REACTIVE EXTRUSION ADDITIVE MANUFACTURING OF A SHORT FIBER REINFORCED THERMOSET COMPOSITE

2021 ◽  
Author(s):  
PRATIK KOIRALA PRATIK KOIRALA ◽  
OLIVER LIAM UITZ ◽  
ADEMOLA A. ORIDATE ◽  
CAROLYN CONNER SEEPERSAD ◽  
MEHRAN TEHRANI
Keyword(s):  
Additive Manufacturing ◽  
Carbon Fibers ◽  
High Performance ◽  
Length Distribution ◽  
Reactive Extrusion ◽  
Orientation Distribution ◽  
Fiber Reinforced ◽  
Neat Polymer ◽  
Transverse Tensile ◽  
Fiber Orientation Distribution

Additive manufacturing (AM) of high-performance composites has gained increasing interest over the last few years. Commercially available AM technologies often use thermoplastics as they are easy to process, i.e., to melt and re-solidify. However, thermosetting polymers generally achieve superior mechanical properties and thermostability. This study investigates reactive extrusion additive manufacturing (REAM) of a thermosetting polymer reinforced with carbon fibers. The process utilizes highly exothermic and fast curing resin/catalyst systems, eliminating the need for post-curing. The rheological properties of the liquid resin are first tuned for REAM using ~2wt.% fumed silica and ~10vol.% milled carbon fibers. Then, a robotic arm is used to print the composite samples. The coupons’ longitudinal and transverse tensile properties are measured and correlated with the degree of cure, porosity, fiber length distribution, and fiber orientation distribution. The incorporation of milled carbon fibers, 50-200 m long, primarily affects the stiffness. Compared to neat polymer parts, carbon fiber reinforced composites are 51% stiffer and 8% stronger. In addition, polymeric crosslinking between part layers resulted in strong inter-layer bonding. Short fibers were also randomly oriented within parts due to the nozzle size and shape, resulting in nearly isotropic parts. The results presented here pave the road for fast and low-energy AM of high-performance composites.

Effect of Fiber Orientation on the Tensile Strength in Fiber-Reinforced Polymeric Composite Materials

2005 ◽  
Vol 297-300 ◽  
pp. 2897-2902 ◽  
Author(s):  
Jin Woo Kim ◽  
Jung Ju Lee ◽  
Dong Gi Lee
Keyword(s):  
Tensile Strength ◽  
Composite Material ◽  
Fiber Orientation ◽  
Polymeric Composite ◽  
Orientation Distribution ◽  
Fiber Content ◽  
Fiber Reinforced ◽  
Composite Sheet ◽  
Content Ratio ◽  
Fiber Orientation Distribution

The study for strength calculation of one way fiber-reinforced composites and the study measuring precisely fiber orientation distribution were presented. However, because the DB that can predict mechanical properties of composite material and fiber orientation distribution by the fiber content ratio was not constructed, we need the systematic study for that. Therefore, in this study, we investigated what effect the fiber content ratio and fiber orientation distribution have on the strength of composite sheet after making fiber reinforced polymeric composite sheet by changing fiber orientation distribution with the fiber content ratio. The result of this study will become a guide to design data of the most suitable parts design or fiber reinforced polymeric composite sheet that uses the fiber reinforced polymeric composite sheet in industry spot, because it was conducted in terms of developing products. We studied the effect the fiber orientation distribution has on tensile strength of fiber reinforced polymeric composite material and achieved this results below. We can say that the increasing range of the value of fiber reinforced polymeric composite’s tensile strength in the direction of fiber orientation is getting wider as the fiber content ratio increases. It shows that the value of fiber reinforced polymeric composite’s tensile strength in the direction of fiber orientation 90° is similar with the value of polypropylene’s intensity when fiber orientation function is J= 0.7, regardless of the fiber content ratio. Tensile strength of fiber reinforced polymeric composite is affected by the fiber orientation distribution more than by the fiber content ratio.

Feasibility and Characterization of Large-Scale Additive Manufacturing With Long Fiber Reinforced Composites

2020 ◽  
Author(s):  
Aditya R. Thakur ◽  
Ming C. Leu ◽  
Xiangyang Dong
Keyword(s):  
Additive Manufacturing ◽  
Carbon Fiber ◽  
Carbon Fibers ◽  
Large Scale ◽  
Flexural Modulus ◽  
High Deposition Rate ◽  
Reinforced Composites ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Long Carbon Fibers

Abstract A new additive manufacturing (AM) approach to fabricate long fiber reinforced composites (LFRC) was proposed in this study. A high deposition rate was achieved by the implementation of a single-screw extruder, which directly used thermoplastic pellets and continuous fiber tows as feedstock materials. Thus, the proposed method was also used as a large-scale additive manufacturing (LSAM) method for printing large-volume components. Using polylactic acid (PLA) pellets and continuous carbon fiber tows, the feasibility of the proposed AM method was investigated through printing LFRC samples and further demonstrated by fabricating large-volume components with complex geometries. The printed LFRC samples were compared with pure thermoplastic and continuous fiber reinforced composite (CFRC) counterparts via mechanical tests and microstructural analyses. With comparable flexural modulus, the flexural strength of the LFRC samples was slightly lower than that of the CFRC samples. An average improvement of 28% in flexural strength and 50% in flexural modulus were achieved compared to those of pure PLA parts, respectively. Discontinuous long carbon fibers, with an average fiber length of 20.1 mm, were successfully incorporated into the printed LFRC samples. The carbon fiber orientation, distribution of carbon fiber length, and dispersion of carbon fiber as well as porosity were further studied. The carbon fibers were highly oriented along the printing direction with a relatively uniformly distributed fiber reinforcement across the LFRC cross section. With high deposition rate (up to 0.8 kg/hr) and low material costs (< $10/kg), this study demonstrated the potentials of the proposed printing method in LSAM of high strength polymer composites reinforced with long carbon fibers.

Prediction for the mechanical property of short fiber-reinforced polymer composites through process modeling method

2018 ◽  
Vol 32 (11) ◽  
pp. 1525-1546 ◽  
Author(s):  
Yue Mu ◽  
Anbiao Chen ◽  
Guoqun Zhao ◽  
Yujia Cui ◽  
Jiejie Feng ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Fiber Orientation ◽  
Orientation Distribution ◽  
Fiber Reinforced Composites ◽  
Fiber Reinforced Polymer ◽  
Reinforced Composites ◽  
Fiber Reinforced ◽  
Reinforced Polymer ◽  
Fiber Reinforced Polymer Composites ◽  
Fiber Orientation Distribution

The fiber-reinforced polymer composites are important alternative for conventional structural materials because of their excellent comprehensive performance and weight reduction. The mechanical properties of such composite materials are mainly determined by the fiber orientation induced through practical manufacturing process. In the study, a through process modeling (TPM) method coupling the microstructure evolution and the mechanical properties of fiber-reinforced composites in practical processing is presented. The numerical methodology based on the finite volume method is performed to investigate three-dimensional forming process in the injection molding of fiber-reinforced composites. The evolution of fiber orientation distribution is successfully predicted by using a reduced strain closure model. The corresponding finite volume model for TPM is detailedly derived and the pressure implicit with splitting of operators (PISO) algorithm is employed to improve computational stability. The flow-induced multilayer structure is successfully predicted according to essential flow characteristics and the fiber orientation distribution. The mechanical properties of such anisotropy composites is further calculated based on the stiffness analysis and the Tandon–Weng model. The improvement of mechanical properties in each direction of the injection molded product are evaluated by using the established mathematical model and numerical algorithm. The influences of the geometric structure of injection mold cavity, the fiber volume fractions, and the fiber aspect ratios on the mechanical properties of composite products are further discussed. The mathematical model and numerical method proposed in the study can be successfully adopted to investigate the structural response of composites in practical manufacturing process that will be helpful for optimum processing design.

Design of Discontinuous Fiber Reinforced Injection Molded Polymer Matrix Composite Parts

2014 ◽  
Vol 633-634 ◽  
pp. 266-269 ◽  
Author(s):  
Zoltan Major ◽  
Martin Reiter
Keyword(s):  
Mean Field ◽  
Orientation Distribution ◽  
Fiber Reinforced ◽  
Glass Fiber Reinforced ◽  
Fiber Orientation Distribution ◽  
Discontinuous Fiber ◽  
Homogenization Approach ◽  
Component Strength ◽  
Injection Molded ◽  
Phd Thesis

Injection molded discontinuous fiber reinforced components are widely used in many demanding engineering applications and are exposed to a complex combination of thermo-mechanical loads. Mean field homogenization approach was successfully applied for predicting the global stiffness behavior over wide part geometry complexity, fiber orientation distribution (FOD) and loading situations including loading rate and temperature dependence. The prediction of the component strength, however, is significantly more complicated and requires additional and theoretical considerations as well as the application of various numerical tools and sophisticated experiments. To overcome above difficulties the MFH technique was extended with the first pseudo grain failure or damage (FPGF or FPGD) approach proposed by the research group of Doghri [1] elaborated in detail using short glass fiber reinforced PP-GF in the PhD Thesis of Reiter [2] and shortly described in this study.

scholarly journals Uncertainty quantification of fiber orientation distribution measurements for long-fiber-reinforced thermoplastic composites

2017 ◽  
Vol 52 (13) ◽  
pp. 1781-1797 ◽  
Author(s):  
Bhisham N Sharma ◽  
Diwakar Naragani ◽  
Ba Nghiep Nguyen ◽  
Charles L Tucker ◽  
Michael D Sangid
Keyword(s):  
Cross Sections ◽  
Fiber Orientation ◽  
Surface Preparation ◽  
Orientation Distribution ◽  
Elastic Stiffness ◽  
Thermoplastic Composites ◽  
Fiber Reinforced ◽  
Fiber Orientation Distribution ◽  
Discontinuous Fiber ◽  
Reinforced Thermoplastics

We present a detailed methodology for experimental measurement of fiber orientation distribution in injection-molded discontinuous fiber composites using the method of ellipses on two-dimensional cross sections. Best practices to avoid biases occurring during surface preparation and optical imaging of carbon-fiber-reinforced thermoplastics are discussed. A marker-based watershed transform routine for efficient image segmentation and the separation of touching fiber ellipses is developed. The sensitivity of the averaged orientation tensor to the image sample size is studied for the case of long-fiber thermoplastics. A Mori–Tanaka implementation of the Eshelby model is then employed to quantify the sensitivity of elastic stiffness predictions to biases in the fiber orientation distribution measurements.

Effect of Fiber Content and Fiber Orientation on the Tensile Strength in Glass Mat Reinforced Thermoplastic Sheet

2007 ◽  
Vol 334-335 ◽  
pp. 337-340
Author(s):  
Jin Woo Kim ◽  
Dong Gi Lee
Keyword(s):  
Tensile Strength ◽  
Fiber Orientation ◽  
Orientation Distribution ◽  
Fiber Content ◽  
Fiber Reinforced ◽  
Composite Sheet ◽  
Design Data ◽  
Content Ratio ◽  
Fiber Orientation Distribution ◽  
Glass Mat

The study for strength calculation of one way fiber-reinforced composites and the study measuring precisely fiber orientation distribution were presented. Need the systematic study for the DB that can predict mechanical properties of composite material and fiber orientation distribution by the fiber content ratio was not constructed. Therefore, this study investigated what affect the fiber content ratio and fiber orientation distribution have on the strength of composite sheet after making Glass Mat Reinforced Thermoplastic Sheet by changing fiber orientation distribution with the fiber content ratio. The result of this study will become a guide to design data of the most suitable parts design or fiber reinforced polymeric composite sheet that uses the Glass Mat Reinforced Thermoplastic Sheet in industry part, because it was conducted in terms of developing products. It studied the effect the fiber orientation distribution has on tensile strength of Glass Mat Reinforced Thermoplastic Sheet and achieved this result below. The increasing range of the value of Glass Mat Reinforced Thermoplastic Sheet’s tensile strength in the fiber orientation direction is getting wider as the fiber content increases.

scholarly journals Investigation on the Coupling Effects between Flow and Fibers on Fiber-Reinforced Plastic (FRP) Injection Parts

Polymers ◽  
2020 ◽  
Vol 12 (10) ◽  
pp. 2274
Author(s):  
Chao-Tsai Huang ◽  
Cheng-Hong Lai
Keyword(s):  
Coupling Effect ◽  
Flow Direction ◽  
Cross Flow ◽  
Orientation Distribution ◽  
Tensor Component ◽  
Fiber Reinforced ◽  
Orientation Tensor ◽  
Fiber Coupling ◽  
Fiber Orientation Distribution ◽  
The Cross

Glass or carbon fibers have been verified that can enhance the mechanical properties of the polymeric composite injection molding parts due to their orientation distribution. However, the interaction between flow and fiber is still not fully understood yet, especially for the flow–fiber coupling effect. In this study, we have tried to investigate the flow–fiber coupling effect on fiber reinforced plastics (FRP) injection parts utilizing a more complicated geometry system with three ASTM D638 specimens. The study methods include both numerical simulation and experimental observation. Results showed that in the presence of flow–fiber coupling effect, the melt flow front advancement presents some variation, specifically the “convex-flat-flat” pattern will change to a “convex-flat-concave” pattern. Furthermore, through the fiber orientation distribution (FOD) study, the flow–fiber coupling effect is not significant at the near gate region (RG). It might result from the strong shear force to repress the appearance of the flow–fiber interaction. However, at the end of filling region (ER), the flow–fiber coupling effect tries to diminish the flow direction orientation tensor component A11 and enhance the cross-flow orientation tensor component A22 simultaneously. It results in the dominance in the cross-flow direction at the ER. This orientation distribution behavior variation has been verified using a micro-computerized tomography (micro-CT) scan and image analysis technology.

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