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Consolidation of Additive Manufactured Continuous Carbon Fiber Reinforced Polyamide 12 Composites and the Development of Process-Related Numerical Simulation Methods

Additive manufacturing of high-performance polymers—such as PA12, PPS, PEEK, and PEKK—combined with industrial-grade carbon fibers with a high fiber volume ratio of up to 60% allows a weight reduction of over 40% compared to classic metal construction. Typically, these 3D-printed composites have a p...

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Autores principales: Grieder, Stefan, Zhilyaev, Igor, Küng, Marco, Brauner, Christian, Akermann, Michael, Bosshard, Jonas, Inderkum, Petra, Francisco, João, Willemin, Yannick, Eichenhofer, Martin
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2022
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9416529/
https://www.ncbi.nlm.nih.gov/pubmed/36015685
http://dx.doi.org/10.3390/polym14163429
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author Grieder, Stefan
Zhilyaev, Igor
Küng, Marco
Brauner, Christian
Akermann, Michael
Bosshard, Jonas
Inderkum, Petra
Francisco, João
Willemin, Yannick
Eichenhofer, Martin
author_facet Grieder, Stefan
Zhilyaev, Igor
Küng, Marco
Brauner, Christian
Akermann, Michael
Bosshard, Jonas
Inderkum, Petra
Francisco, João
Willemin, Yannick
Eichenhofer, Martin
author_sort Grieder, Stefan
collection PubMed
description Additive manufacturing of high-performance polymers—such as PA12, PPS, PEEK, and PEKK—combined with industrial-grade carbon fibers with a high fiber volume ratio of up to 60% allows a weight reduction of over 40% compared to classic metal construction. Typically, these 3D-printed composites have a porosity of 10–30% depending on the material and the printing process parameters, which significantly reduces the quality of the part. Therefore, the additive manufacturing of load-bearing structural applications requires a proper consolidation after the printing process—the so-called ‘additive fusion technology’—allowing close to zero void content in the consolidated part. By means of the upfront digital modeling of the consolidation process, a highly optimized composite component can be produced while decreasing the number of expensive prototyping iterations. In this study, advanced numerical methods are presented to describe the consolidation process of additive manufactured continuous carbon fiber reinforced composite parts based on the polyamide 12 (PA12) matrix. The simulation of the additive fusion step/consolidation provides immediate accuracy in determining the final degree of crystallization, process-induced deformation and residual stresses, final engineering constants, as well as porosity. The developed simulation workflow is demonstrated and validated with experimental data from consolidation tests on the final porosity, thickness, and fiber–volume ratio.
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spelling pubmed-94165292022-08-27 Consolidation of Additive Manufactured Continuous Carbon Fiber Reinforced Polyamide 12 Composites and the Development of Process-Related Numerical Simulation Methods Grieder, Stefan Zhilyaev, Igor Küng, Marco Brauner, Christian Akermann, Michael Bosshard, Jonas Inderkum, Petra Francisco, João Willemin, Yannick Eichenhofer, Martin Polymers (Basel) Article Additive manufacturing of high-performance polymers—such as PA12, PPS, PEEK, and PEKK—combined with industrial-grade carbon fibers with a high fiber volume ratio of up to 60% allows a weight reduction of over 40% compared to classic metal construction. Typically, these 3D-printed composites have a porosity of 10–30% depending on the material and the printing process parameters, which significantly reduces the quality of the part. Therefore, the additive manufacturing of load-bearing structural applications requires a proper consolidation after the printing process—the so-called ‘additive fusion technology’—allowing close to zero void content in the consolidated part. By means of the upfront digital modeling of the consolidation process, a highly optimized composite component can be produced while decreasing the number of expensive prototyping iterations. In this study, advanced numerical methods are presented to describe the consolidation process of additive manufactured continuous carbon fiber reinforced composite parts based on the polyamide 12 (PA12) matrix. The simulation of the additive fusion step/consolidation provides immediate accuracy in determining the final degree of crystallization, process-induced deformation and residual stresses, final engineering constants, as well as porosity. The developed simulation workflow is demonstrated and validated with experimental data from consolidation tests on the final porosity, thickness, and fiber–volume ratio. MDPI 2022-08-22 /pmc/articles/PMC9416529/ /pubmed/36015685 http://dx.doi.org/10.3390/polym14163429 Text en © 2022 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Grieder, Stefan
Zhilyaev, Igor
Küng, Marco
Brauner, Christian
Akermann, Michael
Bosshard, Jonas
Inderkum, Petra
Francisco, João
Willemin, Yannick
Eichenhofer, Martin
Consolidation of Additive Manufactured Continuous Carbon Fiber Reinforced Polyamide 12 Composites and the Development of Process-Related Numerical Simulation Methods
title Consolidation of Additive Manufactured Continuous Carbon Fiber Reinforced Polyamide 12 Composites and the Development of Process-Related Numerical Simulation Methods
title_full Consolidation of Additive Manufactured Continuous Carbon Fiber Reinforced Polyamide 12 Composites and the Development of Process-Related Numerical Simulation Methods
title_fullStr Consolidation of Additive Manufactured Continuous Carbon Fiber Reinforced Polyamide 12 Composites and the Development of Process-Related Numerical Simulation Methods
title_full_unstemmed Consolidation of Additive Manufactured Continuous Carbon Fiber Reinforced Polyamide 12 Composites and the Development of Process-Related Numerical Simulation Methods
title_short Consolidation of Additive Manufactured Continuous Carbon Fiber Reinforced Polyamide 12 Composites and the Development of Process-Related Numerical Simulation Methods
title_sort consolidation of additive manufactured continuous carbon fiber reinforced polyamide 12 composites and the development of process-related numerical simulation methods
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9416529/
https://www.ncbi.nlm.nih.gov/pubmed/36015685
http://dx.doi.org/10.3390/polym14163429
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