Experimental and computational analysis of structure-property relationship in carbon fiber reinforced polymer composites fabricated by selective laser sintering

Published on Jan 1, 2021in Composites Part B-engineering7.635
· DOI :10.1016/J.COMPOSITESB.2020.108499
Haibin Tang5
Estimated H-index: 5
(NUS: National University of Singapore),
Hui Chen11
Estimated H-index: 11
(NUS: National University of Singapore)
+ 2 AuthorsWentao Yan18
Estimated H-index: 18
(NUS: National University of Singapore)
Source
Abstract
Abstract A fundamental understanding of structure-property relationship of carbon fiber reinforced polymer (CFRP) composites fabricated by selective laser sintering (SLS) is essential to provide guidance to improve the mechanical properties in this promising additive manufacturing process. In the present study, we propose a new computational framework to evaluate the mechanical behavior of SLSed CFRP based on the representative volume element (RVE) model. Firstly, a new voxel-based fiber packing algorithm is proposed with the three-dimensional fiber orientation tensor to describe the fiber distribution. The porosity generated in the manufacturing process is also considered by adding spherical voids in the matrix region. In order to remove the artificial stress concentration induced by the voxel-based algorithm, a python script is developed to regenerate the geometries of different phases with conforming mesh. Meanwhile, the constitutive models of different phases in SLSed CFRP, i.e., matrix, fiber and interface, are established according to the material characteristics. Next, the proposed computational framework of SLSed CFRP is validated by the X-ray computed tomography (XCT) measurements and tensile tests of a representative SLSed carbon fiber/polyamide 12 (CF/PA12) composite. The effects of fiber volume fraction and fiber orientation distribution on the mechanical behavior of SLSed CF/PA12 composite are further quantitatively explored and ranked with regards to their influence on stiffness and failure strength.
References51
Newest
#1Haibin Tang (NUS: National University of Singapore)H-Index: 5
#2Zhangxing ChenH-Index: 7
Last. Xuming Su (Ford Motor Company)H-Index: 18
view all 9 authors...
Abstract Chopped carbon fiber sheet molding compound has a great potential in lightweight automotive, marine, and aerospace applications. One of the most challenging tasks is to predict the failure strength of the material due to its anisotropy and heterogeneity, as well as complex stress states in real-world working conditions. In this paper, a novel constitutive model of carbon fiber chip is proposed to capture the pre- and post-failure behaviors under different loading modes. On this basis, w...
3 CitationsSource
#1Haibin Tang (NUAA: Nanjing University of Aeronautics and Astronautics)H-Index: 5
#2Zhangxing Chen (Ford Motor Company)H-Index: 5
Last. Xuming Su (Ford Motor Company)H-Index: 18
view all 8 authors...
Abstract This study focuses on the notch effect on the fatigue failure of chopped carbon fiber chip-reinforced sheet molding compound (SMC) composites by using both experimental and numerical methods. The S-N diagrams of notched specimens are first obtained experimentally, which exhibit large scatter and are shown to depend on the spatial distribution of local fiber orientations. After considering the effect of this spatial distribution by adopting a new fatigue damage parameter to normalize the...
5 CitationsSource
#1Naseem A. CharooH-Index: 12
#2Sogra F. Barakh Ali (A&M: Texas A&M University)H-Index: 8
Last. Ziyaur Rahman (A&M: Texas A&M University)H-Index: 25
view all 7 authors...
Food and Drug Administration (FDA) has approved a drug product (Spritam(R)) and many medical devices manufactured by 3-dimensional printing (3DP) processes for human use. There is immense potential to print personalized medicines using 3DP. Many 3DP methods have been reported in the literature for pharmaceutical applications. However, selective laser sintering (SLS) printing has remained least explored for pharmaceutical applications. There are many advantages and challenges in adopting a SLS me...
11 CitationsSource
#1Claudio Francesco Badini (Polytechnic University of Turin)H-Index: 33
#2Elisa Padovano (Polytechnic University of Turin)H-Index: 13
Last. Mario Pietroluongo (Polytechnic University of Turin)H-Index: 4
view all 5 authors...
6 CitationsSource
#1Imad Hanhan (Purdue University)H-Index: 4
#2Ronald F. Agyei (Purdue University)H-Index: 4
Last. Michael D. Sangid (Purdue University)H-Index: 26
view all 4 authors...
Abstract Due to their lightweight, relatively high stiffness properties, and formability into complex shapes, discontinuous fiber composites are advantageous for producing small and medium size components. Improved characterization techniques and post-processing methodologies are required for more reliable quantification of the microstructure and defect distributions in these materials, in order to employ model-based approaches to assess their structural integrity. This work compares a non-destr...
8 CitationsSource
#1Sogra F. Barakh Ali (Texas A&M Health Science Center)H-Index: 8
#2Eman M. Mohamed (Beni-Suef University)H-Index: 8
Last. Ziyaur Rahman (Texas A&M Health Science Center)H-Index: 25
view all 7 authors...
Abstract The focus of the study was to understand the effects of formulation and process variables on the printlets quality manufactured by selective laser sintering (SLS) 3D printing. The Box-Behnken response surface methodology was used to evaluate effects of individual variables and combinations thereof. The formulation and process variables studied were printing chamber temperature (°C, X1), laser scanning speed (mm/sec, X2) and lactose monohydrate concentration (%, X3). The responses studie...
18 CitationsSource
#1Kaifeng Wang (PSU: Pennsylvania State University)H-Index: 15
#2Shenli Pei (PSU: Pennsylvania State University)H-Index: 3
Last. Nannan Chen (PSU: Pennsylvania State University)H-Index: 7
view all 8 authors...
Abstract This paper explored the 3D progressive fracture process of a short carbon fiber reinforced polymer composite under uniaxial tensile loading via high-resolution in-situ micro X-ray computed tomography (μXCT). Microstructural features extracted from the μXCT images were analyzed with the Halpin-Tsai model, laminate analogy approach, and shear-lag model to calculate the mechanical properties and interpret the different fracture morphologies and progressions observed in the “skin-core-skin”...
6 CitationsSource
#1E.P. Motta (Federal Fluminense University)H-Index: 4
#2João Marciano Laredo dos Reis (Federal Fluminense University)H-Index: 23
Last. H.S. da Costa Mattos (Federal Fluminense University)H-Index: 13
view all 3 authors...
Abstract The mechanical behaviour of polymeric materials presents some peculiarities, especially regarding the evolution of their hardening under stresses above the proportional limit. For many types of polymers (Epoxy, Polyamides, Polyvinylidene, etc.) the elastic properties are not rate-dependent, and the behaviour is elasto-viscoplastic. Also, in the case of load-unload tensile tests, preliminary studies show that the kinematic hardening of this kind of material can be much more significant t...
4 CitationsSource
#1Lili ChenH-Index: 2
#2Boqin GuH-Index: 8
Last. Jiahui TaoH-Index: 2
view all 4 authors...
The effectiveness of the representative volume elements (RVEs) established by a modified random sequential adsorption method for random short fiber reinforced elastomer composites (SFECs) was studied. The RVE is considered to be effective when the RVE’s fiber orientation is isotropic. And the effectiveness of the RVEs was verified by evaluating the mechanical properties in different loading directions based on the finite element method. The results show that the fiber number N=4000 can be regard...
5 CitationsSource
#1Yanhui LiuH-Index: 1
#2Lingjie ZhuH-Index: 2
Last. Yongjiu LiH-Index: 1
view all 4 authors...
This paper aims to explore the influence of the reinforcement included either glass beads (GBs) or carbon fiber (CF) on the reinforced polyamide 12 (PA12) composite samples prepared by selective laser sintering (SLS).,In this paper, the microstructure and mechanical properties are investigated, and the results are compared with those obtained for non-reinforced pure PA12 samples prepared by SLS.,The tensile fracture surface of the non-reinforced pure PA12 sample presents strong micro-deformation...
3 CitationsSource
Cited By3
Newest
#1Haibin Tang (Nanjing University of Science and Technology)H-Index: 5
#2Qingping Sun (Ford Motor Company)H-Index: 8
Last. Wentao Yan (NUS: National University of Singapore)H-Index: 18
view all 5 authors...
Abstract Fused filament fabrication (FFF) with continuous carbon fiber filaments has proven to be a promising manufacturing technique in engineering applications. To provide guidance in the design of 3D printed carbon fiber reinforced polymer (CFPR) components, the longitudinal compression failure of continuous CFPR composites using the FFF technique is investigated systematically. First, longitudinal compression tests are performed for 3D printed continuous CFRP composites with and without desi...
Source
#1Vahid Monfared (IAU: Islamic Azad University)H-Index: 8
In this research article, a mini-review study is performed on the additive manufacturing (AM) of the polymeric matrix composites (PMCs) and nanocomposites. In this regard, some methods for manufacturing and important and applied results are briefly introduced and presented. AM of polymeric matrix composites and nanocomposites has attracted great attention and is emerging as it can make extensively customized parts with appreciably modified and improved mechanical properties compared to the unrei...
Source
#1Qingping Sun (Nanjing University of Science and Technology)H-Index: 8
#2Guowei Zhou (SJTU: Shanghai Jiao Tong University)H-Index: 11
Last. Xuming Su (Ford Motor Company)H-Index: 18
view all 8 authors...
Abstract In this study, integrated experimental tests and computational modeling are proposed to investigate the failure mechanisms of open-hole cross-ply carbon fiber reinforced polymer (CFRP) laminated composites. In particular, we propose two effective methods, which include width-tapered double cantilever beam (WTDCB) and fixed-ratio mixed-mode end load split (FRMMELS) tests, to obtain the experimental data more reliably. We then calibrate the traction-separation laws of cohesive zone model ...
Source
#1Luca Michele Martulli (Polytechnic University of Milan)
#1Luca M. Martulli (Polytechnic University of Milan)H-Index: 3
Last. Andrea Bernasconi (Polytechnic University of Milan)H-Index: 20
view all 6 authors...
Additively manufactured polymer parts are often designed like composite sandwich structures. In this work, sandwich beam-like specimens with hexagonal, triangular and rectangular infills were manuf...
Source
#1Qingping Sun (Nanjing Tech University)H-Index: 8
#1Qingping Sun (Nanjing Tech University)
Last. Weijian Han (Nanjing Tech University)H-Index: 1
view all 7 authors...
Abstract In this work, multi-scale finite element analyses based on three-dimensional (3D) hybrid macro/micro-scale computational models subjected to various loading conditions are carried out to examine the in-situ effect imposed by the neighboring plies on the failure initiation and propagation of cross-ply laminates. A detailed comparative study on crack suppression mechanisms due to the effect of embedded laminar thickness and adjacent ply orientation is presented. Furthermore, we compare th...
1 CitationsSource