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Extrusion based high-throughput Additive Manufacturing (AM) provides a rapid and versatile approach for producing complex structures by using a variety of polymer materials. An underexplored aspect of this technique is concerned with the formation of interfaces between successively deposited layers. This is particularly important for large-scale additive manufacturing of semi-crystalline polymers because of the highly non-isothermal conditions involved, which influence both nucleation and crystal growth. The objective of this work is to investigate the microstructure and the corresponding viscoelastic properties of carbon fiber (CF) reinforced polyphenylene sulfide (PPS) resulting from extrusion-based high-throughput AM process. Questions on development of morphology focus on polymer crystal structure and carbon fiber orientation in the vicinity of the interface between successive layers. This study attempts to establish a fundamental understanding of the role of the AM has in transferring a set of intrinsic material properties to the macroscopic properties of the final AM structure.

Short carbon fiber reinforced thermoplastic composites (S-CFRTP) are currently used in interior parts of aircraft such as electronic circuitry and assemblies, and their usage in aircraft's exterior is also being studied. A lightning strike study on S-CFRTPs is presented in this paper. High performance thermoplastics such as a polyphenylene sulfide (PPS) reinforced with 50% weight (wt.) short carbon fiber (CF), a polyphenyl sulfone (PPSU) reinforced with 25 % wt. Short CF and a acrylonitrile butadiene styrene (ABS) with 20 % wt. short CF were tested against artificial lightning strikes. All samples were prepared using an extrusion compression molding (ECM) technique. A modified component A (100 kA) of lightning waveform, as defined by SAE ARP 5412-B, was applied. High speed imaging, thermography, scanning electron microscopy (SEM) and ultrasonic non-destructive evaluation were performed to understand the effect of lightning strikes on the thermoplastic panels. The results show that electrical conductivity of the composite, thermal stability of the polymers, and CF orientation significantly affected the damage from artificial lightning strikes. PPS composite had the highest resilience against lightning strike damage, retaining 95% and 89% residual flexural strength and modulus, respectively. CF exfoliation due to internal arcing was observed in the carbon fiber-reinforced ABS polymer (CF-ABS) composite. CF exfoliation damage has been reported for the first time.

Additive manufacturing, diverging from traditional manufacturing techniques, such as casting and machining materials, can handle complex shapes with great design flexibility without the typical waste. Although this technique has been mainly used for rapid prototyping, interest is growing in using this method to directly manufacture actual parts of complex shape. To use 3D-printing additive manufacturing in wide spread applications, the technique and the feedstock materials require improvements to meet the mechanical requirements of load-bearing components. Thus, we investigated the short fiber (0.2 mm to 0.4 mm) reinforced acrylonitrile-butadiene-styrene composites as a feedstock for 3D-printing in terms of their processibility, microstructure and mechanical performance; and also provided comparison with traditional compression molded composites. The tensile strength and modulus of 3D-printed samples increased ~115% and ~700%, respectively. 3D-printer yielded samples with very high fiber orientation in printing direction (up to 91.5 %), whereas, compression molding process yielded samples with significantly less fiber orientation. Microstructure-mechanical property relationships revealed that although the relatively high porosity is observed in the 3D-printed composites as compared to those produced by the conventional compression molding technique, they both exhibited comparable tensile strength and modulus. Furthermore, this phenomena is explained based on the changes in fiber orientation, dispersion andmore » void formation.« less