Enhancement of Lightweight Composite Parts with Robust Cellular Structures by Combining Fused Deposition Modeling and Electromagnetic Induction Heating

Abstract

A novel approach combining fused deposition modeling and electromagnetic induction heating is developed to fabricate lightweight cellular composite parts, where the composite filaments are prepared by adding the Babbitt alloy powders (LSn-03) and the foaming agents (PTSS) into ABS matrix. The electromagnetic induction furnace is employed to heat the fabricated parts to form porous structures with rougher surfaces and improve the interfacial behaviors by making the interfaces getting blurred. Three types of pores are observed, including physical gaps, defects, and spherical holes. It is found that the heating time plays an important role in pore sizes and has little influence on porosity. The effects of content of LSn-03 and PTSS on pore sizes and porosity are also investigated to gain insight into the cellular structures. The testing results show that the heating treatment exerts a positive influence on the mechanical properties at a relatively high filling density. Polycarbonates are adopted as shells to further improve the mechanical properties of the fabricated parts, revealing that the tensile and compressive strength increase by 20% and 25%, respectively. The instance of the honeycomb parts further demonstrates the advantages of the approach to fabricate the lightweight cellular composite parts with excellent performance.

Effect of heat‐treatment on compressive response of 3D printed continuous carbon fiber reinforced composites under different loading directions

“…And the porosity (P) of specimens could be calculated by the following formulas: where the was the measured volume obtained by the Archimedes approach, and Va represent the dimensionally calculated volume of the specimens. Va can be calculated as follows 32,33 : where m was the measured mass of the specimens; , , was the density of the pure PA matrix (1.1 g/cm 3 ), short carbon fiber (1.76 g/cm 3 ) and continuous carbon fiber (2.1 g/cm 3 ), respectively 34 …”

Evolution of microstructure and thermo‐mechanical attributes of fiber reinforced polyamide during fused deposition modeling 3D printing: A comprehensive characterization study

“…FDM leverages the adhesive properties of thermoplastic materials, wherein a heated nozzle deposits molten material layer by layer to construct the desired object. [2][3][4] While thermoplastic polymers like polylactic acid (PLA), acrylonitrile butadiene styrene (ABS), and polyamide (PA) are commonly utilized as feedstock in FDM, the demand for enhanced mechanical properties has propelled the integration of short fiber reinforcements into these materials. [5][6][7] Incorporating short fibers, such as Glass fibers (GF), Carbon fibers (CF), or Kevlar fibers (KF), into the filament matrix enables the creation of composite systems with unparalleled structural and functional attributes.…”

“…While, the average weight of PA and CF-PA printed coupons were found to be 2.1187 ± 0.0326 g and 2.1866 ± 0.0200 g, respectively. The average volume of PA and CF-PA filament was calculated as 0.2042 ± 0.0029 cm 3 and 0.2351 ± 0.0056 cm 3 , respectively. The volume of 3D-printed tested coupons comes out to be 1.8689 cm 3 .…”

“…The average volume of PA and CF-PA filament was calculated as 0.2042 ± 0.0029 cm 3 and 0.2351 ± 0.0056 cm 3 , respectively. The volume of 3D-printed tested coupons comes out to be 1.8689 cm 3 . The density of PA filament and CF-PA filament were computed to be 1.15 ± 0.027 and 1.20 ± 0.026 g/cm 3 , respectively.…”

“…The volume of 3D-printed tested coupons comes out to be 1.8689 cm 3 . The density of PA filament and CF-PA filament were computed to be 1.15 ± 0.027 and 1.20 ± 0.026 g/cm 3 , respectively. The density of PA and CF-PA samples were 1.13 ± 0.027 and 1.17 ± 0.012 g/cm 3 , respectively with a drop of 1.74%, and 2.42%, compared to the filament.…”