Introduction Of Continuous Fiber Reinforced Polymer A New Additive Manufacturing Path For Aerospace

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Introduction Of Continuous Fiber Reinforced Polymer A New Additive Manufacturing Path For Aerospace

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Author :
language : en
Publisher:
Release Date : 2023

Introduction Of Continuous Fiber Reinforced Polymer A New Additive Manufacturing Path For Aerospace written by and has been published by this book supported file pdf, txt, epub, kindle and other format this book has been release on 2023 with categories.

SAE EDGE Research Reports provide state-of-the-art and state-of-industry examinations of the most significant topics in mobility engineering. SAE EDGE contributors are experts from research, academia, and industry who have come together to explore and define the most critical advancements, challenges, and future direction in areas such as vehicle automation, unmanned aircraft, IoT and connectivity, cybersecurity, advanced propulsion, and advanced manufacturing.

Additive Manufacturing Of High Strength Continuous Fiber Reinforced Polymer Composites

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Author : Pedram Parandoush
language : en
Publisher:
Release Date : 2019

Additive Manufacturing Of High Strength Continuous Fiber Reinforced Polymer Composites written by Pedram Parandoush and has been published by this book supported file pdf, txt, epub, kindle and other format this book has been release on 2019 with categories.

Additive manufacturing (AM), also referred to as 3D printing, of polymer-fiber composites has transformed AM into a robust manufacturing paradigm and enabled producing highly customized parts with significantly improved mechanical properties compared to un-reinforced polymers. 3D printing of continuous carbon fiber reinforced thermoplastics (CFRTP) composites is increasingly under development owing to its unparalleled flexibility of manufacturing 3D structures over traditional manufacturing processes. However, key issues, such as weak interlayer bonding, voids between beads and layers, and low volume ratio of carbon fiber, in the mainstream fused deposition modeling (FDM) and extrusion suppress the applications of these techniques in mission-critical applications, such as aerospace and defense industries. In this work, we proposed a new laser assisted AM method that utilizes prepreg composites with continuous fiber reinforcement as feedstock to fabricate 3D objects by implementing laser assisted bonding and laser cutting. This technique is inspired by laminated object manufacturing (LOM), for AM of continuous CFRTPs using prepreg composite sheets. AM of continuous glass and carbon fiber reinforced thermoplastic composites is demonstrated using this technique. The continuous fiber reinforced prepreg is laser cut and laser bonded layer upon layer to produce 3D composite objects. Microstructure and mechanical properties (strength, modulus, interfacial, and shear properties) of the additively manufactured continuous fiber composites are studied and compared to other additive and conventional manufacturing methods. The interlayer properties of these additively manufactured composites was superior to other AM technologies, resulting to an excellent mechanical properties relative to other AM techniques. The microstructure analysis, by micro computed tomography (CT) scans, scanning electron microscopy (SEM), and optical microscopy, showed low void content and full consolidation of prepreg layers. The temperature at the material interface during the 3D process is crucial to achieve a strong bonding strength. This temperature can be predicted via the developed finite element (FE) heat transfer model in this work. This numerical model is able to predict the temperature history during the laser bonding process with great accuracy when compared to the experimental values. The surface quality of the additively manufactured CFRTPs were also studied and compared with the FDM technology. In addition, mechanical finishing methods, namely CNC milling and rotary ultrasonic machining (RUM), were employed to improve the surface quality of the 3D printed composites and drill precise holes in the structures. Overall, the proposed AM method can be broadly beneficial for industries requiring high performance and lightweight structural materials with complex geometries. This method is also easily scalable for high volume productions and could additionally reduce the waste associated with current CFRTP production techniques and improve the process from the production time standpoint by automation.

Additive Manufacturing Of Aerospace Composite Structures

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Author : Rani Elhajjar
language : en
Publisher: SAE International
Release Date : 2017-05-20

Additive Manufacturing Of Aerospace Composite Structures written by Rani Elhajjar and has been published by SAE International this book supported file pdf, txt, epub, kindle and other format this book has been release on 2017-05-20 with Technology & Engineering categories.

Additive Manufacturing of Aerospace Composite Structures: Fabrication and Reliability introduces the reader to the current state of technologies involved in processing and design of polymer-reinforced fiber composites using additive manufacturing's automated fiber placement methods, through ten seminal SAE International papers. Currently, the material layup strategy in terms of process selection and manufacturability is usually not prioritized in the design phase. Engineers do not have a good way to see how their design choices can affect the manufacturing process beyond their initial structural-level considerations. The result is typically a large amount of experimental testing necessary to qualify the materials and structures typified in the classical building-block approach. Such an environment makes mistakes difficult to solve and, should redesign be required, obtaining reliable information is hard to piece together. Additive Manufacturing of Aerospace Composite Structures: Fabrication and Reliability approaches the question of quality in these structures from a hands-on, solution-driven perspective.

Additive Manufacturing Of Polymer Based Composite Materials

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Author : Fabienne Touchard
language : en
Publisher: Elsevier
Release Date : 2024-06-28

Additive Manufacturing Of Polymer Based Composite Materials written by Fabienne Touchard and has been published by Elsevier this book supported file pdf, txt, epub, kindle and other format this book has been release on 2024-06-28 with Technology & Engineering categories.

Additive Manufacturing of Polymer Composites: Materials, Processes, and Properties presents the latest developments in AM of polymer matrix composites and illustrates the large range of composite materials that can be obtained. Different technologies with their own specificities such as: fused filament fabrication, selective laser sintering, stereolithography, and direct-ink-writing. Composites with chopped or continuous reinforcement, with synthetic or natural fibers, with thermoplastic or thermoset resin are compared and described in detail. Their thermal, physical, electrical, and mechanical properties are discussed. The book is dedicated to professionals involved in engineering design and production, as well as industrial communities who want to gain in-depth knowledge in the field of 3D printed composites. Provides an overview of different methods for additive manufacturing of polymer-based matrix composites Covers long and short fiber-based composites and corresponding application examples Addresses the development and properties of a wide range of matrices (thermoplastics, thermosets), and fibers (natural and synthetic) in a user-specified orientation, continuous or random organization and hierarchical structures Presents sustainability and structural reliability of composite structures Displays a careful balance between materials science and technology, providing a detailed understanding of how composites’ properties, processing, performance, and structure are interrelated

High Performance Composite Structures

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Author : A. Praveen Kumar
language : en
Publisher: Springer Nature
Release Date : 2021-12-08

High Performance Composite Structures written by A. Praveen Kumar and has been published by Springer Nature this book supported file pdf, txt, epub, kindle and other format this book has been release on 2021-12-08 with Technology & Engineering categories.

This book covers advanced 3D printing processes and the latest developments in novel composite-based printing materials, thus enabling the reader to understand and benefit from the advantages of this groundbreaking technology. The rise in ecological anxieties has forced scientists and researchers from all over the world to find novel lightweight materials. Therefore, it is necessary to expand knowledge about the processing, applications, and challenges of 3D printing of composite materials to expanding the range of their application. This book presents an extensive survey on recent improvements in the research and development of additive manufacturing technologies that are used to make composite structures for various applications such as electronic, aerospace, construction, and biomedical applications. Advanced printing techniques including fused deposition modeling (FDM), selective laser sintering (SLS), selective laser melting (SLM), electron beam melting (EBM), inkjet 3D printing (3DP), stereolithography (SLA), and 3D plotting will be covered and discussed thoroughly in this book. This book also focuses the recent advances and challenges in polymer nanocomposite and introduces potential applications of these materials in various sectors.

Towards Advancement Of Continuous Fiber Composite Additive Manufacturing

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Author : Mallory Elizabeth Parker
language : en
Publisher:
Release Date : 2021

Towards Advancement Of Continuous Fiber Composite Additive Manufacturing written by Mallory Elizabeth Parker and has been published by this book supported file pdf, txt, epub, kindle and other format this book has been release on 2021 with categories.

Additive manufacturing (AM) of composite materials could play an unlimited role in the future of advanced engineering structures, particularly in aerospace. Specifically, fiber reinforced polymers (both thermoplastic and thermoset) offer incredible weight savings, with mechanical properties comparable to metal alloys. In turn, AM can provide design freedom and unlimited component complexity, qualities unavailable from traditional methods of manufacturing with composites. AM technologies, including fused deposition modelling in particular, have undergone rapid growth within industry and academia in the last several decades; new materials are being developed frequently. However, contributions from the printing process to the “printed” material properties are often overlooked, which are of critical importance to material reliability and aerospace applications. In this effort the printability, material property variability and potential applications of a novel filament with high volume fraction of continuous fiber reinforcement were evaluated. The material is a new prototype system manufactured by Toray Industries, which consists of a 6k tow of continuous carbon fibers (CCF) within a polyphenylene sulfide (PPS) matrix. Filaments of CCF/PPS with fiber volume fractions between 30 and 50% nominal fiber volume fraction were printed, and results were compared with those achieved with commercially available composite material systems. Multiple design of experiments were performed to understand the effect of process parameters on the printed material quality, including nozzle Z-height, nozzle temperature, printing speed, and material flow rate. Results showed that the printed quality in terms of dimensionality and roughness, matrix crystallinity, and fiber distribution within the printed filament were a function of the printing parameters. The prototype Toray filament achieved a tensile strength that exceeded 2 GPa, an elastic modulus of 155 GPa and a strain to failure of approximately 1.5%. Complimentary Weibull analyses were performed and combined with microstructural evaluation to assess the characteristics of filament failure in the unprinted and printed state. Although the strength of the CCF/PPS filament is the highest reported of any composite printed using the FDM process, there are several sources of defects that substantially reduce the strength of the printed material, by as much as 25%. Hence, further process optimization is needed for this CCF /PPS system and other continuous fiber composite materials to reach their full potential when used to manufacture components by FDM.

Additive Manufacturing Hybrid Processes For Composites Systems

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Author : António Torres Marques
language : en
Publisher: Springer Nature
Release Date : 2020-04-27

Additive Manufacturing Hybrid Processes For Composites Systems written by António Torres Marques and has been published by Springer Nature this book supported file pdf, txt, epub, kindle and other format this book has been release on 2020-04-27 with Technology & Engineering categories.

This book focuses on the emerging additive manufacturing technology and its applications beyond state-of-the-art, fibre-reinforced thermoplastics. It also discusses the development of a hybrid, integrated process that combines additive and subtractive operations in a single-step platform, allowing CAD-to-Part production with freeform shapes using long or continuous fibre-reinforced thermoplastics. The book covers the entire value chain of this next-generation technology, from part design and materials composition to transformation stages, product evaluation, and end-of-life studies. Moreover, it addresses the following engineering issues: • Design rules for hybrid additive manufacturing; • Thermoplastic compounds for high-temperature and -strength applications; • Advanced extrusion heads and process concepts; • Hybridisation strategies; • Software ecosystems for hAM design, pre-processing, process planning, emulating and multi-axis processing; • 3D path generators for hAM based on a multi-objective optimisation algorithm that matches the recent curved adaptive slicing method with a new transversal scheme; • hAM parameters, real-time monitoring and closed-loop control; • Multiparametric nondestructive testing (NDT) tools customised for FRTP AM parts; • Sustainable manufacturing processes validated by advanced LCA/LCC models.

Additive Manufacturing Of Continuous Fiber Reinforced Polymer Composites

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Author : Xiaoyong Tian
language : en
Publisher: Elsevier
Release Date : 2024-04-01

Additive Manufacturing Of Continuous Fiber Reinforced Polymer Composites written by Xiaoyong Tian and has been published by Elsevier this book supported file pdf, txt, epub, kindle and other format this book has been release on 2024-04-01 with Technology & Engineering categories.

Additive Manufacturing of Continuous Fiber Reinforced Polymer Composites covers the additive manufacturing of continuous fiber reinforced polymer composites (CFRPCs), discussing their materials, mechanical behaviors, structure, process, performance, and application. The raw materials involved, manufacturing processes for specific CFRPCs (thermoplastic, thermosetting, self-reinforcing), modeling, design, and failure analysis of these materials are each covered at length. An entire chapter is dedicated to the performance of these materials based on their structure and design, with lightweight composite structure, shape-morphing composite structure, and electromagnetic wave manipulating structure each studied. Embedded sensing by CFRPCs, mechanical metamaterials, and the applications of CFRPCs in aerospace, consumer products, and industrial tooling are each covered as well.

Additive Manufacturing

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Author : Emrah Celik
language : en
Publisher: Walter de Gruyter GmbH & Co KG
Release Date : 2020-07-06

Additive Manufacturing written by Emrah Celik and has been published by Walter de Gruyter GmbH & Co KG this book supported file pdf, txt, epub, kindle and other format this book has been release on 2020-07-06 with Science categories.

This book covers additive manufacturing of polymers, metals, ceramics, fiber reinforced polymer composites, energy harvesting materials, and biomaterials. Hybrid manufacturing is discussed. Topology optimization methodology is described and finite element software examples are provided. The book is ideal for graduate students and career starters in the industry.

Process Structure Properties In Polymer Additive Manufacturing

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Author : Swee Leong Sing
language : en
Publisher: MDPI
Release Date : 2021-09-01

Process Structure Properties In Polymer Additive Manufacturing written by Swee Leong Sing and has been published by MDPI this book supported file pdf, txt, epub, kindle and other format this book has been release on 2021-09-01 with Technology & Engineering categories.

Additive manufacturing (AM) methods have grown and evolved rapidly in recent years. AM for polymers is an exciting field and has great potential in transformative and translational research in many fields, such as biomedical, aerospace, and even electronics. Current methods for polymer AM include material extrusion, material jetting, vat polymerisation, and powder bed fusion. With the promise of more applications, detailed understanding of AM—from the processability of the feedstock to the relationship between the process–structure–properties of AM parts—has become more critical. More research work is needed in material development to widen the choice of materials for polymer additive manufacturing. Modelling and simulations of the process will allow the prediction of microstructures and mechanical properties of the fabricated parts while complementing the understanding of the physical phenomena that occurs during the AM processes. In this book, state-of-the-art reviews and current research are collated, which focus on the process–structure–properties relationships in polymer additive manufacturing.