Additive manufacturing of continuous carbon fiber/epoxy composites with structured core-shell towpreg: Methods, characterization, and mechanics

IF 12.7 1区材料科学 Q1 ENGINEERING, MULTIDISCIPLINARY

Composites Part B: Engineering Pub Date : 2024-11-23 DOI:10.1016/j.compositesb.2024.112001

Kaiyue Deng , Md Habib Ullah Khan , Soyeon Park , Dae Han Sung , Kelvin Fu

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引用次数: 0

Abstract

Continuous carbon fiber thermoset composites are acclaimed for their exceptional structural integrity, environmental durability, and extended service life, yet their additive manufacturing (AM) has been relatively underexplored. This study investigates the mechanical performances of 3D-printed continuous carbon fiber/epoxy composites fabricated using the Tow-Preg Cladding (TPC) method. This novel approach integrates in-situ epoxy impregnation, dual-cure cladding, and tow-preg deposition to enhance the producibility of such composites via AM. The resulting composite showcases a fiber volume fraction exceeding 50 %, offering remarkable mechanical properties. We report a tensile strength of 1295.72 MPa, a compressive strength of 544.13 MPa, a flexural strength of 659.30 MPa, and an interlaminar shear strength of 50.87 MPa. Furthermore, the tensile strength and modulus achieved 41.5 % and 58.1 % of the values predicted by a modified rule of mixture equation, indicating competitive performance among various AM systems for continuous fiber composites. By addressing challenges in uniform fiber distribution and optimizing composite morphology, this research marks a significant advancement in AM for thermally curable thermoset composites. The comparative analysis of diverse AM techniques positions our TPC approach as a promising solution in the field, potentially transforming future high-performance composite fabrication.

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来源期刊

Composites Part B: Engineering 工程技术-材料科学：复合

CiteScore

24.40

自引率

11.50%

发文量

784

审稿时长

21 days

期刊介绍： Composites Part B: Engineering is a journal that publishes impactful research of high quality on composite materials. This research is supported by fundamental mechanics and materials science and engineering approaches. The targeted research can cover a wide range of length scales, ranging from nano to micro and meso, and even to the full product and structure level. The journal specifically focuses on engineering applications that involve high performance composites. These applications can range from low volume and high cost to high volume and low cost composite development. The main goal of the journal is to provide a platform for the prompt publication of original and high quality research. The emphasis is on design, development, modeling, validation, and manufacturing of engineering details and concepts. The journal welcomes both basic research papers and proposals for review articles. Authors are encouraged to address challenges across various application areas. These areas include, but are not limited to, aerospace, automotive, and other surface transportation. The journal also covers energy-related applications, with a focus on renewable energy. Other application areas include infrastructure, off-shore and maritime projects, health care technology, and recreational products.