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

Abstract

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.

Authors:
 [1]; ORCiD logo [2];  [2];  [2]; ORCiD logo [2]; ORCiD logo [1]; ORCiD logo [2];  [1]
  1. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Univ. of Tennessee, Knoxville, TN (United States)
  2. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Publication Date:
Research Org.:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Sponsoring Org.:
USDOE Office of Science (SC), Basic Energy Sciences (BES)
OSTI Identifier:
1661267
Grant/Contract Number:  
AC05-00OR22725
Resource Type:
Accepted Manuscript
Journal Name:
Journal of Thermoplastic Composite Materials
Additional Journal Information:
Journal Volume: TBD; Journal Issue: TBD; Journal ID: ISSN 0892-7057
Country of Publication:
United States
Language:
English
Subject:
Big area additive manufacturing; high-temperature thermoplastics; reinforced thermoplastics; rheological characteristics; printability

Citation Formats

Ajinjeru, Christine, Kishore, Vidya, Chen, Xun, Hershey, Christopher, Lindahl, John, Kunc, Vlastimil, Hassen, Ahmed, and Duty, Chad. Rheological survey of carbon fiber-reinforced high-temperature thermoplastics for big area additive manufacturing tooling applications. United States: N. p., 2019. Web. doi:10.1177/0892705719873941.
Ajinjeru, Christine, Kishore, Vidya, Chen, Xun, Hershey, Christopher, Lindahl, John, Kunc, Vlastimil, Hassen, Ahmed, & Duty, Chad. Rheological survey of carbon fiber-reinforced high-temperature thermoplastics for big area additive manufacturing tooling applications. United States. doi:10.1177/0892705719873941.
Ajinjeru, Christine, Kishore, Vidya, Chen, Xun, Hershey, Christopher, Lindahl, John, Kunc, Vlastimil, Hassen, Ahmed, and Duty, Chad. Sun . "Rheological survey of carbon fiber-reinforced high-temperature thermoplastics for big area additive manufacturing tooling applications". United States. doi:10.1177/0892705719873941. https://www.osti.gov/servlets/purl/1661267.
@article{osti_1661267,
title = {Rheological survey of carbon fiber-reinforced high-temperature thermoplastics for big area additive manufacturing tooling applications},
author = {Ajinjeru, Christine and Kishore, Vidya and Chen, Xun and Hershey, Christopher and Lindahl, John and Kunc, Vlastimil and Hassen, Ahmed and Duty, Chad},
abstractNote = {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.},
doi = {10.1177/0892705719873941},
journal = {Journal of Thermoplastic Composite Materials},
number = TBD,
volume = TBD,
place = {United States},
year = {2019},
month = {9}
}

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