skip to main content
US FlagAn official website of the United States government
dot gov icon
Official websites use .gov
A .gov website belongs to an official government organization in the United States.
https lock icon
Secure .gov websites use HTTPS
A lock ( lock ) or https:// means you've safely connected to the .gov website. Share sensitive information only on official, secure websites.


Title: INTERLAYER FRACTURE OF LARGE AREA ADDITIVE MANUFACTURED SHORT FIBER COMPOSITES
This paper proposes an efficient experimental method to measure the mode I fracture toughness of large-area additive manufactured polymeric composites. By utilizing either single-bead or double-bead systems bonded to the double cantilever beam (DCB) configuration, we measure intrabead and interbead fracture toughness of acrylonitrile butadiene styrene (ABS) and short carbon fiber-reinforced ABS. The effect of rigid doublers (which are used to eliminate a premature compressive failure) is excluded in the calculation of total energy dissipation, producing a purely interlayer fracture toughness. We found that the critical fracture toughness of carbon fiber/ABS is lower than that of ABS due to the voids within and between the beads. The experimental and data reduction methods developed here can be utilized to optimize the interlayer adhesion of large-scale 3D printed materials.  more » « less
Award ID(s):
2055628
PAR ID:
10608199
Author(s) / Creator(s):
; ;
Publisher / Repository:
2024 Solid Freeform Fabrication Conference
Date Published:
Format(s):
Medium: X
Location:
Austin, Texas
Sponsoring Org:
National Science Foundation
More Like this
  1. Large-Area Additive Manufacturing (LAAM) has seen increased application in manufacturing meter-scale, polymeric composite structural parts, especially for tooling and fixturing. Unfortunately, LAAM introduces manufacturing-induced defects in printed composites, e.g., intrabead microvoids and poor interbead adhesion that are not otherwise seen when traditional manufacturing methods are used, causing degradation of mechanical and fracture properties. In this paper, the fracture behavior of neat acrylonitrile butadiene styrene (ABS) and short carbon fiber-reinforced ABS (CF/ABS) fabricated by LAAM is compared and analyzed by evaluating their energy release rate 𝐺𝐼𝑐 and fracture mechanisms. A double cantilever beam with doublers (DCB-D) test for single-bead, double-bead, and multiple-bead configurations is developed by incorporating rigid doublers to reduce the compressive failure at the crack tip, allowing for the measurement of crack propagation. A new data reduction method for these configurations is derived to remove the doubler effect from the 𝐺𝐼𝑐 calculation, producing ‘pure’ intrabead and interbead 𝐺𝐼𝑐 values. We show that CF/ABS is more damage tolerant than ABS at the intrabead level, but less damage tolerant than ABS at the interbead level. The development of plastic ligaments in ABS helps dissipate additional strain energy, improving the overall energy release rate. The experimental fracture test approach developed here is expected to provide mechanistic insight into their damage tolerance capability, accelerating the qualification process of LAAM-produced polymer and polymer composites. 
    more » « less
  2. Abstract The current study confirms that modified carbon fiber reinforced polymer (CFRP) composites have higher fracture toughness than unmodified CFRP composites achieved by exploiting the synergistic effect of a polycarbonate (PC)/acrylonitrile butadiene styrene (ABS) blend in toughening the diglycidyl ether of bisphenol A (DGEBA) epoxy resin. The CFRP composite specimens are tested at near cryogenic temperatures using TMA, DMA, and microcrack analysis to determine the best‐suited concentration of ABS in the PC/ABS blend. TMA and DMA results, as well as microcrack analysis at cryogenic temperatures (CT), confirm that the blend 90/10 is effective in reducing the brittle nature of DGEBA resin and increasing bond strength, resulting in the fracture toughness enhancement of CFRP specimens at CT. Further investigation of 90/10 modified CFRP (90/10 m‐CFRP) and unmodified CFRP specimens using Mode II fracture using ENF test and SEM analysis reveal significant reduction in brittle characteristics of matrix with increase in elongation at failure and fracture surface morphologies confirm nano web‐like structures bridging the CF layers, proving to improve fiber/matrix bond strength. This study concludes the effectiveness of hybrid PC/ABS blend in synergistically‐modifying DGEBA resin for improved fracture toughness of CFRP laminates across a wide temperature range (−150°C to 150°C). 
    more » « less
  3. 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. 
    more » « less
  4. An experimental study is performed to investigate the quasi-static fracture toughness and damage monitoring capabilities of liquid metal (75.5% Gallium/24.5% Indium) reinforced intraply glass/carbon hybrid composites. Two different layups (G-0, where glass fibers are along the crack propagation direction; C-0, where carbon fibers are along the crack propagation direction) and two different weight percentages of liquid metal (1% and 2%) are considered in the fabrication of the composites. A novel four-probe technique is employed to determine the piezo-resistive damage response under mode-I fracture loading conditions. The effect of layups and liquid metal concentrations on fracture toughness and changes in piezo-resistance response is discussed. The C-composite without liquid metal demonstrated higher fracture toughness compared to that of the G-composite due to carbon fiber breakage. The addition of liquid metal decreases the fracture initiation toughness of both G- and C-composites. Scanning electron microscopy images show that liquid metal takes the form of large liquid metal pockets and small spherical droplets on the fracture surfaces. In both C- and G-composites, the peak resistance change of composites with 2% liquid metal is substantially lower than that of both no-liquid metal and 1% liquid metal composites. 
    more » « less
  5. 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. 
    more » « less