Integrated manufacturing and performance study of continuous functionally graded materials-structures based on multi-material 3D printing and constraint sacrifice layer
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摘要: 针对现有功能梯度材料制备技术存在低黏度液体难以精准控形、层间结合强度差、成形结构单一等方面的不足和局限性，提出了一种基于多材料3D打印和约束牺牲层连续功能梯度材料-结构一体化制造新工艺，实现了聚合物基连续功能梯度材料的全新制备。通过理论分析和实验研究，揭示了挤出速度、打印速度、线间距等主要工艺参数对打印连续功能梯度材料质量和性能的影响规律。利用自主搭建的实验装置制备的石墨烯/光敏树脂介电功能梯度材料(d-FGM)，实现了聚合物基连续功能梯度绝缘子的一体化制造，与均质光敏树脂相比，介电常数增加了1倍，电阻率降低了93.3%，沿面电场强度提升幅值超过了14%。Al2O3/聚二甲基硅氧烷（Al2O3/PDMS）连续变刚度功能梯度材料，相较于单一PDMS材料，质量分数为40wt%的Al2O3一侧刚度增加了1倍，实现了Al2O3粉末的连续梯度分布。该3D打印工艺为聚合物基连续功能梯度材料的制备提供了一种低成本、高效率的解决方案。Abstract: An integrated manufacturing of continuous functionally graded materials-structures based on multi-material 3D printing and constrained sacrificial layer was proposed to solve the limitations of the existing functionally graded material preparation methods, such as difficult to control the shape of low-viscosity liquids accurately, poor interlayer bonding strength, and simple forming structure. This technology is capable of realizing the brand-new preparation of polymer-based continuous functionally graded materials. Through theoretical analysis and experimental investigation, the influence law of main process parameters including extrusion speed, printing speed and line spacing, on the forming quality and performance of printing continuous functionally graded materials are revealed. Graphene/UV curable resin dielectric functionally graded material (d-FGM) were prepared by using lab self-developed device, and realizing the integrated manufacturing of polymer-based continuous functionally graded insulators. Compared with the homogeneous UV curable resin, the dielectric constant has doubled, the resistivity has been reduced by 93.3%, and the amplitude of the creeping electric field strength has increased by more than 14%. Besides, the rigidity of the Al2O3 side with 40% content has doubled than a single polydimethylsiloxane (PDMS) material. With the features of realizing the continuous gradient distribution of the Al2O3. The 3D printing process provides a low-cost and high-efficiency solution for the preparation of polymer-based continuous functionally graded materials.
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图 1 （a） 3D打印系统示意图；（b）工作原理图；（c）被动混合内部结构；（d）混合过程
Figure 1. (a) Sketch of 3D printing system; (b) Working principle diagram; (c) Passive mixing internal structure; (d) Mixing process
图 3 挤出速度对打印层厚的影响及规律：(a) 聚二甲基硅氧烷（PDMS）；(b)光敏树脂
Figure 3. Influence of extrusion speed on layer thickness: (a) Polydimethylsiloxane (PDMS); (b) UV curable resin
图 4 打印速度对打印层厚的影响及规律：(a) PDMS；(b)光敏树脂
Figure 4. Influence of printing speed on layer thickness: (a) PDMS; (b) UV curable resin
图 5 线间距对打印层厚的影响及规律：(a) PDMS；(b)光敏树脂
Figure 5. Influence of line spacing on layer thickness: (a) PDMS; (b) UV curable resin
图 6 石墨烯/光敏树脂介电功能梯度材料 (d-FGM)：(a)圆台；(b)圆台截面图
Figure 6. Graphene/UV curable resin dielectric functionally graded material (d-FGM): (a) Round table; (b) Sectional view of round table
图 7 石墨烯/光敏树脂d-FGM中不同石墨烯含量的介电性能变化及其规律：(a)介电常数；(b)电阻率
Figure 7. Dielectric properties of different graphene content in graphene/UV curable resin d-FGM: (a) Dielectric constant; (b) Resistivity
图 8 石墨烯/光敏树脂介电功能梯度材料在不同电场强度的闪络概率变化：(a)交流电压；(b)直流电压
Figure 8. Variation of flashover probability with different electric field intensity for graphene/UV curable resin d-FGM: (a) AC voltage; (b) DC voltage
图 9 Al2O3/PDMS变刚度FGM：(a)三维构件；(b)构件截面
Figure 9. Al2O3/PDMS variable stiffness FGM: (a) Three-dimensional components; (b) Sectional view of component
图 10 Al2O3/PDMS功能梯度材料中Al元素分布图(亮点代表Al) (a) 及不同浓度的硬度变化及其规律 (b)
Figure 10. Distribution of Al elements (bright spots represent Al) (a) and hardness changes at different concentrations (b) for Al2O3/PDMS functionally graded material
表 1 材料组分变化
Table 1. Change of material composition
No. Feeding speed ratio (RI∶RII) 1 RI=15 r/min 2 RI∶RII=4∶1 3 RI∶RII=3∶2 4 RI∶RII=2∶3 5 RI∶RII=1∶4 6 RI=0 r/min Notes: RI—Speed of feeding module I; RII—Speed of feeding module II. 
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表 2 Al2O3/PDMS功能梯度材料层间拉伸对比实验数据
Table 2. Experimental data of interlayer tensile for Al2O3/PDMS functionally graded material
No. Single-layer one-step curing Single-layer two-step curing Max load/N Interlaminar tensile strength/MPa Max load/N Interlaminar tensile strength/MPa 1 256.8 0.642 462.4 1.156 2 247.2 0.618 456.3 1.141 3 229.2 0.573 451.6 1.129 4 220.4 0.551 445.2 1.113 5 210.4 0.526 438.8 1.097 6 119.2 0.498 432.8 1.082
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