Title: Feasibility Study of Novel Magnetic Compaction Force Assisted Additive Manufacturing (MCFA-AM) Methodology for Continuous Carbon Fiber Reinforced Polymer (C-CFRP) Composites

Authors: Bikash Ranabhat, Sebastian Kirmse, and Kaung-Ting Hsiao

DOI: 10.33599/nasampe/s.19.1535

Abstract: Composite parts manufactured by the current additive manufacturing (AM) methods are inferior in strength and stiffness compared to traditional composite manufacturing. Major issues include voids, physical gaps at layer/layer interface, and the low reinforcing fiber content. This paper experimentally examined the feasibility of a patent-pending novel method, Magnetic Compaction Force Assisted-Additive Manufacturing (MCFA-AM), that utilized a magnetic compaction force to print and support curve-shaped continuous carbon fiber reinforced polymer (C-CFRP) composites in free space without any mold. C-CFRP prepreg tapes were fed through a magnet-assisted roller-like-setting, which was a part of the 3D printing head, and consolidated with a magnetic compaction pressure of 0.21 MPa in this feasibility trial. Short beam shear tests (ASTM D2344) showed that the 0.21 MPa MCFA-AM samples’ interlaminar shear strength (ILSS) was 8 % and 9 % stronger and 7% weaker compared with the C-CFRP samples manufactured by the hand layup, the Tension-Tape-Placement-Without Compaction-AM, and the Out-Of-Autoclave Vacuum-Bag-Only (OOA-VBO) methods, respectively. Microscopic observations showed the size and number of voids were significantly reduced by the magnetic compaction. Finally, it demonstrated that printing stiff, strong, and complex shaped C-CFRP parts with great freedom can be done within a few minutes with this exciting AM-Composites technology advance.

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Conference: SAMPE 2019 - Charlotte, NC

Publication Date: 2019/05/20

SKU: TP19--1535

Pages: 15

Price: FREE