CAREER: Additive Manufacturing of Polymer Composites via in-situ Polymerization

职业：通过原位聚合增材制造聚合物复合材料

• 批准号: 2239563
• 负责人: Mostafa Yourdkhani
• 金额: $ 66.55万
• 依托单位: Colorado State University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2023
• 资助国家: 美国
• 起止时间: 2023-05-01 至 2028-04-30
• 项目状态: 未结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2239563&HistoricalAwards=false
• 关键词: CAREER; Additive; Manufacturing; Polymer; Composites

Traditional manufacturing of fiber-reinforced polymer composites is slow, energy-inefficient, and labor-intensive. It requires using expensive molds that severely limit the flexibility in the design and fabrication of complex composite structures. Additive manufacturing provides a promising alternative for rapidly creating desired composite structures without needing molds; however, additive manufacturing of high-quality fiber-reinforced composites is challenging, mainly because it is difficult to mix the matrix polymer with solid fiber reinforcements uniformly prior to deposition and then rigidize them in place along the desired print path. This Faculty Early Career Development (CAREER) award will support fundamental research that will enable additive manufacturing of composites containing a high concentration of carbon fibers by instantaneously rigidizing the composite material during the printing process. If successful, this project will lay a theoretical foundation for rapid manufacturing of composites without molds or even in midair. This project will provide hands-on activities to encourage Colorado’s middle and high school students, particularly women and Hispanic/Latinx students, in STEM education. New courses and experiential activities will be developed to train the next generation of composites workforce.Current approaches for the additive manufacturing of continuous fiber-reinforced polymer composites are mainly focused on using thermoplastic polymers or photocurable resins as the matrix polymer of composites, which typically have poor mechanical properties and/or are hard to process with a high volume-fraction of fibers. This project will investigate the manufacturing science of a new composite additive manufacturing method based on in-situ thermal polymerization of the matrix resin of composites. Central to this project is a new composite manufacturing platform that uses a remote stimulus to locally heat the thermo-responsive liquid resin of the composite filament to instantaneously polymerize and rigidize the printed composite. This project will elucidate the intrinsic interplay between process parameters, spatiotemporal variations in material composition and properties, and multiscale performance of printed composites. The proposed research is expected to uncover the mechanisms of interface formation and bonding control between adjacent layers. Experimental and numerical studies will be used to understand the viscoelastic deformation behavior and fiber distribution within filaments along multilayered, curvilinear paths during the manufacturing process. Finally, a new sensing and control framework will be developed to determine multiscale physical and thermochemical properties of materials during the manufacturing process and update the processing parameters on the fly to manufacture high-quality complex composite structures.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

传统的纤维增强聚合物复合材料制造速度慢、能源效率低、劳动密集型。它需要使用昂贵的模具，这严重限制了复杂复合材料结构的设计和制造的灵活性。添加剂制造为快速制造所需的复合材料结构提供了一种很有前途的替代方案，而无需模具；然而，高质量纤维增强复合材料的添加剂制造是具有挑战性的，主要是因为很难在沉积之前将基质聚合物与固体纤维增强材料均匀混合，然后沿着所需的打印路径将它们在适当的位置硬化。该学院早期职业发展(CALEAR)奖将支持基础研究，这些研究将通过在印刷过程中对复合材料进行瞬时硬化来实现含有高浓度碳纤维的复合材料的添加剂制造。如果该项目成功，将为无模甚至半空快速制造复合材料奠定理论基础。该项目将提供实践活动，鼓励科罗拉多州的初中生和高中生，特别是女性和西班牙裔/拉丁裔学生接受STEM教育。为了培养下一代复合材料工作者，将开发新的课程和体验活动。目前，连续纤维增强聚合物复合材料的添加剂制造方法主要集中在使用热塑性聚合物或光固化树脂作为复合材料的基质聚合物，这些聚合物通常力学性能较差和/或纤维体积分数高难以加工。本项目将研究一种基于复合材料基质树脂原位热聚合的新型复合材料添加剂制造方法的制造科学。该项目的核心是一种新的复合材料制造平台，该平台使用远程刺激来局部加热复合长丝的热敏性液体树脂，从而瞬间聚合并硬化印刷的复合材料。这个项目将阐明工艺参数、材料组成和性能的时空变化以及印刷复合材料的多尺度性能之间的内在相互作用。这项研究有望揭示界面形成和相邻层间结合控制的机制。实验和数值研究将用于了解制造过程中纤维在多层曲线路径上的粘弹性变形行为和纤维分布。最后，将开发一种新的传感和控制框架，以确定制造过程中材料的多尺度物理和热化学性质，并动态更新工艺参数，以制造高质量的复杂复合材料结构。该奖项反映了NSF的法定使命，并通过使用基金会的智力优势和更广泛的影响审查标准进行评估，被认为值得支持。