Development of continuous fiber reinforced polymer composites using in-situ co-extrusion towpreg material extrusion process with optimized cooling and evaluation of their mechanical performance and quality

IF 6.8 3区材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Science: Advanced Materials and Devices Pub Date : 2025-08-08 DOI:10.1016/j.jsamd.2025.100966

Nabeel Maqsood , Jawad Ullah , Marius Rimašauskas , Kateřina Skotnicová , Genrik Mordas , Conor McCrickard , Joamin Gonzalez-Gutierrez , Alistair McIlhagger , Edward Archer

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引用次数: 0

Abstract

Polymer composites mainly reinforced with continuous fibers manufactured using the material extrusion technique have gained attention due to their light weight and high-performance capabilities. Thermoplastics reinforced with continuous carbon fiber (CCF) offer exceptional mechanical properties. Polymer composites are fabricated using the material extrusion process, adapting various methods. Manufacturing such composites using fused filament fabrication (FFF) with high quality and reduced air void content is challenging due to the complexity of the process. In this study, in-situ co-extrusion with the towpreg process is used to manufacture CCF reinforced composites using the FFF technique. Two important printing parameters (layer thickness and line width) are considered. Mechanical properties (tensile, shear and compressive) were studied after the manufacturing of the composites. The porosity in the composites was observed using X-ray micro computed tomography scan, and the carbon fiber contents were estimated using the dissolution method, while the fracture analysis was performed using SEM. The results obtained suggested that both the printing parameters have a significant impact on the quality and mechanical properties of the additively manufactured composites. The polymer composite fabricated using a layer thickness of 0.4 mm and a line width of 1 mm showed the highest tensile, shear, and compressive strength of 364.69 MPa, 33.89 MPa, and 121.25 MPa, respectively, with a minimum porosity of 16.14 % and a reinforcement content of 26.12 % volume fraction. This thorough research gave insights into how differences in printing settings affect the structural integrity, mechanical properties, and quality of composites, directing future optimizations for improving the performance and quality of 3D-printed thermoplastic composites.

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采用原位共挤法开发连续纤维增强聚合物复合材料，优化冷却工艺，并对其力学性能和质量进行评价

以连续纤维为主要增强材料的聚合物复合材料以其轻质、高性能而备受关注。用连续碳纤维（CCF）增强的热塑性塑料具有卓越的机械性能。采用材料挤压工艺，采用多种方法制备聚合物复合材料。由于工艺的复杂性，使用高质量的熔融长丝制造（FFF）制造这种具有低空隙率的复合材料具有挑战性。在本研究中，采用原位共挤法与towpreg工艺，利用FFF技术制备CCF增强复合材料。考虑了两个重要的打印参数（层厚和线宽）。对复合材料的拉伸、剪切和压缩力学性能进行了研究。利用x射线显微计算机断层扫描观察复合材料的孔隙率，利用溶解法估算复合材料的碳纤维含量，利用扫描电镜分析复合材料的断裂情况。结果表明，两种打印参数对增材制造复合材料的质量和力学性能都有显著影响。当层厚为0.4 mm、线宽为1 mm时，聚合物复合材料的拉伸、剪切和抗压强度最高，分别为364.69 MPa、33.89 MPa和121.25 MPa，孔隙率最小，为16.14%，补强体积分数最小，为26.12%。这项深入的研究深入了解了打印设置的差异如何影响复合材料的结构完整性、机械性能和质量，指导未来优化3d打印热塑性复合材料的性能和质量。

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来源期刊

Journal of Science: Advanced Materials and Devices Materials Science-Electronic, Optical and Magnetic Materials

CiteScore

11.90

自引率

2.50%

发文量

审稿时长

47 days

期刊介绍： In 1985, the Journal of Science was founded as a platform for publishing national and international research papers across various disciplines, including natural sciences, technology, social sciences, and humanities. Over the years, the journal has experienced remarkable growth in terms of quality, size, and scope. Today, it encompasses a diverse range of publications dedicated to academic research. Considering the rapid expansion of materials science, we are pleased to introduce the Journal of Science: Advanced Materials and Devices. This new addition to our journal series offers researchers an exciting opportunity to publish their work on all aspects of materials science and technology within the esteemed Journal of Science. With this development, we aim to revolutionize the way research in materials science is expressed and organized, further strengthening our commitment to promoting outstanding research across various scientific and technological fields.