Novel high performance polymeric composite materials for additive manufacturing of multifunctional components

用于多功能部件增材制造的新型高性能聚合物复合材料

• 批准号: EP/N034627/1
• 负责人: Yanqiu Zhu
• 金额: $ 79.6万
• 依托单位: UNIVERSITY OF EXETER
• 依托单位国家: 英国
• 项目类别: Research Grant
• 财政年份: 2016
• 资助国家: 英国
• 起止时间: 2016 至 无数据
• 项目状态: 已结题
• 来源: https://gtr.ukri.org/projects?ref=EP%2FN034627%2F1
• 关键词: Novel; performance; polymeric; composite; materials

The aim of this proposal is to develop novel high performance, nanocomposite feed materials for Additive Manufacturing (AM). The field of AM, also known also as 3D Printing, has expanded significantly over the last couple of decades across virtually all-industrial sectors due a number of key advantages that traditional manufacturing just cannot offer. These include mass customisation, geometrical complexity, tool-less manufacture and sustainable manufacturing. Among the companies using AM are GE (medical devices, and home appliance parts), Lockheed Martin and Boeing (aerospace and defense), Invisalign (dental devices) and LUXeXcel (lenses for light-emitting diodes, or LEDs). The worldwide revenue from 3D printing is expected to grow from $3.07 billion in 2013 to $12.8 billion by 2018, and exceed $21 billion by 2020, and has a potential of generating an economic impact of $230 billion to $550 billion per year by 2025. While the forecast for AM products is huge this will only be achieved if we can actually manufacture parts with the desired properties. The majority of polymeric AM research is however focused on low glass transition temperature (Tg) polymers such as Polyamide 11, 12 , Polycarbonate and Poly Lactic acid (PLA), due to their good processing characteristics (rheological, thermal and crystallization). For advanced, high value applications in aerospace, telecommunication and defense where harsh environmental conditions often exist (and in some key biomedical application) these low Tg polymers for AM are not acceptable so there is a real need to develop materials for these applications. Whilst a sufficiently high Tg polymer could offer the required high performance, nanocomposites with increased functionalities and potential combinations of properties such as high stiffness, strength, wear and specific thermal, electrical and microwave response can really transform the performance of AM components. The ability to manipulate other properties, such as rheological and thermal performance, by the addition of nanoparticles offers further potential advantages in terms of processing characteristics. This proposal will examine the potential of inorganic fullerene-like (IF) tungsten disulfide (WS2) or IF-WS2 as nanofillers for high value, PAEK (Poly Aryl Ether Ketone) based products made via the AM processes of Selective Laser Sintering (SLS) and Fused Deposition Modelling (FDM). The incorporation of IF particles has been shown to be efficient for improving thermal, mechanical and tribological properties of various thermoplastic polymers, such as polypropylene, nylon-6, poly(phenylene sulfide), poly(ether ether ketone). These nanocomposites were fabricated by simple melt-processing routes without the need for modifiers or surfactants . IF-WS2 have been proven to exhibit extremely high tribological performance in composites to reduce wear and coefficient of friction .These characteristics will also have important processability benefits for AM processes as will their dispersion characteristics which are superior to 1D and 2D nanoparticles. They are also the best shock absorbing cage structures known to mankind. Importantly, they are non-toxic, and thermally stable. We will examine the two main AM processes for producing parts with engineering properties, Selective Laser Sintering (SLS) in which a laser is used to melt and sinter powdered polymer into the final part and Fused Deposition Modelling (FDM) in which a polymer filament is melted in a heated nozzle and deposited in the required pattern to form the part.

该提案的目的是开发用于增材制造（AM）的新型高性能纳米复合材料。由于具有传统制造业无法提供的许多关键优势，增材制造（也称为 3D 打印）领域在过去几十年中已显着扩展，几乎遍及所有工业领域。其中包括大规模定制、几何复杂性、无工具制造和可持续制造。使用增材制造的公司包括 GE（医疗设备和家用电器零件）、洛克希德·马丁公司和波音公司（航空航天和国防）、Invisalign（牙科设备）和 LUXeXcel（发光二极管或 LED 透镜）。全球 3D 打印收入预计将从 2013 年的 30.7 亿美元增长到 2018 年的 128 亿美元，到 2020 年将超过 210 亿美元，到 2025 年可能产生每年 2300 亿美元到 5500 亿美元的经济影响。虽然增材制造产品的预测巨大，但只有我们能够实际制造具有所需性能的零件，才能实现这一目标。然而，大多数聚合物增材制造研究都集中在低玻璃化转变温度 (Tg) 聚合物，例如聚酰胺 11、12、聚碳酸酯和聚乳酸 (PLA)，因为它们具有良好的加工特性（流变、热和结晶）。对于航空航天、电信和国防领域经常存在恶劣环境条件的先进高价值应用（以及在一些关键的生物医学应用中），这些用于增材制造的低 Tg 聚合物是不可接受的，因此确实需要为这些应用开发材料。虽然足够高的 Tg 聚合物可以提供所需的高性能，但具有增强功能和潜在性能组合（例如高刚度、强度、耐磨性以及特定的热、电和微波响应）的纳米复合材料可以真正改变增材制造组件的性能。通过添加纳米粒子来控制其他性能（例如流变性能和热性能）的能力在加工特性方面提供了进一步的潜在优势。该提案将研究无机类富勒烯 (IF) 二硫化钨 (WS2) 或 IF-WS2 作为纳米填料的潜力，用于通过选择性激光烧结 (SLS) 和熔融沉积成型 (FDM) 的增材制造工艺制造的高价值、基于 PAEK（聚芳基醚酮）的产品。 IF 颗粒的掺入已被证明可有效改善各种热塑性聚合物（如聚丙烯、尼龙 6、聚苯硫醚、聚醚醚酮）的热性能、机械性能和摩擦学性能。这些纳米复合材料是通过简单的熔融加工路线制造的，不需要改性剂或表面活性剂。 IF-WS2 已被证明在复合材料中表现出极高的摩擦学性能，可减少磨损和摩擦系数。这些特性也将为增材制造工艺带来重要的可加工性优势，其分散特性也优于一维和二维纳米颗粒。它们也是人类已知的减震效果最好的笼式结构。重要的是，它们无毒且热稳定。我们将研究用于生产具有工程特性的零件的两种主要增材制造工艺：选择性激光烧结 (SLS)，其中使用激光将粉末状聚合物熔化并烧结成最终零件；以及熔融沉积成型 (FDM)，其中聚合物细丝在加热喷嘴中熔化并沉积成所需的图案以形成零件。

项目成果

Metal-organic-frameworks derived cobalt embedded in various carbon structures as bifunctional electrocatalysts for oxygen reduction and evolution reactions.

• DOI: 10.1038/s41598-017-05636-y
• 发表时间: 2017-07-13
• 期刊: Scientific reports
• 影响因子: 4.6
• 作者: Chen B;Ma G;Zhu Y;Xia Y
• 通讯作者: Xia Y

In-situ synthesis of Metal Organic Frameworks (MOFs)-PA12 powders and their laser sintering into hierarchical porous lattice structures

• DOI: 10.1016/j.addma.2020.101774
• 发表时间: 2021-02
• 期刊: Additive manufacturing
• 影响因子: 11
• 作者: Binling Chen;R. Davies;Hong Chang;Yongde Xia;Yanqiu Zhu;O. Ghita

Effect of water on the breakdown and dielectric response of polypropylene/nano-aluminium nitride composites

• DOI: 10.1007/s10853-020-04635-1
• 发表时间: 2020-07-01
• 期刊: JOURNAL OF MATERIALS SCIENCE
• 影响因子: 4.5
• 作者: Wang, Xinyu;Qiang, Dayuan;Andritsch, Thomas
• 通讯作者: Andritsch, Thomas

A generic method to synthesise graphitic carbon coated nanoparticles in large scale and their derivative polymer nanocomposites.

• DOI: 10.1038/s41598-017-12200-1
• 发表时间: 2017-09-19
• 期刊: Scientific reports
• 影响因子: 4.6
• 作者: Wang N;Yang Z;Xu F;Thummavichai K;Chen H;Xia Y;Zhu Y
• 通讯作者: Zhu Y

Interface and properties of inorganic fullerene tungsten sulphide nanoparticle reinforced poly (ether ether ketone) nanocomposites

• DOI: 10.1016/j.rinp.2017.07.018
• 发表时间: 2017
• 期刊: Results in physics
• 影响因子: 5.3
• 作者: Nannan Wang;Zhuxian Yang;Yuan Wang;Kunyapat Thummavichai;Yongde Xia;O. Ghita;Yanqiu Zhu