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Micro-voids within the bead microstructure of additively manufactured short carbon fiber- reinforced polymer composites are known to compromise the material performance. Unfortunately, a comprehensive understanding of the formation mechanisms of micro-voids during polymer processing is currently lacking. The present study considers micro-void nucleation at fiber inter-faces, particularly those occurring at the end of suspended fibers. Micro-computed tomography (μCT) image acquisition techniques are used to characterize microstructural features of a 13wt% carbon fiber reinforced ABS compo-site bead manufactured via Large Area Additive Manufacturing (LAAM). The results reveal a significant collection of micro-voids at the tips of fibers approaching 80% of the total micro-void volume fraction. In addition, fiber tip micro-voids are relatively larger and less spherical than micro-voids isolated within the ABS matrix. Theoretical formulations of several known mechanisms for micro-void nucleation during LAAM material processing indicate that local-ized fluid pressure likely plays a pivotal role in micro-void formation. To better expose this mechanism, we simulate the hydrostatic flow-field pressure distri-bution surrounding a single rigid fiber suspended in simple shear flow using fi-nite element analysis (FEA). Computed results demonstrate that the polymer matrix pressure decreases significantly at the fiber ends where micro-void nucleation is experimentally observed to occur. Our approach provides the fiber surface pressure distribution in simple shear flow that typifies nozzle regions with extreme flow conditions, enhancing our understanding of micro-void development mechanisms as the polymer melt flows through the nozzle.
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This content will become publicly available on March 1, 2026
Micro-void nucleation at fiber-tips within the microstructure of additively manufactured polymer composites bead
The presence of voids within the microstructure of short carbon fiber polymer composites produced by additive manufacturing (AM) technology are known to alter the expected material behavior that impair part performance. Previous research efforts aimed at understanding the formation mechanisms of these micro-voids during the polymer extrusion/deposition process have not kept up with the advancement of this AM technology. The present study investigates the phenomenon of micro-void nucleation at the fiber/matrix interface, especially those that form at fiber tips, by characterizing the microstructural configuration of a 13 % carbon fiber filled ABS polymer composite print bead specimen using 3D X-ray micro computed tomography image acquisition and analysis. The results reveal a high level of micro-voids segregation at the ends of fibers that are relatively larger in size and less spherical as compared to micro-voids isolated within the ABS matrix. Additionally, by simulating the hydrostatic flow-field pressure distribution surrounding a single rigid ellipsoidal fibre in colloidal suspension using Jeffery’s model equations, we show that the pressure drops to a critical value at the fibre tips where the micro-voids nucleation is experimentally observed to occur. The study helps to improve our understanding of the potential mechanisms that may be responsible for micro-void development within beads printed with extrusion/ deposition AM.
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- Award ID(s):
- 2055628
- PAR ID:
- 10608172
- Publisher / Repository:
- Elsevier
- Date Published:
- Journal Name:
- Composites Part A: Applied Science and Manufacturing
- Volume:
- 190
- Issue:
- C
- ISSN:
- 1359-835X
- Page Range / eLocation ID:
- 108629
- Subject(s) / Keyword(s):
- Additive Manufacturing Fiber Suspensions Porosity Polymer Composites
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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