Additive manufacturing of two-phase lightweight, stiff and high damping carbon fiber reinforced polymer microlattices

Xu, Zhenpeng; Ha, Chan Soo; Kadam, Ruthvik; Lindahl, John; Kim, Pum; Kunc, Vlastimil; Zheng, Xiaoyu; Wu, H. Felix

doi:10.1016/j.addma.2020.101106

Additive manufacturing of two-phase lightweight, stiff and high damping carbon fiber reinforced polymer microlattices

Journal Article · Fri Jan 31 23:00:00 EST 2020 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2020.101106· OSTI ID:1651385

Xu, Zhenpeng ^[1]; Ha, Chan Soo ^[2]; Kadam, Ruthvik ^[2]; ^[3]; ^[3]; ^[3]; Zheng, Xiaoyu ^[4]; Wu, H. Felix ^[5]

Univ. of California, Los Angeles, CA (United States)
Virginia Polytechnic Inst. and State Univ. (Virginia Tech), Blacksburg, VA (United States)
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Univ. of California, Los Angeles, CA (United States); Virginia Polytechnic Inst. and State Univ. (Virginia Tech), Blacksburg, VA (United States)
US Department of Energy (USDOE), Washington DC (United States)

Carbon fiber reinforced polymer (CFRP) composite is known for its high stiffness-to-weight ratio and hence is of great interest in several engineering fields such as aerospace, automotive, defense, etc. However, such a composite is not suitable for energy dissipation as failure occurs with very little or no plastic deformation. Herein, we present an extendable multi-material projection microstereolithography process capable of producing carbon-fiber-reinforced cellular materials that achieve simultaneously high specific stiffness and damping coefficient. Inspired by the upper bounds of stiffness-loss coefficient in a two-phase composite, we designed and additively manufactured CFRP microlattices with soft phases architected into selected stiff-phase struts. Our results, confirmed by experimental and analytical calculations, revealed that the damping performance can be significantly enhanced by the addition of only a small fraction of the soft phase. The presented design and additive manufacturing strategy allow for optimizing mutually exclusive properties. As a result, these CFRP microlattices achieved high specific stiffness comparable to commercial CFRP, technical ceramics, and composites, while being dissipative like elastomers.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Transportation Office. Vehicle Technologies Office

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1651385

Alternate ID(s):: OSTI ID: 1704007

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Journal Issue: 1 Vol. 32; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

References (29)

Advanced Micro-Lattice Materials: Advanced Micro-Lattice Materials Xiong, Jian; Mines, Robert; Ghosh, Ranajay Advanced Engineering Materials, Vol. 17, Issue 9 https://doi.org/10.1002/adem.201400471	journal	February 2015
Nanolattices: An Emerging Class of Mechanical Metamaterials Bauer, Jens; Meza, Lucas R.; Schaedler, Tobias A. Advanced Materials, Vol. 29, Issue 40 https://doi.org/10.1002/adma.201701850	journal	September 2017
Analysis of high-loss viscoelastic composites Chen, C. P.; Lakes, R. S. Journal of Materials Science, Vol. 28, Issue 16 https://doi.org/10.1007/BF01154935	journal	January 1993
Effective properties of the octet-truss lattice material Deshpande, V. S.; Fleck, N. A.; Ashby, M. F. Journal of the Mechanics and Physics of Solids, Vol. 49, Issue 8 https://doi.org/10.1016/S0022-5096(01)00010-2	journal	August 2001
Mechanical behavior of carbon fiber composite lattice core sandwich panels fabricated by laser cutting Xiong, J.; Ma, L.; Vaziri, A. Acta Materialia, Vol. 60, Issue 13-14 https://doi.org/10.1016/j.actamat.2012.06.004	journal	August 2012
Topology optimization of multiphase architected materials for energy dissipation Asadpoure, Alireza; Tootkaboni, Mazdak; Valdevit, Lorenzo Computer Methods in Applied Mechanics and Engineering, Vol. 325 https://doi.org/10.1016/j.cma.2017.07.007	journal	October 2017
Additive manufacturing of carbon fiber reinforced thermoplastic composites using fused deposition modeling Ning, Fuda; Cong, Weilong; Qiu, Jingjing Composites Part B: Engineering, Vol. 80 https://doi.org/10.1016/j.compositesb.2015.06.013	journal	October 2015
Highly oriented carbon fiber–polymer composites via additive manufacturing Tekinalp, Halil L.; Kunc, Vlastimil; Velez-Garcia, Gregorio M. Composites Science and Technology, Vol. 105 https://doi.org/10.1016/j.compscitech.2014.10.009	journal	December 2014
A novel strengthening method for carbon fiber composite lattice truss structures Wu, Qianqian; Ma, Li; Wu, Linzhi Composite Structures, Vol. 153 https://doi.org/10.1016/j.compstruct.2016.06.060	journal	October 2016
Honeytubes: Hollow lattice truss reinforced honeycombs for crushing protection Yin, Sha; Li, Jiani; Liu, Binghe Composite Structures, Vol. 160 https://doi.org/10.1016/j.compstruct.2016.11.007	journal	January 2017
Refinements on fracture toughness of PUR foams Marsavina, Liviu; Constantinescu, Dan M.; Linul, Emanoil Engineering Fracture Mechanics, Vol. 129 https://doi.org/10.1016/j.engfracmech.2013.12.006	journal	October 2014
Mechanical response of Ti–6Al–4V octet-truss lattice structures Dong, Liang; Deshpande, Vikram; Wadley, Haydn International Journal of Solids and Structures, Vol. 60-61 https://doi.org/10.1016/j.ijsolstr.2015.02.020	journal	May 2015
The temperature and anisotropy effect on compressive behavior of cylindrical closed-cell aluminum-alloy foams Linul, Emanoil; Movahedi, Nima; Marsavina, Liviu Journal of Alloys and Compounds, Vol. 740 https://doi.org/10.1016/j.jallcom.2018.01.102	journal	April 2018
Ceramic fabrication using Mask-Image-Projection-based Stereolithography integrated with tape-casting Song, Xuan; Chen, Yong; Lee, Tae Woo Journal of Manufacturing Processes, Vol. 20 https://doi.org/10.1016/j.jmapro.2015.06.022	journal	October 2015
Recent developments in brittle and quasi-brittle failure assessment of engineering materials by means of local approaches Berto, F.; Lazzarin, P. Materials Science and Engineering: R: Reports, Vol. 75 https://doi.org/10.1016/j.mser.2013.11.001	journal	January 2014
Ultrasonic assembly of anisotropic short fibre reinforced composites Scholz, M. -S.; Drinkwater, B. W.; Trask, R. S. Ultrasonics, Vol. 54, Issue 4 https://doi.org/10.1016/j.ultras.2013.12.001	journal	April 2014
Multiscale metallic metamaterials Zheng, Xiaoyu; Smith, William; Jackson, Julie Nature Materials, Vol. 15, Issue 10 https://doi.org/10.1038/nmat4694	journal	July 2016
Three-dimensional printing of piezoelectric materials with designed anisotropy and directional response Cui, Huachen; Hensleigh, Ryan; Yao, Desheng Nature Materials, Vol. 18, Issue 3 https://doi.org/10.1038/s41563-018-0268-1	journal	January 2019
Porous polymeric materials by 3D printing of photocurable resin Mu, X.; Bertron, T.; Dunn, C. Materials Horizons, Vol. 4, Issue 3 https://doi.org/10.1039/C7MH00084G	journal	January 2017
Additive manufacturing of complex micro-architected graphene aerogels Hensleigh, Ryan M.; Cui, Huachen; Oakdale, James S. Materials Horizons, Vol. 5, Issue 6 https://doi.org/10.1039/C8MH00668G	journal	January 2018
Design and optimization of a light-emitting diode projection micro-stereolithography three-dimensional manufacturing system Zheng, Xiaoyu; Deotte, Joshua; Alonso, Matthew P. Review of Scientific Instruments, Vol. 83, Issue 12 https://doi.org/10.1063/1.4769050	journal	December 2012
Fabrication and experimental demonstration of a hybrid resonant acoustic gradient index metasurface at 40 kHz Gerard, Nikhil JRK; Cui, Huachen; Shen, Chen Applied Physics Letters, Vol. 114, Issue 23 https://doi.org/10.1063/1.5095963	journal	June 2019
Resilient 3D hierarchical architected metamaterials Meza, Lucas R.; Zelhofer, Alex J.; Clarke, Nigel Proceedings of the National Academy of Sciences, Vol. 112, Issue 37 https://doi.org/10.1073/pnas.1509120112	journal	September 2015
Rotational 3D printing of damage-tolerant composites with programmable mechanics Raney, Jordan R.; Compton, Brett G.; Mueller, Jochen Proceedings of the National Academy of Sciences, Vol. 115, Issue 6 https://doi.org/10.1073/pnas.1715157115	journal	January 2018
3D printed components with ultrasonically arranged microscale structure Llewellyn-Jones, Thomas M.; Drinkwater, Bruce W.; Trask, Richard S. Smart Materials and Structures, Vol. 25, Issue 2 https://doi.org/10.1088/0964-1726/25/2/02LT01	journal	January 2016
Hybrid Hollow Microlattices With Unique Combination of Stiffness and Damping Salari-Sharif, L.; Schaedler, T. A.; Valdevit, L. Journal of Engineering Materials and Technology, Vol. 140, Issue 3 https://doi.org/10.1115/1.4038672	journal	February 2018
Ultralight, ultrastiff mechanical metamaterials Zheng, X.; Lee, H.; Weisgraber, T. H. Science, Vol. 344, Issue 6190 https://doi.org/10.1126/science.1252291	journal	June 2014
Energy dissipation mechanisms in hollow metallic microlattices Salari-Sharif, Ladan; Schaedler, Tobias A.; Valdevit, Lorenzo Journal of Materials Research, Vol. 29, Issue 16 https://doi.org/10.1557/jmr.2014.226	journal	August 2014
Additive Manufacturing and size-dependent mechanical properties of three-dimensional microarchitected, high-temperature ceramic metamaterials Cui, Huachen; Hensleigh, Ryan; Chen, Hongshun Journal of Materials Research, Vol. 33, Issue 3 https://doi.org/10.1557/jmr.2018.11	journal	February 2018

Similar Records

Optimization of material damping and stiffness of laminated fiber-reinforced composite structural elements

Thesis/Dissertation · Tue Dec 31 23:00:00 EST 1985 · OSTI ID:7252643

Lightweighting Technology by Enhanced Composite with Fully Recyclable Particles (LiTE CFRP)

Technical Report · Thu Sep 30 00:00:00 EDT 2021 · OSTI ID:2208813

Damping characteristics of Zn-Al matrix composites

Journal Article · Sun May 15 00:00:00 EDT 1994 · Scripta Metallurgica et Materialia; (United States) · OSTI ID:7302893

Related Subjects

36 MATERIALS SCIENCE

Additive manufacturing of two-phase lightweight, stiff and high damping carbon fiber reinforced polymer microlattices

Citation Formats

References (29)

Similar Records

Related Subjects