Systematic Evaluation of Adhesion and Fracture Toughness in Multi-Material Fused Deposition Material Extrusion.

Material extrusion (MEX) additive manufacturing has successfully fabricated assembly-free structures composed of different materials processed in the same manufacturing cycle. Materials with different mechanical properties can be employed for the fabrication of bio-inspired structures (i.e., stiff materials connected to soft materials), which are appealing for many fields, such as bio-medical and soft robotics. In the present paper, process parameters and 3D printing strategies are presented to improve the interfacial adhesion between carbon fiber-reinforced nylon (CFPA) and thermoplastic polyurethane (TPU), which are extruded in the same manufacturing cycle using a multi-material MEX setup. To achieve our goal, a double cantilever beam (DCB) test was used to evaluate the mode I fracture toughness. The results show that the application of a heating gun (assembled near the nozzle) provides a statistically significant increase in mean fracture toughness energy from 12.3 kJ/m2 to 33.4 kJ/m2. The underlying mechanism driving this finding was further investigated by quantifying porosity at the multi-material interface using an X-ray computed tomography (CT) system, in addition to quantifying thermal history. The results show that using both bead ironing and the hot air gun during the printing process leads to a reduction of 24% in the average void volume fraction. The findings from the DCB test and X-ray CT analysis agree well with the polymer healing theory, in which an increased thermal history led to an increased fracture toughness at the multi-material interface. Moreover, this study considers the thermal history of each printed layer to correlate the measured debonding energy with results obtained using the reptation theory.

Nondestructive quantification of internal raster path for additively manufactured components via ultrasonic testing.

This work investigates the viability of discerning the raster pattern of additively manufactured components using high frequency ultrasonic nondestructive testing. Test coupons were fabricated from poly cyclohexylenedimethylene terephthalate glycol using the fused filament fabrication process, in which layers were deposited at various predetermined raster angles. Each printed part was scanned using spherically focused, high-resolution, ultrasonic transducers of various peak frequencies between 7.5 and 15 MHz. From the captured waveform data, images are extracted to observe the raster pattern in a layer-by-layer manner, with the results from the 10 MHz element yielding the best performance. An in-house MATLAB script was developed to analyze the transducer signal to investigate C-scan images at various depths throughout the component. From the resulting C-scan images, one can consistently identify the proper raster orientation within 2°-4° in each of the first 10 deposited layers, with the accuracy decreasing as a function of depth into the component. Due to signal attenuation, there is insufficient data at depths beyond the 11th and 12th layer, to properly analyze the present data sets accurately. Validation was performed using X-ray computed tomography scans to demonstrate the accuracy of the ultrasonic inspection method.

Automated Quantification of Interlaminar Delaminations in Carbon-Fiber-Reinforced Polymers via High-Resolution Ultrasonic Testing.

This article presents a method of ultrasonic testing (UT) that detects and quantifies interlaminar delaminations in CFRP composites with high resolution in terms of both spatial resolution in the planar dimension and depth into the laminate. Unidirectional and woven CFRP laminates were fabricated for this study, with a PTFE film inserted at various depths throughout the laminate to act as intentional crack initiation sites. All samples were mechanically tested via a three-point, end-notched flexure (ENF) test, followed by a quantification of the extent of the induced interlaminar delaminations using UT and X-ray computed tomography (CT). UT analysis for unidirectional CFRP samples was able to show a clear contrast between the delaminated area and the non-delaminated area. UT analysis of the woven CFRP samples yielded comparable results but required finer tuning of analysis parameters due to the interlocking woven fabric. CT results revealed a significant contrast between the crack and composite; thus, fine geometrical features of the crack front could be observed. UT and CT measurements were then compared, revealing an average difference of 1.09% in the delamination area, with UT overestimating as compared to CT. A UT depth study was also performed to automatically locate the interlaminar delamination at different depths throughout the components, with the delamination being predicted within one lamina interface for all samples. These results demonstrate UT's ability to accurately detect and quantify the extent and location of interlaminar delaminations due to bending.

Metabolic and ruck performance effects of a novel, light-weight, energy-dense ketogenic bar.

NEW FINDINGS: What is the central question of the study? Can a novel, energy-dense and lightweight ketogenic bar (1000 kcal) consumed 3 h before exercise modulate steady-state incline rucksack march ('ruck') performance compared to isocaloric carbohydrate bars in recreationally active, college-aged men? What is the main finding and its importance? Acute ingestion of either nutritional bar sustained ∼1 h of exhaustive rucking with a 30% of body weight rucksack. This proof-of-concept study is the first to demonstrate that carbohydrate bars and lipid bars are equally feasible for preserving ruck performance. Novel ketogenic nutrition bars may have military-relevant applications to lessen carry load without compromising exercise capacity. ABSTRACT: Rucksack marches ('rucks') are strenuous, military-relevant exercises that may benefit from pre-event fuelling. The purpose of this investigation was to explore whether acute ingestion of carbohydrate- or lipid-based nutritional bars before rucking can elicit unique advantages that augment exercise performance. Recreationally active and healthy males (n = 29) were randomized and counterbalanced to consume 1000 kcal derived from a novel, energy-dense (percentage energy from carbohydrate/fat/protein: 5/83/12) ketogenic bar (KB), or isocaloric high-carbohydrate bars (CB; 61/23/16) 3 h before a time-to-exhaustion (TTE) ruck. Conditions were separated by a 1-week washout. The rucksack weight was standardized to 30% of bodyweight. Steady-state treadmill pace was set at 3.2 km/h (0.89 m/s) and 14% grade. TTE was the primary outcome; respiratory exchange ratio (RER), capillary ketones (R-ß-hydroxybutyrate), glucose and lactate, plus subjective thirst/hunger were the secondary outcomes. Mean TTE was similar between conditions (KB: 55 ± 25 vs. CB: 54 ± 22 min; P = 0.687). The RER and substrate oxidation rates revealed greater fat and carbohydrate oxidation after the KB and CB, respectively (all P < 0.0001). Capillary R-ßHB increased modestly after the KB ingestion (P < 0.0001). Neither bar influenced glycaemia. Lactate increased during the ruck independent of the condition (P < 0.0001). Thirst/fullness perceptions changed independent of the nutritional bar consumed. A novel KB nutritional bar produced equivalent TTE ruck results to the isocaloric CBs. The KB's energy density relative to CB (6.6 vs. 3.8 kcal/g) may provide a lightweight (-42% weight), pre-event fuelling alternative that does not compromise ruck physical performance.