Investigation of the dynamic mechanical analysis and mechanical response of 3D printed nylon carbon fiber composites with different build orientation (original) (raw)
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Journal of Materials Research and Technology, 2022
3D printed fiber reinforced composites are replacing metals and thermosetting polymers due to their lightweight structure and mechanical performance. Fused deposition modeling (FDM) is an additive manufacturing technology that can produce complicated functioning parts. Samples of Nylforce composite materials were manufactured at three different raster orientations (0 , 45 , and 90) with the help of a 3D printer. In order to evaluate the mechanical properties of the nylon composites with carbon fibers (CF) and glass fiber (GF); 3-point flexural tests were carried out. The highest stiffness (modulus) was found for nylon þ GF composite at room temperature, indicating that the material can better resist bending forces. On the other hand, the nylon þ CF composite exhibited elastic behavior, lower flexural strength, and higher deflection. Overall, the flexural strength of composites was improved because the interface between the nylon matrix and fibers provided good stress transfer. Dynamic mechanical analysis (DMA) also clearly indicated that the nylon þ GF composite material had maximum storage modulus, loss modulus and complex modulus with low tan d, indicating improved fiber/matrix interfacial interaction and limitation of polymer chain mobility. Moreover, scanning electron microscope (SEM) images revealed that the main drawbacks for nylon composite material were void formation, fiber pull-out, and fiber breakage. Generally, the results of this research provide a unique knowledge base regarding the structural behaviors and the mechanical properties of nylon composites built with 3D printing technology. Finally, the findings of the current research will be beneficial in the application of these composite materials in their end-use.
Static and Fatigue Properties of 3D Printed Continuous Carbon Fiber Nylon Composites
2019
CFRPs provide excellent mechanical properties and tailor-made designs for several applications. Using continuous fiber fabrication (CFF) 3D printing technology, 3D printed constructs with mechanical properties higher than common 3D printed components can be printed. However, challenges remain such as the standardization of processes and characterization techniques to ensure the production of 3D printed CFRPs with good consolidation of reinforcement fibers into the polymer matrix and controlled fiber orientation. In this work, 3D printed carbon fiber nylon mechanical properties are investigated through static tensile and fatigue tests in order to assess the performance of such structures. Also, the mechanical properties of 3D printed PLA and nylonareexaminedfor comparison. As expected, the results areshown that the pure nylon specimens had plastic deformation behaviour (as it was also for PLA) in contrast to carbon fiber reinforced nylon, which had almost elastic deformation behaviou...
Machines
Additive manufacturing (i.e., 3D printing) has rapidly developed in recent years. In the recent past, many researchers have highlighted the development of in-house filaments for fused filament fabrication (FFF), which can extend the corresponding field of application. Due to the limited mechanical properties and deficient functionality of printed polymer parts, there is a need to develop printable polymer composites that exhibit high performance. This study analyses the actual mechanical characteristics of parts fabricated with a low-cost printer from a carbon fibre-reinforced nylon filament. The results show that the obtained values differ considerably from the values presented in the datasheets of various filament suppliers. Moreover, the hardness and tensile strength are influenced by the building direction, the infill percentage, and the thermal stresses, whereas the resilience is affected only by the building direction. Furthermore, the relationship between the mechanical prope...
Tensile Performance of 3D-Printed Continuous Fiber-Reinforced Nylon Composites
Journal of Manufacturing and Materials Processing
Fused Filament Fabrication (FFF) is a promising technology for production of fiber-reinforced composite parts with complex geometries. Continuous Fiber Reinforced Additively Manufactured (CFRAM) parts are becoming more prominent due to their mechanical performance, light weight, and recyclability. CFRAM components are lighter, yet they are strong materials with a wide range of potential applications in the automotive industry, aerospace, medical tools, and sports goods. The wide range of applications of these novel materials justifies the need to study their properties. Tensile is one of the most important tests to evaluate the mechanical performance of CFRAM parts. In this paper, a comprehensive study is conducted on tensile properties of CFRAM components. The composite parts are printed using a dual nozzle 3D printing machine and their tensile performance is investigated. Furthermore, the effect of fiber type, fiber content, infill density, infill pattern, and layer thickness on t...
3D printing of composites: design parameters and flexural performance
Rapid Prototyping Journal, 2020
Purpose 3D printing of composites has a high degree of design freedom, which allows for the manufacture of complex shapes that cannot be achieved with conventional manufacturing processes. This paper aims to assess the design variables that might affect the mechanical properties of 3D-printed fibre-reinforced composites. Design/methodology/approach Markforged Mark-Two printers were used to manufacture samples using nylon 6 and carbon fibres. The effect of fibre volume fraction, fibre layer location and fibre orientation has been studied using three-point flexural testing. Findings The flexural strength and stiffness of the 3D-printed composites increased with increasing the fibre volume fraction. The flexural properties were altered by the position of the fibre layers. The highest strength and stiffness were observed with the reinforcement evenly distributed about the neutral axis of the sample. Moreover, unidirectional fibres provided the best flexural performance compared to the o...
Mechanical characterization of Polymer matrix composites produced by 3D printing
2017
In the last decade, additive manufacturing (AM) technology has undergone exponential growth and gained more and more importance in the recent research, mainly due to the freedom of creating sophisticated geometries that are impossible to produce using either one or a combination of several alternative production techniques. AM technology has mostly been used for prototyping application during the product design and development phase in many different industrial sectors. However, 3D printed prototypes have limited mechanical properties and the printed parts usually cannot fulfil mechanical requirements for functional applications. As a consequence, this problem has given rise to a new concept of 3D printing technique based on adding fibers to the polymeric material matrix. By means of this technique, the mechanical properties of the printed parts can be enhanced. The current thesis has researched in carbon fiber reinforcement for nylon specimens printed by the Mark One printer from M...
Materials, 2022
Additively manufactured composite specimens exhibit anisotropic properties, meaning that the elastic response changes with respect to orientation. Both in-plane and out-of-plane mechanical properties are important for designing purpose. Recent studies have characterised the in-plane performance. In this study, however, through-thickness tensile strength of 3D polymer composites were determined by printing of continuous carbon fibre reinforced thermoplastic polyamide-based composite, manufactured using a Markforged Two 3D printer. This paper discusses sample fabrication and geometry, adhesive used, and testing procedure. Test standards used to determine out-of-plane properties are tedious as most of the premature failures occur between the specimens and the tabs. Two types of samples were printed according to ASTM flatwise tension standard and the results were compared to determine the geometry effect on the interlaminar strength. This test method consists of subjecting the printed s...
Materials
This paper introduces novel research into specific mechanical properties of composites produced by 3D printing using Continuous-Fiber Fabrication (CFF). Nylon (Onyx) was used as the composite base material, while carbon constituted the reinforcement element. The carbon fiber embedment was varied in selected components taking values of 0°, 45°, 90°, and 135° for parts undergoing tensile testing, while one specific part type was produced combining all angles. Carbon-fiber-free components with 100% and 37% fillings were also produced for comparison purposes. Parts undergoing the Charpy impact test had the fibers deposited at angles of 0° and 90°, while one part type was also produced combining the four angles mentioned before. Carbon-fiber-free parts with 100% and 37% fillings were also produced for comparison purposes as with the first part. The Markforged MARK TWO 3D printer was used for printing the parts. These were subsequently scanned in the METROTOM 1500 computed tomography and ...
3D-Printed Carbon Fiber Reinforced Polymer Composites: A Systematic Review
Journal of Composites Science
Fiber reinforced composites offer exceptional directional mechanical properties, and combining their advantages with the capability of 3D printing has resulted in many innovative research fronts. This review aims to summarize the methods and findings of research conducted on 3D-printed carbon fiber reinforced composites. The review is focused on commercially available printers and filaments, as their results are reproducible and the findings can be applied to functional parts. As the process parameters can be readily changed in preparation of a 3D-printed part, it has been the focus of many studies. In addition to typical composite driving factors such as fiber orientation, fiber volume fraction and stacking sequence, printing parameters such as infill density, infill pattern, nozzle speed, layer thickness, built orientation, nozzle and bed temperatures have shown to influence mechanical properties. Due to the unique advantages of 3D printing, in addition to conventional unidirectio...
3D printed fiber reinforced polymer composites - Structural analysis
Composites Part B: Engineering, 2019
In this research, mechanical and structural properties of Continuous Fiber Reinforced Additively Manufactured (CFRAM) components are studied. Structural analysis is performed to understand the failure behaviour of CFRAM components. Based on the SEM analysis of the tested parts, correlations between results of mechanical test and microstructure of the parts have been investaged. CFRAM components are lightweight yet strong materials with a wide range of potential applications in auto industry, aerospace, sport goods, and medical tools. CFRAM components benefit from both cutting-edge 3D printing technology and fiber reinforcement to improve mechanical properties. Produced parts have lightweight compared with metals, strong mechanical properties, and short manufacturing time. In addition, thermoplastic polymer used for CFRAM components makes product recyclable. In this study, samples were printed using Markforged Mark Two printer and the effect of the fiber type, fiber orientations, infill density, and temperatures on tensile, fatigue, and creep properties were investigated. Carbon fiber (CF), fiberglass (FG), and Kevlar were used as reinforcing agents, and nylon as the base material. Microstructural analysis was conducted to investigate the fracture mechanism, morphology, and printing quality of the specimens. It was observed that the main failing mechanisms for CFRAM components are fiber pull-out,fiber breakage, and delamination. Further, it was understood that there is a correlation between the fiber stacking density and mechanical properties. Overall, the information provided in this study reports a unique knowledge base about the mechanical and structural behaviours of the components built with the CFRAM technology.