Additive Preform Molding of continuous carbon fiber thermoset composites

IF 6.5 2区 材料科学 Q1 MATERIALS SCIENCE, COMPOSITES
Kaiyue Deng , Md Habib Ullah Khan , Kelvin Fu
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Abstract

Continuous carbon fiber thermoset composites are renowned for their exceptional mechanical and thermal properties. However, fabricating complex 3D composites has historically presented challenges due to their structural complexity. This study presents the Additive Preform Molding (APM) strategy, a novel hybrid manufacturing method that integrates additive manufacturing with overmolding to produce high-performance composite structures. APM optimizes the alignment of continuous fibers based on load requirements and enhances structural integrity, starting with the creation of semi-cured preforms. These preforms are precisely shaped into specific configurations and subsequently overmolded with an infusion of short fiber-reinforced epoxy, thus enhancing their mechanical properties and facilitating the design of intricate geometries. The versatility of APM is represented through fabrication of various bracket designs. Mechanical testing reveals a tensile strength of 1109.3 MPa, a tensile modulus of 103.5 GPa, a flexural strength of 854.7 MPa and a flexural modulus of 96.6 GPa, confirming its substantial load-bearing capabilities for high-performance applications. This study demonstrates that APM is not only a viable alternative to traditional composite manufacturing methods but also an ideal solution for producing complex, high-strength 3D composite structures.
连续碳纤维热固性复合材料的添加剂预成型
连续碳纤维热固性复合材料以其卓越的机械和热性能而闻名。然而,由于结构的复杂性,制造复杂的3D复合材料一直面临着挑战。本文提出了增材预制成型(APM)策略,这是一种将增材制造与复模制造相结合的新型混合制造方法,可生产高性能复合材料结构。APM根据负载要求优化连续纤维的排列,并从半固化预制体的创建开始提高结构完整性。这些预制体被精确地塑造成特定的结构,随后用短纤维增强环氧树脂的注入进行覆盖,从而提高了它们的机械性能,并促进了复杂几何形状的设计。APM的多功能性通过制造各种支架设计来体现。力学测试表明,抗拉强度为1109.3 MPa,抗拉模量为103.5 GPa,抗弯强度为854.7 MPa,抗弯模量为96.6 GPa,证明了其在高性能应用中的强大承载能力。该研究表明,APM不仅是传统复合材料制造方法的可行替代方案,也是生产复杂、高强度3D复合材料结构的理想解决方案。
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来源期刊
Composites Communications
Composites Communications Materials Science-Ceramics and Composites
CiteScore
12.10
自引率
10.00%
发文量
340
审稿时长
36 days
期刊介绍: Composites Communications (Compos. Commun.) is a peer-reviewed journal publishing short communications and letters on the latest advances in composites science and technology. With a rapid review and publication process, its goal is to disseminate new knowledge promptly within the composites community. The journal welcomes manuscripts presenting creative concepts and new findings in design, state-of-the-art approaches in processing, synthesis, characterization, and mechanics modeling. In addition to traditional fiber-/particulate-reinforced engineering composites, it encourages submissions on composites with exceptional physical, mechanical, and fracture properties, as well as those with unique functions and significant application potential. This includes biomimetic and bio-inspired composites for biomedical applications, functional nano-composites for thermal management and energy applications, and composites designed for extreme service environments.
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