Charpy impact energy absorption of 3D printed continuous Kevlar reinforced composites

Abstract

Additive manufacturing (AM) has been used widely to produce three-dimensional (3D) parts from computer-aided design (CAD) software. Traditional Fused Deposition Modeling (FDM) 3D printed polymer parts lack the necessary strength to be used for functional parts in service. The potential of printing continuous fiber reinforced composites has resulted in parts with better mechanical properties and enhanced performance. Very few studies have investigated the impact energy absorption of continuous fiber reinforced 3 D printed composites. The purpose of this work is to investigate the effect of different fiber patterns (unidirectional versus concentric), different stacking patterns (consolidated versus alternating layers), and fiber orientations (0°, 90°, 45°) on the impact energy absorption of 3 D printed continuous Kevlar fiber reinforced Onyx composites. Charpy impact testing was used to determine the impact energy absorption of the specimens. It was concluded that alternating the fiber and matrix layers as opposed to consolidating all the fiber layers in the center of the specimen results in lower impact energy absorption. Additionally, the specimens with unidirectional 90° fiber orientation had the lowest impact energy absorption among the specimens with alternating stacking pattern and those with consolidated [Formula: see text]45° angle-ply fiber orientations had the highest impact energy absorption.

Experimental investigations on thermal, flame retardant, and impact properties of additively manufactured continuous FRPC

“…The specimen with layer configuration 21O|20K|20O|20K|21O and specimen with 0° fiber angle has the highest impact strength among the specimens with different fiber arrangement and fiber orientation, respectively. Five different failure modes of fiber were observed, that is, partial fracture, complete fracture, fiber bridging, path fracture, and fiber peel off 25 . The failure in the onyx matrix was found to be brittle in all the specimens.…”

“…Five different failure modes of fiber were observed, that is, partial fracture, complete fracture, fiber bridging, path fracture, and fiber peel off. 25 The failure in the onyx matrix was found to be brittle in all the specimens. Due to poor bonding between fiber and matrix layers or fiber layers, the failure initiated and the total energy absorption capacity of fiber and matrix cannot be utilized.…”

“…Similar studies have been done by Dickson et al 24 by reinforcing carbon, glass, and kevlar fiber and found up to 6.3x and 5x increase in UTS and bending strength compared to the unreinforced nylon material. Hetrick et al 25 investigated the effect of various fiber patterns, fiber orientations, and various stacking sequences composites made of 3D‐printed continuous kevlar fiber reinforcement. They reported that the alternating stacking sequence of fiber results in minimum impact energy absorption than the consolidated stacking sequence of fiber.…”

Consideration of Yarn Anisotropy in the Investigation of the Puncture Resistance of Fibrous Materials

“…As 3D printing technology matures, researchers also apply it to the field of stab prevention. Hetrick et al [ 12 ] proposed the technology of continuous Kevlar fiber reinforced 3D printing composites. This material was used to study the effects of different fiber modes, stacking modes, and fiber orientations on the impact properties of the material.…”

Comparing Performance of 3D-Printed and Injection-Molded Fiber-Reinforced Composite Parts in Ring-Spinning Traveler Application

“…Additive manufacturing, also called 3D printing, is at the vertex of widely accepted advanced manufacturing technologies because of its unique ability to develop intricate geometric structures with numerous design flexibilities in a single setup, involving minimum process steps and waste generation [1,2]. The recent advent of reinforcing 3D-printed structures with fillers (short and long fibers) has brought a phenomenal improvement in the performance of the printed part and put the technology far forward with regard to high-performance applications [3,4].…”