Continuous Fiber Research Articles

Demonstration of computer vision for void characterisation of 3D-printed continuous carbon fibre composites

Microstructural void formation during the processing of continuous fibre-reinforced polymer composites are a significant limitation of processes such as 3D printing, as voids inhibit resultant mechanical properties. Traditional optical microscopy approaches to void characterisation are tedious and are prone to errors due to non-ideal but realistic image conditions, including low contrast typical of microscopic images. This paper proposes a novel application of automated computer vision image processing techniques (i.e. a contrast-limited adaptive histogram equalisation (CLAHE) algorithm and Otsu's method) for detailed void characterisation of continuous fibre-reinforced composites. Microstructural void fraction was subsequently determined for both unidirectional and bi-axial laminates of a variety of thicknesses. The void characterisation by computer vision was shown to produce comparable results with manual contrast/brightness control, but with significantly less standard deviation. The computer vision software used in void characterisation is made freely available online at https://github.com/Xiao-ying/VoidDetector.

Utilizing in-nozzle impregnation for enhancing the strength of recycled PET-derived 3D printed continuous banana fiber reinforced bio-composites

Purpose This study aims to evaluate the potential of using the in-nozzle impregnation approach to reuse recycled PET (RPET) to develop continuous banana fiber (CBF) reinforced bio-composites. The mechanical properties and fracture morphology behavior are evaluated to establish the relationships between layer spacing–microstructural characteristics–mechanical properties of CBF/RPET composite. Design/methodology/approach This study uses RPET filament developed from post-consumer PET bottles and CBF extracted from agricultural waste banana sap. RPET serves as the matrix material, while CBF acts as the reinforcement. The test specimens were fabricated using a customized fused deposition modeling 3D printer. In this process, customized 3D printer heads were used, which have a unique capability to extrude and deposit print fibers consisting of a CBF core coated with an RPET matrix. The tensile and flexural samples were 3D printed at varying layer spacing. Findings The Young’s modulus (E), yield strength (sy) and ultimate tensile strength of the CBF/RPET sample fabricated with 0.7 mm layer spacing are 1.9 times, 1.25 times and 1.8 times greater than neat RPET, respectively. Similarly, the flexural test results showed that the flexural strength of the CBF/RPET sample fabricated at 0.6 mm layer spacing was 47.52 ± 2.00 MPa, which was far greater than the flexural strength of the neat RPET sample (25.12 ± 1.94 MPa). Social implications This study holds significant social implications highlighting the growing environmental sustainability and plastic waste recycling concerns. The use of recycled PET material to develop 3D-printed sustainable structures may reduce resource consumption and encourages responsible production practices. Originality/value The key innovation lies in the concept of in-nozzle impregnation approach, where RPET is reinforced with CBF to develop a sustainable composite structure. CBF reinforcement has made RPET a superior, sustainable, environmentally friendly material that can reduce the reliance on virgin plastic material for 3D printing.

Degradation characteristics of 3D printed continuous fibre-reinforced PA6/chopped fibre composites in simulated saltwater

AbstractThis paper investigates the performance of continuous fibre-reinforced 3D printed components in salt water medium at room temperature. Markforged® Mark Two 3D printer was employed to fabricate standard specimens made of Onyx and reinforced Onyx specimens with continuous carbon, high-strength high-temperature glass, and Kevlar fibres. Aging process was conducted to characterize the long-term effect of salt water on the mechanical behaviour of fibre-reinforced 3D printed samples. Several mechanical tests including tensile, 3-point bending test and indentation testing have been carried out on the dry and aged standard samples to evaluate tensile strength, flexural strength, micro-hardness, and modulus of elasticity in micro-scale. The mechanical tests revealed the degradation and loss in mechanical properties of the printed samples after aging in salt water. The data highlighted that Onyx samples without continuous fibres experienced the most significant reduction in both tensile (33.54%) and flexural (63.47%) strengths after 1 year, while continuous carbon fibre-reinforced Onyx samples showed comparatively lower strength reductions (28.46% in tensile strength and 18.73% in flexural strength). Optical and scanning electron microscopy were performed to investigate the fracture behaviour of the tested specimens. In addition, the DSC assessment showed a slight change in the thermal properties of aged specimens.

Energy absorption response of functionally graded 3D printed continuous fiber reinforced composite cellular structures: Experimental and numerical approaches

Energy absorption response of functionally graded 3D printed continuous fiber reinforced composite cellular structures: Experimental and numerical approaches

Impact of accelerated aging cycles on the performance of extruded cement-based composites reinforced with non-bleached eucalyptus fibers.

Thermo-mechanical pulping produces well-individualized fibers compared to wood particles and less fragile fibers compared to Kraft pulping, besides presenting higher volume, higher yield, and lower production cost, which can be an exciting alternative for the fiber-cement industries. This study evaluated the impact of soak and dry-aging cycles on the performance of extruded composites reinforced with non-bleached eucalyptus fibers. The cement matrix comprised cement (70%) and limestone (30%). Composites were reinforced with 1 to 5% of eucalyptus fiber by cement mass and tested on the 28th day of cure at 99% relative humidity and after 400 accelerated aging cycles. The water absorption and apparent porosity gradually increased with the reinforcement level. Composites with 4 and 5% fibers showed the highest toughness (0.21 and 0.23kJ/m2, respectively). The aging by 400 soak-dry cycles reduced the composites' water absorption and apparent porosity. The modulus of elasticity (MOE), rupture (MOR), and toughness increased, except for toughness for composites reinforced with 1 and 5% fibers, explained by the cementitious matrix's continuous hydration, fiber mineralization, and natural carbonation. In general, eucalyptus thermo-mechanical fibers were suitable for producing cementitious composites. Cementitious composites with 3% fibers presented a higher MOR, MOE, low water absorption, and apparent porosity after 400 accelerated aging cycles. In addition, the composites with 4% fibers also presented remarkable improvements in these properties. The aging cycles did not result in composites with less resistance, a positive fact for their application as tiles and materials for external use in civil construction.

Highly precisive arrangement of continuous carbon fiber and its reinforcing effect on hydroxyapatite

In order to efficiently prepare continuous fiber reinforced composites with high mechanical property, a macro-micro operation device was developed to arrange fiber with high precision. Continuous carbon fiber reinforced hydroxyapatite (CF/HA) composites with highly precisive fiber arrangement was subsequently prepared according to a demanded performance. The arranged fiber spacing and fiber angle of the CF preforms by this device was 101.15 ± 11.72 μm and 0.14 ± 0.38°, respectively. Compared to the traditional arrangement with the arranged fiber spacing of about 300–500 μm, the arrangement accuracy by this device enhanced about 66 %–80 %. The continuous CF/HA composites with designed fiber spacing prepared by this device possessed synchronously enhanced toughness and strength. Compressive strength of the CF/HA composites with designed fiber spacing of 300 μm (CF03p/HA) increased by 311.54 % compared with pure HA. Fracture toughness of the CF03p/HA composites was 1.68 MPa m1/2. Even though the fiber content in CF03p/HA composites was only one-sixth to one-tenth of that in the composites prepared by the traditional method, the compressive strength was 4.12 times that of pure HA. The study provides an effective method for preparing micro fiber reinforced composites featuring excellent mechanical performance even by adding low fiber content.

Homogeneously Planar-Exposure LiB Fiber Skeleton Toward Long-Lifespan Practical Li Metal Pouch Cells.

LiB alloy is promising lithium (Li) metal anode material because the continuous internal LiB fiber skeleton can effectively suppress Li dendrites and structural pulverization. However, the unvalued surface states limit the practical application of LiB alloy anodes. Herein, the study examined the influence of the different exposure manners of the internal LiB fiber skeleton owing to the various surface states of the LiB alloy anode on electrochemical performance and targetedly proposed a scalable friction coating strategy to construct a lithiated fumed silica (LFS) functional layer with abundant electrochemically active sites on the surface of the LiB alloy anode. The LFS significantly suppresses the inhomogeneous interfacial electrochemical behavior of the LiB alloy anode and enables the exposure of the internal LiB fiber skeleton in a homogeneously planar manner (LFS-LiB). Thus, a 0.5Ah LFS-LiB||LiCoO2 (LCO) pouch cell exhibits a discharge capacity retention rate of 80% after 388 cycles. Moreover, a 6.15Ah LFS-LiB||S pouch cell with 409.3Whkg-1 exhibits a discharge capacity retention rate of 80% after 30 cycles. In conclusion, the study findings provide a new research perspective for Li alloy anodes.

Load Bearing Capacity and Failure Analysis of Fibrous Plaster Wads

ABSTRACT Fibrous plaster is a culturally significant material used in high-status buildings from the late nineteenth century. Fibrous plaster ceilings are typically suspended using load-bearing fibrous plaster wads, which are attached to roof structure components. Understanding the behaviour of wads is highly significant, with important safety implications emphasised by the partial collapse of the Apollo Theatre ceiling in 2013. This study demonstrates an original, innovative test method for fibrous plaster wads that enables quantification of load capacities, with manufactured specimens representative of historic in situ wads. The methodology is rigorously evaluated for traditional and alternative wad designs, reinforced with hessian scrim or continuous fibre glass (CFG) mat, with and without steel wires in looped (untwisted) or looped-twisted configurations. Tensile tests generated load-displacement characteristics and determined failure modes including cracking of plaster, deformation and tearing of fibrous reinforcement, and if present, plastic failure of a wire. Results demonstrate that hessian performs better than CFG in axial tension and inclusion of a wire increases tensile load capacity and ductility. An industry standard repair wad with hessian and looped-twisted wire can typically support 3 kN. Looped wire performed better in isolation than looped-twisted wire, with higher peak loads and greater ductility, while looped-twisted wire carried a greater load as part of a fibrous plaster composite wad. The test methodology and findings have revealed new insights into the mechanical behaviour of wads which will inform commercial practice and conservation of historic buildings, preserving important heritage and promoting safe longevity.

Development of a heavy vehicle torque rod applying continuous fiber reinforced thermoplastic composite materials instead of forged steel material: Design, analysis and optimization

The torque rod is an important component of the suspension system that connects the axle to the chassis in heavy commercial vehicles. The main motivation of this study is the development of a torque rod made of (1) plus cross-section, (2) continuous carbon and glass fiber reinforced hybrid thermoplastic composites, which can replace a forged steel torque rod used in heavy vehicles, has superior mechanical properties, provides minimum cost and weight. This study aims to develop a torque rod before its production within the framework of integration with Computer Aided Design (CAD), Finite Element Analysis (FEA), and Multi-Criteria Decision Making (MCDM). In this study, the design data and the properties of the composite materials were chosen as control factors. The minimum displacement, the best mechanical properties such as tensile stress, compressive stress, torsional shear stress, maximum critical buckling load, and the minimum part weight minimum production cost per piece were selected as quality characteristics. As a result of the FEA study, considering the experimental set of the Taguchi Method L25 orthogonal array, the data on mechanical properties, weight, and production cost per piece were subjected to the MCDM process using the Entropy Weighted TOPSIS method. As a result of the MCDM study, a torque rod made of continuous fiber-reinforced thermoplastic composite material, instead of a torque rod produced by forged steel, had the highest mechanical properties produced, the weight of the torque rod can be reduced by 64.76%, and the production costs per piece can be reduced by 37.5%. This study’s findings have shown that the torque rod produced from continuous fiber-reinforced thermoplastic composite materials in a new geometry with a plus cross-section can be substituted for the torque rod produced by steel forging. Thus, it will contribute to reducing the fixed vehicle weight, especially in heavy commercial vehicles, reducing CO2 emissions, and increasing the range of the vehicles.

Continuous Carbon Fiber Reinforced SiC Ceramic Matrix Composites by Vertical Fiber Laying Combined with Material Extrusion 3D Printing

3D printing is reported in the fabrication of continuous carbon fiber reinforced silicon carbide ceramic matrix composites (Cf/SiC CMCs), however, there are layer defects in the 3D printed materials, manifested as weak mechanical properties between layers. Therefore, it is essential and urgent to study how to improve the mechanical properties of 3D printed Cf/SiC CMCs at the layers. In this article, a novel processing technique which combined vertical fiber laying method with material extrusion (ME) 3D printing is proposed to manufacture Cf/SiC CMCs. A self‐developed 3D printing fixed‐axis rotating lifting synchronizer is adopted. The vertical fiber laying of continuous carbon fibers (Cf) in Z‐direction is introduced into the X−Y printing plane. Five cycles of precursor infiltration and pyrolysis (PIP) are performed to achieve the densification of Cf/SiC CMCs. The effects of Cf bundle numbers on the flexural strength and fracture work of Cf/SiC CMCs are studied. The best performing composite is Cf/SiC CMC with six bundles, and the maximum flexural strength and fracture work is 63.84 ± 6.62 MPa and 1291.99 ± 161.39 J m−3, respectively. Compared with pure SiC, the fracture work of Cf/SiC CMC with 6 bundles Cf is increased by 2.54 times.

Woven Agarose-Cellulose Composite Aerogel Fibers with Outstanding Radial Elasticity for Personal Thermal Management.

Aerogel fibers are good thermal insulators, suitable for weaving, and show potential as the next generation of intelligent textiles that can effectively reduce heat consumption for personal thermal management. However, the production of continuous aerogel fibers from biomass with sufficient strength and radial elasticity remains a significant challenge. Herein, continuous gel fibers were produced via wet spinning using agarose (AG) as the matrix, 2,2,2,6,6-tetramethylpiperidine-1-oxyl radical-oxidized cellulose nanofibers (TOCNs) as the reinforcing agent, and no other chemical additives by utilizing the gelling properties of AG. Supercritical drying and chemical vapor deposition (CVD) were then used to produce hydrophobic AG-TOCN aerogel fibers (HATAFs). During CVD, the HATAF gel skeleton was covered with an isostructural silica coating. Consequently, the HATAFs can recover from radial compression under 60% strain. Moreover, the HATAFs have low densities (≤0.14 g cm-3), high porosities (≥91.8%), high specific surface areas (≥188 m2 g-1), moderate tensile strengths (≤1.75 MPa), excellent hydrophobicity (water contact angles of >130°), and good thermal insulating properties at different temperatures. Thus, HATAFs are expected to become a new generation of materials for efficient personal thermal management.

Multi-Pass Laser Polishing of As-Built Directed Energy Deposition Surfaces

Abstract Laser polishing (LP) provides a fast and efficient way of remelting part surfaces manufactured by additive manufacturing to alter both their geometric as well as physical properties. Depending on the laser parameters, remelted surfaces with different properties are achieved, with a majority exhibiting lower surface roughness compared to the original surface. In this study, a high-power continuous fiber laser is used to polish Inconel 718 (IN718) surfaces produced by depositing a single layer of clads on a steel substrate by the powder-blown directed energy deposition (DED) process. Polishing was performed under different sets of parameters, namely, laser power, beam diameter, feed rate or feed, hatch spacing, and the number of polishing passes. Their effects on the surface roughness profiles and the microstructural properties of the sample cross section were analyzed after one and two polishing passes. Optical microscopic images of the sample's cross sections show the presence of supersaturated γ phase particles, γ′+γ″ precipitates, Laves phases, and δ phase needles. The combined effect of high-temperature gradients and lower solidification rates in certain regions within the cross section results in undercooled regions and pseudo-heat treatment of unmelted regions close to the undercooled regions. These results are corroborated by indenting the various regions of the IN718 sample cross section with a pyramidal diamond indenter in the form of a grid, resulting in different micro-hardness values due to different densities of precipitate and phase transformed δ particles.

Shape recovery and energy absorption properties of 3D printed continuous ramie fiber reinforced thin‐walled biocomposite structures

AbstractContinuous fiber reinforced composites are widely used in thin‐walled structures due to their high specific strength and stiffness. In this work, continuous natural fiber was introduced into thin‐walled biocomposite structures via 3D printing technique to enhance energy absorbing properties and promote ecological compatibility. The effects of varying configurations of printing speed, layer thickness, and path optimization on the deposition quality of continuous ramie fiber and polylactic acid matrix were explored. The results showed that reduced printing speed (100 mm/min) and optimal layer thickness (0.25 mm) effectively minimized structural forming defects. In addition, further enhancements in the printing quality could be achieved by smoothing the path with rounded corners. Based on optimal printing strategies, different configurations of thin‐walled biocomposite structures were fabricated. Lateral monotonic and cyclic load tests were performed to investigate their energy absorption and shape recovery capacities. When the loading displacement was 10 mm (strain was 20%), the circular structure presented good shape recovery capability, with measured recovery ratio remaining above 89%. The hexagonal structure showed a similar variation in shape recovery ratio as the quadrangular structure, both remaining above 75%. Moreover, the specific energy absorption of all the structures converged after two cycles, indicating their remarkable and stable repeatable load‐bearing capacity.Highlights Continuous ramie fiber reinforced thin‐walled structures were prepared. The deformation patterns of structures under lateral compression were analyzed. Energy absorption and shape recovery radio were studied under cycle loading. Printed structures exhibited great and stable repeatable load‐bearing capacity.

Effect of Y0.5Er0.5Ho0.5Yb0.5O3 addition on the microstructure and thermal stability of continuous alumina fibers

Effect of Y0.5Er0.5Ho0.5Yb0.5O3 addition on the microstructure and thermal stability of continuous alumina fibers

A shape-performance synergistic strategy for design and additive manufacturing of continuous fiber reinforced transfemoral prosthetic socket

A shape-performance synergistic design and additive manufacturing strategy was developed for the transfemoral prosthetic sockets (TPS) to fulfill the demands of customized geometry and long-term load bearing. The 3D printing path of the continuous fiber reinforced polymer composites (CFRPC) was generated by reversing the milling path of subtractive manufacturing. The mechanical properties of the 3D printed CFRPC samples were investigated as a foundation, and the customized fiber trajectories were designed based on the analyzed stress pattern of the TPS in daily gait. The CFRPC TPS with weight of 28 % less than those made by pure resin had a safety factor larger than 3 and passed the fatigue testing of 3 million cycles. The design and additive manufacturing strategy developed in this study was also applicable for other parts with freeform surfaces.

High stiffness 3D-printed continuous pitch carbon fiber reinforced polymer composites

This study presents a method for 3D printing very high stiffness pitch-based carbon fiber (CF) reinforced polylactic acid (PLA) composites using a modified open-source 3D printer. The fused filament fabrication (FFF) technique was used to fabricate the samples with alternating layers of PLA and PLA-coated pitch CF. The tensile Young’s modulus of the 3D-printed composite samples was measured to characterize the effect of different grades and volume fractions of pitch CF on the behaviour of the printed composites. Three grades of pitch CF which have different Young’s modulus were used with volume fractions ranging from 2.4 to 8.4%. Tensile tests showed that the K1392U CF reinforced composite with a 7.3% volume fraction demonstrated the highest improvement in Young’s modulus of 850% compared to neat 3D-printed PLA. This improvement is notably higher than any previous 3D-printed carbon-based composites at a relatively low volume fraction of CF. Statistical analysis showed increased Young’s modulus in all of 3D-printed composite samples tested. The experimental values were compared to the Halpin-Tsai model and suggest that some degree of fibre breakage occurred during the 3D printing process owing to the relative stiffness of the pitch-based fibers. Future directions and suggestions for process improvements are discussed.

A study on the strand arrangement in 3D printing of continuous carbon fiber composite materials with multiple strands

3D printing of continuous carbon fiber composite materials with multiple strands has significant potential for improving model forming efficiency. However, in this field, we are faced with the challenge of arranging multiple fiber strands closely without excessive overlap consolidation, to avoid damage to the original model. The inability to effectively control the arrangement of multiple strands can significantly affect the print accuracy and mechanical performance of the model. Therefore, in this study, a predictive formula for the line width of carbon fiber strands is first presented. Subsequently, a device dedicated to 3D printing with multiple strands is designed using this formula, and the interrelationship between pressure and the arrangement of multiple strands is delved into. Comparative tests are also conducted on printed parts for tension and bending to investigate the influence of strand arrangement tightness on the mechanical performance of printed samples under different pressure conditions. Through electron microscopy experiments to analyze the microstructure of fracture surfaces, the causes of differences in mechanical performance and the potential effects of different pressures on print accuracy are explained. The results of the study indicate that when pressure can be precisely controlled to ensure a tight arrangement between multiple strands, the mechanical performance of printed parts reaches its optimal state. The tensile strength can reach 360.62 MPa, and the bending strength is 311.04 MPa. At the same time, for test samples printed under the optimal printing pressure, their surface accuracy is also at its best.

3D printing path method for multi-tow continuous carbon fiber

Carbon fiber composite materials have many excellent characteristics such as high temperature resistance, friction resistance, thermal conductivity and corrosion resistance, so carbon fiber composite materials have become the first choice for printing materials. In order to improve the printing efficiency of carbon fiber 3D printing technology, it has been expanded to four side-by-side nozzles based on traditional single nozzles, and four nozzles are bound to print side by side. The four-nozzle side-by-side printing path has the problem of coordinating the motion planning of each nozzle, controlling the squeezing difference of each nozzle, and adjusting the angle of the print head, so it is necessary to reasonably control the squeezing amount of each nozzle and the angle of the print head. After the slicing processing based on the existing model, the Gcode code of the model is obtained. The Gcode code of the model is processed through the multi-tow continuous carbon fiber 3D printing path planning algorithm. The movement trajectory of each nozzle of the printer is reasonably planned based on the outer wall coordinates and the extrusion amount of each nozzle is controlled. Finally, the snipping instruction is executed after a circle of trajectory to print the next layer of motion trajectory, which ultimately improves the 3D printing while ensuring the accuracy of multi-beam model 3D printing.

Assessment of damage sequence in additive manufactured composite laminates under quasi-static out-of-plane loading

The understanding of the impact behaviour of additive manufactured continuous fibre reinforced polymers must start from the analysis of the damage mechanisms. In this investigation, the impact damage in a 3D-printed continuous carbon fibre reinforced polymer is studied by means of quasi-static indentation tests. The coupons are manufactured with Fused Filament Fabrication (FFF) using a thermoplastic resin. Three indentation displacement levels were tested, analysing different phases of the impact using X-ray Computed Tomography. The effects of fibre orientation were considered, establishing a comparison between one laminate with conventional orientations (0, 90, ±45) and one with disperse orientations. Results show a progressive damage generation influenced by the inherent defects of the manufacturing process, characterized by delamination growth and stiffness reduction. Fibre and matrix breakage only appear at the final stages when the laminate peak load is reached. The considered dispersed laminate shows less delaminated interfaces compared to the conventional one.

Mechanical and dynamic performance of 3D-printed continuous carbon fibre Onyx composites

Mechanical and dynamic performance of 3D-printed continuous carbon fibre Onyx composites