C. Martín-Pérez, Daniel Rodriguez-Del Rosario, E. Rodríguez-Senín, N. González-Castro
ECO-CLIP has developed a novel recycled 40wt% short CF/LMPAEK material from factory scrap that has been used to manufacture aircraft structural parts using injection molding (IM), the conventional manufacturing process, and fussed granulated fabrication (FGF) as an alternative one. In this sense, a technical study of the material processability has been made for FGF. The most important results are presented in this work, such as fiber breakage, carbon fiber percentage after and before processing, thermal behavior and thermal induce history, and mechanical properties such as compression, tensile and flexural behavior Three different nozzle diameters (0.8, 1.2, and 1.5mm) were used to ensure processability, mechanical requirements, and physical performance. Carrying out a direct comparison with the results achieved by IM. Other PAEKs have been processed by FGF or traditional fused filament fabrication (FFF) for comparative purposes.
{"title":"Fused Granulated Fabrication (FGF) Processing Study for Novel sCF/LMPAEK Recycled Material to Manufacture Aeronautic Structural Parts","authors":"C. Martín-Pérez, Daniel Rodriguez-Del Rosario, E. Rodríguez-Senín, N. González-Castro","doi":"10.1115/iam2022-93890","DOIUrl":"https://doi.org/10.1115/iam2022-93890","url":null,"abstract":"\u0000 ECO-CLIP has developed a novel recycled 40wt% short CF/LMPAEK material from factory scrap that has been used to manufacture aircraft structural parts using injection molding (IM), the conventional manufacturing process, and fussed granulated fabrication (FGF) as an alternative one.\u0000 In this sense, a technical study of the material processability has been made for FGF. The most important results are presented in this work, such as fiber breakage, carbon fiber percentage after and before processing, thermal behavior and thermal induce history, and mechanical properties such as compression, tensile and flexural behavior Three different nozzle diameters (0.8, 1.2, and 1.5mm) were used to ensure processability, mechanical requirements, and physical performance. Carrying out a direct comparison with the results achieved by IM.\u0000 Other PAEKs have been processed by FGF or traditional fused filament fabrication (FFF) for comparative purposes.","PeriodicalId":184278,"journal":{"name":"2022 International Additive Manufacturing Conference","volume":"23 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"126664860","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Max D. A. Valentine, Arjun Radhakrishnan, V. Maes, E. Pegg, Maria D. R. Valero, J. Kratz, V. Dhokia
As the flexibility and reliability of additive manufacturing (AM) and its corresponding design tools increases, it is becoming a viable option for more industries. One application area that could benefit from AM is composite component manufacture. The layup and molding of composite materials face significant challenges presented by tight design timescales, growing demand for productivity, and the complexity of components and end products. Therefore, there is an immediate potential to save energy by reducing the mass of the curing equipment and tooling to enhance process heat transmission. The goal of this paper is to demonstrate the reduction of embodied energy within mold tools that are printed using an AM process. Using an AM approach, it is possible to design lightweight curing tools to increase the curing rate and quality of heat distribution in the mold. The viability of additively producing these cure tools was assessed by analyzing the geometrical precision of the composite mold outputs, material utilization, and heat transmission qualities of each sample. In this study, 14 cure tools were designed and manufactured with a 100 mm2 curing surface area, top plate thickness of 1–2 mm, and stiffening lattices behind the curing surface with a depth of 10 mm. Four lattice geometries, gyroid, dual-wall gyroid, planar diamond, and stochastic, were tested based on their overall geometrical accuracy and thermal responsiveness. While the stochastic lattice had the best single tool properties, the planar diamond and gyroid lattice tools had better potential for future use in the design of additively manufactured composite tooling.
{"title":"A Feasibility Study of Additively Manufactured Composite Tooling","authors":"Max D. A. Valentine, Arjun Radhakrishnan, V. Maes, E. Pegg, Maria D. R. Valero, J. Kratz, V. Dhokia","doi":"10.1115/iam2022-93952","DOIUrl":"https://doi.org/10.1115/iam2022-93952","url":null,"abstract":"\u0000 As the flexibility and reliability of additive manufacturing (AM) and its corresponding design tools increases, it is becoming a viable option for more industries. One application area that could benefit from AM is composite component manufacture. The layup and molding of composite materials face significant challenges presented by tight design timescales, growing demand for productivity, and the complexity of components and end products. Therefore, there is an immediate potential to save energy by reducing the mass of the curing equipment and tooling to enhance process heat transmission. The goal of this paper is to demonstrate the reduction of embodied energy within mold tools that are printed using an AM process. Using an AM approach, it is possible to design lightweight curing tools to increase the curing rate and quality of heat distribution in the mold. The viability of additively producing these cure tools was assessed by analyzing the geometrical precision of the composite mold outputs, material utilization, and heat transmission qualities of each sample. In this study, 14 cure tools were designed and manufactured with a 100 mm2 curing surface area, top plate thickness of 1–2 mm, and stiffening lattices behind the curing surface with a depth of 10 mm. Four lattice geometries, gyroid, dual-wall gyroid, planar diamond, and stochastic, were tested based on their overall geometrical accuracy and thermal responsiveness. While the stochastic lattice had the best single tool properties, the planar diamond and gyroid lattice tools had better potential for future use in the design of additively manufactured composite tooling.","PeriodicalId":184278,"journal":{"name":"2022 International Additive Manufacturing Conference","volume":"4 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130620878","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Additive manufacturing with plastics enables the production of lightweight and resilient components with a high degree of design freedom. In the low-cost sector, Material Extrusion as Fused Layer Modeling (FLM) has so far been the leading method, as it offers simple 3D printers and a variety of inexpensive 3D materials. However, printing times for 6FLM are very long and dimensional accuracy and surface finish are rather poor. Recently, new processes from the field of Vat Polymerization have appeared on the market, such as masked Stereolithography (mSLA), which offer a significant improvement in component quality and build speed at equally favorable machine costs. This paper therefore analyzes the technical and economic capabilities of the two competing additive processes. For this purpose, the achievable dimensional and surface qualities are determined using a test specimen which represents various important geometry elements. In addition, the machine and material costs are determined and compared with each other. Finally, the resulting environmental impact is determined in the form of the CO2 footprint. In order to optimize the strength of the printed components, material properties of the tensile specimens produced additively with mSLA are determined. The use of ABS-like resins will also be investigated to determine optimal processing settings.
{"title":"Comparison of Technical and Economic Properties of Additively Manufactured Components Using Masked Stereolithography and Fused Layer Modeling","authors":"S. Junk, Felix Bär","doi":"10.1115/iam2022-94087","DOIUrl":"https://doi.org/10.1115/iam2022-94087","url":null,"abstract":"\u0000 Additive manufacturing with plastics enables the production of lightweight and resilient components with a high degree of design freedom. In the low-cost sector, Material Extrusion as Fused Layer Modeling (FLM) has so far been the leading method, as it offers simple 3D printers and a variety of inexpensive 3D materials. However, printing times for 6FLM are very long and dimensional accuracy and surface finish are rather poor. Recently, new processes from the field of Vat Polymerization have appeared on the market, such as masked Stereolithography (mSLA), which offer a significant improvement in component quality and build speed at equally favorable machine costs.\u0000 This paper therefore analyzes the technical and economic capabilities of the two competing additive processes. For this purpose, the achievable dimensional and surface qualities are determined using a test specimen which represents various important geometry elements. In addition, the machine and material costs are determined and compared with each other. Finally, the resulting environmental impact is determined in the form of the CO2 footprint. In order to optimize the strength of the printed components, material properties of the tensile specimens produced additively with mSLA are determined. The use of ABS-like resins will also be investigated to determine optimal processing settings.","PeriodicalId":184278,"journal":{"name":"2022 International Additive Manufacturing Conference","volume":"15 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131963944","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
A major applications of thermoplastic additive manufacturing (typically completed using the fused deposition modeling or fused filament fabrication (FDM/FFF) process) is in the production of polymer matrix composites. Several different reinforcing materials have been proposed and studied, a common one of which is chopped carbon fibers (CCF). Most of the published research on the properties and effect of the CCF reinforcement has relied upon a poly(lactic acid) (PLA) matrix, as it has a low and stable melting temperature, low cost, and mixes readily with particulate or chopped reinforcing materials. For commercially available CCF filament for FDM/FFF, the typical fiber content is around 15–25% by volume, with the remainder being the thermoplastic matrix. To better explore the influence of the matrix material on the properties of these materials, this study compares the IZOD impact properties of standard CCF PLA with CCF-reinforced materials using polyamide/nylon (PA), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), and polyethylene terephthalate glycol (PETG) matrices. All cases were printed at full (100%) density. For each material, samples of 5 mm thickness were tested in the Type A (notch in tension) and Type E (notch in compression) configurations. Two print orientations (flat and horizontal) and two raster angles (0–90° and ±45°) were considered for each combination. As required by ASTM D256, the tests were replicated five times each. The results are compared with the major literature for CCF reinforced PLA, as well as benchmark tests using injection molded samples and non-CCF PLA, PA, PC, ABS, and PETG processed by FDM/FFF.
{"title":"Influence of Matrix Material on Impact Properties of Chopped Carbon Fiber-Thermoplastic Composites Made Using FDM/FFF","authors":"A. Patterson, S. Hasanov, Bhaskar Vajipeyajula","doi":"10.1115/iam2022-88941","DOIUrl":"https://doi.org/10.1115/iam2022-88941","url":null,"abstract":"\u0000 A major applications of thermoplastic additive manufacturing (typically completed using the fused deposition modeling or fused filament fabrication (FDM/FFF) process) is in the production of polymer matrix composites. Several different reinforcing materials have been proposed and studied, a common one of which is chopped carbon fibers (CCF). Most of the published research on the properties and effect of the CCF reinforcement has relied upon a poly(lactic acid) (PLA) matrix, as it has a low and stable melting temperature, low cost, and mixes readily with particulate or chopped reinforcing materials. For commercially available CCF filament for FDM/FFF, the typical fiber content is around 15–25% by volume, with the remainder being the thermoplastic matrix. To better explore the influence of the matrix material on the properties of these materials, this study compares the IZOD impact properties of standard CCF PLA with CCF-reinforced materials using polyamide/nylon (PA), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), and polyethylene terephthalate glycol (PETG) matrices. All cases were printed at full (100%) density. For each material, samples of 5 mm thickness were tested in the Type A (notch in tension) and Type E (notch in compression) configurations. Two print orientations (flat and horizontal) and two raster angles (0–90° and ±45°) were considered for each combination. As required by ASTM D256, the tests were replicated five times each. The results are compared with the major literature for CCF reinforced PLA, as well as benchmark tests using injection molded samples and non-CCF PLA, PA, PC, ABS, and PETG processed by FDM/FFF.","PeriodicalId":184278,"journal":{"name":"2022 International Additive Manufacturing Conference","volume":"189 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134592201","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Benedict A. Rogers, Max D. A. Valentine, E. Pegg, A. Lunt, V. Dhokia
Additive manufacturing has been the driving force behind the growth of metamaterials as a field. Commonly taking the form of lattices, these structures can achieve a range of novel macroscale properties that stem from the cumulative effects of locally designed mechanisms. A wide array of mechanical metamaterials have already been designed using computational methods, but these rarely undergo physical testing, often as a result of manufacturing difficulties. This work approaches the problem of manufacturing complex metamaterial test samples though a case study of 3D petal-based auxetic star lattices. These lattice structures have linkage structures with overhanging elements, which is a common feature in metamaterial concepts but challenging to print. Trials of the test samples were manufactured using a thermoplastic polyurethane filament combined with polyvinyl acetate support at 20, 30 and 40 mm unit cell sizes. It was found that the main geometric challenges for successful printing were the link thickness and the reliability of the prints. To address unreliability, the geometry was cut into layers of cells with adhesive-connected feet and printed in parts for post-process assembly. The layered approach was tested successfully and was estimated to reduce the number of cells needed to be attempted to print the full lattice by over 80%. The use of dissolvable support material proved viable for printing overhanging links, but requires use of fused deposition modelling so a relatively low part resolution. The trial led to a five point design guide methodology for metamaterial test samples. Combined with cell mathematical definitions that strictly bound link thickness to take minimum print resolution into account, this methodology can be applied to other metamaterials and help bridge the gap between theoretical lattices and physical testing.
{"title":"Additive Manufacturing of Star Structured Auxetic Lattices With Overhanging Links","authors":"Benedict A. Rogers, Max D. A. Valentine, E. Pegg, A. Lunt, V. Dhokia","doi":"10.1115/iam2022-93965","DOIUrl":"https://doi.org/10.1115/iam2022-93965","url":null,"abstract":"\u0000 Additive manufacturing has been the driving force behind the growth of metamaterials as a field. Commonly taking the form of lattices, these structures can achieve a range of novel macroscale properties that stem from the cumulative effects of locally designed mechanisms. A wide array of mechanical metamaterials have already been designed using computational methods, but these rarely undergo physical testing, often as a result of manufacturing difficulties.\u0000 This work approaches the problem of manufacturing complex metamaterial test samples though a case study of 3D petal-based auxetic star lattices. These lattice structures have linkage structures with overhanging elements, which is a common feature in metamaterial concepts but challenging to print. Trials of the test samples were manufactured using a thermoplastic polyurethane filament combined with polyvinyl acetate support at 20, 30 and 40 mm unit cell sizes. It was found that the main geometric challenges for successful printing were the link thickness and the reliability of the prints. To address unreliability, the geometry was cut into layers of cells with adhesive-connected feet and printed in parts for post-process assembly.\u0000 The layered approach was tested successfully and was estimated to reduce the number of cells needed to be attempted to print the full lattice by over 80%. The use of dissolvable support material proved viable for printing overhanging links, but requires use of fused deposition modelling so a relatively low part resolution. The trial led to a five point design guide methodology for metamaterial test samples. Combined with cell mathematical definitions that strictly bound link thickness to take minimum print resolution into account, this methodology can be applied to other metamaterials and help bridge the gap between theoretical lattices and physical testing.","PeriodicalId":184278,"journal":{"name":"2022 International Additive Manufacturing Conference","volume":"12 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124977795","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
G. Moneta, Michal Fedasz, Michał Szmidt, Sławomir Cieślak, W. Krzymień
Classical turbine blade design philosophy assumes so-called resonance-free dynamic solution (avoiding resonances for characteristic rotational speeds) achieved by eigenfrequency tunning. To meet current market demands, modern engines need: to operate with higher load, operate at higher firing temperatures, to startup and shutdown faster and more frequently. Therefore, the rotating blade must be more often designed as the resonance-proof component under circumstances of the variable rotational speed and varying thermal conditions. A century of turbine engine development has provided many solutions for improvement of High Cycle Fatigue lifetime of the blading. One of them is damping optimization through advanced design of parts. There are few main damping mechanisms occurring during blade vibrations: material damping, aerodynamical damping (usually below 0.3%) and frictional damping (depending on the design). Nowadays, the Additive Manufacturing (AM) and especially Laser Powder Bed Fusion (LPBF) allow to manufacture multifunctional and complex components with high structural integrity and extended lifetime. An example of uncooled turbine blade design of a jet engine has been studied. Two designs have been modelled and manufactured using LPBF technology: a baseline design (‘Solid Blade’) and a new design where the airfoil was filled with a matrix of pockets with pins and lattice bars surrounded by non-fused powder (‘Lattice Blade’). Then, the damping ratio has been assessed for both designs using electrodynamic shaker tests — the response was measured by laser vibrometer. Except material damping occurring in the baseline design, the new sophisticated design has additional damping mechanisms: the wave propagates through different media (changes of wave propagation speed, wave reflections), energy dissipates in the non-fused metal powder (friction between powder particles), solid pins in the pockets vibrate independently (act as dynamic dampers and improve energy dissipation in the powder), lattice bars in the pockets transfer the vibration wave to the powder (activate energy dissipation in the whole volume of the non-fused powder). The results of shaker tests show significant damping ratio increase for all investigated modes in this study — comparable to such damping features like friction under-platform dampers and damping bolts. Additionally, the LPBF approach has a multi-functional character — except significant improvement of damping ratio, the mass can be reduced (in this case decreased by about 6%), eigenfrequency can be tuned to avoid resonance, the stress concentration factors can be reduced (which is planned for next studies), etc. The proposed new design has not been optimized so far, giving wide margin for further improvements of the damping performance.
{"title":"Advantages of Additive Manufacturing Technology in Damping Improvement of Turbine Blading","authors":"G. Moneta, Michal Fedasz, Michał Szmidt, Sławomir Cieślak, W. Krzymień","doi":"10.1115/iam2022-96752","DOIUrl":"https://doi.org/10.1115/iam2022-96752","url":null,"abstract":"\u0000 Classical turbine blade design philosophy assumes so-called resonance-free dynamic solution (avoiding resonances for characteristic rotational speeds) achieved by eigenfrequency tunning. To meet current market demands, modern engines need: to operate with higher load, operate at higher firing temperatures, to startup and shutdown faster and more frequently. Therefore, the rotating blade must be more often designed as the resonance-proof component under circumstances of the variable rotational speed and varying thermal conditions. A century of turbine engine development has provided many solutions for improvement of High Cycle Fatigue lifetime of the blading. One of them is damping optimization through advanced design of parts. There are few main damping mechanisms occurring during blade vibrations: material damping, aerodynamical damping (usually below 0.3%) and frictional damping (depending on the design). Nowadays, the Additive Manufacturing (AM) and especially Laser Powder Bed Fusion (LPBF) allow to manufacture multifunctional and complex components with high structural integrity and extended lifetime. An example of uncooled turbine blade design of a jet engine has been studied. Two designs have been modelled and manufactured using LPBF technology: a baseline design (‘Solid Blade’) and a new design where the airfoil was filled with a matrix of pockets with pins and lattice bars surrounded by non-fused powder (‘Lattice Blade’). Then, the damping ratio has been assessed for both designs using electrodynamic shaker tests — the response was measured by laser vibrometer. Except material damping occurring in the baseline design, the new sophisticated design has additional damping mechanisms: the wave propagates through different media (changes of wave propagation speed, wave reflections), energy dissipates in the non-fused metal powder (friction between powder particles), solid pins in the pockets vibrate independently (act as dynamic dampers and improve energy dissipation in the powder), lattice bars in the pockets transfer the vibration wave to the powder (activate energy dissipation in the whole volume of the non-fused powder). The results of shaker tests show significant damping ratio increase for all investigated modes in this study — comparable to such damping features like friction under-platform dampers and damping bolts. Additionally, the LPBF approach has a multi-functional character — except significant improvement of damping ratio, the mass can be reduced (in this case decreased by about 6%), eigenfrequency can be tuned to avoid resonance, the stress concentration factors can be reduced (which is planned for next studies), etc. The proposed new design has not been optimized so far, giving wide margin for further improvements of the damping performance.","PeriodicalId":184278,"journal":{"name":"2022 International Additive Manufacturing Conference","volume":"295 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131965446","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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