Title: Mechanical and Physical Properties of Carbon-PEKK Composite 3D-Printed using an EOS P810

Authors: L. M. Brosh, A. S. Schalo, N. J. Bryant, C. A. Buck, T. J. Kacsandy, and J. L. Orr

DOI: 10.33599/nasampe/c.24.0344

Abstract: Advanced Laser Materials (ALM) HT-23 is a high temperature polyetherketoneketone (PEKK) thermoplastic polymer matrix material containing encapsulated carbon fiber reinforcement. HT-23 is inherently flame-retardant, UV-resistant and meets aerospace and mobility industry regulations. The EOS P810 is a selective laser sintering (SLS) powder bed 3-dimensional printer in which parts are manufactured layer-by-layer within a powder cake. The EOS P810 has CO2 dual laser system with a build volume 700 x 380 x 380 mm. This allows complex shapes to be printed without secondary support structure as opposed to traditional fused filament fabrication (FFF) printing. In this study, HT-23 coupons printed using the EOS P810 were evaluated for tensile (ASTM D638), compression (ASTM D695), flexural (ASTM D790), and Izod impact (ASTM D256) strengths. Statistically derived dimensional tolerances and tensile T99 (1-in-100) material allowables were established. Tensile T99 material allowables were established in the spirit of Composite Materials Handbook (CMH) – 17 requirements and means were established for all properties. Density, porosity, and thermal properties were also characterized. Specimen properties relative to location in the build chamber and laser region were investigated and were consistent throughout the build chamber. This study provides basic properties necessary for 3D printing reliable parts using HT-23 on an EOS P810 SLS printer.

References: [1] Wichita State University, Composite Materials Handbook, Horsham, PA: Federal Aviation Administration, 2012. [2] ASTM International, ASTM D638-22 Standard Test Methods for Tension Testing of Plastics, West Conshohocken, PA: ASTM International, 2022. [3] ASTM International, ASTM D695-15 Standard Test Method for Compressive Properties of Rigid Plastics, West Conshohocken, PA: ASTM International, 2015. [4] ASTM International, ASTM D790-17 Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials, West Conshohocken, PA: ASTM International, 2017. [5] ASTM International, ASTM D256-10(2018) Standard Test Methods for Determining the Izod Pendulum Impact Resistance of Plastics, West Conshohocken, PA: ASTM International, 2018. [6] ASTM International, ASTM D792-20 Standard Test Methods for Density and Specific Gravity (Relative Density) of Plastics by Displacement, West Conshohocken, PA: ASTM International, 2020.

Conference: CAMX 2024 | San Diego CA

Publication Date: 2024/9/9

SKU: TP24-0000000344

Pages: 15

Price: $30.00