Extrusion optimization and advanced mechanical characterization of fibre-reinforced polycarbonate filaments: Improving performance for fused filament fabrication

IF 8.1 2区材料科学 Q1 ENGINEERING, MANUFACTURING Composites Part A: Applied Science and Manufacturing Pub Date : 2025-04-01 Epub Date: 2025-01-27 DOI:10.1016/j.compositesa.2025.108752

Farimah Tikhani , Pascal Hubert

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Abstract

This study explores the optimization of extrusion process parameters for fabrication of short glass fibre-reinforced polycarbonate filaments suitable for Fused Filament Fabrication. Employing Response Surface Methodology, the effects of fibre content, screw speed, and die temperature on mechanical properties and dimensional stability of filaments were investigated. This work introduces the application of Digital Image Correlation directly on filaments during tensile testing, contributing to the development of advanced filament characterization techniques. The optimal parameters—10 wt% fibre content, 40 rpm screw speed, and 239.9 °C die temperature—achieved a balance between high tensile modulus, high tensile strength, and minimal diameter deviation. The optimal processing condition led to a 148 % increase in tensile modulus, while maintaining good tensile strength and acceptable diameter deviation. Overall, fibre content had the most significant impact on filament properties, followed by screw speed. Fracture surface analysis provided valuable insights about the effects of process parameters on microstructure of the composites.

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纤维增强聚碳酸酯长丝的挤出优化和先进的机械特性：提高熔融长丝制造的性能

本研究探讨了适合熔丝制造的玻璃纤维增强聚碳酸酯短长丝的挤出工艺参数的优化。采用响应面法，研究了纤维含量、螺杆转速和模具温度对长丝力学性能和尺寸稳定性的影响。这项工作介绍了在拉伸测试中直接在长丝上应用数字图像相关，有助于发展先进的长丝表征技术。最佳参数- 10 wt%纤维含量，40 rpm螺杆转速和239.9°C模具温度-实现了高抗拉模量，高抗拉强度和最小直径偏差之间的平衡。优化后的工艺条件使拉伸模量提高了148%，同时保持了良好的拉伸强度和可接受的直径偏差。总体而言，纤维含量对长丝性能的影响最为显著，其次是螺杆转速。断口分析提供了工艺参数对复合材料微观结构影响的宝贵见解。

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来源期刊

Composites Part A: Applied Science and Manufacturing 工程技术-材料科学：复合

CiteScore

15.20

自引率

5.70%

发文量

492

审稿时长

30 days

期刊介绍： Composites Part A: Applied Science and Manufacturing is a comprehensive journal that publishes original research papers, review articles, case studies, short communications, and letters covering various aspects of composite materials science and technology. This includes fibrous and particulate reinforcements in polymeric, metallic, and ceramic matrices, as well as 'natural' composites like wood and biological materials. The journal addresses topics such as properties, design, and manufacture of reinforcing fibers and particles, novel architectures and concepts, multifunctional composites, advancements in fabrication and processing, manufacturing science, process modeling, experimental mechanics, microstructural characterization, interfaces, prediction and measurement of mechanical, physical, and chemical behavior, and performance in service. Additionally, articles on economic and commercial aspects, design, and case studies are welcomed. All submissions undergo rigorous peer review to ensure they contribute significantly and innovatively, maintaining high standards for content and presentation. The editorial team aims to expedite the review process for prompt publication.