Rheological survey of carbon fiber-reinforced high-temperature thermoplastics for big area additive manufacturing tooling applications

Ajinjeru, Christine; Kishore, Vidya; Chen, Xun; Hershey, Christopher; Lindahl, John; Kunc, Vlastimil; Hassen, Ahmed Arabi; Duty, Chad

doi:10.1177/0892705719873941

Cited by 31 publications

(22 citation statements)

References 42 publications

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“…Rheological properties of filler-modified resin formulations have great significance in extrusion-based additive manufacturing processes [ 38 , 39 ]. In the present rheological study, changes in material behavior as a result of two different additive loadings are investigated.…”

Section: Resultsmentioning

confidence: 99%

Rheology-Assisted Microstructure Control for Printing Magnetic Composites—Material and Process Development

et al. 2020

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Magnetic composites play a significant role in various electrical and electronic devices. Properties of such magnetic composites depend on the particle microstructural distribution within the polymer matrix. In this study, a methodology to manufacture magnetic composites with isotropic and anisotropic particle distribution was introduced using engineered material formulations and manufacturing methods. An in-house developed material jetting 3D printer with particle alignment capability was utilized to dispense a UV curable resin formulation to the desired computer aided design (CAD) geometry. Formulations engineered using additives enabled controlling the rheological properties and the microstructure at different manufacturing process stages. Incorporating rheological additives rendered the formulation with thixotropic properties suitable for material jetting processes. Particle alignment was accomplished using a magnetic field generated using a pair of permanent magnets. Microstructure control in printed composites was observed to depend on both the developed material formulations and the manufacturing process. The rheological behavior of filler-modified polymers was characterized using rheometry, and the formulation properties were derived using mathematical models. Experimental observations were correlated with the observed mechanical behavior changes in the polymers. It was additionally observed that higher additive content controlled particle aggregation but reduced the degree of particle alignment in polymers. Directionality analysis of optical micrographs was utilized as a tool to quantify the degree of filler orientation in printed composites. Characterization of in-plane and out-of-plane magnetic properties using a superconducting quantum interference device (SQUID) magnetometer exhibited enhanced magnetic characteristics along the direction of field structuring. Results expressed in this fundamental research serve as building blocks to construct magnetic composites through material jetting-based additive manufacturing processes.

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Section: Resultsmentioning

confidence: 99%

Rheology-Assisted Microstructure Control for Printing Magnetic Composites—Material and Process Development

et al. 2020

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“…The most common feedstock for LFAM printers is acrylonitrile butadiene styrene (ABS), often blended with chopped fibers to improve mechanical properties and reduce warp [99][100][101]. Depending on processing, the reported flexural modulus for neat ABS used in the BAAM printer ranges from 1.87 GPa-2.45 GPa, while flexural strength varies from 58.6 MPa-68.3 MPa [4].…”

Section: Flexural Testingmentioning

confidence: 99%

Photoinitiator Selection and Concentration in Photopolymer Formulations towards Large-Format Additive Manufacturing

et al. 2022

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Photopolymers are an attractive option for large-format additive manufacturing (LFAM), because they can be formulated from structural thermosets and cure rapidly in ambient conditions under low-energy ultraviolet light-emitting diode (UV LED) lamps. Photopolymer cure is strongly influenced by the depth penetration of UV light, which can be limited in the 2–4 mm layer thicknesses typical of LFAM. Photoinitiator (PI) systems that exhibit photobleaching have proven useful in thick-section cure applications, because they generate a photoinitiation wavefront, but this effect is time-dependent. This study investigates the light transmission and through-thickness cure behavior in (meth)acrylate photopolymer formulations with the photobleaching initiator bis(2,4,6-trimethylbenzoyl)-phenylphosphine oxide (BAPO). Utilizing an optical model developed by Kenning et al., lower concentrations (0.1 wt% to 0.5 wt%) of BAPO were predicted to yield rapid onset of photoinitiation. In situ cure measurements under continuous UV LED irradiation of 380 mW/cm2 showed that a 0.1 wt% concentration of BAPO achieved peak polymerization rate within 2.5 s at a 3-mm depth. With only 1 s of irradiation at 1.7 W/cm2 intensity, the 0.1 wt% BAPO formulation also achieved the highest level of cure of the formulas tested. For an irradiation dose of 5.5 J/cm2 at a duration of 3.7 s, cured polymer specimens achieved a flexural strength of 108 MPa and a flexural modulus of 3.1 GPa. This study demonstrates the utility of optical modeling as a potential screening tool for new photopolymer formulations, primarily in identifying an upper limit to PI concentration for the desired cure depth. The results also show that photobleaching provides only a limited benefit for LFAM applications with short (1.0 s to 3.7 s) UV irradiation times and indicate that excess PI concentration can inhibit light transmission even under extended irradiation times up to 60 s.

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“…The material composed of epoxy resin as resin matrix and combined with CF reinforcement material is called CF epoxy resin composite material [10]. The research on CF reinforced epoxy resin matrix composites mainly includes: CF surface modification research [11], composite toughening modification research [12], curing and composite molding process [13] and so on.…”

Section: Cf Reinforced Epoxy Resin Matrix Compositesmentioning

confidence: 99%

Mechanical Properties Testing of Carbon Fiber Reinforced Composites

2022

IJOMAM

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the current research in the field of materials focuses on the analysis of the properties of carbon fiber (CF). There are relatively few studies related to the structural design of CF composite reinforcements in practical applications. In order to improve the traditional laminate structure of aircraft engine blades, CF reinforced epoxy resin matrix composites are used as the research object. Its surface modification method, toughening method, and molding process ae studied. Then, the laminate structure of aircraft engine blades is studied and designed based on CF reinforced epoxy resin matrix composites combined with the concept of bionics. The root, middle, and tip parts of the engine blade are designed with layered structure and angle. Finally, the mechanical properties of the designed blades are tested through experiments. The results show that among the threelayered design structures of the blade root, the bionic synchronous double helix structure of the blade root has the highest tensile strength, which is 419.13MPa. The bending strength of the leaf root bionic variable angle double helix structure is the highest, which is 1349.45MPa. Among the three-layered design structures in the blade, the biomimetic nonlinear structure in the leaf has the highest tensile strength and bending strength values, which are 468.23MPa and 1222.44MPa, respectively. Among the three-layered design structures of the blade tip, the tensile strength and bending strength of the blade tip bionic variable-angle double helix structure are the highest, which are 457.78MPa and 1126.33MPa, respectively. These results provide research experience for further improving the performance of aircraft engines.

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Rheological survey of carbon fiber-reinforced high-temperature thermoplastics for big area additive manufacturing tooling applications

Cited by 31 publications

References 42 publications

Rheology-Assisted Microstructure Control for Printing Magnetic Composites—Material and Process Development

Rheology-Assisted Microstructure Control for Printing Magnetic Composites—Material and Process Development

Photoinitiator Selection and Concentration in Photopolymer Formulations towards Large-Format Additive Manufacturing

Mechanical Properties Testing of Carbon Fiber Reinforced Composites

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