Longitudinal compression failure of 3D printed continuous carbon fiber reinforced composites: An experimental and computational study

Tang, Haibin; Sun, Qingping; Su, Xuming; Yan, Wentao

doi:10.1016/j.compositesa.2021.106416

Cited by 27 publications

(10 citation statements)

References 34 publications

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“…Many authors found that process-induced defects, such as high void content, poor interlayer bonding and inhomogeneous fibers distribution, has a high impact on interlaminar shear strength and failure behavior of the printed objects [ 17 , 18 , 19 , 20 , 21 ]. However, a remarkable improvement in the mechanical properties has been reported for various load cases: tension [ 16 , 17 , 18 , 19 , 20 , 22 ], compression [ 18 , 20 , 23 , 24 ], bending [ 24 , 25 , 26 ], fatigue [ 27 ], creep [ 27 ] and impact [ 28 ]. The effect of build orientation, fiber content and infill pattern (i.e., isotropic or concentric fiber orientation inside a single layer) on the mechanical behavior of the 3D printed composites was also studied [ 15 , 21 , 29 , 30 ].…”

Section: Introductionmentioning

confidence: 99%

Experimental Characterization and Modeling of 3D Printed Continuous Carbon Fibers Composites with Different Fiber Orientation Produced by FFF Process

et al. 2022

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The development of 3D printed composites showing increased stiffness and strength thanks to the use of continuous carbon fibers has offered new prospects for Fused Filament Fabrication (FFF) technique. This work aims to investigate the microstructure and mechanical properties of 3D printed CCF/PA composites with various layups, and also to apply predictive models. The mechanical properties of the printed parts were directly related to the adopted laminate layup as well as to the microstructure and defects induced by the FFF process. The highest stiffness and strength were reported for longitudinal composites, where the fibers are unidirectionally aligned in the loading direction. In addition, it was found that the reduction in tensile properties obtained for cross-ply and quasi-isotropic laminate layups can be described by using the Angle Minus Longitudinal. A step-like failure with extensive fibers breakage and pull-out was observed for the longitudinal composites. By contrast, the rupture mode of the quasi-isotropic laminates mainly exhibited debonding between beads. Moreover, the predictions obtained using the Volume Average Stiffness method and Classical Laminate Theory were in good agreement with the tensile test results. This work could help engineers to design complex laminates with specific mechanical requirements by tailoring the orientation of continuous carbon fibers.

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Section: Introductionmentioning

confidence: 99%

Experimental Characterization and Modeling of 3D Printed Continuous Carbon Fibers Composites with Different Fiber Orientation Produced by FFF Process

et al. 2022

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“…Compared to conventional composite materials (2.5–3.7%, 28 0.02–3.75% 29 ), these values are significantly larger and can negatively influence mechanical properties. Tang et al 30 showed that an initial fiber misalignment angle of 7° in predicting the longitudinal compressive strength of unidirectional materials agreed with experimental values. They also mentioned that the initial misalignment angle was greater than that of conventional composite materials.…”

Section: Resultsmentioning

confidence: 58%

Open-hole tensile properties of 3D-printed continuous carbon-fiber-reinforced thermoplastic laminates: Experimental study and multiscale analysis

Hoshikawa

Shirasu

Yamamoto

et al. 2022

Journal of Thermoplastic Composite Materials

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The mechanical properties of open-hole tensile (OHT) specimens made of 3D-printed continuous carbon-fiber-reinforced thermoplastics (CFRTPs) were investigated. The stacking sequence of the OHT specimens were [0/90]2s, and the as-printed specimens possessed higher porosity (15.19%) than conventional fiber reinforced composites. The OHT tests demonstrated that the tensile modulus and fracture strength of the as-printed specimens exhibited 36.7 ± 0.3 GPa and 226.0 ± 9.0 MPa, respectively. To evaluate the effects of voids on the OHT properties, the 3D-printed CFRTPs were hot-pressed, where fiber orientation and porosity (3.41 ± 0.10%) were improved. Additionally, the tensile modulus was increased to 45.1 ± 0.8 GPa, which is 23% higher than the as-printed specimens, even though the fracture strength were comparable or lower than that of as-printed specimens. To validate such OHT properties, a numerical multiscale model was introduced, with a microscale periodic unit cell (PUC) analysis for determining the effective tensile moduli and mesoscale extended finite element method (XFEM) analysis for OHT properties. In the PUC analysis, we considered a two-scale numerical model including a fiber-resin scale with fiber orientation for effective tensile moduli of a CFRTP filament, and filament-void scale for those of a CFRTP laminate. The porosity and fiber orientation were measured by X-ray computed tomography and digital microscopy observations, and the porosity for the 0° specimen were 14.86%. By substituting the effective tensile moduli of the filament-void scale and those of the fiber-resin scale into the XFEM, respectively, the stress-strain responses of the computational OHT models were found to be in good agreement with those of the experimental results of as-printed and hot-pressed CFRTP, respectively. Both the OHT models showed that the Weibull criterion was satisfied without significant delamination at the failure strain, corresponding to the brittle failure mode due to fiber breakage, which agreed reasonably well with the experimental observations.

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“…29,30 These unanticipated alterations in fiber morphology were shown to diminish the mechanical properties of composites. [31][32][33][34] Different measurement techniques were developed to regulate fiber tension, thereby advancing the production of high-performance 3D composite preforms. [35][36][37][38][39] The FO3DWP technology uses the Guide Bar Array (GBA) as yarn nodes to ensure the structural integrity of 3D woven preforms.…”

Section: Introductionmentioning

confidence: 99%

Optimization control of guide bar array deformation in flexible‐oriented 3D woven process

Liu,

Shan,

Liu

et al. 2024

Polymer Composites

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The flexible‐oriented 3D woven process (FO3DWP) enables the production of high‐performance 3D composite preforms. However, the deformation of the Guide Bar Array (GBA) during the weaving process poses a major challenge and hinders the further advancement of FO3DWP. This study aimed to address this challenge by developing an optimization control method for automatic GBA correction during the manufacturing of 3D orthogonal preforms. The deformation state was predicted using a theoretical model and a control path was designed to reverse the GBA deformation. The height and fiber tension of the control paths were calculated using the particle swarm optimization (PSO) algorithm. A series of 3D woven experiments were conducted to evaluate the effectiveness of the proposed method. The results showed good agreement between the experimental and theoretical deformation eigenvalues (with a difference of less than 15%), and the control path significantly reduced the deformation eigenvalues. This method holds great potential for aerospace applications as it enables high‐quality production through automatic GBA correction by the weaving mechanism.Highlights A control path was designed to automatically correct the deformed GBA. The height and the fiber tension of the control path were calculated using the PSO algorithm. The experimental eigenvalues in the y‐direction were significantly reduced by the optimization control method.

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Longitudinal compression failure of 3D printed continuous carbon fiber reinforced composites: An experimental and computational study

Cited by 27 publications

References 34 publications

Experimental Characterization and Modeling of 3D Printed Continuous Carbon Fibers Composites with Different Fiber Orientation Produced by FFF Process

Experimental Characterization and Modeling of 3D Printed Continuous Carbon Fibers Composites with Different Fiber Orientation Produced by FFF Process

Open-hole tensile properties of 3D-printed continuous carbon-fiber-reinforced thermoplastic laminates: Experimental study and multiscale analysis

Optimization control of guide bar array deformation in flexible‐oriented 3D woven process

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