scholarly journals 3D printing of a continuous fiber-reinforced composite based on a coaxial Kevlar/PLA filament

2021 ◽  
Vol 30 ◽  
pp. 263498332110000
Author(s):  
Trenton Cersoli ◽  
Bharat Yelamanchi ◽  
Eric MacDonald ◽  
Jose Gonzalo Carrillo ◽  
Pedro Cortes
Keyword(s):  
Additive Manufacturing ◽  
High Velocity ◽  
Fiber Volume Fraction ◽  
Mechanical Performance ◽  
Volume Fraction ◽  
High Velocity Impact ◽  
Fused Filament Fabrication ◽  
Fiber Volume ◽  
Velocity Impact ◽  
3D Printed

Additive manufacturing has allowed for the production of complex and mass customized geometries, but often at the expense of mechanical performance, a penalty which can be in part mitigated with the fabrication of composite parts. Thermoplastic structures fabricated with material extrusion additive manufacturing stand to be improved in terms of fracture toughness with the integration of continuous fibers. The present research program has investigated the production of a continuously reinforced filament to be used in open-source fused filament fabrication systems. Three different volume fractions of Kevlar fibers were incorporated into a polylactic acid (PLA) thermoplastic filament. It was observed that a 20% fiber volume fraction resulted in a doubling of the tensile strength relative to the unreinforced PLA parts. High-velocity impact tests were also performed on the reinforced printed thermoplastic material, and it was observed that the composite with the highest fiber volume fraction provided an impact energy resistance improved by a factor of four, relative to the plain PLA. The reinforced fibers have shown to restrain the penetration of the projectile at velocities similar to those that perforated the unreinforced PLA. The present work has demonstrated the production of printed composites without the need of modifying the extruding systems of a commercial 3D printer. This approach could represent an alternate and feasible process for producing continuously reinforced 3D-printed thermoplastic parts with utility for high-velocity impact applications.

scholarly journals The Mechanical Properties of Fiber Metal Laminates Based on 3D Printed Composites

Materials ◽  
2020 ◽  
Vol 13 (22) ◽  
pp. 5264
Author(s):  
Bharat Yelamanchi ◽  
Eric MacDonald ◽  
Nancy G. Gonzalez-Canche ◽  
Jose G. Carrillo ◽  
Pedro Cortes
Keyword(s):  
Mechanical Properties ◽  
3D Printing ◽  
High Velocity ◽  
Mechanical Performance ◽  
High Velocity Impact ◽  
Low Velocity ◽  
Fiber Metal Laminates ◽  
Velocity Impact ◽  
3D Printed ◽  
Fiber Metal

The production and mechanical properties of fiber metal laminates (FMLs) based on 3D printed composites have been investigated in this study. FMLs are structures constituting an alternating arrangement of metal and composite materials that are used in the aerospace sector due to their unique mechanical performance. 3D printing technology in FMLs could allow the production of structures with customized configuration and performance. A series of continuous carbon fiber reinforced composites were printed on a Markforged system and placed between layers of aluminum alloy to manufacture a novel breed of FMLs in this study. These laminates were subjected to tensile, low velocity and high velocity impact tests. The results show that the tensile strength of the FMLs falls between the strength of their constituent materials, while the low and high velocity impact performance of the FMLs is superior to those observed for the plain aluminum and the composite material. This mechanism is related to the energy absorption process displayed by the plastic deformation, and interfacial delamination within the laminates. The present work expects to provide an initial research platform for considering 3D printing in the manufacturing process of hybrid laminates.

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

Polymers ◽  
2022 ◽  
Vol 14 (2) ◽  
pp. 298
Author(s):  
Sander Rijckaert ◽  
Lode Daelemans ◽  
Ludwig Cardon ◽  
Matthieu Boone ◽  
Wim Van Paepegem ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Composite Materials ◽  
Fiber Volume Fraction ◽  
Volume Fraction ◽  
Low Cost ◽  
Fiber Direction ◽  
Continuous Fiber ◽  
Fiber Volume ◽  
Fiber Loading ◽  
3D Printed

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.

The Effects of Layer-by-Layer Thickness and Fiber Volume Fraction Variation on the Mechanical Performance of a Pressure Vessel

2018 ◽  
Author(s):  
Emre Özaslan ◽  
Ali Yetgin ◽  
Volkan Coşkun ◽  
Bülent Acar ◽  
Tarık Olğar
Keyword(s):  
Finite Element ◽  
Layer Thickness ◽  
Pressure Vessel ◽  
Fiber Volume Fraction ◽  
Mechanical Performance ◽  
Volume Fraction ◽  
Element Model ◽  
Layer By Layer ◽  
Fiber Volume ◽  
Filament Wound

Due to high stiffness/weight ratio, composite materials are widely used in aerospace applications such as motor case of rockets which can be regarded as a pressure vessel. The most commonly used method to manufacture the pressure vessels is the wet filament winding. However, the mechanical performance of a filament wound pressure vessel directly depends on the manufacturing process, manufacturing site environmental condition and material properties of matrix and fiber. The designed ideal pressure vessel may not be manufactured because of the mentioned issues. Therefore, manufacturing of filament wound composite structures are based on manufacturing experience and experiment. In this study, the effect of layer-by-layer thickness and fiber volume fraction variation due to manufacturing process on the mechanical performance was investigated for filament wound pressure vessel with unequal dome openings. First, the finite element model was created for designed thickness dimensions and constant material properties for all layers. Then, the model was updated. The updated finite element model considered the layer-by-layer thickness and fiber volume fraction variation. Effects of the thickness and fiber volume fraction on the stress distribution along the motor axial direction were shown. Also hydrostatic pressurization test was performed to verify finite element analysis in terms of fiber direction strain through the motor case outer surface. Important aspects of analyzing a filament wound pressure vessel were addressed for designers.

The Effects of Layer-by-Layer Thickness and Fiber Volume Fraction Variation on the Mechanical Performance of a Pressure Vessel

2020 ◽  
Vol 142 (4) ◽  
Author(s):  
Emre Özaslan ◽  
Ali Yetgin ◽  
Bülent Acar ◽  
Volkan Coşkun ◽  
Tarık Olğar
Keyword(s):  
Finite Element ◽  
Pressure Vessel ◽  
Material Properties ◽  
Fiber Volume Fraction ◽  
Mechanical Performance ◽  
Volume Fraction ◽  
Element Model ◽  
Layer By Layer ◽  
Fiber Volume ◽  
Filament Wound

Abstract Due to high stiffness/weight ratio, composite materials are widely used in aerospace applications such as motor case of rockets which can be regarded as a pressure vessel. The most commonly used method to manufacture pressure vessels is the wet filament winding. However, the mechanical performance of a filament wound pressure vessel directly depends on the manufacturing process, manufacturing site environmental condition, and material properties of matrix and fiber. The designed pressure vessel may not be manufactured because of the mentioned issues. Therefore, manufacturing of filament wound composite structures are based on manufacturing experience and experiment. In this study, effects of layer-by-layer thickness and fiber volume fraction variation due to manufacturing process on the mechanical performance were investigated for filament wound pressure vessel with unequal dome openings. First, the finite element model was created for designed thickness dimensions and constant material properties for all layers. Then, the model was updated. The updated finite element model considered the thickness of each layer separately and variation of fiber volume fraction between the layers. Effects of the thickness and fiber volume fraction on the stress distribution along the motor axial direction were shown. Also hydrostatic pressurization tests were performed to verify finite element analysis in terms of fiber direction strain through the motor case outer surface. Important aspects of analyzing a filament wound pressure vessel were addressed for designers.

Single and repeated low-velocity impact response of E-glass fiber-reinforced epoxy and polypropylene composites for different impactor shapes

2019 ◽  
pp. 089270571988691 ◽  
Author(s):  
Akar Dogan
Keyword(s):  
Glass Fiber ◽  
Fiber Volume Fraction ◽  
Volume Fraction ◽  
Low Velocity Impact ◽  
Fiber Reinforced ◽  
Low Velocity ◽  
Fiber Volume ◽  
Velocity Impact ◽  
Polypropylene Composites ◽  
Glass Fiber Reinforced

This study focuses on the effects of low-velocity impact (LVI) response of thermoset (TS) and thermoplastic (TP) matrix-based composites. In this study, the effects of the impactor shapes on the low-velocity impact response of the composite panels that produced from different matrix was investigated. Unidirectional E-glass fiber fabrics with an areal density of 300 g/m2 as reinforcement and epoxy matrix were used to produce TS composite. The vacuum-assisted resin infusion molding (VARIM) method was used to manufacture composite panels. The thermoplastic composites were manufactured with E-glass fiber-reinforced polypropylene prepregs. The tensile strength of TS matrix-based composites is higher than TP matrix-based composites that have the same fiber volume fraction. Despite being under the same impact energy, the TP specimens possess higher perforation threshold than TS specimens. The shape of the impactor significantly affected the perforation threshold. Besides, the impact number that caused perforation reduced dramatically in conical impactor. The repeated impact number that caused perforation is 36 for hemispherical (HS) impactor, but it is only 3 for conical impactor for polypropylene matrix-based composite. Moreover, a significant effect of fiber volumetric ratio on impact resistance was observed. The perforation threshold of glass fiber-reinforced polypropylene composites for 40% and 50% fiber volume fraction are 61 and 98 J, respectively. The perforation threshold of TP and TS specimens for HS impactor that has the same stacking sequence is 61 and 55 J, respectively.

Evaluating the effect of variable fiber content on mechanical properties of additively manufactured continuous carbon fiber composites

2020 ◽  
pp. 073168442096321
Author(s):  
Dakota R Hetrick ◽  
Seyed Hamid Reza Sanei ◽  
Charles E Bakis ◽  
Omar Ashour
Keyword(s):  
Mechanical Properties ◽  
Carbon Fiber ◽  
Fiber Volume Fraction ◽  
Volume Fraction ◽  
Fiber Content ◽  
Fiber Volume ◽  
Transverse Strength ◽  
Continuous Carbon Fiber ◽  
3D Printed ◽  
Properties Of Composites

Fiber volume fraction is a driving factor in mechanical properties of composites. Micromechanical models are typically used to predict the effective properties of composites with different fiber volume fractions. Since the microstructure of 3D-printed composites is intrinsically different than conventional composites, such predictions need to be evaluated for 3D-printed composites. This investigation evaluates the ability of the Voigt, Reuss, and Halpin–Tsai models to capture the dependence of modulus and strength of 3D-printed composites on varying fiber volume fraction. Tensile coupons were printed with continuous carbon fiber-reinforced Onyx matrix using a Markforged Mark Two printer. Specimens were printed at five different volume fractions with unidirectional fibers oriented at either [Formula: see text] to obtain longitudinal, shear, and transverse properties, respectively. It is shown that the Voigt model provides an excellent fit for the longitudinal tensile strength and a reasonable fit for the longitudinal modulus with varied fiber content. For the transverse direction, while the Reuss model fails to capture the transverse modulus trend, the Halpin–Tsai model provides a reasonable fit as it incorporates more experimental parameters. Like conventional composites, addition of fibers degrades the transverse strength, and the transverse strength decreases with increasing fiber volume fraction. The shear modulus variation with fiber content could not be fitted reasonably with either Halpin–Tsai model or Reuss model.

Investigating the Void Content, Fiber Content, and Fiber Orientation of 3D Printed Recycled Carbon Fiber

2019 ◽  
Vol 801 ◽  
pp. 276-281
Author(s):  
Peng Hao Wang ◽  
Ronald Sterkenburg ◽  
Garam Kim ◽  
Yu Wei He
Keyword(s):  
Composite Materials ◽  
Carbon Fiber ◽  
Fiber Orientation ◽  
Fiber Volume Fraction ◽  
Volume Fraction ◽  
Aerospace Industry ◽  
Void Content ◽  
Fiber Volume ◽  
3D Printed ◽  
Recycling Techniques

Composite materials continue to grow in popularity within the aerospace industry as the preferred material for manufacturing large airframe structures. However, the popularity of composite materials has also led to the increase in composite waste. As the popularity of composite materials continues to grow, the proper management and recycling of these composite waste materials becomes increasingly crucial to the sustainability of the environment. In order to investigate potential recycling techniques for composite waste, a team of Purdue University School of Aviation and Transportation Technology (SATT) faculty and students teamed up to investigate the characteristics of 3D printed recycled carbon fiber. A prototype 3D printed recycled carbon fiber part was used for the study. Through the use of microscopy and ImageJ image analyzing software, the researchers were able to determine the void content, fiber volume fraction, and fiber orientation of the prototype 3D printed recycled carbon fiber part and identified potential improvements to the 3D printing process in order to improve the 3D printed part’s characteristics.

scholarly journals A Numerical Study on High Velocity Impact Behavior of Titanium Based Fiber Metal Laminates

2018 ◽  
Vol 2 (4) ◽  
pp. 62 ◽  
Author(s):  
Gin Chai ◽  
Periyasamy Manikandan ◽  
Xin Li
Keyword(s):  
High Velocity ◽  
Volume Fraction ◽  
Numerical Study ◽  
Composite Layer ◽  
Fe Model ◽  
High Velocity Impact ◽  
Fiber Metal Laminates ◽  
Residual Velocity ◽  
Velocity Impact ◽  
Fiber Metal

The present paper gives details of the structural response of titanium-based fiber metal laminates (TFML) subjected to high velocity impact. Dynamic perforation behavior of two different sample configurations, TFML-2/1 and 3/2 are presented. The behavior of the metal and composite layer is defined using two independent appropriate constitutive material models. Both experimental and numerically predicted residual velocity follows the Recht-Ipson model variation with impact velocity. Being larger in thickness, residual velocity, peak contact force and total energy absorbed were found to be larger for TFML-3/2 than 2/1. However, the contact duration was rather insignificantly affected. Having similar metal volume fraction (MVF), energy dissipated by means of plastic deformation of metal layers was found to be constant for both TFML configurations that were considered. The axisymmetric loading, boundary conditions and having balanced material property distribution along the principle axes resulted in doubly symmetric damage surfaces, both layer-wise and overall. The developed finite element (FE) model adequately simulated the contact behavior and all of the experimentally realized damage modes in the metal and composite layers and confirmed its reliability. Having limited experimental information, the obtained numerical information allows one to briefly understand the dynamic perforation behavior of TFML laminates.

Effect of shape memory alloy wires on high-velocity impact response of basalt fiber metal laminates

2017 ◽  
Vol 37 (5) ◽  
pp. 300-309 ◽  
Author(s):  
Reza Eslami-Farsani ◽  
Masoud Khazaie
Keyword(s):  
Mechanical Properties ◽  
Shape Memory Alloy ◽  
Shape Memory ◽  
High Velocity ◽  
Volume Fraction ◽  
High Velocity Impact ◽  
Absorbed Energy ◽  
Fiber Metal Laminates ◽  
Velocity Impact ◽  
Fiber Metal

Fiber metal laminates are commonly used materials in industrial applications due to low density and excellent mechanical properties such as impact resistance. In this study, the effect of shape memory alloy wires on the impact properties of fiber metal laminates is evaluated and discussed. The volume fraction of wires and the pre-strain of wires were selected as the variables of the experiments. The samples were fabricated using hand lay-up method and their behavior was evaluated under high-velocity impact test. Based on the results, a significant change in the amount of absorbed energy was obtained using embedded wires. However, with increasing the volume fraction of wires, the absorbed energy decreases due to the discontinuity in mechanical properties of the specimens. On the other hand, applying pre-strain leads to residual stresses in samples. The observed residual stress in specimens with four embedded wires and 2% pre-strain level shows the most absorbed energy.

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