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Two-Step Preparation of CCF/PEEK Wrapped Yarn for 3D Printing Composites with Enhanced Mechanical Properties.

ABSTRACT: Continuous fiber reinforced thermoplastic composites (CFTPCs) have shown advantages such as high strength, long life, corrosion resistance, and green recyclability. Three-dimensional printing of CFTPCs opened up a new strategy for the fabrication of composites with complicated structures, low cost, and short production cycles. However, a traditional 3D printing process usually causes poor impregnation of the fiber or surface damage of the fiber due to the short impregnation time or high viscosity of the thermoplastic resin. Here, continuous carbon fiber/poly(ether-ether-ketones) (CCF/PEEK) wrapped yarn was fabricated via powder impregnation and using double spinning technology for the 3D printing. The concentration of PEEK powder suspension and wire speed were optimized as 15% and 2.0 m/min. The twist of wrapped yarn was optimized as 1037 T/m. Mechanical testing showed that the 3D-printed composite wire had excellent tensile and bending strength, which was about 1.6~4.2 times larger than those without the powder pre-impregnation process. It is mainly attributed to the improved impregnation of the CF which took place during the powder pre-impregnation process. We believe that our research on wrapped yarn for 3D-printed composites provides an effective strategy for the 3D printing of composites with enhanced mechanical properties.

SUBMITTER: Zhang J

PROVIDER: S-EPMC9921352 | biostudies-literature | 2023 Jan

REPOSITORIES: biostudies-literature

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Two-Step Preparation of CCF/PEEK Wrapped Yarn for 3D Printing Composites with Enhanced Mechanical Properties.

Zhang Jianghu J Shen Hao H Yang Lili L Ge Dengteng D

Materials (Basel, Switzerland) 20230130 3

Continuous fiber reinforced thermoplastic composites (CFTPCs) have shown advantages such as high strength, long life, corrosion resistance, and green recyclability. Three-dimensional printing of CFTPCs opened up a new strategy for the fabrication of composites with complicated structures, low cost, and short production cycles. However, a traditional 3D printing process usually causes poor impregnation of the fiber or surface damage of the fiber due to the short impregnation time or high viscosit ...[more]

PMID: 36770176

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Project description:This work developed novel jute-yarn, non-crimp, unidirectional (UD) preforms and their composites, with three different types of warp jute yarns of varying linear densities and twists in the dry UD preforms, in order to present a possible solution to the detrimental effects of higher yarn twists and crimp at the warp-weft yarn interlacements of traditional, woven, preform-based composites on their mechanical properties. In the developed UD preforms, warp jute yarns were placed in parallel by using a wooden picture-frame pin board, with the minimal number of glass weft yarns to avoid crimp at the warp-weft yarns interlacements, which can significantly enhance the load-bearing ability of UD composites compared to traditional, woven, preform composites. It was found that an optimal combination of jute warp yarn linear densities and twists in the UD preforms is important to achieve the best possible mechanical properties of newly developed UD composites, because it encourages a proper polymer-matrix impregnation on jute fibres, leading to excellent fibre-matrix interface bonding. Composites made from the 25 lb/spindle jute warp yarn linear density (UD25) exhibited higher tensile and flexural properties than other UD composites (UD20, UD30). All the UD composites showed a much better performance compared to the traditional woven preform composites (W20), which were obviously related to the higher crimp and yarn interlacements, less load-carrying capacity, and poor fiber-matrix interfaces of W20 composites. UD25 composites exhibited a significant enhancement in tensile modulus by ~232% and strength by ~146%; flexural modulus by 138.5% and strength by 145% compared to W20 composites. This reveals that newly developed, non-crimp, UD preform composites can effectively replace the traditional woven composites in lightweight, load-bearing, complex-shaped composite applications, and hence, this warrants further investigations of the developed composites, especially on long-term and dynamic-loading mechanical characterizations.

Dataset Information

Two-Step Preparation of CCF/PEEK Wrapped Yarn for 3D Printing Composites with Enhanced Mechanical Properties.

Publications

Two-Step Preparation of CCF/PEEK Wrapped Yarn for 3D Printing Composites with Enhanced Mechanical Properties.

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