Short carbon fiber-reinforced composite materials produced by large-area additive manufacturing (LAAM) are attractive due to their lightweight, favorable mechanical properties, multifunctional applications, and low manufacturing costs. However, the physical and mechanical properties of short carbon-fiber-reinforced composites 3D printed via LAAM systems remain below expectations due in part to the void formation within the bead microstructure. This study aimed to assess void characteristics including volume fraction and sphericity within the microstructure of 13 wt% short carbon fiber acrylonitrile butadiene styrene (SCF/ABS). Our study evaluated SCF/ABS as a pellet, a single freely extruded strand, a regularly deposited single bead, and a single bead manufactured with a roller during the printing process using a high-resolution 3D micro-computed tomography (µCT) system. Micro voids were shown to exist within the microstructure of the SCF/ABS pellet and tended to become more prevalent in a single freely extruded strand which showed the highest void volume fraction among all the samples studied. Results also showed that deposition on the print bed reduced the void volume fraction and applying a roller during the printing process caused a further reduction in the void volume fraction. This study also reports the void’s shape within the microstructure in terms of sphericity which indicated that SCF/ABS single freely extruded strands had the highest mean void sphericity (voids tend to be more spherical). Moreover, this study evaluated the effect of printing process parameters, including nozzle temperature, extrusion speed and nozzle height above the printing table on the void volume fraction and sphericity within the microstructure of regularly deposited single beads.
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This content will become publicly available on October 31, 2024
FIBER AND VOID PROPERTY CORRELATION WITHIN BEAD MICROSTRUCTURE OF LARGE AREA ADDITIVE MANUFACTURING POLYMER COMPOSITES
Short carbon fiber-reinforced polymer composites are widely employed in additive manufacturing (AM) techniques, including Large Area Additive Manufacturing (LAAM) polymer extrusion-deposition, due to their superior mechanical properties compared to neat polymers. The mechanical and thermal properties of these composites are significantly influenced by factors such as fiber volume fraction, orientation, length, and distribution, and void distribution and volume fraction within the microstructure of the printed beads. This paper presents an experimental study that aims to quantitatively assess the relationship between void volume fraction and fiber orientation within the microstructure of both single freely extruded strands and single deposited beads of Short Carbon Fiber reinforced Acrylonitrile Butadiene Styrene (SCF/ABS) manufactured via a LAAM system. The study employs high-resolution 3D microcomputed tomography (μCT) to evaluate the fiber orientation, fiber volume fraction, and void volume fraction within the microstructure of the SCF/ABS composite parts. The findings demonstrate that the print direction 𝐴zz component of the fiber orientation tensor in the regions near the edges of the single freely extruded strand is higher than those near the center, likely due to increased nozzle shear rate near the wall. Furthermore, within a single deposited bead on the print bed, the 𝐴zz component varies throughout the microstructure. Measurements also show that regions with relatively higher void volume fraction have a corresponding lower fiber 𝐴zz and fiber volume fraction for both the single freely extruded strand and the single deposited bead.
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- Award ID(s):
- 2055628
- NSF-PAR ID:
- 10507585
- Publisher / Repository:
- https://www.iccm-central.org/Proceedings/ICCM23proceedings/index.htm
- Date Published:
- Journal Name:
- Proceedings of ICCM23
- Format(s):
- Medium: X Size: 1.618MB
- Size(s):
- 1.618MB
- Location:
- Belfast, Ireland
- Sponsoring Org:
- National Science Foundation
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