Evaluating the effect of variable fiber content on mechanical properties of additively manufactured continuous carbon fiber composites

Hetrick, Dakota; Sanei, Seyed Hamid Reza; Bakis, Charles E.; Ashour, Omar

doi:10.1177/0731684420963217

Cited by 37 publications

(19 citation statements)

References 28 publications

(48 reference statements)

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“…This result indicates a good correlation between the increasing Young’s modulus in the printed parts and increasing the glass fibre content. The same conclusions were observed in the literature for similar printed composites 18,24,27,35,36 and other composites made with conventional manufacturing processes. 37–39 Figure 8(c) shows that the tensile strength increases proportionally with the glass fibre content up to V f = 10.8%, the tensile strength measured at V f = 17.1% being only slightly above the value at 10.8%.…”

Section: Resultssupporting

confidence: 90%

3D printed continuous glass fibre-reinforced polyamide composites: Fabrication and mechanical characterisation

Saidane

Arnold

Louis

et al. 2021

Journal of Reinforced Plastics and Composites

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Fused Filament Fabrication is a very common additive manufacturing technology and several manufacturers have developed commercial 3D-printers that enable the use of fibre-reinforced filaments in order to improve the mechanical properties of the printed parts. The obtained material is a composite that exhibits complex mechanical properties. The aim of this study is to characterize the mechanical behaviour of 3D-printed continuous glass fibre-reinforced polyamide composites. In a first step, we focus on the reinforced filament: the heterogeneity of its microstructure is evidenced as well as its brittle elastic tensile behaviour. In a second step, parts of different fibre orientations and fibre volume contents are manufactured using a Mark Two 3D-printer (MarkForged®), their microstructure is analysed and tensile, flexural and short beam bending tests are performed. As expected, the results show a significant influence of fibre volume content and fibre orientation. Standard homogenization methods are used to compare the predicted mechanical behaviour to the experimental results. Regarding the elastic stiffness, a good correlation is observed when the material is loaded in the direction of the fibres. Regarding the tensile strength, the results show that no benefit is obtained above a fibre volume content of about 11%. These results highlight the importance of choosing an optimised stacking sequence prior to the printing process, in order to obtain composites with the desired mechanical properties. The mechanical results are analysed in the light of Scanning Electron Microscopy observations of specimen cross-sections before and after testing.

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Section: Resultssupporting

confidence: 90%

3D printed continuous glass fibre-reinforced polyamide composites: Fabrication and mechanical characterisation

Saidane

Arnold

Louis

et al. 2021

Journal of Reinforced Plastics and Composites

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“…It is an established fact that the fiber content (i.e., fiber volume fraction, FVF) has significant positive impact on the mechanical properties of the composite. Consequently, maximizing fiber content is of interest to manipulate the mechanical properties, such as loading fiber in the test direct significantly increases tensile strength [4,5]. The intrinsic nature of the 3D printing process developing a structure in layer-by-layer fashion involves relatively more matrix material than traditional composite manufacturing technology, such as injection molding, resin transfer molding and compression molding to ensure good adhesion between adjacent print beads and layers for improved structural integrity [6].…”

Section: Introductionmentioning

confidence: 99%

Maximizing the Performance of 3D Printed Fiber-Reinforced Composites

2021

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Fiber-reinforced 3D printing technology offers significant improvement in the mechanical properties of the resulting composites relative to 3D printed (3DP) polymer-based composites. However, 3DP fiber-reinforced composite structures suffer from low fiber content compared to the traditional composite, such as 3D orthogonal woven preforms solidified with vacuum assisted resin transfer molding (VARTM) that impedes their high-performance applications such as in aerospace, automobile, marine and building industries. The present research included fabrication of 3DP fiberglass-reinforced nylon composites, with maximum possible fiber content dictated by the current 3D printing technology at varying fiber orientations (such as 0/0, 0/90, ±45 and 0/45/90/−45) and characterizing their microstructural and performance properties, such as tensile and impact resistance (Drop-weight, Izod and Charpy). Results indicated that fiber orientation with maximum fiber content have tremendous effect on the improvement of the performance of the 3DP composites, even though they inherently contain structural defects in terms of voids resulting in premature failure of the composites. Benchmarking the results with VARTM 3D orthogonal woven (3DOW) composites revealed that 3DP composites had slightly lower tensile strength due to poor matrix infusion and voids between adjacent fiber layers/raster, and delamination due to lack of through-thickness reinforcement, but excellent impact strength (224% more strong) due to favorable effect of structural voids and having a laminated structure developed in layer-by-layer fashion.

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“…9,11,12,17,19 Several studies have investigated the tensile and bending properties of continuous fiber reinforced thermoplastic composites printed by FDM. 10,16,[24][25][26][29][30][31][32][33][34][35] While other research focused on the relationships between FDM process parameters (e.g., build orientation, fiber volume fraction, layer thickness, etc.) and the mechanical properties of continuous fiber reinforced thermoplastic composites, 13,33,36 however, there are few studies on the impact behavior of continuous fiber reinforced thermoplastic composites printed by the FDM process.…”

Section: Introductionmentioning

confidence: 99%

Charpy impact energy absorption of 3D printed continuous Kevlar reinforced composites

Hetrick

Sanei

Ashour

et al. 2021

Journal of Composite Materials

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Additive manufacturing (AM) has been used widely to produce three-dimensional (3D) parts from computer-aided design (CAD) software. Traditional Fused Deposition Modeling (FDM) 3D printed polymer parts lack the necessary strength to be used for functional parts in service. The potential of printing continuous fiber reinforced composites has resulted in parts with better mechanical properties and enhanced performance. Very few studies have investigated the impact energy absorption of continuous fiber reinforced 3 D printed composites. The purpose of this work is to investigate the effect of different fiber patterns (unidirectional versus concentric), different stacking patterns (consolidated versus alternating layers), and fiber orientations (0°, 90°, 45°) on the impact energy absorption of 3 D printed continuous Kevlar fiber reinforced Onyx composites. Charpy impact testing was used to determine the impact energy absorption of the specimens. It was concluded that alternating the fiber and matrix layers as opposed to consolidating all the fiber layers in the center of the specimen results in lower impact energy absorption. Additionally, the specimens with unidirectional 90° fiber orientation had the lowest impact energy absorption among the specimens with alternating stacking pattern and those with consolidated [Formula: see text]45° angle-ply fiber orientations had the highest impact energy absorption.

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Evaluating the effect of variable fiber content on mechanical properties of additively manufactured continuous carbon fiber composites

Cited by 37 publications

References 28 publications

3D printed continuous glass fibre-reinforced polyamide composites: Fabrication and mechanical characterisation

3D printed continuous glass fibre-reinforced polyamide composites: Fabrication and mechanical characterisation

Maximizing the Performance of 3D Printed Fiber-Reinforced Composites

Charpy impact energy absorption of 3D printed continuous Kevlar reinforced composites

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