Carbon Fiber-reinforced Polyether Ether Research Articles

Thermo-mechanical coupled three-dimensional finite element simulation analysis of drilling thermoplastic braided carbon fiber composite and optimization of process parameters

Optimizing the process parameters of thermoplastic composites during drilling is paramount for mitigating tearing, delamination, and other forms of damage, while simultaneously enhancing the tensile strength and extending the long-term service life of the overall structure. This study focuses on exploring a thermal-mechanical coupling method for predicting dynamic mechanical progressive failure and determining optimal process parameters during the drilling of Braided Carbon Fiber Reinforced Polyether Ether Ketone (BCF/PEEK). Initially, a thermal conduction constitutive model of BCF/PEEK was developed based on the proposed thermal distribution ratio calculation method. Concurrently, a user-defined material subroutine VUMAT and a bilinear cohesive element model, were implemented on the ABAQUS/Explicit platform to simulate the delamination behaviors of drilling BCF/PEEK using a tapered drill-reamer. Subsequently, a comprehensive BCF/PEEK drilling experiment platform was constructed, and the simulation accuracy of the drilling finite element (FE) model was verified through temperature, thrust force, and hole-wall morphology analyses. Finally, response surface regression models were established for process parameters, and the optimal parameters were predicted and validated. The results indicate that minimum thrust force and temperature can be achieved using the tapered drill-reamer with a spindle speed set at 4878.79/3000 r/min and a feed speed of 34.04/30 mm/min, respectively, with a maximum error of only 8.78 %.

Influence of Curvature Feature on Laser Heating during Tape Placement Process for Carbon Fiber Reinforced Polyether Ether Ketone Composite

The curvature feature makes the irradiance and absorptivity change, resulting in an uneven power density distribution, which affects the quality of composite parts. In this study, a theoretical model-based Super-Gaussian profile beam in the laser irradiation area was established to obtain the heat flux distribution on the curved surface. The effect of curvature on the surface scattering reflection, temperature distribution, and surface morphology were investigated and verified the validity of the theoretical model. Furthermore, the influence of the laser intensity distribution, laser inclination and curvature radius on the power density distribution and distribution uniformity were studied. Research indicated that the power density increases as the distance from the origin increase resulting from the variation of the irradiance and absorptance along the circumference. The flatter the intensity distribution of the laser beam in the height direction, the less uniform the power density distribution. Accordingly, the typical Gaussian profile beam significantly ameliorates the power density distribution. This research provides a novel understanding of using heat sources during laser heating thermoplastic tape placement.

Failure mechanism and heat treatment effect of 3D-printed bio-inspired helicoidal CF/PEEK composites

The bio-inspired helicoidal structure has displayed a unique combination of lightweight, high strength, and high impact resistance. This study presents an experimental and numerical investigation of the failure mechanism and heat treatment effect of 3D-printed helicoidal composites by adopting a helicoidal laminate stacking configuration found in the dactyl club in Homarus americanus. The helicoidal specimens were additively manufactured with short carbon fiber reinforced Polyether ether ketone (PEEK) composites and their mechanical performance was characterized through quasi-static three-point bending. The results showed that the flexural strength, flexural modulus, and absorbed energy of the helicoidal composites with the twisted crack pattern were 6.9%, 23.9%, and 5.9% higher than those of the quasi-isotropic composites with the flat crack pattern. Stress analysis was then carried out to investigate the underlying failure mechanism of helicoidal materials. The stress component of σ33 and σ13 in helicoidal specimens showed a milder distribution than that of quasi-isotropic specimens, which plays a major role in the resulting fracture-resistant behavior. Further results showed that the helicoidal specimens under heat treatment of 250 °C over 6 h achieved 24.9% and 20.9% enhancement in flexural strength and modulus. The cracking surface area was increased with extensive translaminar twisted cracks observed with a scanning electron microscope. Experiment results show that heat treatment can exert a significant influence on the crack path of the CF/PEEK helicoidal specimens. Meanwhile, the increased degree of crystallization and crosslinking at the interface could inhibit the initiation of delamination failure.

Finite element analysis of the biomechanical effects of titanium and Cfr-peek additively manufactured subperiosteal jaw implant (AMSJI) on maxilla

The aim of this study is to examine the stresses that will occur under occlusal forces on the cortical bone, spongious bone and the subperiosteal implant systems made of Titanium and%60 Carbon fiber reinforced Polyether ether ketone (PEEK) material. Two different models of subperiosteal implant systems on maxilla made of Titanium and %60 Carbon fiber reinforced Polyether ether ketone (PEEK) material. As a result of vertical and oblique forces, the stress values and distributions on the subperiosteal implant systems and bone were examined. After applying the three different force protocols, von Mises stress, Maximum principal stress and Minimum principal stress values and distribution on the subperiosteal implant body, fixation screws, cortical and spongious bone were analyzed by finite element analysis. In all scenarios, the von Mises values ​​on the Titanium subperiosteal implant system were found to be approximately twice on the 60% carbon fiber reinforced PEEK subperiosteal implant system plates. Subperiosteal implants produced from titanium and carbon fiber reinforced PEEK material exhibited similar stress values on cortical and spongious bone. According to the results of this study, 60% Carbon fiber reinforced PEEK material can be considered as an alternative material to titanium since it exhibits similar biomechanical behavior with titanium subperiosteal implants on cortical and spongious bone. In order to be routinely used as dental subperiosteal implant material, it should be supported by long-term in vivo studies.

Influence of Curvature Feature on Laser Heating During Tape Placement Process for Carbon Fiber Reinforced Polyether Ether Ketone Composite

Influence of Curvature Feature on Laser Heating During Tape Placement Process for Carbon Fiber Reinforced Polyether Ether Ketone Composite

Management of Spinal Dumbbell Tumors via a Minimally Invasive Posterolateral Approach and Carbon Fiber–Reinforced Polyether Ether Ketone Instrumentation: Technical Note and Surgical Case Series

Stand-alone minimally invasive approaches for the surgical management of spinal dumbbell tumors carry the risk of incomplete resections and impaired hemostasis. More-extensive approaches require subsequent instrumentation with metal artifacts impairing follow-up imaging. Here, we present a technical note on percutaneous instrumentation using carbon fiber-reinforced polyether ether ketone (CFR-PEEK) hardware combined with a minimally invasive posterolateral approach for tumor resection. We present a Technical Note and according case series of 7 patients with dumbbell tumors in the lumbar and thoracolumbar spine operated on between 2017 and 2020. CFR-PEEK pedicle screws and rods were inserted percutaneously. Afterwards, a dedicated self-standing retractor for posterolateral approaches was connected to the screws. Following a unilateral facetectomy, the tumor was resected in a microsurgical fashion. Clinical data are reported with respect to the Preferred Reporting Of CasE Series in Surgery (PROCESS) guidelines. Four patients presented with de novo tumors. Three patients were treated for residual tumor mass after previous surgeries. Gross total resection was achieved in all 7 cases, as demonstrated by early postoperative magnetic resonance imaging. Histopathology demonstrated 5 World Health Organization grade I schwannomas, 1 grade II hemangiopericytoma, and 1 cavernous hemangioma. No postoperative complications were observed. CFR-PEEK hardware allowed unambiguous visualization of the resection cavity on follow-up imaging. Resection of dumbbell tumors via a minimally invasive posterolateral approach and instrumentation with CFR-PEEK hardware allows maximal and safe resection. Due to lack of major metal artifacts, carbon fiber hardware improves the interpretation of follow-up imaging as well as planning of radiation if required for tumor recurrence.

Enhancing Distraction Osteogenesis With Carbon Fiber Reinforced Polyether Ether Ketone Bone Pins and a Three-Dimensional Printed Transfer Device to Permit Artifact-Free Three-Dimensional Magnetic Resonance Imaging.

To: (1) design an artifact-free 3D-printed MR-safe temporary transfer device, (2) engineer bone-pins from carbon fiber reinforced polyether ether ketone (CFR-PEEK), (3) evaluate the imaging artifacts of CFR-PEEK, and (4) confirm the osteointegration potential of CFR-PEEK, thus enhancing 3D-planning of bony advancements in hemifacial microsomia using sequential magnetic resonance imaging (MRI). Engineered CRF-PEEK bone pins and a 3D printed ex-fix device were implanted into a sheep head and imaged with MRI and computed tomography . The osseointegration and bony compatibility potential of CFR-PEEK was assessed with scanning electron microscopy images of MC3T3 preosteoblast cells on the surface of the material. The CFR-PEEK pins resulted in a signal void equivalent to the dimension of the pin, with no adjacent areas of MR-signal loss or computed tomography artifact. MCT3 cells adhered and proliferated on the surface of the discs by forming a monolayer of cells, confirming compatibility and osseointegration potential. A 3D printed transfer device could be utilized temporarily during MRI to permit artifact-free 3D planning. CFR-PEEK pins eliminate imaging artifact permitting sequential MRI examination. In combination, this has the potential to enhance distraction osteogenesis, by permitting accurate three-dimensional planning without ionizing radiation.

A Fatigue Crack Growth Model for Random Fiber Composites

Fatigue crack growth behavior of a randomly oriented short carbon fiber rein-forced polyether ether ketone (PEEK) composite is studied at four different load ratios. Based on the experimental data, a new fatigue crack growth model is proposed which accounts for crack growth throughout the entire fatigue cycle and not just at the maximum load. The proposed model involves a weighted averaging procedure and is found to fit the fatigue crack growth rates at all load ratios in a single power law equation. Finally, it is observed that the fatigue threshold intensity of this material decreases with increasing load ratio.