Strength and its Variability in 3D Printing of Polymer Composites with Continuous Fibers
Strength and its Variability in 3D Printing of Polymer Composites with Continuous Fibers
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DOI：
10.1016/j.matdes.2022.111505
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发表时间：
2022-12
期刊：
影响因子：
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通讯作者：
M. Parker;N. Ezeokeke;R. Matsuzaki;D. Arola
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文献类型：
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作者：
M. Parker;N. Ezeokeke;R. Matsuzaki;D. Arola
具有连续纤维的聚合物复合材料的增材制造（AM）可能在未来的航空航天及其他领域发挥重要作用，但需要打印材料达到新的可靠性水平。本研究的特征在于所选的热塑性基体复合材料的强度分布作为通过熔丝制造（FFF）打印的函数。连续碳纤维或凯夫拉纤维的实验和商业复合材料长丝被打印，其体积分数（Vf）范围为约28至56%。在打印的特定阶段后，在单轴拉伸下评估强度，并应用威布尔统计来表征强度分布。有一个显着的印刷材料的强度相对于未印刷的条件下，无论增强类型，纤维体积分数或打印机使用。由长丝的进料挤出引入的损伤和在材料沉积时引起的纤维失效是最有害的。对于碳纤维长丝，减少的范围从实验材料的约10%到商业长丝的超过60%。强度退化或变异性与Vf无关。防止与工艺相关的纤维损伤是推进连续纤维复合材料AM和应用于应力关键应用设计的关键。
Additive manufacturing (AM) of polymer composites with continuous fibers could play a major role in the future of aerospace and beyond but will require printed materials to achieve new levels of reliability. This study characterized the strength distribution of selected thermoplastic matrix composites as a function of printing via fused filament fabrication (FFF). Experimental and commercial composite filaments of continuous carbon or Kevlar fibers were printed with volume fraction (Vf) ranging from approximately 28 to 56 %. The strength was evaluated under uniaxial tension after specific stages of printing and Weibull statistics were applied to characterize the strength distribution. There was a significant reduction in strength of the printed material with respect to the unprinted condition, regardless of reinforcement type, fiber volume fraction or printer used. Damage introduced by feed extrusion of the filament, and fiber failures induced at material deposition were most detrimental. For carbon fiber filaments, the reduction ranged from approximately 10 % for an experimental material to over 60 % for a commercial filament. There was no correlation in the strength degradation or variability with Vf. The prevention of process-related fiber damage is key to advancing AM for continuous fiber composite and application to designs intended for stress-critical applications.