{"title":"Microstructure evolution and anisotropic mechanical performance of CF/PEEK composites fabricated by LPBF additive manufacturing","authors":"Shuai Zhao, Jingpeng Luo, Jiaming Bai","doi":"10.1016/j.coco.2025.102587","DOIUrl":null,"url":null,"abstract":"<div><div>Laser Powder Bed Fusion (LPBF) has emerged as a promising additive manufacturing technique for fabricating high-performance carbon fiber-reinforced polyetheretherketone (CF/PEEK) composites. This study systematically investigates their processability, microstructural evolution, and anisotropic behavior. Angle of repose (AOR) measurements confirmed that composites containing up to 15 wt%CF maintained good flowability suitable for LPBF. Thermal analysis revealed that CF incorporation had little effect on the melting behavior of PEEK, while enhancing thermal stability and narrowing the crystallization window. Mechanical testing demonstrated that optimal performance was achieved at a laser power of 25 W, where the 15 wt%CF/PEEK composite exhibited a tensile strength of 119.8 MPa and an elastic modulus of 8.0 GPa, accompanied by reduced porosity (2.12 %) that reflects effective densification. XRD analysis further revealed strong correlations between lattice parameter variations and mechanical performance, highlighting the role of crystalline structure. Pronounced anisotropy was observed due to fiber alignment induced by the recoating process: tensile strength followed the order <em>x-</em> > <em>xy-</em> > <em>y-</em> orientation, while thermal conductivity of the 15 wt% composite increased by 343 % and 109 % along the X and Y directions, respectively, compared with pure PEEK. These findings contribute to a clearer understanding of the relationships between processing conditions, microstructural features, and performance in LPBF-fabricated CF/PEEK composites.</div></div>","PeriodicalId":10533,"journal":{"name":"Composites Communications","volume":"59 ","pages":"Article 102587"},"PeriodicalIF":7.7000,"publicationDate":"2025-09-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Composites Communications","FirstCategoryId":"88","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S2452213925003407","RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"MATERIALS SCIENCE, COMPOSITES","Score":null,"Total":0}
引用次数: 0
Abstract
Laser Powder Bed Fusion (LPBF) has emerged as a promising additive manufacturing technique for fabricating high-performance carbon fiber-reinforced polyetheretherketone (CF/PEEK) composites. This study systematically investigates their processability, microstructural evolution, and anisotropic behavior. Angle of repose (AOR) measurements confirmed that composites containing up to 15 wt%CF maintained good flowability suitable for LPBF. Thermal analysis revealed that CF incorporation had little effect on the melting behavior of PEEK, while enhancing thermal stability and narrowing the crystallization window. Mechanical testing demonstrated that optimal performance was achieved at a laser power of 25 W, where the 15 wt%CF/PEEK composite exhibited a tensile strength of 119.8 MPa and an elastic modulus of 8.0 GPa, accompanied by reduced porosity (2.12 %) that reflects effective densification. XRD analysis further revealed strong correlations between lattice parameter variations and mechanical performance, highlighting the role of crystalline structure. Pronounced anisotropy was observed due to fiber alignment induced by the recoating process: tensile strength followed the order x- > xy- > y- orientation, while thermal conductivity of the 15 wt% composite increased by 343 % and 109 % along the X and Y directions, respectively, compared with pure PEEK. These findings contribute to a clearer understanding of the relationships between processing conditions, microstructural features, and performance in LPBF-fabricated CF/PEEK composites.
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.