Enhancing the Interlaminar Shear Strength and Void Control of 3D-Printed Continuous Carbon-Fiber-Reinforced Polymer Composites Using a Robotic Magnetic Compaction Force-Assisted Additive Manufacturing (MCFA-AM) Process and Carbon-Nanofiber Z-Threads
Enhancing the Interlaminar Shear Strength and Void Control of 3D-Printed Continuous Carbon-Fiber-Reinforced Polymer Composites Using a Robotic Magnetic Compaction Force-Assisted Additive Manufacturing (MCFA-AM) Process and Carbon-Nanofiber Z-Threads
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DOI：
10.3390/app13105914
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发表时间：
2023-05
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通讯作者：
Mohammad Rakibul Islam;W. Taylor;Ryan Warren;K. Hsiao
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文献类型：
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作者：
Mohammad Rakibul Islam;W. Taylor;Ryan Warren;K. Hsiao
使用连续碳纤维增强聚合物 (C-CFRP) 复合材料进行三维 (3D) 打印正在不断发展，因为它比传统成型工艺（例如仅使用热压罐真空袋 (OOA-VBO) 工艺）提供更多的多功能性。然而，由于材料的逐层沉积，层间会形成空隙，从而削弱零件的某些性能，例如层间剪切强度 (ILSS)。在本文中，采用新型无模具磁力压实力辅助增材制造（MCFA-AM）方法来打印碳纳米纤维（CNF）z螺纹CFRP（ZT-CFRP）层压板，与使用无压3D打印工艺（类似于传统的C-CFRP层压板）打印相比，其ILSS显着改善并降低了空隙率 熔融沉积成型工艺）。利用径向流对准 (RFA) 和树脂共混技术来制造兼容打印的快速固化 ZT-CFRP 预浸带，作为安装在机械臂上的 MCFA-AM 打印头的原料。在ILSS方面，MCFA-AM方法与ZT-CFRP纳米材料技术相结合，显着优于传统无压3D打印工艺和OOA-VBO成型工艺制成的C-CFRP。此外，无模MCFA-AM工艺的生产速度比OOA-VBO成型工艺提高了一倍多。这表明，通过集成新型纳米材料和 3D 打印技术，可以实现 C-CFRP 制造的范式转变，从而显着提高性能、多功能性、敏捷性、效率和更低的成本。
Three-dimensional (3D) printing with continuous carbon-fiber-reinforced polymer (C-CFRP) composites is under increasing development, as it offers more versatility than traditional molding processes, such as the out-of-autoclave-vacuum bag only (OOA-VBO) process. However, due to the layer-by-layer deposition of materials, voids can form between the layers and weaken some of the parts’ properties, such as the interlaminar shear strength (ILSS). In this paper, a novel mold-less magnetic compaction force-assisted additive manufacturing (MCFA-AM) method was used to print carbon nanofiber (CNF) z-threaded CFRP (ZT-CFRP) laminates with significantly improved ILSS and reduced void content compared to traditional C-CFRP laminates, which are printed using a no-pressure 3D-printing process (similar to the fused-deposition-modeling process). The radial flow alignment (RFA) and resin-blending techniques were utilized to manufacture a printing-compatible fast-curing ZT-CFRP prepreg tape to act as the feedstock for a MCFA-AM printhead, which was mounted on a robotic arm. In terms of the ILSS, the MCFA-AM method coupled with ZT-CFRP nanomaterial technology significantly outperformed the C-CFRP made with both the traditional no-pressure 3D-printing process and the OOA-VBO molding process. Furthermore, the mold-less MCFA-AM process more than doubled the production speed of the OOA-VBO molding process. This demonstrates that through the integration of new nanomaterials and 3D-printing techniques, a paradigm shift in C-CFRP manufacturing with significantly better performance, versatility, agility, efficiency, and lower cost is achievable.