Title: COMPRESSION MOLDING OF HYBRID CONTINUOUS AND DISCONTINUOUS FIBER REINFORCED THERMOPLASTICS FOR ENHANCING STRENGTH CHARACTERISTICS

Authors: Eduardo Barocio, Martin Eichenhofer, Jordan Kalman, Ludvik M. Fjeld, Joseph Kirchhoff, Garam Kim, R. Byron Pipes

DOI: 10.33599/nasampe/s.23.0284

Abstract: Compression molding with long discontinuous fiber-reinforced thermoplastics enables replacing traditionally machined metallic components with geometrical complexity and with reductions in weight and potential enhancements in structural characteristics like durability, fatigue, and serviceability. Fiber length is critical in fiber-reinforced composites. While long continuous fibers limit the geometrical complexity that can be fabricated but provides exceptional mechanical properties, discontinuous fibers provide manufacturing flexibility but with a penalty in strength. This work demonstrates enhancement in strength and reduction in strength variability achieved by compression molding of long discontinuous fiber platelets and continuous fiber preforms. This approach was demonstrated for an overhead bin pin bracket geometry. Continuous fiber preforms were manufactured with 60% by volume of carbon fiber-reinforced Poly Ether Ketone Ketone (PEKK) using the 9T Labs continuous fiber Additive Fusion Technology (AFT). Similarly, fiber platelets with 60% by volume of carbon fiber reinforced PEKK were utilized. Continuous fiber preforms were designed considering both the concurrent flow of continuous and discontinuous fibers with the desired mesostructure of continuous and discontinuous fibers. The results presented in this work showed an increase of 99.6% in the load at the onset of damage by reinforcing the pin bracket with about 17% by weight of continuous fiber preforms. Similarly, the coefficient of variance of the load at the onset of failure decreased by 46%. Finally, reinforcing the pin bracket with continuous fiber preforms not only enhanced the strength characteristics but also decreased the variability in strength characteristics.

References: [1] B. N. Nguyen et al., “Fiber length and orientation in long-fiber injection-molded thermoplastics - Part I: Modeling of microstructure and elastic properties,” J Compos Mater, vol. 42, no. 10, pp. 1003–1029, 2008, doi: 10.1177/0021998308088606. [2] M. Gupta and K. K. Wang, “Fiber orientation and mechanical properties of short‐fiber‐reinforced injection‐molded composites: Simulated and experimental results,” Polym Compos, vol. 14, no. 5, pp. 367–382, 1993, doi: 10.1002/pc.750140503. [3] S. P. Haanappel, U. Sachs, R. H. W. ten Thije, B. Rietman, and R. Akkerman, “Forming of Thermoplastic Composites,” Key Eng Mater, vol. 504–506, pp. 237–242, 2012, doi: 10.4028/www.scientific.net/KEM.504-506.237. [4] A. J. Favaloro, D. E. Sommer, and R. B. Pipes, “Flow Pattern Predictions & Validation for Discontinuous Prepreg Using Anisotropic Viscous Flow Simulation,” in Proc. 18th Annu. SPE Automot. Compos. Conf. Exhib., Novi, Michigan, 2018. [5] A. J. Favaloro, D. E. Sommer, B. R. Denos, and R. B. Pipes, “Simulation of prepreg platelet compression molding: Method and orientation validation,” J Rheol (N Y N Y), vol. 62, no. 6, pp. 1443–1455, Nov. 2018, doi: 10.1122/1.5044533. [6] D. E. Sommer, A. J. Favaloro, and R. B. Pipes, “Coupling anisotropic viscosity and fiber orientation in applications to squeeze flow,” J Rheol (N Y N Y), vol. 62, no. 3, pp. 669–679, 2018. [7] S. G. Kravchenko et al., “Tensile properties of a stochastic prepreg platelet molded composite,” Compos Part A Appl Sci Manuf, vol. 124, p. 105507, 2019, doi: 10.1016/j.compositesa.2019.105507. [8] S. G. Kravchenko, D. E. Sommer, B. R. Denos, W. B. Avery, and R. B. Pipes, “Structure-property relationship for a prepreg platelet molded composite with engineered meso-morphology,” Compos Struct, vol. 210, pp. 430–445, 2019, doi: 10.1016/j.compstruct.2018.11.058. [9] S. G. Kravchenko, “Failure Analysis in Platelet Molded Composite Systems,” Doctoral Dissertation, Purdue University, West Lafayette, 2017. [Online]. Available: https://www.proquest.com/dissertations-theses/failure-analysis-platelet-molded-composite/docview/1975367643/se-2?accountid=13360 [10] T. D. Ngo, A. Kashani, G. Imbalzano, K. T. Q. Nguyen, and D. Hui, “Additive manufacturing (3D printing): A review of materials, methods, applications and challenges,” Compos B Eng, vol. 143, pp. 172–196, Jun. 2018, doi: 10.1016/j.compositesb.2018.02.012. [11] B. Brenken, E. Barocio, A. Favaloro, V. Kunc, and R. B. Pipes, “Fused filament fabrication of fiber-reinforced polymers: A review,” Addit Manuf, vol. 21, 2018, doi: 10.1016/j.addma.2018.01.002. [12] E. Barocio, B. Brenken, A. Favaloro, and R. B. Pipes, “Extrusion deposition additive manufacturing of composite molds for high-temperature applications,” in International SAMPE Technical Conference, 2017. [13] M. Khorasani, A. Ghasemi, B. Rolfe, and I. Gibson, “Additive manufacturing a powerful tool for the aerospace industry,” Rapid Prototyp J, vol. 28, no. 1, pp. 87–100, Jan. 2022, doi: 10.1108/RPJ-01-2021-0009. [14] N. van de Werken, H. Tekinalp, P. Khanbolouki, S. Ozcan, A. Williams, and M. Tehrani, “Additively manufactured carbon fiber-reinforced composites: State of the art and perspective,” Addit Manuf, vol. 31, p. 100962, Jan. 2020, doi: 10.1016/j.addma.2019.100962. [15] H. Zhao, X. Liu, W. Zhao, G. Wang, and B. Liu, “An Overview of Research on FDM 3D Printing Process of Continuous Fiber Reinforced Composites,” J Phys Conf Ser, vol. 1213, no. 5, p. 052037, Jun. 2019, doi: 10.1088/1742-6596/1213/5/052037. [16] S. M. F. Kabir, K. Mathur, and A.-F. M. Seyam, “A critical review on 3D printed continuous fiber-reinforced composites: History, mechanism, materials and properties,” Compos Struct, vol. 232, p. 111476, Jan. 2020, doi: 10.1016/j.compstruct.2019.111476. [17] H. Zhang, T. Huang, Q. Jiang, L. He, A. Bismarck, and Q. Hu, “Recent progress of 3D printed continuous fiber reinforced polymer composites based on fused deposition modeling: a review,” J Mater Sci, vol. 56, no. 23, pp. 12999–13022, Aug. 2021, doi: 10.1007/s10853-021-06111-w. [18] K. Fayazbakhsh, M. Movahedi, and J. Kalman, “The impact of defects on tensile properties of 3D printed parts manufactured by fused filament fabrication,” Mater Today Commun, vol. 18, pp. 140–148, Mar. 2019, doi: 10.1016/j.mtcomm.2018.12.003. [19] V. Chandran, J. Kalman, K. Fayazbakhsh, and H. Bougherara, “A comparative study of the tensile properties of compression molded and 3D printed PLA specimens in dry and water saturated conditions,” Journal of Mechanical Science and Technology, vol. 35, no. 5, pp. 1977–1985, May 2021, doi: 10.1007/s12206-021-0415-5. [20] R. J. Zaldivar, D. B. Witkin, T. McLouth, D. N. Patel, K. Schmitt, and J. P. Nokes, “Influence of processing and orientation print effects on the mechanical and thermal behavior of 3D-Printed ULTEM® 9085 Material,” Addit Manuf, vol. 13, pp. 71–80, Jan. 2017, doi: 10.1016/J.ADDMA.2016.11.007. [21] R. Hajiha et al., “Additive Manufactured ULTEM 9085 Part Qualification and Allowable Generation,” 2020. [22] S. Miri, J. Kalman, J.-P. Canart, J. Spangler, and K. Fayazbakhsh, “Tensile and thermal properties of low-melt poly aryl ether ketone reinforced with continuous carbon fiber manufactured by robotic 3D printing,” The International Journal of Advanced Manufacturing Technology, vol. 122, no. 2, pp. 1041–1053, Sep. 2022, doi: 10.1007/s00170-022-09983-7. [23] S. Grieder et al., “Consolidation of Additive Manufactured Continuous Carbon Fiber Reinforced Polyamide 12 Composites and the Development of Process-Related Numerical Simulation Methods,” Polymers (Basel), vol. 14, no. 16, p. 3429, Aug. 2022, doi: 10.3390/polym14163429. [24] Wichita State University, “National Center for Advanced Materials Performance (NCAMP).” https://www.wichita.edu/research/NIAR/Research/ncamp.php [25] I. Zhilyaev et al., “Experimental and numerical analysis of the consolidation process for additive manufactured continuous carbon fiber-reinforced polyamide 12 composites,” Front Mater, vol. 9, Dec. 2022, doi: 10.3389/fmats.2022.1068261.

Conference: SAMPE 2023

Publication Date: 2023/04/17

SKU: TP23-0000000284

Pages: 14

Price: $28.00