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Effect of Process Parameters on Void Distribution, Volume Fraction, and Sphericity within the Bead Microstructure of Large-Area Additive Manufacturing Polymer Composites

Short carbon fiber-reinforced composite materials produced by large-area additive manufacturing (LAAM) are attractive due to their lightweight, favorable mechanical properties, multifunctional applications, and low manufacturing costs. However, the physical and mechanical properties of short carbon-...

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Autores principales: Sayah, Neshat, Smith, Douglas E.
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2022
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9740531/
https://www.ncbi.nlm.nih.gov/pubmed/36501502
http://dx.doi.org/10.3390/polym14235107
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author Sayah, Neshat
Smith, Douglas E.
author_facet Sayah, Neshat
Smith, Douglas E.
author_sort Sayah, Neshat
collection PubMed
description Short carbon fiber-reinforced composite materials produced by large-area additive manufacturing (LAAM) are attractive due to their lightweight, favorable mechanical properties, multifunctional applications, and low manufacturing costs. However, the physical and mechanical properties of short carbon-fiber-reinforced composites 3D printed via LAAM systems remain below expectations due in part to the void formation within the bead microstructure. This study aimed to assess void characteristics including volume fraction and sphericity within the microstructure of 13 wt% short carbon fiber acrylonitrile butadiene styrene (SCF/ABS). Our study evaluated SCF/ABS as a pellet, a single freely extruded strand, a regularly deposited single bead, and a single bead manufactured with a roller during the printing process using a high-resolution 3D micro-computed tomography (µCT) system. Micro voids were shown to exist within the microstructure of the SCF/ABS pellet and tended to become more prevalent in a single freely extruded strand which showed the highest void volume fraction among all the samples studied. Results also showed that deposition on the print bed reduced the void volume fraction and applying a roller during the printing process caused a further reduction in the void volume fraction. This study also reports the void’s shape within the microstructure in terms of sphericity which indicated that SCF/ABS single freely extruded strands had the highest mean void sphericity (voids tend to be more spherical). Moreover, this study evaluated the effect of printing process parameters, including nozzle temperature, extrusion speed and nozzle height above the printing table on the void volume fraction and sphericity within the microstructure of regularly deposited single beads.
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spelling pubmed-97405312022-12-11 Effect of Process Parameters on Void Distribution, Volume Fraction, and Sphericity within the Bead Microstructure of Large-Area Additive Manufacturing Polymer Composites Sayah, Neshat Smith, Douglas E. Polymers (Basel) Article Short carbon fiber-reinforced composite materials produced by large-area additive manufacturing (LAAM) are attractive due to their lightweight, favorable mechanical properties, multifunctional applications, and low manufacturing costs. However, the physical and mechanical properties of short carbon-fiber-reinforced composites 3D printed via LAAM systems remain below expectations due in part to the void formation within the bead microstructure. This study aimed to assess void characteristics including volume fraction and sphericity within the microstructure of 13 wt% short carbon fiber acrylonitrile butadiene styrene (SCF/ABS). Our study evaluated SCF/ABS as a pellet, a single freely extruded strand, a regularly deposited single bead, and a single bead manufactured with a roller during the printing process using a high-resolution 3D micro-computed tomography (µCT) system. Micro voids were shown to exist within the microstructure of the SCF/ABS pellet and tended to become more prevalent in a single freely extruded strand which showed the highest void volume fraction among all the samples studied. Results also showed that deposition on the print bed reduced the void volume fraction and applying a roller during the printing process caused a further reduction in the void volume fraction. This study also reports the void’s shape within the microstructure in terms of sphericity which indicated that SCF/ABS single freely extruded strands had the highest mean void sphericity (voids tend to be more spherical). Moreover, this study evaluated the effect of printing process parameters, including nozzle temperature, extrusion speed and nozzle height above the printing table on the void volume fraction and sphericity within the microstructure of regularly deposited single beads. MDPI 2022-11-24 /pmc/articles/PMC9740531/ /pubmed/36501502 http://dx.doi.org/10.3390/polym14235107 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
Sayah, Neshat
Smith, Douglas E.
Effect of Process Parameters on Void Distribution, Volume Fraction, and Sphericity within the Bead Microstructure of Large-Area Additive Manufacturing Polymer Composites
title Effect of Process Parameters on Void Distribution, Volume Fraction, and Sphericity within the Bead Microstructure of Large-Area Additive Manufacturing Polymer Composites
title_full Effect of Process Parameters on Void Distribution, Volume Fraction, and Sphericity within the Bead Microstructure of Large-Area Additive Manufacturing Polymer Composites
title_fullStr Effect of Process Parameters on Void Distribution, Volume Fraction, and Sphericity within the Bead Microstructure of Large-Area Additive Manufacturing Polymer Composites
title_full_unstemmed Effect of Process Parameters on Void Distribution, Volume Fraction, and Sphericity within the Bead Microstructure of Large-Area Additive Manufacturing Polymer Composites
title_short Effect of Process Parameters on Void Distribution, Volume Fraction, and Sphericity within the Bead Microstructure of Large-Area Additive Manufacturing Polymer Composites
title_sort effect of process parameters on void distribution, volume fraction, and sphericity within the bead microstructure of large-area additive manufacturing polymer composites
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9740531/
https://www.ncbi.nlm.nih.gov/pubmed/36501502
http://dx.doi.org/10.3390/polym14235107
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