Session: 01-01 Polymers: Characterization and Mechanical Properties I

Paper Number: 88941

88941 - Influence of Matrix Material on Impact Properties of Chopped Carbon Fiber-Thermoplastic Composites Made Using Fdm/fff 

One of the most important 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, two different sample thicknesses (3.2 mm and 10 mm according to ASTM D256) were tested in the Type A (notch in tension) and Type E (notch in compression) configurations using a standard IZOD machine manufactured by Tinius Olsen. 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 produced from the same filament as the main samples and non-CCF PLA, PA, PC, ABS, and PETG processed by FDM/FFF. An evaluation of the possible influence of the volume fraction of carbon fibers was done as well. The results show a clear influence in the choice of matrix material. It is expected that this study will provide useful insight for designers considering using CCF polymer matrix composites fabricated using FDM/FFF and other methods.  

Presenting Author: Albert E. Patterson Texas A&M University

Presenting Author Biography: Dr. Albert E. Patterson is an Assistant Professor of Manufacturing and Mechanical Engineering Technology in the Department of Engineering Technology and Industrial Distribution, with a courtesy appointment in the Department of Mechanical Engineering, at Texas A&M University. He is the director of the TAMU Manufacturability-Driven Design Lab (MDDL) and related research group. He holds a PhD in Industrial Engineering (Manufacturing and Design) from the University of Illinois at Urbana-Champaign, as well as degrees in Mechanical and Industrial Engineering from the University of Alabama in Huntsville. He has more than 8 years of experience with additive manufacturing (AM) and has over 40 publications on AM, fracture mechanics, design-for-manufacturing, engineering design, systems engineering/autonomous construction systems, and related topics. Dr. Patterson has been a member of ASME for more than 10 years and is an active member of the ASTM committees on AM and fatigue/fracture mechanics. Prior to obtaining his doctorate, he worked for several years as a practicing engineer/analyst with Boeing and the US Department of Defense (Missile Defense Agency).

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