3D printed continuous CF/PA6 composites: Effect of microscopic voids on mechanical performance

He, Qinghao; Wang, Hongjian; Fu, Kunkun; Ye, Lin

doi:10.1016/j.compscitech.2020.108077

Cited by 175 publications

(129 citation statements)

References 29 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…When the layer thickness is small, the number of layers required to complete the part increases; hence, the production time will also increase. Several experiments have observed many void formations within the extruded filament, which were smaller than 16.4 μm, and they greatly affected the porosity percentage in the printed part [ 196 , 197 ]. All above-mentioned voids act as a failure initiation point when a load is applied to these samples.…”

Section: Common Defects In Fdm Printed Polymers and Fibre-reinforcmentioning

confidence: 99%

See 1 more Smart Citation

FDM-Based 3D Printing of Polymer and Associated Composite: A Review on Mechanical Properties, Defects and Treatments

2020

View full text Add to dashboard Cite

Fused deposition modelling (FDM) is one of the fastest-growing additive manufacturing methods used in printing fibre-reinforced composites (FRC). The performances of the resulting printed parts are limited compared to those by other manufacturing methods due to their inherent defects. Hence, the effort to develop treatment methods to overcome these drawbacks has accelerated during the past few years. The main focus of this study is to review the impact of those defects on the mechanical performance of FRC and therefore to discuss the available treatment methods to eliminate or minimize them in order to enhance the functional properties of the printed parts. As FRC is a combination of polymer matrix material and continuous or short reinforcing fibres, this review will thoroughly discuss both thermoplastic polymers and FRCs printed via FDM technology, including the effect of printing parameters such as layer thickness, infill pattern, raster angle and fibre orientation. The most common defects on printed parts, in particular, the void formation, surface roughness and poor bonding between fibre and matrix, are explored. An inclusive discussion on the effectiveness of chemical, laser, heat and ultrasound treatments to minimize these drawbacks is provided by this review.

show abstract

Section: Common Defects In Fdm Printed Polymers and Fibre-reinforcmentioning

confidence: 99%

“…He et al [ 197 ] identified a large distribution of voids near the crack initiation point and recorded poor resistance to crack growth within those void areas. These micro voids are one of the main reasons for the poor strength exhibited by parts printed with the FDM process.…”

Section: Common Defects In Fdm Printed Polymers and Fibre-reinforcmentioning

confidence: 99%

FDM-Based 3D Printing of Polymer and Associated Composite: A Review on Mechanical Properties, Defects and Treatments

2020

View full text Add to dashboard Cite

show abstract

“…As a reference, flexural properties of unidirectional fiber-reinforced composites fabricated by the proposed method were compared with additively manufactured fiber-reinforced composites by other methods, including short carbon-fiber (SCF) composites printed by SLS, 35 FDM, 36 and continuous carbon-fiber (CCF) composites fabricated by FDM, 12,[14][15][16]19,20,[37][38][39][40] ultrasonic-assisted auto-fiber placement (UAFP), 32 and laser-assisted laminated object manufacturing (LA-LOM). 21 As shown in Figure 3B, the proposed method exhibits the highest flexural modulus and strength for all reported AM methods.…”

Section: Flexural Strength and Flexural Modulusmentioning

confidence: 99%

“…Table 3 shows a summary of the average tensile strength, modulus, and SD of the AM CFRTPCs. Figure 4B shows the tensile property map of this work compared with fiber composites fabricated by FDM, 11,12,15,16,20,[36][37][38][39]41,42 extrusion, 43 SLS, 35,43 SLA, [43][44][45] and LA-LOM. 21 The HPP unidirectional CFRTPCs prepared by the proposed method exhibited impressive tensile strength and stiffness, which are 80% and 27% higher than the strongest FDM printed CFRTPCs, respectively.…”

Section: Flexural Strength and Flexural Modulusmentioning

confidence: 99%

Ultrafast printing of continuous fiber‐reinforced thermoplastic composites with ultrahigh mechanical performance by ultrasonic‐assisted laminated object manufacturing

Chang

Parandoush

et al. 2020

Polymer Composites

View full text Add to dashboard Cite

Additive manufacturing (AM) of continuous fiber-reinforced thermoplastic composites (CFRTPCs) has drawn increasing interest and great attention in academic and industrial communities due to its capability of manufacturing complex lightweight structures with high strength at a low cost. In this study, we proposed a novel AM technique to fabricate CFRTPCs using carbon fiber prepreg sheets based on a novel method: ultrasonic-assisted laminated object manufacturing (UA-LOM). The prepreg sheets were first cut into 2D shapes, then every eight layers of the sheets were successively consolidated by an ultrasonic-vibration roller to fabricate one 3D composite part at a faster speed than conventional AM processes where materials are deposited layer by layer. Samples with controlled fiber alignments were prepared for mechanical tests. The post-processing hot press was carried out to further improve mechanical properties of the additively manufactured components. Results showed that the unidirectional composite samples displayed an ultra-high tensile strength of 1760.2 (±71.7) MPa and a tensile modulus of 105.7 (±7.2) GPa. The proposed method exhibited superior mechanical performance compared to state-of-theart AM techniques. The hot-press-treated AM composite parts in this work approached the benchmark mechanical properties provided by the prepreg manufacturing company using traditional fabrication methods. Overall, the proposed AM methods of CFRTPCs show great potential applications in aerospace and transportation industries.

show abstract

“…AM technology has been adopted by a very wide range of fields such as aerospace, automobile, manufacturing, designing, tissue, and biomedical engineering industries [ 1 , 2 , 3 , 4 , 5 , 6 ]. Fused deposition modelling (FDM) is one of the most widely used AM technologies owing to its operational flexibility and low cost [ 7 ]. FDM creates three-dimensional objects by laying up successive layers of thermoplastic material upon one another.…”

Section: Introductionmentioning

confidence: 99%

On the Effects of Process Parameters and Optimization of Interlaminate Bond Strength in 3D Printed ABS/CF-PLA Composite

et al. 2020

View full text Add to dashboard Cite

The scope of additive manufacturing, particularly fused deposition modelling (FDM), can indeed be explored with the fabrication of multi-material composite laminates using this technology. Laminar composite structures made up of two distinct materials, namely acrylonitrile butadiene styrene (ABS) and carbon fiber reinforced polylactic acid (CF-PLA), were produced using the FDM process. The current study analyzes the effect of various printing parameters on the interfacial bond strength (IFBS) of the ABS/CF-PLA laminar composite by employing response surface methodology. The physical examination of the tested specimens revealed two failure modes, where failure mode 1 possessed high IFBS owing to the phenomenon of material patch transfer. Contrarily, failure mode 2 yielded low IFBS, while no patch transfer was observed. The analysis of variance (ANOVA) revealed that printing parameters were highly interactive in nature. After extensive experimentation, it was revealed that good quality of IFBS is attributed to the medium range of printing speed, high infill density, and low layer height. At the same time, a maximum IFBS of 20.5 MPa was achieved. The study presented an empirical relation between printing parameters and IFBS that can help in forecasting IFBS at any given printing parameters. Finally, the optimized printing conditions were also determined with the aim to maximize IFBS.

show abstract

3D printed continuous CF/PA6 composites: Effect of microscopic voids on mechanical performance

Cited by 175 publications

References 29 publications

FDM-Based 3D Printing of Polymer and Associated Composite: A Review on Mechanical Properties, Defects and Treatments

FDM-Based 3D Printing of Polymer and Associated Composite: A Review on Mechanical Properties, Defects and Treatments

Ultrafast printing of continuous fiber‐reinforced thermoplastic composites with ultrahigh mechanical performance by ultrasonic‐assisted laminated object manufacturing

On the Effects of Process Parameters and Optimization of Interlaminate Bond Strength in 3D Printed ABS/CF-PLA Composite

Contact Info

Product

Resources

About