The effect of resin-rich layers on mechanical properties of 3D printed woven fiber-reinforced composites

Idrees, Mohanad; Ibrahim, Ahmed Mohamed Hassan; Tekerek, Emine; Kontsos, Antonios; Palmese, Giuseppe R.; Alvarez, Nicolas J.

doi:10.1016/j.compositesa.2021.106339

Cited by 20 publications

(12 citation statements)

References 37 publications

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“…A study was conducted by Idress et al [39] on the effect of resin-rich layers on mechanical properties of 3D printed woven fiber-reinforced composites to determine the effects of resin-rich layer (RRL) thickness on mechanical properties of the composites. In their experiment, laminated composites were fabricated with controlled RRL thickness in the range of 0-200 µm and further tested for Mode I and Mode II interlaminar properties, short beam shear, flexure, and tensile.…”

Section: Resin-rich Zonesmentioning

confidence: 99%

Delamination and Manufacturing Defects in Natural Fiber-Reinforced Hybrid Composite: A Review

et al. 2021

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In recent years, most boat fabrication companies use 100% synthetic fiber-reinforced composite materials, due to their high performance of mechanical properties. In the new trend of research on the fabrication of boat structure using natural fiber hybrid with kevlar/fiberglass-reinforced composite, the result of tensile, bending, and impact strength showed that glass fiber-reinforced polyester composite gave high strength with increasing glass fiber contents. At some point, realizing the cost of synthetic fiber is getting higher, researchers today have started to use natural fibers that are seen as a more cost-effective option. Natural fibers, however, have some disadvantages, such as high moisture absorption, due to repelling nature; low wettability; low thermal stability; and quality variation, which lead to the degradation of composite properties. In recent times, hybridization is recommended by most researchers as a solution to natural fiber’s weaknesses and to reduce the use of synthetic fibers that are not environmentally friendly. In addition, hybrid composite has its own special advantages, i.e., balanced strength and stiffness, reduced weight and cost, improved fatigue resistance and fracture toughness, and improved impact resistance. The synthetic–nature fiber hybrid composites are used in a variety of applications as a modern material that has attracted most manufacturing industries’ attention to shift to using the hybrid composite. Some of the previous studies stated that delamination and manufacturing had influenced the performance of the hybrid composites. In order to expand the use of natural fiber as a successful reinforcement in hybrid composite, the factor that affects the manufacturing defects needs to be investigated. In this review paper, a compilation of the reviews on the delamination and a few common manufacturing defect types illustrating the overview of the impact on the mechanical properties encountered by most of the composite manufacturing industries are presented.

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Section: Resin-rich Zonesmentioning

confidence: 99%

Delamination and Manufacturing Defects in Natural Fiber-Reinforced Hybrid Composite: A Review

et al. 2021

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“…We utilized vat polymerization additive manufacturing, a previously validated method, to produce laminated composites with controlled RRL thickness and tested mode I interlaminar fracture toughness of control and interleaved composites with different combinations of resin. This technique is discussed in detail and compared with vacuum-assisted resin transfer molding in Idrees et al 25 Note that controlled interleaved specimens could not be made without the use of additive manufacturing. 25 The results obtained are combined with findings from a previous study to establish a correlation between resins' fracture toughness ratio, composite mode I fracture mechanisms, and overall toughness translation.…”

Section: Introductionmentioning

confidence: 99%

“…This technique is discussed in detail and compared with vacuum-assisted resin transfer molding in Idrees et al 25 Note that controlled interleaved specimens could not be made without the use of additive manufacturing. 25 The results obtained are combined with findings from a previous study to establish a correlation between resins' fracture toughness ratio, composite mode I fracture mechanisms, and overall toughness translation. 19…”

Section: Introductionmentioning

confidence: 99%

The effect of resin properties on toughness translation in interleaved composites

Idrees,

Palmese,

Alvarez

2024

Journal of Composite Materials

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Interleaving is a well-recognized method for enhancing the interlaminar fracture toughness of composite materials. However, theoretical toughness is often not realized since cracks tend to propagate through regions of lower toughness. While most studies have focused on the effect of interleaf properties, e.g., thickness and interleaf resin properties, on composite interlaminar fracture toughness, the effect of matrix resin properties on interleaved composite toughness has been overlooked. Recently, we hypothesized that there is a relationship between toughness translation and the ratio of matrix to interleaf resin toughness. In this work, we use additive manufacturing to test this hypothesis with a range of resins in interleaved composite. Toughness is quantified via mode I delamination resistance. Our results confirm our hypothesis that the ratio of matrix to interleaf resin fracture toughness, i.e., the ratio of [Formula: see text], is directly correlated to the degree of toughness translation. More specifically, a ratio of approximately 0.5 is required for effective interleaving; below 0.5, the toughness translation is significantly below the theoretical value. This approach has important implications for the design and fabrication of tough composites via choice of resins.

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“…Furthermore, there is an optimum thickness of RRL whereby additional thickness does not offer any further delamination resistance. However, this thickness is not well known, but is argued to depend on the plastic zone length of the toughening resin [21]. The trade-off between delamination resistance and reduction in fiber volume fraction highlights the necessity of optimizing δ RRL thickness.…”

Section: Introductionmentioning

confidence: 99%

Engineered Interleaved Random Glass Fiber Composites Using Additive Manufacturing: Effect of Mat Properties, Resin Chemistry, and Resin-Rich Layer Thickness

et al. 2023

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Standard lay-up fabrication of fiber-reinforced composites (FRCs) suffer from poor out-of-plane properties and delamination resistance. While advanced manufacturing techniques (e.g., interleaving, braiding, and z-pinning) increase delamination resistance in FRCs, they typically result in significant fabrication complexity and limitations, increased manufacturing costs, and/or overall stiffness reduction. In this work, we demonstrate the use of facile digital light processing (DLP) technique to additively manufacture (AM) random glass FRCs with engineered interleaves. This work demonstrates how vat photo-polymerization techniques can be used to build composites layer-by-layer with controlled interleaf material, thickness, and placement. Note that this engineering control is almost impossible to achieve with traditional manufacturing techniques. A range of specimens were printed to measure the effect of interleaf thickness and material on tensile/flexural properties as well as fracture toughness. One important observation was the ≈60% increase in interlaminar fracture toughness achieved by using a tough resin material in the interleaf. The comparison between AM and traditionally manufactured specimens via vacuum-assisted resin transfer molding (VARTM) highlighted the limitation of AM techniques in achieving high mat consolidation. In other words, the volume fraction of AM parts is limited by the wet fiber mat process, and engineering solutions are discussed. Overall, this technique offers engineering control of FRC design and fabrication that is not available with traditional methods.

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The effect of resin-rich layers on mechanical properties of 3D printed woven fiber-reinforced composites

Cited by 20 publications

References 37 publications

Delamination and Manufacturing Defects in Natural Fiber-Reinforced Hybrid Composite: A Review

Delamination and Manufacturing Defects in Natural Fiber-Reinforced Hybrid Composite: A Review

The effect of resin properties on toughness translation in interleaved composites

Engineered Interleaved Random Glass Fiber Composites Using Additive Manufacturing: Effect of Mat Properties, Resin Chemistry, and Resin-Rich Layer Thickness

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