3D printed aluminum matrix composites with well-defined ordered structures of shear-induced aligned carbon fibers

Carbon fiber reinforced aluminum composites with ordered architectures of shear-induced aligned carbon fibers were fabricated by 3D printing.The microstructures of the printed and sintered samples and mechanical properties of the composites were investigated.Carbon fibers and aluminum powder were bonded together with resin.The spatial arrangement of the carbon fibers was fixed in the aluminum matrix by shear-induced alignment in the3D printing process.As a result,the elongation of the composites with a parallel arrangement of aligned fibers and the impact toughness of the composites with an orthogonal arrangement were 0.82%and 0.41 J/cm^(2),respectively,about 0.4 and 0.8 times higher than that of the random arrangement.

High Strain-Rate and Shock Response of Carbon SupercompositeTM

This study focuses on assessing the dynamic behaviors of carbon SupercompositeTM laminates when subjected to high strain-rates and air blast loads, using a shock tube for testing. The investigation aims to understand the response of these advanced materials under extreme conditions, which is crucial for applications in aerospace, military, and other high-performance industries. SupercompositeTM (CZE) prepreg, made up of a 3K plain weave carbon fabric with milled carbon fibers as interlaminar reinforcements impregnated with epoxy, is used to create SupercompositeTM (CZE) laminates. A woven carbon composite (CBE) laminate was also created using 3K plain weave Carbon/Epoxy (CBE) prepreg. Both types of laminates were designed and fabricated using the autoclave process. The dynamic behaviors of CZE and CBE laminate under transverse compression loads were evaluated using a modified Split Hopkinson Pressure Bar (SHPB). The study found that the 3D reinforcement with milled carbon fibers significantly affected the dynamic behavior of the CZE laminate. Stereo imaging videos, captured using two SHIMADZU high-speed video cameras in shock tube experiments, recorded the time history of back surface deflection. The plate specimens exhibited low deflections without any visible damage. The experimentally observed center point deflections of the CZE plates decayed sooner than those of the CBE laminates, indicating an improvement in damping due to the presence of 3D reinforced milled carbon fibers. This research shows that optimized utilization of milled carbon fibers as 3D reinforcement can withstand high stress in the thickness direction and higher energy absorption when subjected to impact and high strain-rate loading.

Tensile Properties of 3-Dimension-4-directional Braided C_f/Si C Composite based on Double-scale Model

The longitude tensile properties of 3-Dimension-4-directional（3D-4d） braided C/Si C composites（CMCs） were investigated with the help of a double scale model. This model involves micro-scale and unit-cell scale. In micro-scale, the tensile properties of fiber tows which involves matrix cracking, interfacial debonding, and fiber failure are studied. The unit-cell scale model can reflect the braided structure and simulate the tensile properties of 3D-4d CMCs by introducing the tensile properties of fiber tows into it. Quasi-static tensile tests of 3D-4d braided CMCs were performed on a PWS-100 test system. The predicted tensile stressstrain curve by the double scale model is in good agreement with that of the experimental results.

Yarn Architecture Analysis of Two-step 3D Braided Composites

A comprehensive study of yarn architecture of two-step rectangle 3D braided composites is presented. Firstly, the braided surface, the shapes of yarns and the intertwining between braider yams and axial yams are analyzed from experimentation. With the microstructure being defined, three levels of unit cell structure are identified, i.e. large unit cell, second unit cell and minimal unit cell. Secondly, based on the minimal unit cell in the interior and on the boundary of the entire cross-section, the deformations of axial yams squashed by braider yams contribute to the increase of the fiber packing factors of axial yams. Finally, the predicted fiber volume fraction of the composites decreases with the increase of linear density of the braider yam and the pitch length. Favorable correlations between the predicted and the experimental results arc found for six groups of the composites.

Fiber Traction Printing:A 3D Printing Method of Continuous Fiber Reinforced Metal Matrix Composite

A novel metal matrix composite freeform fabrication approach,fiber traction printing(FTP),is demonstrated through controlling the wetting behavior between fibers and the matrix.This process utilizes the fiber bundle to control the cross-sectional shape of the liquid metal,shaping it from circular to rectangular which is more precise.The FTP process could resolve manufacturing difficulties in the complex structure of continuous fiber reinforced metal matrix composites.The printing of the first layer monofilament is discussed in detail,and the effects of the fibrous coating thickness on the mechanical properties and microstructures of the composite are also investigated in this paper.The composite material prepared by the FTP process has a tensile strength of 235.2 MPa,which is close to that of composites fabricated by conventional processes.The complex structures are printed to demonstrate the advantages and innovations of this approach.Moreover,the FTP method is suited to other material systems with good wettability,such as modified carbon fiber,surfactants,and aluminum alloys.

Using Acoustic Emissions to Detect Damage in Three-Dimensional Braided Composites

Three-dimensional(3D)braided composites with better properties have been used in some particular industries.Some have had obvious signs of crack when they are braided.Others have had catastrophic failures occuring without warning.A new methodology for the analysis of failure modes in composite materials by means of acoustic emission techniques has been developed.The occurrence of fiber-breakage during tensile loading tests has been observed by the acoustic emission technology.Using acoustic emission technology is investigated as a means of monitoring 3D braided composites structures,detecting damage,and predicting impending damage.Some of the findings of the research project were presented.

3D碳纤维预制体中料浆浸渗引入SiC微粉工艺研究

为了在厚度为10mm的3D碳纤维预制体中大量引入SiC微粉,在料浆不变的基础上采用真空浸渗法、加压浸渗法、加压过滤法、真空吸滤法等四种料浆浸渗法进行试验,并对引入微粉的量及其分布进行分析对比。结果表明,对于含1μm SiC微粉4vol%的料浆,加压过滤法效果最佳,3次浸渗即能引入27.4vol%的SiC微粉,SiC微粉均匀致密填充。

3D打印碳纤维增强PLA试件的力学性能分析

以300目短切碳纤维(CF)和聚乳酸(PLA)为实验原料,分别配制CF质量分数为5%、10%、15%和20%的CF/PLA混合料,再经双螺杆挤出机挤出造粒后得到CF/PLA复合材料。分别以纯PLA和不同组分的CF/PLA复合材料为实验材料,在粒料3D打印机上制备抗拉伸、压缩、弯曲和冲击试样,并做力学性能测试。实验结果表明,随着CF含量的增加,材料最大拉伸强度呈先增大后减小的趋势,当CF含量为5%时,材料的平均拉伸强度最大,为48.45 MPa。材料的平均弯曲和压缩强度随CF含量的增加均呈先减小后增大再减小的趋势,且无CF填充时,二者的强度值最大,分别为114.77 MPa和103.94 MPa。材料的抗冲击强度随着CF含量的增大呈先增大后减小的趋势,当CF含量为5%时,材料的抗冲击强度最大,为14.49 kJ/m^2。

Preparation and 3D printing of high-thermal-conductivity continuous mesophase-pitch-based carbon fiber/epoxy composites

To meet the requirements of spacecraft for the thermal conductivity of resins and solve the problem of low thermal conduction efficiency when 3D printing complex parts,we propose a new type of continuous mesophase-pitch-based carbon fiber/thermoplastic polyurethane/epoxy(CMPCF/TPU/epoxy)composite filament and its preparation process in this study.The composite filament is based on the high thermal conductivity of CMPCF,the high elasticity of TPU,and the high-temperature resistance of epoxy.The tensile strength and thermal conductivity of the CMPCF/TPU/epoxy composite filament were tested.The CMPCF/TPU/epoxy composites are formed by 3D printing technology,and the composite filament is laid according to the direction of heat conduction so that the printed part can meet the needs of directional heat conduction.The experimental results show that the thermal conductivity of the printed sample is 40.549 W/(m·K),which is 160 times that of pure epoxy resin(0.254 W/(m·K)).It is also approximately 13 times better than that of polyacrylonitrile carbon fiber/epoxy(PAN-CF/epoxy)composites.This study breaks through the technical bottleneck of poor printability of CMPCF.It provides a new method for achieving directional thermal conductivity printing,which is important for the development of complex high-performance thermal conductivity products.

3D Printing Technology for Short-continuous Carbon Fiber Synchronous Reinforced Thermoplastic Composites:A Comparison between Towpreg Extrusion and In Situ Impregnation Processes

Three-dimensional(3D)printing of carbon fiber-reinforced thermoplastic composites(CFRTPs)provides an ef-fective method for manufacturing the CFRTPs parts with complex structures.To increase the mechanical per-formance of these parts,a 3D printing technology for short-continuous carbon fiber synchronous-reinforced thermoplastic composites(S/C-CFRTPs)has been proposed.However,the synchronous reinforcement that ex-isted only at particular positions led to a limited improvement in the mechanical performance of the 3D-printed S/C-CFRTP part,which made it challenging to meet the engineering requirements.To solve this problem,two methods for achieving synchronous reinforcement at all the positions of the 3D-printed S/C-CFRTP part are pro-posed.To determine a suitable printing process for the S/C-CFRTP part,a comprehensive comparison between the two methods was conducted through theoretical analysis and experimental verification,involving the print-ing mechanism,fiber content,impregnation percentage,and mechanical performance.The results indicated that the towpreg extrusion process was suitable for manufacturing the 3D-printed S/C-CFRTP part.Compared with the in situ impregnation process,the towpreg extrusion process led to a fiber content increase of approximately 7%and void rate reduction of approximately 6%,resulting in 19%and 20%increases in the tensile and flexural strengths of the 3D-printed S/C-CFRTPs,respectively.Additionally,an optimized process parameter setting for fabricating an S/C-CFRTP prepreg filament with excellent mechanical performance was proposed.The findings of this study can provide a new approach for further improving the mechanical performance of the 3D-printed advanced composites.

复合材料齿轮弯曲强度仿真与试验研究

三维编织复合材料的性能与编织参数密切相关,为了研究碳纤维编织复合材料齿轮的弯曲性能及其与编织参数的关系,提出复合材料及齿轮弯曲性能预测模型。基于代表性体积单胞法和均质化思想建立复合材料的细观、宏观双尺度模型,采用体积平均法、借助有限元手段预测复合材料及齿轮的弯曲性能。并且,采用四步法编织及模压成型方法制备两对碳纤维编织复合材料齿轮,通过试验获得特定编织参数下复合材料及齿轮的弯曲性能。预测结果与试验结果吻合良好,验证了预测模型的准确性。最后,进行了多组编织参数下复合材料及齿轮弯曲性能的预测,得到了编织角和纤维体积分数对复合材料及齿轮弯曲性能的影响规律,并给出了使复合材料齿轮弯曲性能最佳的编织参数。

Effects of Low-pressure Annealing on the Performance of 3D Printed CF/PEEK Composites

The interlayer bonding properties are normally unsatisfying for 3D printed composites owing to the layer-by-layer formation process.In this study,low-pressure annealing was performed on 3D printed carbon fiber reinforced polyether ether ketone(CF/PEEK)to improve the interlayer bonding strength.The effects of annealing parameters on the mechanical properties and microstructure were studied.The results showed that the interlaminar shear strength(ILSS)of CF/PEEK improved by up to 55.4%after annealing.SEM and𝜇-CT were also applied to reveal the reinforcing mechanism.This improvement could mainly be attributed to the increased crystallinity of the CF/PEEK after annealing.Additionally,annealing reduced the porosity of the printed CF/PEEK and improved the fiber-resin interface.This resulted in a reduction in the stress concentration areas during loading,thereby enhancing the interlayer bonding strength of CF/PEEK.

三维混杂碳纤维/芳纶纤维增强尼龙复合材料力学性能研究

制备了三维混杂碳纤维 /芳纶纤维增强尼龙复合材料 (HY/PA)并对其力学性能进行了测试。研究表明 :由于芳纶纤维的加入 ,使碳纤维增强尼龙复合材料 (CF/PA)的抗冲击性能有了显著提高 ,HY/PA的抗冲击强度随芳纶纤维体积分数的增大而有所提高 ;另外 ,HY/PA在改善CF/PA的横向剪切强度的同时 ,也改善了芳纶纤维增强尼龙复合材料 (KF/PA)的纵向剪切强度 ;同时 ,混杂效应对HY/PA的弯曲性能的影响最为显著 ,HY/PA的弯曲强度、弯曲模量均高于任一种单一纤维复合材料。

三维编织炭纤维复合材料的摩擦磨损性能研究

用 MM- 2 0 0型摩擦磨损试验机考察了不同条件下三维编织炭纤维增强环氧树脂复合材料的摩擦磨损性能 ,并用 XL30 ESEM型扫描电子显微镜对磨痕和磨屑表面形貌进行了观察和分析 .结果表明 :在干摩擦条件下 ,随着纤维含量的增加 ,复合材料的耐磨性提高 ;当 pv值低于 63N· m/s时 ,材料的摩擦系数和磨损率较高 ,主要磨损机理为粘着磨损和疲劳磨损 ;当 pv值大于 63N· m /s时 ,材料的摩擦系数和磨损率明显降低 ,主要磨损机理为粘着磨损 .在润滑条件下 。

复合材料三维编织结构的单元体模型

复合材料三维编织结构技术是国外八十年代发展起来的高新纺织技术。三维编织结构复合材料是一种新型结构形式的复合材料，它具有优良的抗冲击损伤性能、力学性能和耐烧蚀性能。本文讨论了三维编织结构的单元体模型，推导出有关参数之间的数学关系。

SiO_2涂层制备工艺对三维碳纤维编织体抗氧化性能的影响

采用溶胶-浸渍法,在三维碳纤维编织体的纤维表面涂覆SiO_2涂层。实验研究了涂层制备工艺对编织体抗氧化性能的影响。结果表明,纤维经丙酮、硝酸处理后,再采用粘度为0.01～0.012(Pa·s)、分子生长模式为线性的溶胶浸渍,当涂层厚度为0.5μm左右时,浸渍试样抗氧化性能好,完全氧化失重温度为900℃,较之原始编织体提高300℃。涂层过厚或过薄,编织体抗氧化性能下降,这是由于涂层在纤维表面分布不均匀或与纤维表面结合性较差引起的。

SiC涂层/三维碳纤维编织体的氧化动力学和机理研究

采用原位反应法在三维碳纤维编织体(简称:RB)的纤维表面制得SiC涂层,通过 XRD、SEM、等温氧化失重和非等温热重分析等测试手段研究了制备方法对SiC涂层均匀性 的影响,并对SiC涂层／碳纤维编织体(简称:CB)材料在等温和非等温条件下,氧化反应的 动力学和反应机理进行了研究.结果表明:SiC涂层均匀、完整地涂覆于编织体内外各纤维表 面;材料等温氧化反应的机理为第一阶段反应控制,第二阶段扩散和反应共同控制;材料的非 等温氧化过程呈现自催化特征,氧化机理为随机成核,氧化动力学参数为:lgA=9.615min-1; Ea=201.73kJ·mol-1.

原位反应法制备的碳化硅涂层/三维编织碳纤维的氧化性能研究

采用原位反应法在三维编织碳纤维(原纤维)表面制得β-SiC涂层,通过XRD,SEM,等温氧化失重和非等温热重分析等测试手段研究了制备方法对涂层性能的影响。结果表明:利用此法可得到均匀、完整,界面结合良好的涂层,涂层厚度增加,涂层/三维编织碳纤维(复合纤维)抗氧化性能增强。并对复合纤维氧化反应的机理进行了研究。

纤维表面处理对三维编织碳纤维增强尼龙性能的影响

分别考察了几种纤维表面处理方法对碳纤维表面和复合材料性能的影响。结果表明,纤维表面处理使碳纤维的表面更粗糙;经过处理后的碳纤维表面含氧量明显提高,改善了碳纤维与基体的浸润性;空气氧化处理方法的综合效果比较理想;γ射线辐照处理除冲击强度稍低于空气氧化处理外,其弯曲强度、弯曲弹性模量尤其是剪切强度均高于空气氧化法;空气氧化与偶联剂复合处理的复合材料剪切强度最高。

用溶胶-凝胶法制备碳纤维三维编织物增强氧化铝基复合材料的研究

本文研究了溶胶－凝胶（Ｓｏｌ－ｇｅｌ）法制备碳纤维三维编织物增强氧化铝（Ａｌ２Ｏ３）基复合材料的成型工艺及其力学性能，研究了两种主要起始物Ａｌ（ＮＯ３）３、ＡｌＣｌ３配制的氧化铝溶胶对复合材料成型工艺和力学性能的影响。分别以Ａｌ（ＮＯ３）３和ＡｌＣｌ３为起始物，制备得到Ⅰ＃、Ｉ＃复合材料。研究表明，以Ａｌ（ＮＯ３）３为起始物配制的溶胶粘度较小，利于材料的致密化。经过溶胶浸渍、凝胶、裂解１３个周期后，Ⅰ＃材料的密度和室温三点弯曲强度分别为１．８６ｇ／ｃｍ３和１４５．２ＭＰａ，而ＩＩ＃材料的密度和室温三点弯曲强度分别为１．６３ｇ／ｃｍ３和１０４．１ＭＰａ，材料均呈典型的韧性断裂模式。用扫描电子显微镜（ＳＥＭ）观察试样的断口形貌，发现断口表面有大量的纤维拔出，纤维表现了较好的增韧效果。