Rheological survey of carbon fiber-reinforced high-temperature thermoplastics for big area additive manufacturing tooling applications

Ajinjeru, Christine; Kishore, Vidya; Chen, Xun; Hershey, Christopher; Lindahl, John; Kunc, Vlastimil; Hassen, Ahmed; Duty, Chad

doi:10.1177/0892705719873941

Rheological survey of carbon fiber-reinforced high-temperature thermoplastics for big area additive manufacturing tooling applications

Journal Article · Sun Sep 08 00:00:00 EDT 2019 · Journal of Thermoplastic Composite Materials

DOI:https://doi.org/10.1177/0892705719873941· OSTI ID:1661267

Ajinjeru, Christine ^[1]; ^[2]; Chen, Xun ^[2]; Hershey, Christopher ^[2]; ^[2]; ^[1]; ^[2]; Duty, Chad ^[1]

Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Univ. of Tennessee, Knoxville, TN (United States)
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

Carbon fiber (CF)-reinforced thermoplastic composites have been widely used in different structural applications due to their superior thermal and mechanical properties. The big area additive manufacturing (BAAM) system, developed at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility, has been used to manufacture several composite components, demonstration vehicles, molds, and dies. These components have been designed and fabricated using various CF-reinforced thermoplastics. In this study, the dynamic rheological and mechanical properties of a material commonly used in additive manufacturing, 20 wt% CF-acrylonitrile butadiene styrene (ABS), as well as three CF-reinforced high-temperature polymers, 25 wt% CF-polyphenylsulfone (PPSU), 35 wt% CF-polyethersulfone (PES), and 40 wt% CF-polyphenylene sulfide (PPS), used to print molds were investigated. The viscoelastic properties, namely storage modulus, loss modulus, tan delta, and complex viscosity, of these composites were studied, and the rheological behavior was related to the BAAM extrusion and bead formation process. The results showed 20 wt% CF-ABS and 40 wt% CF-PPS to display a more dominant elastic component at all frequencies tested while 25 wt% CF-PPSU and 35 wt% CF-PES have a more dominant viscous component. This viscoelastic behavior is then used to inform the deposition and bead formation process during extrusion on the BAAM system.

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), Energy Efficiency Office. Advanced Manufacturing Office; USDOE Office of Science (SC), Basic Energy Sciences (BES)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1661267

Journal Information:: Journal of Thermoplastic Composite Materials, Journal Name: Journal of Thermoplastic Composite Materials Journal Issue: 11 Vol. 34; ISSN 0892-7057

Publisher:: SAGECopyright Statement

Country of Publication:: United States

Language:: English

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36 MATERIALS SCIENCE
big area additive manufacturing
high-temperature thermoplastics
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rheological characteristics

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