On the printability of high-density polyethylene (HDPE) reinforced with long glass and short carbon fibres

Abstract

Purpose This research is about the possibilities of using high-density polyethylene (HDPE)-based composites consisting of long glass and short carbon fibres because HDPE is one of the more preferred thermoplastics day by day due to its sustainability, cost-effectiveness and availability in the relevant markets. HDPE has become an increasingly preferred material in the marine industry in recent years due to its high resistance to marine environmental conditions (high resistance to UV, surface-fouling marine organisms and corrosive effects of salty and low-pH water). In the highly competitive boat building industry, additive manufacturing offers new opportunities such as rapid prototyping and design freedom. This study aims to investigate the possibilities of using a material suitable for the marine environment and an additive manufacturing (AM) method offering new possibilities, especially for small craft with complex forms. Design/methodology/approach A total of six new HDPE-based composites consisting of long glass and short carbon fibres at 10, 15 and 20% by weight have been proposed for the first time in this study for the use in boat building industry, proposing the application of these new composite materials with AM method, which the industry is not yet fully adopted, is also an innovative aspect of the study. The performances of the materials in AM’s material extrusion (MEX) method were evaluated using the results obtained from mechanical (tensile, compression, shear and impact) and thermal (melt flow index [MFI], thermogravimetric analysis [TGA] and thermomechanical analysis [TMA]) tests. In addition, the structure of the composites was examined with scanning electron microscopy and micro computed tomography visually, and the rheological properties of the composites were also determined by the related tests. As an industrial case study, a ship propeller was manufactured from the composites produced with CF15, which was thought to give the best performance in marine use, and this propeller was tested under water flow. Findings It is evaluated that the composites proposed in this study can be used in marine industry in line with the analyses and test results. The performance of the propeller produced as a case application also confirms this view. The printability of HDPE-based composites, reinforced by both glass and carbon fibre, is much better than that of pure HDPE, and the composites are suitable for use AM’s MEX method in boat building industry. As the fibre contents in the proposed composites increase, the strength values increase and the impact resistance and hardness decrease. The CF15 composite, which meets each of those mechanical and physical values at an average level, is a recommended option for marine applications. Originality/value This study has two basic originalities: (1) On the basis of HDPE, which is widely used in the marine industry, to produce composites that will overcome the deficiencies of this material in practice and to present them to relevant industry by improving their properties; (2) at the same time, to discuss for the first time the use of new HDPE-based materials in AM, whose printability has also been improved through composite, to help dissemination of AM technologies in marine industry in general and in the boat building industry in particular.