part A: Applied Science and Manufacturing最新文献

{"title":"Facile fabrication of graphene@silicon carbide nanoparticle/aramid nanofiber composite films with enhanced thermal conductivity, flame retardancy and mechanical durability","authors":"Zhao Zhao ,&nbsp;Jing Chen ,&nbsp;Bingfei Nan ,&nbsp;Yuanlie Yu","doi":"10.1016/j.compositesa.2025.109105","DOIUrl":"10.1016/j.compositesa.2025.109105","url":null,"abstract":"<div><div>Two-dimensional (2D) thermally conductive fillers, such as graphene and boron nitride, demonstrated great potential in thermal management materials due to their unique physical and chemical properties. However, fabricating composite films with excellent through-plane thermal conductivity remains challenging because of the intrinsic anisotropy of 2D materials. Herein, a heterostructure (GS) composed of silicon carbide (SiC) nanoparticle and graphene with high thermal conductivity was fabricated by a one-pot ball milling strategy. The as-obtained GS composite was then hybridized with aramid nanofibers (ANFs) to enhance the thermal conductivity, flame retardancy, and mechanical properties of ANF based films. The experimental results reveal that the ANF/GS composite film achieves an in-plane thermal conductivity of 4.94 W/(m·K), which can be attributed to strong π-π stacking interactions between graphene and ANF network. Simultaneously, SiC nanoparticles create bridging connections between graphene layers, establishing vertical phonon transport pathways that increase the through-plane thermal conductivity of ANF/GS composite film to 0.45 W/(m·K), approximately 3.8 times of that of the pure ANF film. Furthermore, the GS can also function as a high-temperature oxidation barrier and mechanical reinforcement framework, endowing the ANF/GS composite films with exceptional flame retardancy, flexibility and mechanical strength. These properties make the ANF/GS composite films very promising as thermal management materials for practical applications.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"198 ","pages":"Article 109105"},"PeriodicalIF":8.1,"publicationDate":"2025-06-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144254562","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Preparation of bimetallic zeolite-imidazole framework and its synergistic flame-retardant application in thermoplastic polyurethane","authors":"Chenyang Su ,&nbsp;Liang Shao ,&nbsp;Zhuo Chen ,&nbsp;Jie Wang ,&nbsp;Ce Wang ,&nbsp;Jianzhong Ma ,&nbsp;Zhanyou Ji","doi":"10.1016/j.compositesa.2025.109085","DOIUrl":"10.1016/j.compositesa.2025.109085","url":null,"abstract":"<div><div>The development of advanced flame-retardant polymer composites is crucial for enhancing safety in new energy vehicles. Here, we prepared a composite material with excellent flame retardant and smoke suppression properties by the introducing zinc-molybdenum zeolite imidazolium framework (ZIF-ZnMo) and ammonium polyphosphate (APP) into the thermoplastic polyurethane (TPU) matrix, which was denoted as TPU/APP/ZIF-ZnMo. Compared to the pure TPU material, the introduction of 0.5 wt% ZIF-ZnMo significantly reduced the key fire parameters. Among them, peak heat release rate (PHRR), peak smoke production rate (PSPR), and CO₂ yield evidenced by remarkable reductions of 71.8 %, 29.7 %, and 74.3 %, demonstrating excellent flame suppression and smoke reduction capabilities. The composite exhibits a 3.4-fold increase in char residue compared to pure TPU, attributed to the synergistic catalytic carbonization between ZIF-ZnMo and APP. Mechanistic studies reveal a dual-phase flame inhibition mechanism: (1) gas-phase radical quenching through phosphorus-containing species and (2) condensed-phase barrier formation via cross-linked phosphorus-zinc-molybdenum networks. This layered protection system effectively isolates oxygen, combustible gases and heat transfer, providing a promising strategy for producing safer materials for new energy vehicles. In addition, it expands the application of metal–organic frameworks in the field of polymer flame retardancy.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"198 ","pages":"Article 109085"},"PeriodicalIF":8.1,"publicationDate":"2025-06-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144254563","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Characterization, modeling and validation of the crystallization kinetics of carbon fiber-reinforced polyamide-6 composites","authors":"Veit Würfel ,&nbsp;Eric Mischorr ,&nbsp;Michael Müller-Pabel ,&nbsp;Franz Hirsch ,&nbsp;Alexander Liebsch ,&nbsp;Maik Gude ,&nbsp;Niels Modler ,&nbsp;Markus Kästner","doi":"10.1016/j.compositesa.2025.109077","DOIUrl":"10.1016/j.compositesa.2025.109077","url":null,"abstract":"&lt;div&gt;&lt;div&gt;Thermoplastic composite materials have the potential to meet the high-performance demands of the automotive and aviation industries in terms of cost and cycle time due to their rapid consolidation and forming capabilities. To take advantage of the rapid forming capabilities of thermoplastic materials, the processes may include external heating of the semi-finished products, followed by the forming process, including the compaction and solidification in isothermal molding tools. In the forming process, the laminate is continuously cooled whereby a non-isothermal crystallization process occurs in semi-crystalline polymers, which governs the phase transition from liquid to solid. As semi-crystalline thermoplastics can only be formed above their recrystallization temperature, the solidification phase sets the limits for the processing window.&lt;/div&gt;&lt;div&gt;In order to predict the manufacturing process limitations and boundaries, it is necessary to build up a holistic understanding of the solidification behavior. Therefore, this study aims to identify how temperature and crystallinity affect the formability of thermoplastic composites in industrial process conditions. By analyzing a CF/PA6 tape material as well as its neat PA6 polymer using differential scanning calorimetry (DSC) and fast scanning calorimetry (FSC), the necessity and difficulty of scanning fiber–matrix composite samples is evaluated. Using a modified Nakamura-Ziabicki model, the measured relative degree of crystallinity (DoC) is fitted across a wide range of constant cooling rates for both the composite tape material and the neat matrix material. The presence of carbon fibers increases the crystallization growth rate, leading to faster crystallization kinetics at all measured cooling rates. The model is implemented into the commercial FE software Abaqus® using a HETVAL subroutine for numerical heat transfer simulations. To address the unsuitability of conventional mechanical methods for validating crystallization kinetics at the high cooling rates typical of industrial processes, a novel approach utilizing squeezing flow during compaction in a stamp forming experiment was developed to to validate the numerical simulations. The influence of various processing parameters on the forming process is studied by measuring the internal transient temperature of the laminate as well as the displacement of the testing machine during compaction. The analysis concludes that the compaction limit of the stamp-formed specimen due to recrystallization aligns well with both the measured local maximum in cooling rates and the numerically predicted DoC of 50 %. Consequently, implementing the modified Nakamura-Ziabicki model in the process simulation enables accurate prediction of crystallization kinetics. This enables virtual process studies to be integrated into the design phase, facilitating direct feedback into the composite mold development and resource-efficient process optimization.&lt;/div&gt;&lt;/di","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"198 ","pages":"Article 109077"},"PeriodicalIF":8.1,"publicationDate":"2025-06-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144312789","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Significantly Boosted High-Temperature energy storage of polyetherimide film induced by BaTiO3/Al2O3/Ag composites nanofibers","authors":"LiHao Yang ,&nbsp;QingYang Tang ,&nbsp;ShuiMiao Xia ,&nbsp;Jie Huang ,&nbsp;GuanFei Liu ,&nbsp;XuYuan Fan ,&nbsp;Davoud Dastan ,&nbsp;ZhiCheng Shi","doi":"10.1016/j.compositesa.2025.109104","DOIUrl":"10.1016/j.compositesa.2025.109104","url":null,"abstract":"<div><div>Polymer dielectrics are essential materials for next − generation power systems. However, they suffer from low energy density and poor breakdown performance at high temperatures, which restricts their application in high-temperature fields. The BaTiO₃/Al₂O₃/Ag nanofibers (BT/AO/Ag NFs) were fabricated via electrospinning as nanofillers to boost the high-temperature energy storage of polyetherimide (PEI) composites. Experiments and finite electric field simulations demonstrate that combining high permittivity BaTiO₃, highly insulating Al₂O₃, and metallic Ag improves the dielectric permittivity and breakdown strength of PEI composites at high temperatures. Remarkably, the composite film incorporating merely 0.3 wt% BT/AO/Ag NFs achieves an ultra − high energy density of 9.047 J cm⁻³ at 200 ℃, representing a 147 % enhancement compared to pure PEI and surpassing most polymer composites filled with alternative nanofillers. Furthermore, this composite exhibits outstanding charge–discharge cycling stability (&gt;100,000 cycles at 200 MV m⁻¹) and superior power density (&gt;1.145 MW cm⁻³) at 200 ℃, positioning it as an ideal candidate for high-temperature capacitor applications. The work indicates that this nanofiber architectural design not only provides an effective strategy for developing high-temperature dielectric composites, but also shows great potential in next − generation dielectric capacitors.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"198 ","pages":"Article 109104"},"PeriodicalIF":8.1,"publicationDate":"2025-06-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144254551","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Bio-based polymer composites obtained by vat photopolymerization of photocurable resins modified with biochar as sustainable filler","authors":"Giovanna Colucci ,&nbsp;Federica Di Stefano ,&nbsp;Francesca Sacchi ,&nbsp;Michela Licciardello ,&nbsp;Chiara Tonda-Turo ,&nbsp;Luca Lavagna ,&nbsp;Massimo Messori","doi":"10.1016/j.compositesa.2025.109102","DOIUrl":"10.1016/j.compositesa.2025.109102","url":null,"abstract":"<div><div>The present work focuses on the preparation and characterization of novel bio-based photocured composites realized by vat photopolymerization (VP) 3D printing. Acrylate epoxidized soybean oil (AESO) resin was selected as the monomeric starting material and mixed with isobornyl methacrylate (IBOMA), used as reactive diluent at 50 wt%, in the presence of phenylbis(2,4,6-trimethylbenzoyl) phosphine oxide (BAPO), as radical photoinitiator. The polymerization process was carried out by using a VP technology as the liquid crystal display (LCD) 3D printing. Biochar (BC), deriving from biomass pyrolysis, was added to the resin from 0.5 up to 2 wt% to obtain the final bio-based composites formulations. Rheological measurements were firstly performed to evaluate the viscosity and the printability of the photocurable formulations, and photo-DSC analysis was carried out to study the photo-curing phenomenon and the effects of the BC presence on the curing process within the 3D printer.</div><div>After determining the optimal printing parameters, different geometries were printed, leading progressively to the realization of more complex parts with a high number of layers and good dimensional accuracy, such as alternative forearm splints prototypes for biomedical applications. The bio-based composites loaded with biochar underwent several characterization measurements to investigate their thermal, morphological, and mechanical properties. Finally, cell viability and cytocompatibility tests were carried out to study the real applications as bio-based materials for prosthesis development.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"198 ","pages":"Article 109102"},"PeriodicalIF":8.1,"publicationDate":"2025-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144261479","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Thermal history and multi-scale analyses of 3D-printed continuous carbon fibre composites","authors":"Fei Liu ,&nbsp;Shenru Wang ,&nbsp;Jie Zhang ,&nbsp;Wuxiang Zhang ,&nbsp;Laurens Snels ,&nbsp;David Seveno ,&nbsp;Eleonora Ferraris ,&nbsp;Jan Ivens","doi":"10.1016/j.compositesa.2025.109058","DOIUrl":"10.1016/j.compositesa.2025.109058","url":null,"abstract":"<div><div>The interfacial bonding properties of 3D-printed continuous carbon fibre composites are strongly influenced by the thermal history related to various printing parameters. However, there remains a gap in understanding the effects of thermal history on specific properties across multiple scales. This study addresses the gap in understanding these effects across multiple scales by developing a numerical temperature model, a computational fluid dynamics model and a representative volume element approach for the deposition process. The temperature model was validated against experimental profiles, where the maximum mean absolute difference is 4.5<!--> <!-->°C, and the flexural performance with 29.8% error is obtained. Through two models, we found that print speed and layer thickness have a significant impact on interfacial bonding and defect formation. This study provides insights into the relationship between thermal history and interfacial behaviour, aiding machine developers in enhancing structural performance, and promoting the application of high-quality composites.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"198 ","pages":"Article 109058"},"PeriodicalIF":8.1,"publicationDate":"2025-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144279151","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Green multifunctional ionic liquid for enhancing processing flowability, toughness, and flame retardancy of highly filled MH/LLDPE composites","authors":"Rujie Li ,&nbsp;Shiai Xu ,&nbsp;Beibei Sun ,&nbsp;Jiajun Xu ,&nbsp;Jie Xu ,&nbsp;Xue Xu ,&nbsp;Qianqian Zhang ,&nbsp;Jiaxu Cheng","doi":"10.1016/j.compositesa.2025.109101","DOIUrl":"10.1016/j.compositesa.2025.109101","url":null,"abstract":"<div><div>This study proposes a facile and cost-effective strategy to improve the processing flowability and mechanical properties of highly filled (HF) polymer composites while retaining their flame retardancy. Ionic liquids (IL), specifically 1-alkyl-3-methylimidazolium phosphate ([AMIM]PA), were synthesized and incorporated into HF magnesium hydroxide (MH)/linear low-density polyethylene (LLDPE) (60/40 by weight) composites. The MH/LLDPE composite containing 5 wt% of 1-hexadecyl-3-methylimidazole phosphate ([HDMIM]PA) exhibited significant improvements in processing characteristics, demonstrating a 50.7% reduction in equilibrium torque values, a maximum 13 times enhancement in melt flow index, and a 133% increase in impact strength. Morphological and rheological analyses demonstrated that [HDMIM]PA effectively promoted interfacial lubrication and compatibility between MH particles and LLDPE matrix, and consequently enhanced the overall properties. The flame retardancy assessments revealed that [AMIM]PA functioned as an intumescent flame retardant to make the material safer. This study thus provides a comprehensive understanding of the role of IL in enhancing the performance of HF polymer composites, offering a promising strategy for the development of advanced composites.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"198 ","pages":"Article 109101"},"PeriodicalIF":8.1,"publicationDate":"2025-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144254550","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Optimizing the microstructure and synchronous improving the strength and toughness of Nb-Si based alloys via carbon nanotubes (CNTs) addition through laser melting deposition","authors":"Xiuyuan Yin,&nbsp;Jing Liang,&nbsp;Suiyuan Chen,&nbsp;Shuo Shang,&nbsp;Changsheng Liu","doi":"10.1016/j.compositesa.2025.109075","DOIUrl":"10.1016/j.compositesa.2025.109075","url":null,"abstract":"<div><div>CNTs were first employed in Nb-Si based alloys fabricated by laser melting deposition (LMD) to enhance mechanical properties, particularly fracture toughness. The results showed that CNTs underwent complete decomposition in alloys fabricated at LP = 2100 W, and the breakdown of CNTs provides carbon atoms to the molten pool, facilitating the microstructure transformation from a hypoeutectic structure consisting of Nbss and Nb₃Si to a near-eutectic structure consisting of Nbss and γ-Nb₅Si₃, accompanied by a refinement of the microstructure. The fracture toughness of 2100 W-3CNTs alloy reached 15.2 MPa·m^1/2, 1.62 times higher than the alloy without CNTs addition. By optimizing process parameters, CNTs-reinforced Nb-Si based alloys were successfully fabricated at LP = 1800 W, achieving simultaneous improvement in fracture toughness and compressive strength. The fracture toughness of 1800 W-3CNTs alloy increased to 16.7 MPa·m^1/2, which was attributed to the content and size of ductile Nbss increased, as well as the debonding and pull-out of residual CNTs during the fracture process. These factors lead to crack deflection, bridging, and branching, thereby increasing the energy required for crack propagation. The Orowan strengthening caused by the array-like distribution of CNTs in Nbss significantly enhanced the compressive strength of the 1800 W-3CNTs alloy, making its compressive strength superior to other alloys, reaching the maximum value of 2190 MPa among all LMDed alloys.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"198 ","pages":"Article 109075"},"PeriodicalIF":8.1,"publicationDate":"2025-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144261528","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Numerical simulation and experimental analysis of ablation response behavior of silicone rubber based flexible ablative material","authors":"Lu Long ,&nbsp;Lei Zeng ,&nbsp;Yue Tian ,&nbsp;Wenxing Chen ,&nbsp;Jingli Cheng ,&nbsp;Zhengguang Heng ,&nbsp;Yang Chen ,&nbsp;Mei Liang ,&nbsp;Huawei Zou ,&nbsp;Xiao Liu ,&nbsp;Liwei Yan","doi":"10.1016/j.compositesa.2025.109079","DOIUrl":"10.1016/j.compositesa.2025.109079","url":null,"abstract":"<div><div>SR-FAMs play a critical role in the aerospace and fire protection sectors for thermal protection purpose. Nevertheless, the ablation mechanism and internal response behavior of SR-FAMs remain unclear because complex thermochemical reactions occur when they face with high temperature ablation conditions. In this work, a PDMS/CF/SiO₂ composite containing 6 phr CF and 10 phr SiO₂ was selected as the model system, and the pyrolysis mechanism of PDMS/CF/SiO₂ composite was studied through a holistic analysis of the type of gaseous products, the composition of solid residue, and the evolution of microstructure at high temperatures. A multi-stage pyrolysis kinetic analysis was conducted to determine the kinetic parameters associating with each pyrolysis stage, which enabled accurate description of the thermal decomposition characteristics. Moreover, an ablation model was constructed to capture the ablation deformation and simulate ablation process of PDMS/CF/SiO₂. The proposed model successfully predicted the time-dependent evolution of three-dimensional temperature fields, conversion of pyrolysis products, gas-phase flow, and pressure distribution. The simulation results indicated that the transition of horizontal-to-vertical gas flow promoted the formation of columnar barrier structures in the char layer of PDMS/CF/SiO₂. The results of the numerical model agreed well with experimental data in terms of LAR, MAR, surface and back-face temperature, with a prediction error less than 5%. This work provided new insights into the ablation behavior of SR-FAMs and offered reference to the design and optimization of flexible thermal protection materials.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"198 ","pages":"Article 109079"},"PeriodicalIF":8.1,"publicationDate":"2025-06-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144271122","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Design of yield-stress fluids with ultra-low thermal resistance via surface functionalization of aluminum fillers","authors":"Yuanyuan Xiao ,&nbsp;Yimin Wei ,&nbsp;Yunsong Pang ,&nbsp;Xiaoliang Zeng ,&nbsp;Rong Sun","doi":"10.1016/j.compositesa.2025.109099","DOIUrl":"10.1016/j.compositesa.2025.109099","url":null,"abstract":"<div><div>Thermal resistance at the interface between chips and cooling devices is a major impediment to heat removal, especially in the development of high-power-density AI chips. Yield-stress type thermal interfacial materials are inserted to reduce the thermal resistance between chips and cooling devices, meanwhile avoiding pumping out and significant expansion. However, the trade-off between thermal resistance and yield stress for thermal interfacial materials remains a major obstacle to achieving efficient heat dissipation. Here, we report yield-stress fluids consisting of polydimethylsiloxane, polydimethylsiloxane trimethoxysilane-functionalized aluminum powders, exhibiting an ultra-low thermal resistance (0.019 K cm²/W) and moderate yield stress (84.51 Pa). The surface functionalization of aluminium powders achieves homogeneous distribution at high content (81.5 vol%), and enhances interfacial bonding between aluminium powders and polydimethylsiloxane. A jamming phase diagram is constructed to reflect the critical parameters of the solid–liquid yield transition, and a two-phase model is invoked to explain the regulatory mechanism of the aluminum network. Based on the thixotropy, solid–liquid yield transition and ultra-low thermal resistance, the yield-stress fluids demonstrate exceptional thermal management performance in chip dissipation scenarios. This work provides a new direction for the future evolution of high-efficiency thermal interface materials, which has great transformative potential in advancing thermal management technology.</div></div>","PeriodicalId":282,"journal":{"name":"Composites Part A: Applied Science and Manufacturing","volume":"198 ","pages":"Article 109099"},"PeriodicalIF":8.1,"publicationDate":"2025-06-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144271092","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}