Improved carbon fibers dispersion in geopolymer composites

Carbon fibers (CFs) reinforced alkali-activated (AA) ground granulated blast furnace slag (GGBFS) geopolymer composites have excellent mechanical and thermoelectrical properties, as well as low energy consumption and low CO₂ emissions during their production. However, the dispersion of CFs in the geopolymer matrix is always a technical issue in the preparation of the green composite material. Therefore, this study comparatively investigated various dispersion methods, including, mixing sequence (pre-mixing and after-mixing methods), dispersing agent (nano silicon dioxide [nSiO2]), and ultrasonic treatment time (0, 15, 30, and 45 min), as well as CFs content (0.5, 1.0, and 1.5 wt% of GGBFS). The distribution of CFs was then qualitatively and quantitatively evaluated by a series of tests, such as flowability, electrical resistivity, flexural strength, scanning electron microscope (SEM) analysis, and X-ray computed tomography (CT). The experimental results showed that the proposed pre-mixing method provided excellent dispersion characteristics for CFs compared with the after-mixing method. The introduction of nSiO₂ can enhance the dispersion of CFs and the mechanical and electrical properties of AA GGBFS geopolymer composites. At a carbon fiber content of 1.5 %, the pre-mixing method and the addition of nSiO₂ dispersant reduced the resistivity of the 28-day geopolymer composites by 17.0 % and 38 %, respectively, compared with the after-mixing method. It is feasible to use X-ray CT scanning with the gray-scale frequency map to analyze the dispersion effect of CFs in AA GGBFS geopolymer composites. However, the results were not intuitive when less agglomeration of CFs occurred for the low content of CFs. The scanning method is more applicable to the sample with over 1.0 wt% CFs. The average pixel areas of uniformly dispersed CF bundles in the 2D images of the pre-mixing method and the addition of nSiO₂ dispersant specimens were 3.32 % and 6.55 % higher than those of the after-mixing method, respectively. The 2D and 3D scanning results from the dispersion characteristics of CFs were consistent. 2D scanning could provide a time-consuming option for the measurement of CFs dispersion characteristics.