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Progress in Additive Manufacturing

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16-01-2022 | Full Research Article

Experimental investigation of process-structure effects on interfacial bonding strength of a short carbon fiber/polyamide composite fabricated by fused filament fabrication

Authors: Moritz König, Jana Diekmann, Michael Lahres, Peter Middendorf

Published in: Progress in Additive Manufacturing | Issue 4/2022

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Abstract

While fiber reinforced polymers in fused filament fabrication (FFF) provide improved tensile properties in bead direction, only low properties can be reached perpendicular to the bead direction. The effects of process parameters on interlayer and bead-to-bead bonding of a short carbon fiber (0.1–0.3 mm) reinforced polyamide were investigated using tensile specimens loaded transverse to the bead direction. The evaluated process parameters were printing temperature, printing speed, bead width, layer height, and air gap. Mesostructures of printed samples were analyzed for parameter effects on interfacial void content using optical microscopy. Fracture surfaces of tested tensile specimens were analyzed using a scanning electron microscope to explain material failure. Parameter settings that were found to achieve high and low interfacial void contents were selected to print further tensile specimens loaded in bead direction to observe the effect of process parameters on the material’s degree of anisotropy. It was found that the short carbon fibers are not able to increase the interfacial bonding strength significantly compared to previously published results of unreinforced polyamides, due to weak fiber–matrix bonding and the process induced fiber orientation. However, the parameters air gap, layer height, and printing temperature were found to compensate the high melt viscosity and the resulting low material flow of the short carbon fiber reinforced polyamide, leading to stronger bead-to-bead bonding. While the bead-to-bead bonding is highly affected by the resulting contact areas of adjacent beads in the mesostructure, interlayer bonding was found to be most positively affected by decreasing printing speed. Nevertheless, while the process parameters affect interlayer and bead-to-bead bonding differently, the material’s degree of anisotropy was found to be decreased with a low interfacial void content. Based on our findings, considering the direction of mechanical stresses is crucial while selecting process parameters to achieve the best part performance of load-bearing parts printed with short fiber reinforced materials in FFF. For further performance improvement, future research should investigate how to establish FFF materials with strong fiber–matrix bonding and how to consider the materials’ anisotropy in selecting a parts infill pattern and part orientation for the parts load case.

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Title: Experimental investigation of process-structure effects on interfacial bonding strength of a short carbon fiber/polyamide composite fabricated by fused filament fabrication
Authors: Moritz König
Jana Diekmann
Michael Lahres
Peter Middendorf
Publication date: 16-01-2022
Publisher: Springer International Publishing
Published in: Progress in Additive Manufacturing / Issue 4/2022
Print ISSN: 2363-9512
Electronic ISSN: 2363-9520
DOI: https://doi.org/10.1007/s40964-021-00249-4

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