Additively manufactured carbon fiber-reinforced composites: State of the art and perspective

Additive Manufacturing - Tập 31 - Trang 100962 - 2020
Nekoda van de Werken1, Halil Tekinalp2, Pouria Khanbolouki3, Soydan Ozcan4, Andrew Williams5, Mehran Tehrani1,3
1Department of Mechanical Engineering, University of New Mexico, Albuquerque, NM 87131, United States
2Energy and Transportation Science Division, Oak Ridge National Laboratory, Oak Ridge, TN 37831, United States
3Walker Department of Mechanical Engineering, The University of Texas at Austin, Austin, TX 78712, United States
4Chemical Sciences Division, Oak Ridge National Laboratory, Oak Ridge, TN 37831, United States
5US Air Force Research Laboratory, Kirtland Air Force Base, Albuquerque, NM 87117, United States

Tóm tắt

Từ khóa


Tài liệu tham khảo

Park, 1995, Delamination-free and high-efficiency drilling of carbon-fiber-reinforced plastics, J. Compos. Mater., 29, 1988, 10.1177/002199839502901503

Robertson, 2018, Rapid energy-efficient manufacturing of polymers and composites via frontal polymerization, Nature, 557, 223, 10.1038/s41586-018-0054-x

Bikas, 2016, Additive manufacturing methods and modelling approaches: a critical review, Int. J. Adv. Manuf. Technol., 83, 389, 10.1007/s00170-015-7576-2

Ning, 2015, Additive manufacturing of carbon fiber reinforced thermoplastic composites using fused deposition modeling, Compos. Part B: Eng., 80, 369, 10.1016/j.compositesb.2015.06.013

Love, 2014, The importance of carbon fiber to polymer additive manufacturing, J. Mater. Res., 29, 1893, 10.1557/jmr.2014.212

Fu, 2009, 1

Parandoush, 2017, A review on additive manufacturing of polymer-fiber composites, Compos. Struct., 182, 36, 10.1016/j.compstruct.2017.08.088

Wang, 2017, 3D printing of polymer matrix composites: a review and prospective, Compos. Part B: Eng., 110, 442, 10.1016/j.compositesb.2016.11.034

Brenken, 2018, Fused filament fabrication of fiber-reinforced polymers: a review, Addit. Manuf., 21, 1

Hofstätter, 2017, State-of-the-art of fiber-reinforced polymers in additive manufacturing technologies, J. Reinf. Plast. Compos., 36, 1061, 10.1177/0731684417695648

Oh, 2018, 3D printable composite materials: a review and prospective, Compos. Res., 31, 192

Ngo, 2018, Additive manufacturing (3D printing): a review of materials, methods, applications and challenges, Compos. Part B: Eng., 143, 172, 10.1016/j.compositesb.2018.02.012

Balla, 2019, Additive manufacturing of natural fiber reinforced polymer composites: processing and prospects, Compos. Part B: Eng., 174, 10.1016/j.compositesb.2019.106956

Rahim, 2019, Recent developments in fused deposition modeling-based 3D printing of polymers and their composites, Polym. Rev., 59, 589, 10.1080/15583724.2019.1597883

Goh, 2019, Recent progress in additive manufacturing of Fiber reinforced polymer composite, Adv. Mater. Technol.—US, 4

Ferreira, 2019, A review on fibre reinforced composite printing via FFF, Rapid Prototyp. J., 25, 972, 10.1108/RPJ-01-2019-0004

Hofstatter, 2017, State-of-the-art of fiber-reinforced polymers in additive manufacturing technologies, J. Reinf. Plast. Comp., 36, 1061, 10.1177/0731684417695648

Quan, 2016, Microstructural design and additive manufacturing and characterization of 3D orthogonal short carbon fiber/acrylonitrile-butadiene-styrene preform and composite, Compos. Sci. Technol., 126, 139, 10.1016/j.compscitech.2016.02.021

Fu, 1996, Effects of fiber length and fiber orientation distributions on the tensile strength of short-fiber-reinforced polymers, Compos. Sci. Technol., 56, 1179, 10.1016/S0266-3538(96)00072-3

van de Werken, 2019, Investigating the effects of fiber surface treatment and alignment on mechanical properties of recycled carbon fiber composites, Compos. Part A: Appl. Sci. Manuf., 119, 38, 10.1016/j.compositesa.2019.01.012

Fu, 1998, The elastic modulus of misaligned short-fiber-reinforced polymers, Compos. Sci. Technol., 58, 389, 10.1016/S0266-3538(97)00129-2

Tekinalp, 2014, Highly oriented carbon fiber-polymer composites via additive manufacturing, Compos. Sci. Technol., 105, 144, 10.1016/j.compscitech.2014.10.009

https://3dfortify.com, (Accessed 2019).

Kempen, 2011, Microstructure and mechanical properties of selective laser melted 18Ni-300 steel, Phys. Proc., 12, 255, 10.1016/j.phpro.2011.03.033

Manfredi, 2013, From powders to dense metal parts: characterization of a commercial AlSiMg alloy processed through direct metal laser sintering, Materials, 6, 856, 10.3390/ma6030856

Anubis3D, 2017. https://www.anubis3d.com/.

Stratasys, http://www.stratasys.com/, 2017. (Accessed 20 September 2017).

Hall, 2015, Student opportunities in materials design and manufacture: introducing a new manufacturing with composites course, J. Mater. Educ., 37, 155

3DXTECH, https://www.3dxtech.com/, 2019. (Accessed 10 March 2019).

D. Corporation, http://www.dielectriccorp.com/, 2017. (Accessed 20 September 2017).

Li, 2015, The diagnosis of manufacturing defects in composite material radome based on antenna’s far field data, Mater. Res. Innov., 19, 277

Apium, https://apiumtec.com/en/3d-printer/, 2017. (Accessed 20 September 2017).

Dielectric Corporation, http://www.dielectriccorp.com/, 2017. (Accessed 20 September 2017).

Hexcel, HexTow AS4 Carbon Fiber, www.hexcel.com, 2018.

Hexcel, HexTow IM7 Carbon Fiber, 2018 Hexcel Corporation, www.hexcel.com, 2018.

Duty, 2018, What makes a material printable? A viscoelastic model for extrusion-based 3D printing of polymers, J. Manuf. Process., 35, 526, 10.1016/j.jmapro.2018.08.008

Duty, 2017, A viscoelastic model for evaluating extrusion-based print conditions, Solid Freeform Fabrication Symposium

Kishore, 2016, Additive manufacturing of high performance semi-crystalline thermoplastics and their composites, 906

Ajinjeru, 2017, Rheological evaluation of high temperature polymers to identify successful extrusion parameters, Solid Freeform Fabrication Symposium

Kishore, 2017, Infrared preheating to improve interlayer strength of big area additive manufacturing (BAAM) components, Addit. Manuf., 14, 7

Duty, 2019, Z-Pinning approach for 3D printing mechanically isotropic materials, Addit. Manuf., 27, 175

van de Werken, 2019, Improving properties of additively manufactured carbon fiber composites via post pressing, Proceedings of the 34th Annual American Society for Composites Technical Conference

Zhong, 2001, Short fiber reinforced composites for fused deposition modeling, Mater. Sci. Eng. A: Struct., 301, 125, 10.1016/S0921-5093(00)01810-4

Shofner, 2003, Nanofiber-reinforced polymers prepared by fused deposition modeling, J. Appl. Polym. Sci., 89, 3081, 10.1002/app.12496

Shofner, 2003, Single wall nanotube and vapor grown carbon fiber reinforced polymers processed by extrusion freeform fabrication, Compos. Part A: Appl. Sci., 34, 1207, 10.1016/j.compositesa.2003.07.002

Zhang, 2018, Interfacial bonding strength of short carbon fiber/acrylonitrile-butadiene-styrene composites fabricated by fused deposition modeling, Compos. Part B: Eng., 137, 51, 10.1016/j.compositesb.2017.11.018

Hofstätter, 2016, Distribution and orientation of carbon fibers in polylactic acid parts produced by fused deposition modeling, Proceedings of ASPE Summer Topical Meeting

Huang, 1996, Interfacial micromechanics in thermoplastic and thermosetting matrix carbon fibre composites, Compos. Part A: Appl. Sci. Manuf., 27, 973, 10.1016/1359-835X(96)00060-7

Ning, 2017, Additive manufacturing of carbon fiber-reinforced plastic composites using fused deposition modeling: effects of process parameters on tensile properties, J. Compos. Mater., 51, 451, 10.1177/0021998316646169

Jiang, 2017, Anisotropic mechanical properties of oriented carbon fiber filled polymer composites produced with fused filament fabrication, Addit. Manuf., 18, 84

Liao, 2018, Properties of oriented carbon fiber/polyamide 12 composite parts fabricated by fused deposition modeling, Mater. Des., 139, 283, 10.1016/j.matdes.2017.11.027

Naranjo-Lozada, 2019, Tensile properties and failure behavior of chopped and continuous carbon fiber composites produced by additive manufacturing, Addit. Manuf., 26, 227

Lewicki, 2017, 3D-printing of meso-structurally ordered carbon Fiber/Polymer composites with unprecedented orthotropic physical properties, Sci. Rep., 7, 10.1038/srep43401

Hoey, 2012, A review on aerosol-based direct-write and its applications for microelectronics, J. Nanotechnol., 2012, 22, 10.1155/2012/324380

Compton, 2018, Direct-write 3D printing of NdFeB bonded magnets, Mater. Manuf. Process., 33, 109, 10.1080/10426914.2016.1221097

Saito, 2019, Experimental validation of an additively manufactured stiffness-optimized short-fiber reinforced composite clevis joint, Exp. Mech., 59, 859, 10.1007/s11340-019-00514-2

Pierson, 2019, Mechanical properties of printed epoxy-carbon fiber composites, Exp. Mech., 59, 843, 10.1007/s11340-019-00498-z

Rios, 2018, 3D printing via ambient reactive extrusion, Mater. Today Commun., 15, 333, 10.1016/j.mtcomm.2018.02.031

Romberg, 2019, Large-scale additive manufacturing, SAMPE J., 55, 8

Griffini, 2016, 3D-printable CFR polymer composites with dual-cure sequential IPNs, Polymer, 91, 174, 10.1016/j.polymer.2016.03.048

Huang, 2018, 3D printing of carbon fiber-filled conductive silicon rubber, Mater. Des., 142, 11, 10.1016/j.matdes.2017.12.051

Chandrasekaran, 2018, 3D printing of high performance cyanate ester thermoset polymers, J. Mater. Chem. A, 6, 853, 10.1039/C7TA09466C

Compton, 2018, Electrical and mechanical properties of 3D-printed graphene-reinforced epoxy, JOM, 70, 292, 10.1007/s11837-017-2707-x

Pierson, 2019, Mechanical properties of printed epoxy-carbon fiber composites, Exp. Mech., 1

Compton, 2017, Thermal analysis of additive manufacturing of large-scale thermoplastic polymer composites, Addit. Manuf., 17, 77

CINCINNATI, CIBAAM 3D Printed Projects, https://www.e-ci.com/baam-3d-printed-projects/. 2018.

L.J. Love, C. Duty, Cincinnati Big Area Additive Manufacturing (BAAM), info.ornl.gov. http://info.ornl.gov/sites/publications/files/Pub54708.pdf (2015).

Duty, 2017, Structure and mechanical behavior of Big Area Additive Manufacturing (BAAM) materials, Rapid Prototyp. J., 23, 181, 10.1108/RPJ-12-2015-0183

https://www.mvpind.com/3d-printer/.

Kunc, 2016

Ajinjeru, 2016, The influence of rheology on melt processing conditions of amorphous thermoplastics for Big Area Additive Manufacturing (BAAM), 754

Ajinjeru, 2018, Determination of melt processing conditions for high performance amorphous thermoplastics for large format additive manufacturing, Addit. Manuf., 21, 125

V. Kishore, C. Ajinjeru, P. Liu, J. Lindahl, A. Hassen, V. Kunc, C. Duty, Predicting sharkskin instability in extrusion additive manufacturing of reinforced thermoplastics.

Bhushan, 2017, An overview of additive manufacturing (3D printing) for microfabrication, Microsyst. Technol., 23, 1117, 10.1007/s00542-017-3342-8

Karalekas, 2003, Study of the mechanical properties of nonwoven fibre mat reinforced photopolymers used in rapid prototyping, Mater. Des., 24, 665, 10.1016/S0261-3069(03)00153-5

Goodridge, 2011, Processing of a Polyamide-12/carbon nanofibre composite by laser sintering, Polym. Test., 30, 94, 10.1016/j.polymertesting.2010.10.011

Yan, 2011, Preparation, characterisation and processing of carbon fibre/polyamide-12 composites for selective laser sintering, Compos. Sci. Technol., 71, 1834, 10.1016/j.compscitech.2011.08.013

Jansson, 2016, Characterisation of carbon fibre-reinforced polyamide manufactured by selective laser sintering, Addit. Manuf., 9, 7

Wu, 2017, Surface modification of carbon fibers and the selective laser sintering of modified carbon fiber/nylon 12 composite powder, Mater. Des., 116, 253, 10.1016/j.matdes.2016.12.037

Yu, 2019, Tensile and flexural behaviors of additively manufactured continuous carbon fiber-reinforced polymer composites, Compos. Struct., 111147, 10.1016/j.compstruct.2019.111147

Sarvestani, 2018, 3D printed composites with continuous carbon fiber reinforcements, Proceedings of the Asme International Mechanical Engineering Congress and Exposition, 2017, 2

van de Werken, 2019, Design considerations and modeling of fiber reinforced 3D printed parts, Compos. Part B: Eng., 160, 684, 10.1016/j.compositesb.2018.12.094

Ming, 2019, A novel route to fabricate high-performance 3D printed continuous fiber-reinforced thermosetting polymer composites, Materials, 12, 10.3390/ma12091369

Hu, 2018, Manufacturing and 3D printing of continuous carbon fiber prepreg filament, J. Mater. Sci., 53, 1887, 10.1007/s10853-017-1624-2

van de Werken, 2019, Design considerations and modeling of fiber reinforced 3D printed parts, Compos. Part B: Eng., 160, 684, 10.1016/j.compositesb.2018.12.094

Zhong, 2001, Research on rapid-prototyping/part manufacturing (RP&M) for the continuous fiber reinforced composite, Mater. Manuf. Process., 16, 17, 10.1081/AMP-100103694

Matsuzaki, 2016, Three-dimensional printing of continuous-fiber composites by in-nozzle impregnation, Sci. Rep., 6, 10.1038/srep23058

Tian, 2016, Interface and performance of 3D printed continuous carbon fiber reinforced PLA composites, Compos. Part A: Appl. Sci., 88, 198, 10.1016/j.compositesa.2016.05.032

Tian, 2017, Recycling and remanufacturing of 3D printed continuous carbon fiber reinforced PLA composites, J. Clean. Prod., 142, 1609, 10.1016/j.jclepro.2016.11.139

Li, 2016, Rapid prototyping of continuous carbon fiber reinforced polylactic acid composites by 3D printing, J. Mater. Process. Technol., 238, 218, 10.1016/j.jmatprotec.2016.07.025

Liu, 2018, A novel free-hanging 3D printing method for continuous carbon fiber reinforced thermoplastic lattice truss core structures, Mater. Des., 137, 235, 10.1016/j.matdes.2017.10.007

Tse, 2016

Ming, 2019, A novel route to fabricate high-performance 3D printed continuous fiber-reinforced thermosetting polymer composites, Materials, 12, 1369, 10.3390/ma12091369

Hao, 2018, Preparation and characterization of 3D printed continuous carbon fiber reinforced thermosetting composites, Polym. Test., 65, 29, 10.1016/j.polymertesting.2017.11.004

Azarov, 2017, Development of a two-matrix composite material fabricated by 3D printing, Polym. Sci. Ser. D, 10, 87, 10.1134/S1995421217010026

Azarov, 2019, Composite 3D printing for the small size unmanned aerial vehicle structure, Compos. Part B: Eng., 169, 157, 10.1016/j.compositesb.2019.03.073

Azarov, 2019, Composite 3D printing for the small size unmanned aerial vehicle structure, Compos. Part B: Eng., 169, 157, 10.1016/j.compositesb.2019.03.073

Gregory, 2018, In-situ thermography of automated fiber placement parts, AIP Conf. Proc., 1949, 10.1063/1.5031551

https://www.compositesworld.com/news/orbital-composites-introduces-orb-1-industrial-grade-robot-3d-printer.

Van Der Klift, 2015, 3D printing of continuous carbon fibre reinforced thermo-plastic (CFRTP) tensile test specimens, Open J. Compos. Mater., 6, 18, 10.4236/ojcm.2016.61003

Walbran, 2016, Customized 3D printed ankle-foot orthosis with adaptable carbon fibre composite spring joint, Cogent Eng., 3, 10.1080/23311916.2016.1227022

Dickson, 2017, Fabrication of continuous carbon, glass and Kevlar fibre reinforced polymer composites using additive manufacturing, Addit. Manuf., 16, 146

Goh, 2018, Characterization of mechanical properties and fracture mode of additively manufactured carbon fiber and glass fiber reinforced thermoplastics, Mater. Des., 137, 79, 10.1016/j.matdes.2017.10.021

Justo, 2018, Characterization of 3D printed long fibre reinforced composites, Compos. Struct., 185, 537, 10.1016/j.compstruct.2017.11.052

Mohammadizadeh, 2019, 3D printed fiber reinforced polymer composites—structural analysis, Compos. Part B: Eng., 175, 10.1016/j.compositesb.2019.107112

Dutra, 2019, Mechanical characterization and asymptotic homogenization of 3D-printed continuous carbon fiber-reinforced thermoplastic, J. Braz. Soc. Mech. Sci. Eng., 41, 10.1007/s40430-019-1630-1

Karimianteherani, 1979, Determination of Cl, K, Rb, Zn, Se and Hg in paprika by neutron-activation analysis, Acta Aliment. Hung., 8, 189

Impossible Objects, www.impossible-objects.com (2019). (Accessed 3 March 2019).

Lammering, 2018, Structural health monitoring on the SARISTU full scale door surround structure, Stud. Neurosci., 463

Liu, 2018, A planar mechanism with variable topology for automated fiber placement, 2018 International Conference on Reconfigurable Mechanisms and Robots (Remar), 10.1109/REMAR.2018.8449845

Sloan, 2015

Mantis Composites, 2019. http://www.mantiscomposites.com/. (Accessed 10 March 2019).

Ge, 2018, Evaluating and optimization of 7-DOF automated fiber placement robotic manipulator performance index based on AdaBoost algorithm, J. Comput. Methods Sci., 18, 749

Shah, 2018, Computer-aided design and optimization of a redundant robotic system for automated Fiber placement process, Disruptive Innovation in Mechanical Engineering for Industry Competitiveness 1983

Hosseini, 2018, An experimental investigation on the therma field of overlapping layers in laser-assisted tape winding process, Proceedings of 21st International Esaform Conference on Material Forming (Esaform 2018), 1960

Yassin, 2018, Processing of thermoplastic matrix composites through automated fiber placement and tape laying methods: a review, J. Thermoplast. Compos. Mater., 31, 1676, 10.1177/0892705717738305

Yao, 2017, Evaluation of carbon fiber-embedded 3D printed structures for strengthening and structural-health monitoring, Mater. Des., 114, 424, 10.1016/j.matdes.2016.10.078

Brooks, 2016, Design and evaluation of additively manufactured parts with three dimensional continuous fibre reinforcement, Mater. Des., 90, 276, 10.1016/j.matdes.2015.10.123

Mori, 2014, Dieless forming of carbon fibre reinforced plastic parts using 3D printer, Procedia Eng., 81, 1595, 10.1016/j.proeng.2014.10.196

Baumann, 2017, Investigation of a new approach for additively manufactured continuous fiber-reinforced polymers, Proc. CIRP, 66, 323, 10.1016/j.procir.2017.03.276

Parandoush, 2019, 3D printing of ultrahigh strength continuous carbon Fiber composites, Adv. Eng. Mater., 21, 10.1002/adem.201800622

Grossman, 2016

2015

Werner, 2018

Winick, 2017

2014

Vialva, 2018

Goh, 2017, Additive manufacturing in unmanned aerial vehicles (UAVs): challenges and potential, Aerosp. Sci. Technol., 63, 140, 10.1016/j.ast.2016.12.019

Goh, 2017, Additive Additive manufacturing in unmanned aerial vehicles (UAVs): challenges and potential, Aerosp. Sci. Technol., 63, 140, 10.1016/j.ast.2016.12.019

Jones, 2016

G.N.v. COMTEX, Aerojet Rocketdyne Successfully Tests Engine Made Entirely with Additive Manufacturing, MarketWatch.com, (2014).

Drew, 2017

Cooney, 2014

Axe, 2017

Espalin, 2014, 3D Printing multifunctionality: structures with electronics, Int. J. Adv. Manuf. Technol., 72, 963, 10.1007/s00170-014-5717-7

MacDonald, 2018, Fabricating patch antennas within complex dielectric structures through multi-process 3D printing, J. Manuf. Process., 34, 197, 10.1016/j.jmapro.2018.05.013

Prater, 2016, I

Buck, 2017

Buck, 2015

Love, 2015

Talagani, 2015, Numerical simulation of big area additive manufacturing (3D priting) of a full size car, SAMPE J., 51, 27

Nuttall, 2016

Hassen, 2016, The durability of large-scale additive manufacturing composite molds, Composites and Advanced Materials Expo (CAMX) Conference, 26

Li, 2017, Additive manufacturing of near-net-shape bonded magnets: prospects and challenges, Scr. Mater., 135, 100, 10.1016/j.scriptamat.2016.12.035

Li, 2017, A novel method combining additive manufacturing and alloy infiltration for NdFeB bonded magnet fabrication, J. Magn. Magn. Mater., 438, 163, 10.1016/j.jmmm.2017.04.066

Koga, 2019, Three-dimensionally printed designable joint for carbon fibre reinforced plastics, Adv. Compos. Mater., 28, 147, 10.1080/09243046.2018.1470894

Fernandez, 2019, Optimal design of fiber reinforced composite structures and their direct ink write fabrication, Comput. Methods Appl. Mech. Eng., 353, 277, 10.1016/j.cma.2019.05.010

Jiang, 2019, Continuous fiber angle topology optimization for polymer composite deposition additive manufacturing applications, Fibers, 7, 10.3390/fib7020014

Sudbury, 2016, Characterizing material transition for functionally graded material using big area additive manufacturing, Annu Int. Solid Free. Fabr. Symp.

C. Duty, J. Failla, S. Kim, J. Lindahl, B. Post, L. Love, V. Kunc, Reducing Mechanical Anisotropy in Extrusion-Based Printed Parts.

Ferreira, 2017, Experimental characterization and micrography of 3D printed PLA and PLA reinforced with short carbon fibers, Compos. Part B: Eng., 124, 88, 10.1016/j.compositesb.2017.05.013

Invernizzi, 2016, UV-assisted 3D printing of glass and carbon fiber-reinforced dual-cure polymer composites, Materials, 9, 10.3390/ma9070583

Salmoria, 2011, Microstructural and mechanical characterization of PA12/MWCNTs nanocomposite manufactured by selective laser sintering, Polym. Test., 30, 611, 10.1016/j.polymertesting.2011.04.007

van de Werken, 2019

Melenka, 2016, Evaluation and prediction of the tensile properties of continuous fiber-reinforced 3D printed structures, Compos. Struct., 153, 866, 10.1016/j.compstruct.2016.07.018