Optimization of 3D Printing Parameters of High Viscosity PEEK/30GF Composites.

The aim of this study was to optimize a set of technological parameters (travel speed, extruder temperature, and extrusion rate) for 3D printing with a PEEK-based composite reinforced with 30 wt.% glass fibers (GFs). For this purpose, both Taguchi and finite element methods (FEM) were utilized. The artificial neural networks (ANNs) were implemented for computer simulation of full-scale experiments. Computed tomography of the additively manufactured (AM) samples showed that the optimal 3D printing parameters were the extruder temperature of 460 °C, the travel speed of 20 mm/min, and the extrusion rate of 4 rpm (the microextruder screw rotation speed). These values correlated well with those obtained by computer simulation using the ANNs. In such cases, the homogeneous micro- and macro-structures were formed with minimal sample distortions and porosity levels within 10 vol.% of both structures. The most likely reason for porosity was the expansion of the molten polymer when it had been squeezed out from the microextruder nozzle. It was concluded that the mechanical properties of such samples can be improved both by changing the 3D printing strategy to ensure the preferential orientation of GFs along the building direction and by reducing porosity via post-printing treatment or ultrasonic compaction.

Tribological Properties of Composites Based on Single-Component Powdered Epoxy Matrix Filled with Graphite.

Composites based on powdered single-component epoxy matrix are an alternative technological solution for composites produced using liquid epoxy resins. This article describes in detail the process of producing graphite-reinforced composites for tribological applications. The advantages and disadvantages of technological processes where the matrix is a single-component epoxy powder were demonstrated, and the properties of the obtained materials were examined. A series of composite materials with the graphite filler with sizes below 10 µm and below 45 µm and weight additions of 5, 10, 20, 30% were produced. Mechanical tests and tribological tests conducted with the pin-on-block method were performed, and the mechanism of tribological wear was described. The conducted research allowed us to conclude that the incorporation of graphite, regardless of particle size, above 10% by weight results in a significant reduction in the friction coefficient (approximately 40-50% lower than in unfilled epoxy resin), which is beneficial in the production of cheap self-lubricating materials.

Damage Detection in a Polymer Matrix Composite from 4D Displacement Field Measurements.

Standard Digital Volume Correlation (DVC) approaches enable quantitative analyses of specimen deformation to be performed by measuring displacement fields between discrete states. Such frameworks are thus limited by the number of scans (due to acquisition duration). Considering only one projection per loading step, Projection-based Digital Volume Correlation (P-DVC) allows 4D (i.e., space and time) full-field measurements to be carried out over entire loading histories. The sought displacement field is decomposed over a basis of separated variables, namely, temporal and spatial modes. In the present work, the spatial modes are constructed via scan-wise DVC, and only the temporal amplitudes are sought via P-DVC. The proposed method is applied to a glass fiber mat reinforced polymer specimen containing a machined notch, subjected to in situ cyclic tension and imaged via X-ray Computed Tomography. The P-DVC enhanced DVC method employed herein enables for the quantification of damage growth over the entire loading history up to failure.

Digital Image Correlation Analysis of Strain Fields in Fibre-Reinforced Polymer-Matrix Composite under ±45° Off-Axis Tensile Testing.

This study presents an experimental investigation of an in-plane shear of a glass lamina composite using a ±45° off-axis tension test. Typically, the shear stress curve, shear modulus, and in-plane shear strength for composite lamina-type materials are identified. Previous research indicated that a loading rate affects the strength of this composite. This study extends the existing literature by utilising a non-contact optical digital image correlation (DIC) method to measure strain distribution during the test. Two cross-head displacement rates were examined. The obtained strain maps reveal an uneven distribution resembling fabric texture. As the deformation progresses, the differences in the strain pattern increase. Subsequently, a quantitative analysis of the differences between regions with extreme (minimum and maximum) strain values and regions with average values was conducted. Based on these measurements, shear stress-strain curves, indicating variations in their courses, were constructed. These differences may reach several percent and may influence the analysis of numerical simulations. The DIC results were validated using strain gauge measurements, a commonly utilised method in this test. It was demonstrated that the location of the strain gauge installation impacts the results. During the tests, the occurrence of multiple microcracks in the resin was observed, which can contribute to the nonlinearity observed in the shear stress-shear strain curve.

Fiber Orientation Quantification for Large Area Additively Manufactured Parts Using SEM Imaging.

Polymer-based additively manufactured parts are increasing in popularity for industrial applications due to their ease of manufacturing and design form freedom, but their structural and thermal performances are often limited to those of the base polymer system. These limitations can be mitigated by the addition of carbon fiber reinforcements to the polymer matrix, which enhances both the structural performance and the dimensional stability during cooling. The local fiber orientation within the processed beads directly impacts the mechanical and thermal performances, and correlating the orientation to processing parameter variations would lead to better part quality. This study presents a novel approach for analyzing the spatially varying fiber orientation through the use of scanning electron microscopy (SEM). This paper presents the sample preparation procedure including SEM image acquisition and analysis methods to quantify the internal fiber orientation of additively manufactured carbon fiber-reinforced composites. Large area additively manufactured beads with 13% by weight large aspect ratio carbon fiber-reinforced acrylonitrile butadiene styrene (ABS) pellets are the feedstock used in this study. Fiber orientation is quantified using the method of ellipses (MoE), and the spatial change in fiber orientation across the deposited bead cross-section is studied as a function of process parameters including extrusion speed, raster height, and extrusion temperature zones. The results in the present paper show the results from the novel use of SEM to obtain the local fiber orientation, and results show the variation in alignment within the individual processed bead as well as an overall aligned orientation state along the direction of deposition.

The Influence of Porosity on Mechanical Properties of PUR-Based Composites: Experimentally Derived Mathematical Approach.

The work is focused on the mechanical behavior description of porous filled composites that is not based on simulations or exact physical models, including different assumptions and simplifications with further comparison with real behavior of materials with different extents of accordance. The proposed process begins by measurement and further fitting of data by spatial exponential function zc = zm · p1b · p2c, where zc/zm is mechanical property value for composite/nonporous matrix, p1/p2 are suitable dimensionless structural parameters (equal to 1 for nonporous matrix) and b/c are exponents ensuring the best fitting. The fitting is followed by interpolation of b and c, which are logarithmic variables based on the observed mechanical property value of nonporous matrix with additions of further properties of matrix in some cases. The work is dedicated to the utilization of further suitable pairs of structural parameters to one pair published earlier. The proposed mathematical approach was demonstrated for PUR/rubber composites with a wide range of rubber filling, various porosity, and different polyurethane matrices. The mechanical properties derived from tensile testing included elastic modulus, ultimate strength and strain, and energy need for ultimate strain achievement. The proposed relationships between structure/composition and mechanical behavior seem to be suitable for materials containing randomly shaped filler particles and voids and, therefore, could be universal (and also hold materials with less complicated microstructure) after potential following and more exact research.

Evaluation of tensile properties of spherical shaped SiC inclusions inside recycled HDPE matrix using FEM based representative volume element approach.

In the current study, a FEM-based representative volume element (RVE) technique is used to evaluate the elastic modulus of recycled high-density polyethylene (rHDPE) filled spherical-shaped shaped silicon carbide (SiC). In the ANSYS 2019, the material designer (MD) module is used to generate a 3D RVE of 500 × 500 × 500 µm cuboid, with randomly dispersed spherical SiC particles (i.e., 10, 15, 20, and 30% volume fractions) inside rHDPE. The Young's modulus values extracted from the RVE technique at various volume % are substantially nearer to experimental data than other micromechanical models. The tensile performance of the composite is simulated, and it was noted that the maximum equivalent stress of 4.1133 MPa for rHDPE/30% SiC composite, which is decreased to 13.8, 7.8 and 6.8% for rHDPE/10% SiC, rHDPE/15% SiC and rHDPE/20% SiC composite respectively. The results are astounding for immediate application in the relevant field of interest.

Glassy Carbon Open-Celled Foams as a Reinforcement in Polymer Matrix Composites Dedicated for Tribological Applications.

This work presents the results of a tribological examination of polymer matrix composites reinforced with carbon foams with different porosity. The application of open-celled carbon foams allows an easy infiltration process by liquid epoxy resin. At the same time, carbon reinforcement remains its initial structure, which prevents its segregation in polymer matrix. Dry friction tests, conducted under 0.7, 2.1, 3.5 and 5.0 MPa loads, show that higher friction load results in higher mass loss, but it strongly lowers the coefficient of friction (COF). The change in coefficient of friction is related to the size of the pores of the carbon foam. Open-celled foams with pores size below 0.6 mm (40 and 60 ppi), used as a reinforcement in epoxy matrix, allow to obtain COF twice lower than composite reinforced with 20 ppi open-celled foam. This phenomenon occurs due to a change of friction mechanisms. In composites reinforced with open-celled foams, general wear mechanism is related to destruction of carbon components, which results in solid tribofilm formation. The application of novel reinforcement, in the form of open-celled foams with stable distance between carbon components, allows the decrease of COF and the improvement of stability, even under a very high friction load.

Dielectric characterization of paraelectric particle-loaded polymer matrix composites and commercial photoresins at W-band frequencies.

This work presents W-band (75-110 GHz) dielectric characterization of commercially available photoresins in their neat state, as well as in polymer matrix composite (PMC) mixtures with various loading concentrations of the paraelectric barium strontium titanate (BST). Due to difficulties 3D printing the BST-loaded PMC resins detailed within, a custom curing and casting process was used to fabricate testable PMC samples, which were synthesized to demonstrate the dielectric functionalization of the underlying polymer matrix. Dielectric characterization of the PMCs confirmed the functionalization of our composites when compared to the commercial photoresins. For example, a volumetric loading concentration of 25 vol % BST increased the dielectric permittivity (εr ) from 2.78 to 9.60 and the loss tangent (tanδ) from 0.022 to 0.114. These results indicate that the realization of UV-cured photoresins with "designer-dielectric" functionalization based on vol % of filler are strong candidates for use in stereolithography (SLA) 3D printing applications. To accomplish this, and with a special interest for radio/microwave/terahertz (RF/MW/THz) applications, we highlight the need for both (a) better photoresin matrix materials with lower intrinsic tanδ and (b) selection criteria related to the size/geometry and electronic properties of potential filler materials to maintain the printability of PMC photoresins in SLA systems.

Experimental dataset on the in-plane tensile, shear, and compressive properties of a carbon-epoxy twill woven composite.

This data article presents experimental data on the in-plane mechanical behavior of a carbon-epoxy twill woven composite. Properties under tension, shear, and compression are measured and reported, which include force vs. stroke curves, stress vs. strain curves, in-plane on-axis and off-axis moduli, in-plane shear modulus, tensile and compressive strengths, post-peak residual stress under compression, and on-axis and off-axis Poisson ratios. Laminate plates of the composite were ordered from a commercial vendor and specimens of desired dimensions were cut using a waterjet cutter. Tests were conducted in accordance with ASTM standards D3039 and D6641, under on-axis and off-axis tension, and under on-axis compression. The data represents a complete set of in-plane mechanical properties for the composite and can be used directly as lamina level input to numerical FEA models and design analyses with woven composite laminates. It can also serve as benchmark for the calibration and validation of these models. It can be used to calculate properties for other off-axis configurations using transformation equations. Since the data is intended to be a lamina level input, it can be used to determine and model the in-plane behavior of any laminate layup with this composite. The data also serves to demonstrate the marked anisotropy and tension compression asymmetry exhibited by woven composites.

Design and Performance Evaluation of Polymer Matrix Composite Helical Springs.

Helical springs are indispensable mechanical parts widely used in industry. Lightweight is one of the development trends of helical springs. In this study, three kinds of lightweight polymer matrix composite helical springs (PMCHSs) with unidirectional, multistrand, and wrapped textile structural reinforcement (PMCHS-U, PMCHS-M, and PMCHS-W) were designed, manufactured, and evaluated. The performance of these PMCHSs and the relationship between their performance and their corresponding polymer matrix composite spring wire rods (PMCRs) were studied through the torsion test of the PMCRs and the compression and resilience tests of the PMCHSs. The results showed that the performance of the PMCHSs could be effectively improved by using the wrapped structure as the reinforcement. The compression capacity of PMCHS-W was 72.6% and 137.5% higher than that of PMCHS-M and PMCHS-U, respectively. The resilience performance of the PMCHSs decreased with the increase in the spring constant. The performances of the PMCHSs and a steel spring were compared. The results showed that the spring constant of the steel spring could be achieved when the masses of PMCHS-U, PMCHS-M, and PMCHS-W were only 75%, 63%, and 49% of the mass of the steel spring, respectively. This research is of great significance to the improvement in lightweight spring performance.

O-carboxymethyl chitosan/gelatin/silver-copper hydroxyapatite composite films with enhanced antibacterial and wound healing properties.

Wound dressing composite films of O-carboxymethyl chitosan (OCMC) and gelatin were prepared and mixed with hydroxyapatite (HA) composited with Silver (Ag) and Copper (Cu) at different concentrations. The chemical, thermal, morphological, and biological properties of the composite films were studied. The analysis by FTIR confirmed the presence of interactions between gelatin and OCMC, and at the same time, the polymer matrix interactions with Ag-Cu/HA complex. The inclusion of nanoparticle to the composite was associated with an improvement of the thermal stability, morphological roughness, a 9-12% more hydrophobic behavior (composite C1, C5, and C8), increase in antibacterial activity from 23.2 to 33.1% for gram negative bacteria and from 37.28 to 40.59% for gram positive bacteria, and with a cell viability greater than 100% for 24 and 72 h. The films obtained can serve as a wound healing dressing and regenerating biomaterial.

Influence of Process Parameters on the Resistivity of 3D Printed Electrically Conductive Structures.

With recent developments in conductive composites, new possibilities emerged for 3D printed conductive structures. Complementary to a vast number of publications on materials properties, here we investigate the influence of printing parameters on the resistance of 3D printed structures. The influence of printing temperature on the resistance is significant, with too low value (210 °C) leading to nozzle clogging, while increasing the temperature by 20 °C above the recommended printing settings decreases resistivity by 15%, but causing degradation of the polymer matrix. The limitations of the FDM technique, related to the dimension accuracy emerging from the layer-by-layer printing approach, greatly influence the samples' cross-section, causing irregular resistivity values for different layer heights. For samples with layer thickness lower than 0.2 mm, regardless of the nozzle diameter (0.5-1 mm), high resistance is attributed to the quality of samples. But for a 1 mm nozzle, we observe stabilized values or resistance for 0.3 to 1 mm layer height. Comparing resistance values and layer height generated from the slicer software, we observe a direct correlation-for a larger height of the sample resistance value decrease. Presented modifications in printing parameters can affect the final resistance by 50%. Controlling several parameters simultaneously poses a great challenge for designing high-efficiency structural electronics.

Large-area flexible MWCNT/PDMS pressure sensor for ergonomic design with aid of deep learning learning.

The achievement of well-performing pressure sensors with low pressure detection, high sensitivity, large-scale integration, and effective analysis of the subsequent data remains a major challenge in the development of flexible piezoresistive sensors. In this study, a simple and extendable sensor preparation strategy was proposed to fabricate flexible sensors on the basis of multiwalled carbon nanotube/polydimethylsiloxane (MWCNT/PDMS) composites. A dispersant of tetrahydrofuran (THF) was added to solve the agglomeration of MWCNTs in PDMS, and the resistance of the obtained MWCNT/PDMS conductive unit with 7.5 wt.% MWCNTs were as low as 180 Ω/hemisphere. Sensitivity (0.004 kPa-1), excellent response stability, fast response time (36 ms), and excellent electromechanical properties were demonstrated within the pressure range from 0 to 100 kPa. A large-area flexible sensor with 8 × 10 pixels was successfully adopted to detect the pressure distribution on the human back and to verify its applicability. Combining the sensor array with deep learning, inclination of human sitting was easily recognized with high accuracy, indicating that the combined technology can be used to guide ergonomic design.

The Use of the ATD Technique to Measure the Gelation Time of Epoxy Resins.

In this paper, we investigated the thermodynamics of the resin curing process, when it was a part of composition with graphite powder and cut carbon fibers, to precisely determine the time and temperature of gelation. The material for the research is a set of commercial epoxy resins with a gelation time not exceeding 100 min. The curing process was characterized for the neat resins and for resins with 10% by weight of flake graphite and cut carbon fibers. The results recorded in the analysis of temperature derivative (ATD) method unequivocally showed that the largest first derivative registered during the test is the gel point of the resin. The innovative approach to measuring the gelation time of resins facilitates the measurements while ensuring the stability of the curing process compared to the normative tests that introduce mechanical interaction. In addition, it was found during the research that the introduction of 10% by weight of carbon particles in the form of graphite and cut carbon fibers rather shortens the gelation time and lowers the temperature peak due to the effective absorption and storage of heat from the cross-linking system. The inhibiting (or accelerating) action of fillers is probably dependent on chemical activity of the cross-linking system.

An Assessment of ASTM E1922 for Measuring the Translaminar Fracture Toughness of Laminated Polymer Matrix Composite Materials.

The main objective of this work is to predict the exact value of the fracture toughness (KQ) of fiber-reinforced polymer (FRP). The drawback of the American Society for Testing Materials (ASTM) E1922 specimen is the lack of intact fibers behind the crack-tip as in the real case, i.e., through-thickness cracked (TTC) specimen. The novelty of this research is to overcome this deficiency by suggesting unprecedented cracked specimens, i.e., matrix cracked (MC) specimens. This MC exists in the matrix (epoxy) without cutting the glass fibers behind the crack-tip in the unidirectional laminated composite. Two different cracked specimen geometries according to ASTM E1922 and ASTM D3039 were tested. 3-D FEA was adopted to predict the damage failure and geometry correction factor of cracked specimens. The results of the TTC ASTM E1922 specimen showed that the crack initiated perpendicular to the fiber direction up to 1 mm. Failure then occurred due to crack propagation parallel to the fiber direction, i.e., notch insensitivity. As expected, the KQ of the MC ASTM D3039 specimen is higher than that of the TTC ASTM D3039 specimen. The KQ of the MC specimen with two layers is about 1.3 times that of the MC specimen with one layer.

Structure and Mechanical Properties of High-Density Polyethylene Composites Reinforced with Glassy Carbon.

In this paper, we investigated theimpact of glassy carbon (GC) reinforcement oncrystal structure and the mechanical performance of high-density polyethylene (HDPE). We made composite samples by mixing HDPE granules with powder in ethanol followed bymelt mixing in a laboratory extruder. Along with the investigated composite, we also prepared samples with carbon nanotubes (CNT), graphene (GNP) and graphite (Gr) to compare GC impact with already used carbon fillers. To evaluate crystal structure and crystallinity, we used X-ray diffraction (XRD) and differential scanning calorimetry (DSC). We supported the XRD results with a residual stress analysis (RSA) according to the EN15305 standard. Analysis showed that reinforcing with GC leads to significant crystallite size reduction and low residual stress values. We evaluated the mechanical properties of composites with hardness and tensile testing. The addition of glassy carbon results inincreased mechanical strength incomposites with CNT and GNP.

Structural Monitoring of Glass Fiber/Epoxy Laminates by Means of Carbon Nanotubes and Carbon Black Self-Monitoring Plies.

The health monitoring of structures is of great interest in order to check components' structural life and monitor damages during operation. Self-monitoring materials can provide both the structural and monitoring functionality in one component and exploit their piezoresistive behavior, namely, the variation of electrical resistivity with an applied mechanical strain. In this work, self-monitoring plies were developed to be inserted into glass-fiber reinforced epoxy-based laminates in order to achieve structural monitoring. Nanocomposite epoxy-based resins were developed employing different contents of high surface area carbon black (CB, 6 wt%) and multiwall carbon nanotubes (MWCNT, 0.75 and 1 wt%), and rheologically and thermomechanically characterized. Self-monitoring plies were manufactured by impregnating glass woven fabrics with the resins, and were laminated with non-sensing plies via a vacuum-bag process to produce sensored laminates. The self-monitoring performance of the laminates was assessed during monotonic and cyclic three-point bending tests, as well as ball drop impact tests. A higher sensitivity was found for the CB-based systems (Gauge Factor 6.1), while MWCNTs (0.55 and 1.04) ensure electrical percolation at lower filler contents, as expected. The systems also showed the capability of being used to predict residual life and damage occurred under impact.

Detection and Imaging of Damages and Defects in Fibre-Reinforced Composites by Magnetic Resonance Technique.

Defectively manufactured and deliberately damaged composite laminates fabricated with different continuous reinforcing fibres (respectively, carbon and glass) and polymer matrices (respectively, thermoset and thermoplastic) were inspected in magnetic resonance imaging equipment. Two pulse sequences were evaluated during non-destructive examination conducted in saline solution-immersed samples to simulate load-bearing orthopaedic implants permanently in contact with biofluids. The orientation, positioning, shape, and especially the size of translaminar and delamination fractures were determined according to stringent structural assessment criteria. The spatial distribution, shape, and contours of water-filled voids were sufficiently delineated to infer the amount of absorbed water if thinner image slices than this study were used. The surface texture of composite specimens featuring roughness, waviness, indentation, crushing, and scratches was outlined, with fortuitous artefacts not impairing the image quality and interpretation. Low electromagnetic shielding glass fibres delivered the highest, while electrically conductive carbon fibres produced the poorest quality images, particularly when blended with thermoplastic polymer, though reliable image interpretation was still attainable.

Tribological Behavior of Phenolic Resin-Based Friction Composites Filled with Graphite.

In this paper, the influence of graphite (Gr) on the dry sliding tribological properties of phenolic resin (PF) composites was studied under different sliding speeds of 3.1-47.1 m/s. The wear mechanism was investigated by the observation of the morphology of the transfer layer during the dry sliding process. It was found that the addition of Gr could decrease the friction coefficient and wear rate effectively, and the friction coefficient and wear rate decreased with the increase of Gr content in the range of 10-30 vol.%. The dominant wear mechanisms of PF-based friction composites changed from adhesive wear to fatigue wear (in the form of peeling-off) in the high sliding speed condition after the addition of Gr. The addition of Gr effectively reduced the sensitivity of PF-based friction materials to sliding speeds, and thus enhanced the stability of the friction coefficient. When the content of Gr was above 20 vol.%, the stability of the friction coefficient was relatively steady.