Three-dimensional printing of PLA/CF/CNT “micro/nano” multi-scale fiber reinforced polymer composites with enhanced Mode-I fracture toughness and interlaminar shear strength: Effect of thermal press post treatment

Publikation: Beitrag in FachzeitschriftForschungsartikelBeigetragenBegutachtung

Beitragende

  • George Kampourakis - , Hellenic Mediterranean University, TWI (The Welding Institute) (Autor:in)
  • Fivos Simopoulos - , Hellenic Mediterranean University, TWI (The Welding Institute) (Autor:in)
  • George Karalis - , Printed Electronic Devices (PDoT) (Autor:in)
  • Emmanouil Porfyrakis - , Hellenic Mediterranean University (Autor:in)
  • Miron Krassas - , Hellenic Mediterranean University (Autor:in)
  • Stavros Katsiaounis - , Institute of Chemical Engineering and High Temperature Chemical Processes, Aristotle University of Thessaloniki (Autor:in)
  • Konstantinos Papagelis - , Institute of Chemical Engineering and High Temperature Chemical Processes, Aristotle University of Thessaloniki (Autor:in)
  • Aaron Soul - , Queen Mary University of London (Autor:in)
  • Dimitrios G. Papageorgiou - , Queen Mary University of London (Autor:in)
  • Jitong Zhao - , Professur für Baustoffe (Autor:in)
  • Marco Liebscher - , Professur für Baustoffe (Autor:in)
  • Panos Chatzakos - , TWI (The Welding Institute) (Autor:in)
  • Nikolaos Papadakis - , Hellenic Mediterranean University (Autor:in)
  • Lazaros Tzounis - , Hellenic Mediterranean University, Printed Electronic Devices (PDoT) (Autor:in)

Abstract

Fused Filament Fabrication (FFF) three-dimensional (3D) printing empowers advanced and complex fiber-reinforced polymer (FRP) composites, but also possesses unavoidable high void content and limited interlaminar strength. Multi-scale reinforcement can effectively mitigate the out-of-plane performance limitations of 3D printed FRPs, by the incorporation of nano-additives at filament level. 3D printed continuous FRP composites of Polylactic acid (PLA)/ Carbon Fiber (CF)/ multi-walled carbon nanotubes (CNTs) with enhanced interlaminar strength and fracture toughness are reported for the first time. A custom roll-to-roll (R2R) line is developed for the impregnation of CF tows (3 K) with neat PLA and PLA/CNT nanocomposite polymer solutions, further employed as feedstock for single feed FFF 3D printing (3DP). PLA/CF and PLA/CF/CNT unidirectional (UD) 12-ply laminates ([0]12) are manufactured and thoroughly investigated through microstructural and physicochemical analyses, as well as mechanical testing, both for “as printed” (AP) and post-processed “thermally pressed” (TP) specimens. Namely, quasi-static flexural, short beam shear (SBS), Mode-I interlaminar fracture tests, Dynamic Mechanical Analysis (DMA) and fractography investigations elucidate the reinforcing mechanisms of CNTs in the 3DP CFRP laminates, i.e. via matrix stiffening, crack deflection, etc., significantly increasing the interlaminar shear strength (ILSS) and fracture toughness (GIC). The ultimate flexural strength (σUFS) is increased by 8.9 %, the storage modulus (E′) by 6.7 %, the ILSS by 30.1 % and the GIC by 32.0 % for the PLA/CF/CNT (TP) multi-scale composites. This work highlights a versatile approach for the effective utilization of nanoinclusions within the thermoplastic matrix of continuous 3DP FRPs showing enhanced mechanical performance.

Details

OriginalspracheEnglisch
Aufsatznummer119493
FachzeitschriftComposite structures
Jahrgang371
PublikationsstatusVeröffentlicht - 1 Nov. 2025
Peer-Review-StatusJa

Schlagworte

Schlagwörter

  • Additive manufacturing, Carbon fiber reinforced polymers, Carbon nanotubes, Fracture toughness, Interlaminar shear strength, Multi-scale composites, Solution impregnation