A parametric study and characterization of additively manufactured continuous carbon fiber reinforced composites for high-speed 3D printing
A parametric study and characterization of additively manufactured continuous carbon fiber reinforced composites for high-speed 3D printing
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DOI：
10.1007/s00170-021-06723-1
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发表时间：
2021-02
期刊：
影响因子：
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通讯作者：
J. M. Pappas;Aditya Thakur;M. Leu;Xiangyang Dong
中科院分区：
文献类型：
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作者：
J. M. Pappas;Aditya Thakur;M. Leu;Xiangyang Dong
高速3D打印由于其在提高制造复杂几何形状部件的效率和在大规模增材制造（AM）中的应用方面的潜力，最近引起了人们的极大兴趣。在这项研究中，进行了参数研究实验，以研究影响连续碳纤维增强复合材料（CFRCs）的高速3D打印的因素，包括材料沉积速率，打印（喷嘴横向）速度和喷嘴倾斜角度基于一种新的多轴AM方法。该方法使用热塑性粒料和连续碳纤维丝束作为原料材料。所获得的样品的质量和机械性能进行了研究相对于沉积速率，打印速度，和喷嘴倾斜角度。通过微观结构分析考察了纤维浸渍质量，并与工艺条件和力学性能进行了关联。增加沉积速率和倾斜角都能提高纤维浸渍质量，从而实现更高的印刷速度并产生更好的机械性能。这一点，结合打印的复杂几何形状的组件的演示，显示了巨大的潜力，所提出的方法AM连续CFRC在高速。该研究结果还为通过3D打印设计和制造大体积，高强度CFRC提供了进一步的指导。
High-speed 3D printing has recently gained much interest due to its potentials in improving efficiency of fabricating complex geometry components and applications in large-scale additive manufacturing (AM). In this study, a parametric study is performed experimentally to investigate factors affecting high-speed 3D printing of continuous carbon fiber reinforced composites (CFRCs), including material deposition rate, print (nozzle traverse) speed, and nozzle tilt angle based on a novel multi-axis AM approach. The method uses thermoplastic pellets and continuous carbon fiber tows as feedstock materials. The obtained sample quality and mechanical properties are investigated with respect to deposition rate, print speed, and nozzle tilt angle. The fiber impregnation quality is examined through microstructure analysis and correlated with the process conditions and mechanical properties. Increasing deposition rate and tilt angle both improve fiber impregnation quality, enabling implementation of higher print speed and yielding improved mechanical properties. This, combined with demonstrations of printed complex geometry components, shows the great potentials of the proposed method for AM of continuous CFRCs at high speeds. The results of this study also provide further guidance on design and manufacturing of large-volume, high-strength CFRCs through 3D printing.