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Interfacial Transcrystallization and Mechanical Performance of 3D-Printed Fully Recyclable Continuous Fiber Self-Reinforced Composites.

ABSTRACT: To fully exploit the preponderance of three-dimensional (3D)-printed, continuous, fiber-reinforced, thermoplastic composites (CFRTPCs) and self-reinforced composites (which exhibit excellent interfacial affinity and are fully recyclable), an approach in which continuous fiber self-reinforced composites (CFSRCs) can be fabricated by 3D printing is proposed. The influence of 3D-printing temperature on the mechanical performance of 3D-printed CFSRCs based on homogeneous, continuous, ultra-high-molecular-weight polyethylene (UHMWPE) fibers and high-density polyethylene (HDPE) filament, utilized as a reinforcing phase and matrix, respectively, was studied. Experimental results showed a qualitative relationship between the printing temperature and the mechanical properties. The ultimate tensile strength, as well as Young's modulus, were 300.2 MPa and 8.2 GPa, respectively. Furthermore, transcrystallization that occurred in the process of 3D printing resulted in an interface between fibers and the matrix. Finally, the recyclability of 3D-printed CFSRCs has also been demonstrated in this research for potential applications of green composites.

SUBMITTER: Zhang M

PROVIDER: S-EPMC8471758 | biostudies-literature |

REPOSITORIES: biostudies-literature

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Continuous Fiber-Reinforced Aramid/PETG 3D-Printed Composites with High Fiber Loading through Fused Filament Fabrication.

Project description:Recent development in the field of additive manufacturing, also known as three-dimensional (3D) printing, has allowed for the incorporation of continuous fiber reinforcement into 3D-printed polymer parts. These fiber reinforcements allow for the improvement of the mechanical properties, but compared to traditionally produced composite materials, the fiber volume fraction often remains low. This study aims to evaluate the in-nozzle impregnation of continuous aramid fiber reinforcement with glycol-modified polyethylene terephthalate (PETG) using a modified, low-cost, tabletop 3D printer. We analyze how dimensional printing parameters such as layer height and line width affect the fiber volume fraction and fiber dispersion in printed composites. By varying these parameters, unidirectional specimens are printed that have an inner structure going from an array-like to a continuous layered-like structure with fiber loading between 20 and 45 vol%. The inner structure was analyzed by optical microscopy and Computed Tomography (µCT), achieving new insights into the structural composition of printed composites. The printed composites show good fiber alignment and the tensile modulus in the fiber direction increased from 2.2 GPa (non-reinforced) to 33 GPa (45 vol%), while the flexural modulus in the fiber direction increased from 1.6 GPa (non-reinforced) to 27 GPa (45 vol%). The continuous 3D reinforced specimens have quality and properties in the range of traditional composite materials produced by hand lay-up techniques, far exceeding the performance of typical bulk 3D-printed polymers. Hence, this technique has potential for the low-cost additive manufacturing of small, intricate parts with substantial mechanical performance, or parts of which only a small number is needed.

| S-EPMC8778918 | biostudies-literature

Outstanding Strengthening and Toughening Behavior of 3D-Printed Fiber-Reinforced Composites Designed by Biomimetic Interfacial Heterogeneity.

Project description:3D printing of fiber-reinforced composites is expected to be the forefront technology for the next-generation high-strength, high-toughness, and lightweight structural materials. The intrinsic architecture of 3D-printed composites closely represents biomimetic micro/macrofibril-like hierarchical structure composed of intermediate filament assembly among the micron-sized reinforcing fibers, and thus contributes to a novel mechanism to simultaneously improve mechanical properties and structural features. Notably, it is found that an interfacial heterogeneity between numerous inner interfaces in the hierarchical structure enables an exceptional increase in the toughness of composites. The strong interfacial adhesion between the fibers and matrix, with accompanying the inherently weak interfacial adhesion between intermediate filaments and the resultant interfacial voids, provide a close representation of the toughness behavior of natural architectures relying on the localized heterogeneity. Given the critical embedment length of fiber reinforcement, extraordinary improvement has been attained not only in the strength but also in toughness taking advantage of the synergy effect from the aforementioned nature-inspired features. Indeed, the addition of a small amount of short fiber to the brittle bio-filaments results in a noticeable increase of more than 200% in the tensile strength and modulus with further elongation increment. This article highlights the inherent structural hierarchy of 3D-printed composites and the relevant sophisticated mechanism for anomalous mechanical reinforcement.

| S-EPMC8787430 | biostudies-literature

3D Printing of Continuous Fiber Reinforced Low Melting Point Alloy Matrix Composites: Mechanical Properties and Microstructures.

Project description:A novel 3D printing route to fabricate continuous fiber reinforced metal matrix composite (CFRMMC) is proposed in this paper. It is distinguished from the 3D printing process of polymer matrix composite that utilizes the pressure inside the nozzle to combine the matrix with the fiber. This process combines the metallic matrix with the continuous fiber by utilizing the wetting and wicking performances of raw materials to form the compact internal structures and proper fiber-matrix interfaces. CF/Pb50Sn50 composites were printed with the Pb50Sn50 alloy wire and modified continuous carbon fiber. The mechanical properties of the composite specimens were studied, and the ultimate tensile strength reached 236.7 MPa, which was 7.1 times that of Pb50Sn50 alloy. The fracture and interfacial microstructure were investigated and analyzed. The relationships between mechanical properties and interfacial reactions were discussed. With the optimized process parameters, several composites parts were printed to demonstrate the advantages of low cost, short fabrication period and flexibility in fabrication of complex structures.

| S-EPMC7475899 | biostudies-literature

Multiply fully recyclable carbon fibre reinforced heat-resistant covalent thermosetting advanced composites.

Project description:Nondestructive retrieval of expensive carbon fibres (CFs) from CF-reinforced thermosetting advanced composites widely applied in high-tech fields has remained inaccessible as the harsh conditions required to recycle high-performance resin matrices unavoidably damage the structure and properties of CFs. Degradable thermosetting resins with stable covalent structures offer a potential solution to this conflict. Here we design a new synthesis scheme and prepare a recyclable CF-reinforced poly(hexahydrotriazine) resin matrix advanced composite. The multiple recycling experiments and characterization data establish that this composite demonstrates performance comparable to those of its commercial counterparts, and more importantly, it realizes multiple intact recoveries of CFs and near-total recycling of the principal raw materials through gentle depolymerization in certain dilute acid solution. To our best knowledge, this study demonstrates for the first time a feasible and environment-friendly preparation-recycle-regeneration strategy for multiple CF-recycling from CF-reinforced advanced composites.

| S-EPMC5337986 | biostudies-literature

Enhancement of mechanical and electrical properties of continuous-fiber-reinforced epoxy composites with stacked graphene.

Project description:Impregnation of expandable graphite (EG) after thermal treatment with an epoxy resin containing surface-active agents (SAAs) enhanced the intercalation of epoxy monomer between EG layers and led to further exfoliation of the graphite, resulting in stacks of few graphene layers, so-called "stacked" graphene (SG). This process enabled electrical conductivity of cured epoxy/SG composites at lower percolation thresholds, and improved thermo-mechanical properties were measured with either Kevlar, carbon or glass-fiber-reinforced composites. Several compositions with SAA-modified SG led to higher dynamic moduli especially at high temperatures, reflecting the better wetting ability of the modified nanoparticles. The hydrophilic/hydrophobic nature of the SAA dictates the surface energy balance. More hydrophilic SAAs promoted localization of the SG at the Kevlar/epoxy interface, and morphology seems to be driven by thermodynamics, rather than the kinetic effect of viscosity. This effect was less obvious with carbon or glass fibers, due to the lower surface energy of the carbon fibers or some incompatibility with the glass-fiber sizing. Proper choice of the surfactant and fine-tuning of the crosslink density at the interphase may provide further enhancements in thermo-mechanical behavior.

| S-EPMC5629411 | biostudies-literature

Short fiber reinforced 3d printed ceramic composite with shear induced alignment.

Project description:This paper accounts for utilization of shear induced alignment method during ceramic stereolithography. Lateral oscillation mechanism, combined with 3d printed wall pattern, was employed to generate necessary shear to align fiber in desired direction. First, semicircular channel pattern was printed to assess the effect of difference between wall direction and oscillation direction on the fiber alignment. Then, flexural strength of ceramic matrix was tested with nickel coated carbon fiber and ceramic fiber reinforcements. The results demonstrated that the shear induced alignment further improves the flexural strength compare to randomly distributed samples. Flexural strength of aligned samples with 1.0 wt% carbon fiber loading was improved by ~90% compared to randomly orientated samples and by ~333% compared to unreinforced samples. Finally, fracture surface morphology of the flexural strength test specimens was evaluated. The main fracture mechanism was observed as fiber pull-out.

| S-EPMC6191193 | biostudies-literature

Mechanical Characterization and Production of Various Shapes Using Continuous Carbon Fiber-Reinforced Thermoset Resin-Based 3D Printing

Project description: Not available

| S-EPMC11243913 | biostudies-literature

Optimal design and manufacture of variable stiffness laminated continuous fiber reinforced composites.

Project description:Advanced manufacturing methods like multi-material additive manufacturing are enabling realization of multiscale materials with intricate spatially varying microstructures and thus, material properties. This blurs the boundary between material and structure, paving the way to lighter, stiffer, and stronger structures. Taking advantage of these tunable multiscale materials warrants development of novel design methods that effectively marry the concepts of material and structure. We propose such a design to manufacture workflow and demonstrate it with laminated continuous fiber-reinforced composites that possess variable stiffness enabled by spatially varying microstructure. This contrasts with traditional fiber-reinforced composites which typically have a fixed, homogenous microstructure and thus constant stiffness. The proposed workflow includes three steps: (1) Design automation-efficient synthesis of an optimized multiscale design with microstructure homogenization enabling efficiency, (2) Material compilation-interpretation of the homogenized design lacking specificity in microstructural detail to a manufacturable structure, and (3) Digital manufacturing-automated manufacture of the compiled structure. We adapted multiscale topology optimization, a mesh parametrization-based algorithm and voxel-based multimaterial jetting for these three steps, respectively. We demonstrated that our workflow can be applied to arbitrary 2D or 3D surfaces. We validated the complete workflow with experiments on two simple planar structures; the results agree reasonably well with simulations.

| S-EPMC7536228 | biostudies-literature

Mechanical Properties and Synergistic Interfacial Interactions of ZnO Nanorod-Reinforced Polyamide-Imide Composites.

Project description:Metal oxide nanoparticle -reinforced polymers have received considerable attention due to their favorable mechanical properties compared to neat materials. However, the effect of nanoscale reinforcements of the interface on the composites' mechanical properties has not been investigated in-depth to reach their optimal performance in structural applications. Aiming at revealing the effect of synergistic interfacial interactions on the mechanical properties of polymer composites, using a nanoscale reinforcement, herein, a series of zinc oxide nanorod-reinforced polyamide-imide (PAI)/ZnO) composites were fabricated and their mechanical properties and viscoelastic responses were investigated. The composite prepared by reinforcing them with 5 wt % ZnO nanorods resulted in improved elastic modulus, stiffness, and hardness values by 32%, 14% and 35%, respectively, compared to neat polymer thin films. The viscoelastic dynamics of the composites revealed that there was an 11% increase in elastic wave speed in the composite, containing 5 wt % ZnO nanorods, indicating better response to high impacts. Delayed viscoelastic response decreased by 67% spatially and 51% temporally, with a corresponding decrease in the creep rate, for the 5 wt % ZnO nanorod- containing composite, evidencing its potential applicability in high strength lightweight structures. The improved mechanical properties with respect to the filler concentration evidence strong particle-polymer interfacial interactions, creating "chain-bound" clusters, providing clear reinforcement and polymer chain mobility retardation. However, hypervelocity impact testing revealed that all the composites' films were vulnerable to hypervelocity impact, but the spallation region of the composite films reinforced with 2.5 wt % and 5 wt % ZnO nanorods exhibited a cellular-like matrix with shock-induced voids compared to a rather hardened spallation region with cracks in the neat film.

| S-EPMC10055968 | biostudies-literature

Carbon Fiber Reinforced Recycled Polypropylene/Polyolefin Elastomer Composites with High Mechanical Properties.

Project description:The treatment of waste plastics has gradually become a hot topic in the current scientific community. In response to the needs for high-impact performance R-PP-based composites, carbon fiber (CF)-reinforced polyolefin elastomer (POE)/recycled polypropylene (R-PP) composite (CF/POE/R-PP) was prepared by the mechanical blending method, and its mechanical and thermal properties were systematically studied. It was found that the CF could effectively improve the bending and notch impact strength as well as enhance the thermal stability of POE/R-PP. Furthermore, a stable and dispersed composite interface formed by the combination of maleic anhydride-grafted polypropylene (PP-g-MAH) with the surface of CF and the fusion alkyl chains in R-PP and POE further enhanced the CF's reinforcing effect. As a result, the addition of 9 wt.% CF successfully improved the heat resistance of the composite material, and the residual carbon content increased by 97.84% after sintering. The composite toughening of POE and CF effectively improved the impact strength of the composite material, with a maximum increase of over 1000%. This study ultimately resulted in a high-impact-resistant composite material.

| S-EPMC11013364 | biostudies-literature

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