Reactive extrusion of frontally polymerizing continuous carbon fiber reinforced polymer composites

Hmeidat, Nadim S.; Zakoworotny, Michael; Kim, Yun Seong; Le, Thien B.; DeBrun, Gavin; Shah, Rohan; Lessard, Jacob J.; Moore, Jeffery S.; Baur, Jeffery W.; Geubelle, Philippe H.; Sottos, Nancy R.; Tawfick, Sameh H.

doi:10.1016/j.compositesa.2024.108609

Title: Reactive extrusion of frontally polymerizing continuous carbon fiber reinforced polymer composites

Journal Article · 27 November 2024 · Composites. Part A, Applied Science and Manufacturing

DOI: https://doi.org/10.1016/j.compositesa.2024.108609 · OSTI ID:2479014

^[1]; Zakoworotny, Michael ^[2];

^[2]; Le, Thien B. ^[2];

^[2];

^[2]; Lessard, Jacob J. ^[3]; Moore, Jeffery S. ^[2]; Baur, Jeffery W. ^[2];

^[2];

^[2]

University of Illinois at Urbana-Champaign, IL (United States); Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
University of Illinois at Urbana-Champaign, IL (United States)
University of Illinois at Urbana-Champaign, IL (United States); University of Utah, Salt Lake City, UT (United States)

The manufacturing of carbon fiber-reinforced polymer (CFRP) composites demands rapid and energy-efficient strategies. Frontal polymerization (FP) enables the manufacturing of CFRP using dicyclopentadiene (DCPD) thermoset polymer which meets these requirements. In this work, we introduce reactive extrusion of CFRP (RE-CFRP), where two rollers provide localized heat and pressure to sustain the curing reaction and the consolidation of a continuous carbon fiber tow pre-impregnated with DCPD. We study the effect of the extrusion speed, temperature, and compaction force on the properties of the produced CFRP. Mechanical testing confirms that the resulting fiber volume fraction and the elastic modulus are similar to bulk cured tows. A homogenized thermo-chemical model is developed to study the effect of the process parameters on the polymerization reaction. The process produces hollow woven composite tubes directly via extrusion and in situ curing. Overall, this process offers advantages in curing, tooling, speed, and energy.

View Journal Article

Cite

Export

Save

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

Sponsoring Organization:: DARPA; USDOE Office of Energy Efficiency and Renewable Energy (EERE); USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Materials & Manufacturing Technologies Office (AMMTO)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 2479014

Journal Information:: Composites. Part A, Applied Science and Manufacturing, Journal Name: Composites. Part A, Applied Science and Manufacturing Vol. 190; ISSN 1359-835X

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

References (48)

3D-Printing of Lightweight Cellular Composites Compton, Brett G.; Lewis, Jennifer A. Advanced Materials, Vol. 26, Issue 34, p. 5930-5935 https://doi.org/10.1002/adma.201401804	journal	June 2014
Reprocessability in Engineering Thermosets Achieved Through Frontal Ring‐Opening Metathesis Polymerization Cooper, Julian C.; Paul, Justine E.; Ramlawi, Nabil Advanced Materials https://doi.org/10.1002/adma.202402627	journal	May 2024
Self‐Regulative Direct Ink Writing of Frontally Polymerizing Thermoset Polymers Aw, Jia En; Zhang, Xiang; Nelson, Arif Z. Advanced Materials Technologies, Vol. 7, Issue 9 https://doi.org/10.1002/admt.202200230	journal	April 2022
Effects of compaction and UV exposure on performance of acrylate/glass-fiber composites cured layer by layer Duan, Yugang; Li, Jia; Zhong, Weihong Journal of Applied Polymer Science, Vol. 123, Issue 6 https://doi.org/10.1002/app.34909	journal	September 2011
Influence of consolidating process on the properties of composites from thermosetting carbon fiber reinforced tapes Stadler, Hannes; Kiss, Peter; Stadlbauer, Wolfgang Polymer Composites, Vol. 43, Issue 7 https://doi.org/10.1002/pc.26687	journal	April 2022
Analytical estimates of front velocity in the frontal polymerization of thermoset polymers and composites Kumar, Aditya; Gao, Yuan; Geubelle, Philippe H. Journal of Polymer Science, Vol. 59, Issue 11 https://doi.org/10.1002/pol.20210155	journal	April 2021
Environmental impact assessment of aviation emission reduction through the implementation of composite materials Timmis, Andrew J.; Hodzic, Alma; Koh, Lenny The International Journal of Life Cycle Assessment, Vol. 20, Issue 2 https://doi.org/10.1007/s11367-014-0824-0	journal	November 2014
The effect of fiber architecture on the mechanical properties of carbon/carbon fiber composites Neumeister, J.; Jansson, S.; Leckie, F. Acta Materialia, Vol. 44, Issue 2 https://doi.org/10.1016/1359-6454(95)00184-0	journal	February 1996
Tensile properties and failure behavior of chopped and continuous carbon fiber composites produced by additive manufacturing Naranjo-Lozada, Juan; Ahuett-Garza, Horacio; Orta-Castañón, Pedro Additive Manufacturing, Vol. 26 https://doi.org/10.1016/j.addma.2018.12.020	journal	March 2019
Mechanical anisotropy in polymer composites produced by material extrusion additive manufacturing Hmeidat, Nadim S.; Pack, Robert C.; Talley, Samantha J. Additive Manufacturing, Vol. 34 https://doi.org/10.1016/j.addma.2020.101385	journal	August 2020
Revealing filler morphology in 3D-printed thermoset nanocomposites by scanning microbeam X-ray scattering Trigg, Edward B.; Hmeidat, Nadim S.; Smieska, Louisa M. Additive Manufacturing, Vol. 37 https://doi.org/10.1016/j.addma.2020.101729	journal	January 2021
Consolidation of continuous fibre reinforced composites in additive processes: A review Struzziero, Giacomo; Barbezat, Michel; Skordos, Alexandros Antonios Additive Manufacturing, Vol. 48 https://doi.org/10.1016/j.addma.2021.102458	journal	December 2021
Anisotropic thermal and electrical conductivities of individual polyacrylonitrile-based carbon fibers Ji, Xiaoyang; Matsuo, Satoshi; Sottos, Nancy R. Carbon, Vol. 197 https://doi.org/10.1016/j.carbon.2022.06.005	journal	September 2022
Rheological modeling of frontal-polymerization-based direct ink writing of thermoset polymers Zakoworotny, Michael; Balta Bonner, Francisco Javier; Kumar, Aditya Computer Methods in Applied Mechanics and Engineering, Vol. 418 https://doi.org/10.1016/j.cma.2023.116565	journal	January 2024
Manufacture of carbon-fiber prepreg with thermoplastic/epoxy resin blends and microencapsulated solvent healing agents Kim, Sang Yup; Lim, Tae-Wook; Sottos, Nancy R. Composites Part A: Applied Science and Manufacturing, Vol. 121 https://doi.org/10.1016/j.compositesa.2019.03.033	journal	June 2019
Frontal polymerization of unidirectional carbon-fiber-reinforced composites Goli, E.; Parikh, N. A.; Yourdkhani, M. Composites Part A: Applied Science and Manufacturing, Vol. 130 https://doi.org/10.1016/j.compositesa.2019.105689	journal	March 2020
Rapid multiple-front polymerization of fiber-reinforced polymer composites Centellas, P. J.; Yourdkhani, M.; Vyas, S. Composites Part A: Applied Science and Manufacturing, Vol. 158 https://doi.org/10.1016/j.compositesa.2022.106931	journal	July 2022
Through-thickness frontal polymerization: Process development and optimization Vyas, S.; Parikh, N. A.; Price, T. C. Composites Part A: Applied Science and Manufacturing, Vol. 180 https://doi.org/10.1016/j.compositesa.2024.108084	journal	May 2024
Effects of fiber orientation and anisotropy on tensile strength and elastic modulus of short fiber reinforced polymer composites Mortazavian, Seyyedvahid; Fatemi, Ali Composites Part B: Engineering, Vol. 72 https://doi.org/10.1016/j.compositesb.2014.11.041	journal	April 2015
Rheological modelling of thermoset composite processing Geissberger, R.; Maldonado, J.; Bahamonde, N. Composites Part B: Engineering, Vol. 124 https://doi.org/10.1016/j.compositesb.2017.05.040	journal	September 2017
Processing and mechanical characterization of short carbon fiber-reinforced epoxy composites for material extrusion additive manufacturing Hmeidat, Nadim S.; Elkins, Daniel S.; Peter, Hutchison R. Composites Part B: Engineering, Vol. 223 https://doi.org/10.1016/j.compositesb.2021.109122	journal	October 2021
Three-dimensional modeling of frontal polymerization for rapid, efficient, and uniform thermoset composites manufacturing Tarafdar, Amirreza; Jia, Chen; Hu, Weifei Composites Part B: Engineering, Vol. 266 https://doi.org/10.1016/j.compositesb.2023.111029	journal	November 2023
Core-shell structured tow-pregs enabled additive manufacturing of continuously reinforced thermoset composites Deng, Kaiyue; Park, Soyeon; Zhang, Chunyan Composites Part B: Engineering, Vol. 271 https://doi.org/10.1016/j.compositesb.2023.111179	journal	February 2024
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
High-strength epoxy nanocomposites for 3D printing Hmeidat, Nadim S.; Kemp, James W.; Compton, Brett G. Composites Science and Technology, Vol. 160 https://doi.org/10.1016/j.compscitech.2018.03.008	journal	May 2018
Manufacturing of unidirectional glass-fiber-reinforced composites via frontal polymerization: A numerical study Vyas, S.; Goli, E.; Zhang, X. Composites Science and Technology, Vol. 184 https://doi.org/10.1016/j.compscitech.2019.107832	journal	November 2019
A review of recent research on mechanics of multifunctional composite materials and structures Gibson, Ronald F. Composite Structures, Vol. 92, Issue 12 https://doi.org/10.1016/j.compstruct.2010.05.003	journal	November 2010
A critical review on 3D printed continuous fiber-reinforced composites: History, mechanism, materials and properties Kabir, S. M. Fijul; Mathur, Kavita; Seyam, Abdel-Fattah M. Composite Structures, Vol. 232 https://doi.org/10.1016/j.compstruct.2019.111476	journal	January 2020
Economic and environmental assessment of alternative production methods for composite aircraft components Witik, Robert A.; Gaille, Fabrice; Teuscher, Rémy Journal of Cleaner Production, Vol. 29-30 https://doi.org/10.1016/j.jclepro.2012.02.028	journal	July 2012
Automated fiber placement: A review of history, current technologies, and future paths forward Brasington, Alex; Sacco, Christopher; Halbritter, Joshua Composites Part C: Open Access, Vol. 6 https://doi.org/10.1016/j.jcomc.2021.100182	journal	October 2021
Frontal polymerization-assisted 3D printing of short carbon fibers/dicyclopentadiene composites Zhang, Zimeng; Liu, Ruochen; Li, Wei Journal of Manufacturing Processes, Vol. 71 https://doi.org/10.1016/j.jmapro.2021.10.014	journal	November 2021
Processing-structure-property relationships of continuous carbon fiber polymer-matrix composites Chung, D. D. L. Materials Science and Engineering: R: Reports, Vol. 113 https://doi.org/10.1016/j.mser.2017.01.002	journal	March 2017
Preparation and characterization of 3D printed continuous carbon fiber reinforced thermosetting composites Hao, Wenfeng; Liu, Ye; Zhou, Hao Polymer Testing, Vol. 65 https://doi.org/10.1016/j.polymertesting.2017.11.004	journal	February 2018
Frontal Polymerizations: From Chemical Perspectives to Macroscopic Properties and Applications Suslick, Benjamin A.; Hemmer, Julie; Groce, Brecklyn R. Chemical Reviews, Vol. 123, Issue 6 https://doi.org/10.1021/acs.chemrev.2c00686	journal	February 2023
Rapid Controlled Synthesis of Large Polymers by Frontal Ring-Opening Metathesis Polymerization Alzate-Sanchez, Diego M.; Yu, Christina H.; Lessard, Jacob J. Macromolecules https://doi.org/10.1021/acs.macromol.2c01892	journal	February 2023
3D Printing of Short-Carbon-Fiber-Reinforced Thermoset Polymer Composites via Frontal Polymerization Ziaee, Morteza; Johnson, James W.; Yourdkhani, Mostafa ACS Applied Materials & Interfaces, Vol. 14, Issue 14 https://doi.org/10.1021/acsami.2c02076	journal	March 2022
Curing Kinetics and Mechanical Properties of endo -Dicyclopentadiene Synthesized Using Different Grubbs’ Catalysts Yang, Guang; Lee, Jong Keun Industrial & Engineering Chemistry Research, Vol. 53, Issue 8 https://doi.org/10.1021/ie403285q	journal	February 2014
Unraveling Reactivity Differences: Room-Temperature Ring-Opening Metathesis Polymerization (ROMP) versus Frontal ROMP Lessard, Jacob J.; Mejia, Edgar B.; Kim, Abbie J. Journal of the American Chemical Society, Vol. 146, Issue 11 https://doi.org/10.1021/jacs.4c01578	journal	March 2024
A Mechanism-Based Reaction–Diffusion Model for Accelerated Discovery of Thermoset Resins Frontally Polymerized by Olefin Metathesis Bistri, Donald; Arretche, Ignacio; Lessard, Jacob J. Journal of the American Chemical Society, Vol. 146, Issue 31 https://doi.org/10.1021/jacs.4c06527	journal	July 2024
Rapid energy-efficient manufacturing of polymers and composites via frontal polymerization Robertson, Ian D.; Yourdkhani, Mostafa; Centellas, Polette J. Nature, Vol. 557, Issue 7704 https://doi.org/10.1038/s41586-018-0054-x	journal	May 2018
Three-dimensional printing of continuous-fiber composites by in-nozzle impregnation Matsuzaki, Ryosuke; Ueda, Masahito; Namiki, Masaki Scientific Reports, Vol. 6, Issue 1 https://doi.org/10.1038/srep23058	journal	March 2016
3D-Printing of Meso-structurally Ordered Carbon Fiber/Polymer Composites with Unprecedented Orthotropic Physical Properties Lewicki, James P.; Rodriguez, Jennifer N.; Zhu, Cheng Scientific Reports, Vol. 7, Issue 1 https://doi.org/10.1038/srep43401	journal	March 2017
Extrusion Freeform Fabrication of Chopped-Fibre Reinforced Composites Calvert, Paul; Lin, Tung Liang; Martin, Hogan High Performance Polymers, Vol. 9, Issue 4 https://doi.org/10.1088/0954-0083/9/4/008	journal	December 1997
Anisotropic material properties of fused deposition modeling ABS Ahn, Sung‐Hoon; Montero, Michael; Odell, Dan Rapid Prototyping Journal, Vol. 8, Issue 4 https://doi.org/10.1108/13552540210441166	journal	October 2002
Mechanical properties of additively printed, UV cured, continuous fiber unidirectional composites for multifunctional applications Baur, Jeffery W.; Abbott, Andrew C.; Barnett, Philip R. Journal of Composite Materials, Vol. 57, Issue 4 https://doi.org/10.1177/00219983221146264	journal	December 2022
Curing Methods for Advanced Polymer Composites - A Review Abliz, Dilmurat; Duan, Yugang; Steuernagel, Leif Polymers and Polymer Composites, Vol. 21, Issue 6 https://doi.org/10.1177/096739111302100602	journal	July 2013
Mechanical Response and Fracture of Pultruded Carbon Fiber/Epoxy in Various Modes of Loading Bussiba, Arie; Gilad, Ilan; Lugassi, Snir Crystals, Vol. 12, Issue 6, p. 850 https://doi.org/10.3390/cryst12060850	journal	June 2022
A Novel Route to Fabricate High-Performance 3D Printed Continuous Fiber-Reinforced Thermosetting Polymer Composites Ming, Yueke; Duan, Yugang; Wang, Ben Materials, Vol. 12, Issue 9 https://doi.org/10.3390/ma12091369	journal	April 2019

Similar Records

Frontal Polymerization of Dihydrofuran Comonomer Facilitates Thermoset Deconstruction

Journal Article · 2022 · Chemistry of Materials · OSTI ID:2370403

Davydovich, Oleg; Paul, Justine E.; Feist, John David; +7 more

Adaptive Data-Driven Deep-Learning Surrogate Model for Frontal Polymerization in Dicyclopentadiene

Journal Article · 2024 · Journal of Physical Chemistry. B · OSTI ID:2341317

Liu, Qibang; Abueidda, Diab; Vyas, Sagar; +3 more

Active light-controlled frontal ring-opening metathesis polymerization

Journal Article · 2025 · Nature Communications · OSTI ID:2585532

Darby, Daniel Richard; Greenlee, Andrew James; Bean, Ren Harrison; +8 more

Related Subjects

36 MATERIALS SCIENCE
Additive manufacturing
Continuous fiber composites
Dicyclopentadiene
Frontal polymerization
Homogenized thermo-chemical model
Reactive extrusion
Thermoset

Title: Reactive extrusion of frontally polymerizing continuous carbon fiber reinforced polymer composites

Citation Formats

References (48)

Similar Records

Related Subjects