Composite Manufacturing Research Articles

High cycle fatigue behavior of bulk 6061Al prepared by cold spray-friction stir processing composite additive manufacturing

In this work, the high cycle fatigue behavior of bulk 6061Al prepared by cold spray-friction stir processing composite additive manufacturing (CFAM) was studied for the first time. The microstructure and fatigue fracture morphology of CFAM sample were characterized by scanning electron microscopy equipped with electron backscattering diffraction. The stress versus number of cycles of failure (S-N) curve for CFAM sample was established, and the fatigue crack growth behavior of CFAM sample was analyzed. The results showed that the microstructure of CFAM sample was denser and more homogeneous compared with cold spray (CS) sample, and the average grain size was refined to 3.3 μm due to dynamic recrystallisation. The dense, homogeneous and fine microstructure delayed the initiation and growth of fatigue cracks, and thus resulted in a 178% increase in fatigue strength in the CFAM sample over CS sample. The fatigue surface of the CFAM sample could be divided into fatigue source zone, crack growth zone, and transient fracture zone, showing typical fatigue fracture characteristics. The fatigue crack growth rate in the CFAM sample was significantly lower than that of CS sample for the same stress intensity factor range (ΔK). This was because the fine grains uniformly distributed in CFAM sample increased the proportion of grain boundaries and hindered the fatigue cracks growth. Therefore, CFAM is a promising technology for preparing bulk 6061 Al with excellent fatigue properties.

Cross-Scale Industrial Manufacturing of Multifunctional Glass Fiber/Epoxy Composite Tubes via a Purposely Modified Filament Winding Production Line.

In the present research work is demonstrated a cross-scale manufacturing approach for the production of multifunctional glass fiber reinforced polymer (GFRP) composite tubes with a purposely redesigned filament winding process. Up until now, limited studies have been reported towards the multiscale reinforcement direction of continuous fibers for the manufacturing of hierarchical composites at the industrial level. This study involved the development of two different multi-walled carbon nanotube (MWCNT) aqueous-based inks, which were employed for the modification of commercial glass fiber (GF) reinforcing tows via a bath coating unit in a pilot production line. The obtained multifunctional GFRP tubes presented a variety of characteristics in relation to their final mechanical, hydrothermal aging, electrical, thermal and thermoelectric properties. Results revealed that the two individual systems exhibited pronounced differences both in crushing behavior and durability performance. Interestingly, for lateral compression the MWCNT coatings comprising a polymeric dispersant minorly affected the mechanical response of the produced tubes. The crashworthiness indicators of the multifunctional tubes displayed a slight 5% variation to the respective reference values, combined with a more ductile behavior. Moreover, regarding the bulk electrical and thermal conductivity values, as well as the Seebeck coefficient factor, the corresponding tubes displayed a variance of 233% and 19% and an opposite semi-conducting sign denoting a p- and n-type character, respectively.

Enhancing the thermal and mechanical properties of sulfonated peek fiber composites with reduced smoke density and toxicity

AbstractPolyether ether ketone (PEEK) sulfonation process is a reasonably easy but time‐consuming to manufacture composites. This study focuses on altering PEEK powder in a sulfuric acid solution via a sulfonation process to develop sulfonated PEEK (SPEEK) resin for the fiber‐reinforced thermoplastic composite manufacturing and characterization steps. In this study, about 5 wt% PEEK powder was sulfonated in 98% sulfuric acid solution for 12 h at 65°C. The water bath technique was used for the precipitation process to obtain the SPEEK polymer. After proper washing and drying, the SPEEK matrix (resin) was obtained by dissolving it in dimethylformamide in a ratio of 1:2. This resin solution was then used to manufacture thermoplastic Kevlar and glass fiber‐reinforced composites employing wet layup process and cured at an elevated temperature under pressure. These SPEEK composites passed the flame retardancy UL94 test with a V0 rating. The average water contact angle of the glass fiber‐ and Kevlar‐SPEEK composites is 93.67° and 102.24°, respectively. The average tensile strength values of these composites were found 222.22 and 284.35 MPa, correspondingly. The smoke density and toxicity tests of the glass fiber‐SPEEK composite confirmed lower smoke generation with the modifications. These SPEEK‐fiber composites can be considered for various industrial applications, including aviation, energy, drone, defense, and automotive.

But how can I optimise my high-dimensional problem with only very little data? – A composite manufacturing application

In this research, a Gaussian process (GP) surrogate modelling framework for the forming process of dry carbon-fibre textile was investigated. A particular focus of the work is the development of dimension reduction algorithms, allowing to solve high-dimensional sparse optimisation problems. The concept of active subspace is adopted to find the principal space of the problem. Then, a low-dimensional (i.e., active) subspace can be obtained by selecting the directions with highest explained variance. A kernel-combined GP format is developed. This takes advantage of the active subspace to build a robust, high-dimensional emulator that can be regarded as a special case of multi-fidelity GP. A two-step adaptive sequential design approach is adopted, which further improves the efficiency of data design. Different sequential design strategies are compared. A case study with eight input parameters demonstrates the capability of the proposed approach, where an accurate and robust optimum condition is obtained from only tens of simulations.

Effect of Deposition Parameters and Deposition Height on the Microstructure and Properties of Laser-Cold Metal Transfer Composite Additively Manufactured 2319 Aluminum Alloy.

The 2319-Al alloy is widely used in aviation industry. The crack-free 2319 alloy thin-walled sample was fabricated utilizing the laser-CMT composite additive manufacturing technique, achieving a material utilization rate of 96.43%. The impact of deposition parameters and deposition height on the microstructure and mechanical properties was studied. The microhardness of the additive manufacturing samples exhibited a gradual decrease from construction direction, with values reaching 90 HV, 78 HV, and 72 HV, respectively. The tensile property also exhibited a gradual decrease from the bottom to the top; the highest tensile strength was 296 MPa. The grain size along the construction direction of the deposited sample gradually increased, exhibiting respective sizes of 34.7 um, 36.6 um, and 45.7 um. With the increase in the height of the second phase, the segregation at the grain boundary is intensified, and as the size inside the grain increases, the corresponding density decreases. The good laser-CMT composite additively manufactured 2319 aluminum alloy samples could be obtained under the optimized deposition parameters.

Optimizing a canola-gelatine-urea bio-adhesive: effects of crosslinker and incubation time on the bonding performance

The importance of creating eco-friendly and health-conscious materials has become paramount in striving to attain long-term development goals. For the past decades, constant efforts have been made to tackle the issue of formaldehyde release from wood-based panels which, to date, are still mainly produced from unsustainable synthetic adhesives. In the pursuit of sustainable and environmentally responsible adhesive solutions for the wood industry, sodium bisulfate, sodium bisulfite, and sodium nitrite were used under different heat treatment conditions as crosslinkers for canola protein-based bio-adhesive formulations. The developed adhesive formulations showed outstanding mechanical properties, with a viscosity below 4000 mPa/s despite the relatively high solid content, as well as excellent bonding performances. The one-layer particleboards bonded with the canola-based adhesive demonstrated outstanding mechanical properties, with the internal bonding and the bending strength values surpassing 0.60 N/mm2 and 10 N/mm2, respectively. Notably, the sodium nitrite-crosslinked variants exhibited significantly superior performance compared to the UF-bonded control boards. Longer incubation times generally improve bonding strength, with sodium nitrite showing the most pronounced effects. The results of this research showcase not only the possibility of developing a plant protein-based wood adhesive with high solid content, but also the potential superiority of canola protein-based wood adhesives when compared to conventional, synthetic counterparts. These findings offer valuable insights for optimizing bio-based adhesives in wood composite manufacturing, highlighting sodium nitrite as a promising crosslinker for enhancing the adhesive’s performance.

Thermo-mechanical performance characteristics of glass reinforced HDPE composites: A comprehensive review

Millions of tonnes of plastic and glass waste is produced worldwide, with only a limited quantity being recycled with the majority ending up in landfill, our oceans or in stockpiles. Even though current applications exist for recycled glass and plastic, there is still a need to introduce recyclate to different industries. This review presents an investigation aimed at mechanical and thermal property improvements by the incorporation of reinforcement material into a polymeric matrix. The performance of high-density polyethylene (HDPE) and glass composites manufactured with different levels of glass, additives and surface treatments have been evaluated by analysing several past investigations. The critical parameters influencing the mechanical and thermal performance of HDPE-Glass composites were identified to be the type of reinforcement, glass content, additives utilised, and the different manufacturing methods employed. Optimised mix designs proposed by researchers have been analysed along with reaction mechanisms. This review has identified a composite material to be further refined and optimised with the potential to be improved by integrating reclaimed waste to manufacture composites by promoting a zero-waste economy. Improvements in tensile strength up to 71% can be observed with the implementation of 20% by weight of glass reinforcement in HDPE composites. The use of maleic anhydride grafted polyethylene (MAgPE) as a compatibilizer facilitates the stress transfer between the two phases by improving their bonding with tensile and flexural strength increments up to 85% and 25%, respectively. This review is a valuable resource for future researchers as it identifies crucial research gaps in HDPE-Glass composite manufacturing and synthesises key findings in existing literature.

Comprehensive evaluation method based on objective and subjective factors: A case of printed circuit board resin waste treatment technologies in China

Given the significant diversity in printed circuit board (PCB) resin waste compositions, selecting the most suitable treatment technology is urgent. This study proposes a comprehensive evaluation index system integrating resource and energy use, environmental impact, and cost-benefit analysis. The method enhances the accuracy of subjective weight determination and matrix calculation while reducing the impact of subjective bias. Three treatment technologies are examined: incineration, composite manufacturing, and pyrolysis. Pyrolysis consumes fewer resources and less energy, with minimal environmental impact, scoring above 0.2156 for resource and energy use and above 0.2588 for environmental impact. Composite manufacturing yields superior economic benefits, the score is above 0.3219. Incineration's comprehensive evaluation results are notably lower across various copper content levels. Manufacturing composites is optimal below 16 % copper content, while pyrolysis is preferred above. The case study fully demonstrates the method's reliability and advantages, contributing to recommended technological choices for waste management.

METHODS OF QUALITY CONTROL FOR AEROSPACE PARTS, PRODUCED WITH 3D-PRINTING OUT OF COMPOSITE-REINFORCED POLYMERS

One of the features of parts, made from polymer composite materials, is that the part and material are both formed at once, when the part is being made. Complexity of interaction processes between matrix and reinforcing fiber makes it difficult to achieve prognosed characteristics of part due to possible imperfections of manufacturing processes and technology. Therefore, an important part of parts life cycle is quality control. Quality control can be destructive or non-destructive, the latter giving more information and insight on defects of the part itself and, possibly, at flaws in manufacturing technology. With the increase in popularity of use of additive manufacturing technologies, especially – FDM 3d-printing, in aerospace industry, there’s a need to improve the performance of parts. Benefits of FDM 3d-printing is the absence of need for specialized forming equipment and tools, especially for forming the parts with complex, topologically-optimized geometry and structure. One of the ways to improve printed parts performance and its physical properties is to use continuous fiber reinforcement. Because of need to control the state and position of the fiber in the part, quality control is also an important part of this type of additive manufacturing. Existing popular methods of quality control, used in polymer composite materials part manufacturing were reviewed. Also, the features and limitations, imposed by structure of printed parts and printing technology were reviewed as well, the differences of them and polymer composite parts made in traditional forming ways, were noted too. The destructive testing methods reviewed are tensile stress testing, bend testing and impact stress testing. The non-destructive quality control methods reviewed are visual, acoustic, radiological and ultrasound. Also, recommendations on their use on FDM 3d-printed parts were formed. As a result, visual and ultrasound methods were accepted as non-destructive methods of quality control, with need to perform destructive tests on sample parts as well. Also, as a promising method, thermography was proposed, yet because of the limitation of using it with high-temperature polymers, its utility is also limited.

Additive Manufacturing of Continuous Fiber-Reinforced Polymer Composites via Fused Deposition Modelling: A Comprehensive Review.

Additive manufacturing (AM) has arisen as a transformative technology for manufacturing complex geometries with enhanced mechanical properties, particularly in the realm of continuous fiber-reinforced polymer composites (CFRPCs). Among various AM techniques, fused deposition modeling (FDM) stands out as a promising method for the fabrication of CFRPCs due to its versatility, ease of use, flexibility, and cost-effectiveness. Several research papers on the AM of CFRPs via FDM were summarized and therefore this review paper provides a critical examination of the process-printing parameters influencing the AM process, with a focus on their impact on mechanical properties. This review covers details of factors such as fiber orientation, layer thickness, nozzle diameter, fiber volume fraction, printing temperature, and infill design, extracted from the existing literature. Through a visual representation of the process parameters (printing and material) and properties (mechanical, physical, and thermal), this paper aims to separate out the optimal processing parameters that have been inferred from various research studies. Furthermore, this analysis critically evaluates the current state-of-the-art research, highlighting advancements, applications, filament production methods, challenges, and opportunities for further development in this field. In comparison to short fibers, continuous fiber filaments can render better strength; however, delamination issues persist. Various parameters affect the printing process differently, resulting in several limitations that need to be addressed. Signifying the relationship between printing parameters and mechanical properties is vital for optimizing CFRPC fabrication via FDM, enabling the realization of lightweight, high-strength components for various industrial applications.

Interfacing the IoT in composite manufacturing: An overview

Abstract It is a well-known fact that many sophisticated works consume a lot of human resources, leading to the need to find effective alternative. The manufacturing industry demands a lot of human resources, with around half of the global working population participating in this sector. Challenges such as sudden conflicts in the data, disasters, and loss of productivity are encountered by the manufacturing industries and can be overcome by monitoring machine performance data and automatically configuring the machines according to changing needs. This emphasizes the importance of the Internet of Things (IoT) in addressing niche areas of manufacturing. IoT is a buzzword heard everywhere around the globe. Implementing this technology makes most of the work more accessible than other conventional methods. This has created a lot of research interest on this topic. Among many manufacturing sectors, polymer composite material manufacturing is one of the most demanding. This review article purely focuses on polymer composite manufacturing and its allied processes. The consolidation of data is based on the influence of IoT on the extraction of fibers and manufacturing of polymer composite material using novel techniques, quality assessment of manufactured polymer composite material, challenges faced in exploring the use of IoT, and future scope. It can be stated from the survey that various researchers have minimally explored the incorporation of IoT, but its future looks very promising in terms of producing high-quality products at less time and lower cost by integrating this technique with conventional methods.

Basalt fiber reinforced polypropylene to manufacture 3D printed composites

AbstractPolypropylene (PP) is one of the most used polymeric materials worldwide, either as a neat material or as a matrix for composite manufacture employing a molding process. Fused deposition modeling (FDM) 3D printing is an alternative process that offers the potential for manufacturing value‐added products from PP. However, using neat PP for FDM is challenging because 3D‐printed PP warps and shrinks when cooled, and the mechanical properties of PP are poor. PP‐based composites with different fillers (e.g., glass, carbon, and natural fibers) have shown improved properties using FDM processes. An alternative filler for 3D‐printed PP‐based composites is basalt fiber (BF). The objective of this work was to assess the potential and impacts of BF as a filler for BF‐PP composites using FDM processes. PP was compounded with 15, 25, 35, and 45 wt% BF to produce filaments for 3D printing without adding any compatibilizer. Results of rheology studies, morphology, and mechanical and thermal properties of the 3D printed specimens showed that BF positively impacts Young's modulus (E), thermal stability, and dimensional stability of the composite. All composites, when processed at high shear rates (i.e., above 100 1/s), show approximately similar rheological behavior. E is almost doubled in the composite with 25 wt% BF and increased fourfold in the composite with 35 and 45 wt% BF, compared to neat PP. The Izod impact resistance of the formulations containing 35 and 45 wt% BF is ~70% that of neat PP. BF process easily and adequately reinforces PP composites manufactured via FDM.Highlights Neat PP's poor mechanical properties are improved by adding basalt fiber (BF). Up to 45 wt% BF was used to reinforce PP‐based composites. PP‐BF composites are easier to process via DFM compared to neat PP. BF improves PP‐based composite's thermal and dimensional stability.

Development of a Prototype Drone through Carbon Fiber Composite Structures and Additive Manufacturing Techniques

Development of a Prototype Drone through Carbon Fiber Composite Structures and Additive Manufacturing Techniques

Polymer composite additive manufacturing: Applications, challenges and opportunities

Polymer composite prototypes and final products have been produced using additive manufacturing (AM) or three-dimensional printing (3DP). Due to their exceptional physical, chemical, mechanical, and structural properties, composite or reinforced materials, particularly polymers, are gaining popularity in the fields of engineering and science. High-performance printable polymer composites are urgently required due to the mechanical and functional limitations of printed pure polymer components. Customizable geometry, reduced waste, and accessible material shifting are among the benefits of 3D printing. The market expansion of young industrialists may be restricted by the necessity to recognize the potential of 3DP technology. Furthermore, the literature on this subject must be more specialized or cohesive in order to expand beyond the fundamentals for professionals. This article explores the application of 3D printing matrix composite materials with enhanced properties in the fields of electronics, medical, cars, and aircraft. FDM, PLP, DLP, SLA, SLS, and robocasting are among the AM processes that are addressed in this document. Additional applications for these materials are recommended. Finally, the advantages and disadvantages of 3D printing are highlighted in order to facilitate enhancements.

Reducing styrene emissions in composite piping manufacturing

Reducing styrene emissions in composite piping manufacturing

Composite manufacturing of metal porous thin strip with metal wire mesh and powder

Porous metal materials are applied in various industries, among which powder rolling is the most widely used process for preparing porous metal materials. Then, metal porous materials prepared solely from powder as raw materials have the disadvantage of low mechanical properties, while wire mesh as reinforcement can effectively improve tensile strength. The preparation process of wire mesh powder composite is complex and requires the addition of adhesives. In this article, the mechanical properties of thin metal strips prepared by powder and wire mesh composite vertical rolling were much higher than those prepared by pure powder. Moreover, this thin strip had porous characteristics, and the preparation process was simple and easy to promote. This research could provide a reference for the powder metallurgy field, especially for the preparation of metal porous materials by vertical rolling.

Electrical curing of carbon fibre composites with conductive epoxy resins

Direct electric cure (DEC) was used to cure carbon fibre-reinforced polymers (CFRPs). We show that the energy consumption for curing is significantly reduced, with the judicious placement of contact electrodes, by almost twelve-fold, compared to autoclave curing, and threefold compared to oven curing (0.84, 10.0, and 2.64 kW). CFRP samples of an epoxy matrix with 0-3 wt% carbon black (CB) was used to increase matrix conductivity, and the effect of this variation on the curing and mechanical properties was determined. Subsequently, the concentration with the highest flexural strength, a CFRP with 2 wt% CB was prepared, to study the effects of four different contact arrangements (Top-Bottom, Outside-Outside, Outside-Inside, Inside-Inside) under high pressure (about 2 MPa). Top-Bottom mode shows the best performance, here the electrical current flows through the ply stack perpendicular to the fibre direction. This CFRP has similar mechanical properties as samples manufactured by a range of traditional curing methods. Although the degree of cure (DOC) was reduced by 3–7 %, dependent on the placement of the electrical contacts, the through ply cures showed uniform and high degrees of cure. We show that DEC, thus provides a low capital investment solution to high-quality composite manufacture, facilitating market access for small enterprises, as part sizes and curing times are not limited by oven size nor oven thermal mass.

Experimental investigation of 3D printed polylactic acid and polylactic acid – hydroxyapatite composite through material extrusion technique for biomedical application

In biomedical industries, composite additive manufacturing are employed for customization, quicker production, efficient use and capital reduction. This experimental work focuses on the development of poly lactic acid (PLA) and novel extruded hydroxyapatite (HA) reinforced poly lactic acid (HPLA) by material extrusion (ME) technique and their properties were compared with that of standard 3D printed PLA. The extruded composite filaments were subjected to thermal characterization (DSC, TGA) and chemical characterization (FTIR) to ensure filament quality and its implementation in ME technique for 3D printing process. In addition, the melt compounded composite filaments were subjected to annealing to observe the influence of heat treatment upon their mechanical properties and thereby to validate their potential to resist breakage during ME process. Taguchi orthogonal array method using MiniTab software is employed to execute the parameter optimization for the 3D printing process. The 3D printed tensile, flexural and impact specimens, using pure PLA and extruded composite filaments, as per American Society for Testing and Materials (ASTM) standards were subjected to a comparative experimental study which showed that 3D printed specimens using PLA and HPLA performed better than that of standard PLA specimens due to the improvement in their crystalline nature. The ruptured specimens were subjected to microstructural characterization (optical microscopy, SEM) to observe failure modes and ash content test was conducted to validate the homogenous distribution HA filler particles in PLA matrix. In addition, mechanical characterization was also performed on 3D printed bone plate/bone scaffold application using extruded filaments of PLA and HPLA, as per ASTM F543 standards, to validate incorporation of the composite filaments in real-time application in biomedical industry.

Enhanced 3D printing and crack control in melt-grown eutectic ceramic composites with high-entropy alloy doping

As a 3D printing method, laser powder bed fusion (LPBF) technology has been extensively proven to offer significant advantages in fabricating complex structured specimens, achieving ultra-fine microstructures, and enhancing performances. In the domain of manufacturing melt-grown oxide ceramics, it encounters substantial challenges in suppressing crack defects during the rapid solidification process. The strategic integration of high entropy alloys (HEA), leveraging the significant ductility and toughness into ceramic powders represents a major innovation in overcoming the obstacles. The ingenious doping of HEA particles preserves the eutectic microstructures of the Al2O3/GdAlO3(GAP)/ZrO2 ceramic composite. The high damage tolerance of the HEA alloy under high strain rates enables the absorption of crack energy and alleviation of internal stresses during LPBF, effectively reducing crack initiation and growth. Due to increased curvature forces and intense Marangoni convection at the top of the molt pool, particle collision intensifies, leading to the tendency of HEA particles to agglomerate at the upper part of the molt pool. However, this phenomenon can be effectively alleviated in the remelting process of subsequent layer deposition. Furthermore, a portion of the HEA particles partially dissolves and sinks into the molten pool, acting as heterogeneous nucleation particles, inducing the formation of equiaxed eutectic and leading primary phase nucleation. Some HEA particles diffuse into the lamellar ternary eutectic structures, further promoting the refinement of eutectic microstructures due to increased undercooling. The innovative doping of HEA particles has effectively facilitated the fabrication of turbine-structured, conical, and cylindrical ternary eutectic ceramic composite specimens with diameters of about 70 mm, demonstrating significant developmental potential in the field of ceramic composite manufacturing.

Degree of Cure, Microstructures, and Properties of Carbon/Epoxy Composites Processed via Frontal Polymerization.

The frontal polymerization (FP) of carbon/epoxy (C/Ep) composites is investigated, considering FP as a viable route for the additive manufacturing (AM) of thermoset composites. Neat epoxy (Ep) resin-, short carbon fiber (SCF)-, and continuous carbon fiber (CCF)-reinforced composites are considered in this study. The evolution of the exothermic reaction temperature, polymerization frontal velocity, degree of cure, microstructures, effects of fiber concentration, fracture surface, and thermal and mechanical properties are investigated. The results show that exothermic reaction temperatures range between 110 °C and 153 °C, while the initial excitation temperatures range from 150 °C to 270 °C. It is observed that a higher fiber content increases cure time and decreases average frontal velocity, particularly in low SCF concentrations. This occurs because resin content, which predominantly drives the exothermic reaction, decreases with increased fiber content. The FP velocities of neat Ep resin- and SCF-reinforced composites are seen to be 0.58 and 0.50 mm/s, respectively. The maximum FP velocity (0.64 mm/s) is observed in CCF/Ep composites. The degree of cure (αc) is observed to be in the range of 70% to 85% in FP-processed composites. Such a range of αc is significantly low in comparison to traditional composites processed through a long cure cycle. The glass transition temperature (Tg) of neat epoxy resin is seen to be approximately 154 °C, and it reduces slightly to a lower value (149 °C) for SCF-reinforced composites. The microstructures show significantly high void contents (12%) and large internal cracks. These internal cracks are initiated due to high thermal residual stress developed during curing for non-uniform temperature distribution. The tensile properties of FP-cured samples are seen to be inferior in comparison to autoclave-processed neat epoxy. This occurs mostly due to the presence of large void contents, internal cracks, and a poor degree of cure. Finally, a highly efficient and controlled FP method is desirable to achieve a defect-free microstructure with improved mechanical and thermal properties.