Tribological Assessment of As-Built and Annealed Carbon Fiber-Reinforced Polypropylene Composites Fabricated Through FDM with Varying Layer Thicknesses

Abstract

This study examines the effects of FDM-produced carbon fiber-reinforced polypropylene composites, comparing as-built and annealed variants with different layer thicknesses. Such composites, renowned for their remarkable mechanical properties, including high specific stiffness and strength, are extensively utilized across diverse industries like automobile, aerospace, electronics etc. Twenty four test samples, with layer thicknesses of 0.1 mm, 0.16 mm, and 0.24 mm, were manufactured on an FDM printer. Pin-on-disc tribological tests were conducted, applying loads of 5 N, 10 N, 15 N, and 20 N with sliding velocities of 1 and 3 m/s, respectively. Results indicate that the wear rate increases and the coefficient of friction decreases with higher applied load and sliding velocity for both as-built and annealed specimens. This trend persists due to increased compressive load during sliding and reinforced particle presence, ensuring low wear rates and friction coefficients across varying layer thicknesses. The specimen with a 0.1 mm layer thickness displayed superior bonding, resulting in a lower wear rate and coefficient of friction. A better understanding of hardness and surface roughness was observed for annealed samples with lower layer thickness compared to other test samples.