Preparation and properties of 3D printing continuous fiber reinforced polycarbonate composite prepreg filaments
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摘要:
连续纤维增强热塑性复合材料具有强度高、可设计性强和抗冲击等优点，成为当下研究的热点。但由于热塑性树脂黏度大，成形过程中的压力小，导致复合材料孔隙率偏大，力学性能不佳。本文通过熔融浸渍制备连续纤维增强聚碳酸酯预浸丝，相比于原位浸渍，解决了打印过程中树脂浸入纤维束阻力大，复合材料孔隙率偏高的问题，探究了熔融浸渍工艺对预浸丝性能的影响，分析了工艺参数、纤维含量和孔隙率三者之间的关系。碳纤维和玻璃纤维表面涂有热塑性上浆剂，能加速树脂与纤维界面结合。因此，制备的连续碳纤维和玻璃纤维增强聚碳酸酯复合材料拉伸强度分别为644.8 MPa和381.4 MPa，复合材料内部孔隙明显减少。 图1 为不同浸渍温度对预浸丝的拉伸性能影响，图2 为连续碳纤维和玻璃纤维增强复合材料的内部孔隙特征。不同浸渍温度对预浸丝拉伸性能 连续纤维增强聚碳酸酯内部孔隙结构：碳纤维增强聚碳酸酯(a)玻璃纤维增强聚碳酸酯(b) Abstract: To reduce the porosity of 3D printing continuous fiber reinforced polymer (CFRP) composites and improve the degree of resin impregnation on fibers, it is of great necessity to conduct research on the preparation and 3D printing performance of melt-impregnated continuous fiber prepreg filaments, as well as develop integrated fiber prepreg equipment. With glass fiber (GF) and carbon fiber (CF) as reinforcement, and polycarbonate (PC) as matrix, this study aims to develop a melt-impregnated prepreg wire preparation process and study the influence of the impregnation process on prepreg wire properties. Besides, using prepreg yarn as the raw material, this study is aimed at studying the effect of 3D printing forming process parameters on the fiber content, porosity and mechanical properties as well. The results indicated that when the tensile strength of continuous glass fiber reinforced polycarbonate (CGF/PC) prepreg filament was 627.8 MPa, the printing temperature was 260°C, the layering thickness was 0.10 mm, the scan spacing was 1.0 mm, the fiber content of continuous carbon fiber reinforced polycarbonate (CCF/PC) composite was 28.66vol%, the tensile strength and modulus were respectively 644.8 MPa and 85.6 GPa, and the optimized porosity was 3.87%. When the printing temperature was 280°C, the layering thickness was 0.14 mm, and the scan spacing was 1.2 mm, the fiber content of continuous glass fiber reinforced polycarbonate (CGF/PC) composite turned out to be 51.35vol%, the tensile strength and modulus were respectively 381.4 MPa and 23.6 GPa, and the optimized porosity was 4.41%.-
Key words:
- continuous fiber /
- polycarbonate /
- porosity /
- prepreg wire /
- mechanical properties /
- 3 D printing
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图 1 纤维预浸丝熔融浸渍原理: (a)熔融浸渍设备实物图(b)
Figure 1. Fig. 1 Principle of melt impregnation of fiber prepreg yarn: (a) Physical diagram of melt impregnation equipment (b)
图 2 拉伸试样:(a)CCF/PC;(b)连续玻璃纤维增强聚碳酸酯(CGF/PC)
Figure 2. Tensile specimens: (a)CCF/PC; (b) continuous glass fiber reinforced polycarbonate (CGF/PC)
图 3 不同浸渍温度对CGF/PC预浸丝拉伸性能影响
Figure 3. Effect of different impregnation temperatures on the tensile properties of CGF/PC prepreg wires
图 4 不同牵引速度对CGF/PC预浸丝拉伸性能影响
Figure 4. Effect of different traction speeds on the tensile properties of CGF/PC prepreg wirer
图 5 不同牵引速度的CGF/PC预浸丝微观形貌
Figure 5. Microscopic morphology of CGF/PC prepreg wire with different traction speeds
图 6 不同进给速率对CGF/PC预浸丝拉伸性能影响
Figure 6. Effect of different feed rates on the tensile properties of CGF/PC prepreg wire
图 7 分层厚度对CCF/PC(a)和CGF/PC(b)复合材料拉伸性能影响
Figure 7. Effect of delamination thickness on tensile properties of CCF/PC (a) and CGF/PC (b) composite
图 8 CCF/PC复合材料纤维线间结合及搭接示意图
Figure 8. Schematic diagram of CCF/PC the bond and lap between fiber threads
图 9 扫描间距对CCF/PC(a)和CGF/PC(b)复合材料拉伸性能影响
Figure 9. Effect of scan spacing on tensile properties of CCF/PC (a) and CGF/PC (b) composites
图 10 打印温度对CCF/PC(a)和CGF/PC(b)复合材料拉伸性能影响
Figure 10. Effect of printing temperature on tensile properties of CCF/PC (a) and CGF/PC (b) composites
图 11 CCF/PC复合材料内部孔隙结构：(a)分层厚度0.10，(b)分层厚度0.16，(c)扫描间距0.8，(d)扫描距1.2；CGF/PC复合材料内部孔隙结构扫描间距: (e)分层厚度0.14，(f)分层厚度0.20，(g)扫描间距1.0，(h)扫描间距1.4
Figure 11. Internal pore structure of CCF/PC composites: (a)layered thickness 0.10, (b)layered thickness 0.16, (c)scan spacing 0.8, (d)scan spacing 1.4; Internal pore structure of CGF/PC composites scan spacing: (e)layered thickness 0.14, (f)layered thickness 0.20, (g)scan spacing 1.0, (h)scan spacing 1.4
图 12 CCF/PC微观形貌: (a)扫描间距0.8; (b)扫描间距1.0; (c)扫描间距1.2;CGF/PC复合材料微观形貌: (e)扫描间距1.0; (f)扫描间距1.2:(g)扫描间距1.4
Figure 12. CCF/PC microstructure: (a)scan spacing 0.8; (b) scan spacing 1.0; (c) scan spacing 1.2; CGF/PC composite microstructure: (e) scan spacing 1.0; (f) scan spacing 1.2: (g) scan spacing 1.4
图 13 CCF/PC复合材料断面微观形貌：(a)分层厚度0.10，(b)分层厚度0.16，(c)扫描间距0.8，(d)扫描距1.2
Figure 13. Microscopic morphology of CCF/PC composite cross-section: (a)layered thickness 0.10, (b)layered thickness 0.16, (c)scan spacing 0.8, (d)scan spacing 1.4
图 14 CGF/PC复合材料断面微观形貌: (a)分层厚度0.14, (b)分层厚度0.20, (c)扫描间距1.0, (d)扫描间距1.4
Figure 14. Microscopic morphology of CGF/PC composite section: (a) delamination thickness 0.14, (b)delamination thickness 0.20, (c)scan spacing1.0, (d)scan spacing 1.4
表 1 连续碳纤维增强聚碳酸酯(CCF/PC)预浸丝的制备工艺参数
Table 1. Preparation process parameters of continuous carbon fiber reinforced polycarbonate (CCF/PC) prepreg
Main process parameters Range of values Resin feed rate(E)/(r∙min−1) 4.0 Traction speed(U)/( mm∙min−1) 500 Impregnation temperature(t)/ ℃ 260 
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表 2 CGF预浸丝的制备工艺参数
Table 2. Preparation process parameters of CGF prepre
Main process parameters Range of values Other process parameters Resin feed rate(E)/(r∙min−1) 2.0，3.0，4.0，5.0 U300，t270 Traction speed(U)/(mm∙min−1) 100，300，500，700，800 E3.0，t270 Impregnation temperature (t)/℃ 240，250，270，290 E3.0，U300
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表 3 CCF/PC成形工艺参数
Table 3. CCF/PC molding process parameters
Main process parameters Range of values Other process parameters Layering thickness(H)/ mm 0.10，0.13，0.16 S1.0，T260 Scan spacing(S)/ mm 0.8，1.0，1.2 H0.13，T260 Print temperature(T)/℃ 240，260，280 H0.13，S1.0
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表 4 CGF/PC成形工艺参数
Table 4. CGF/PC molding process parameters
Main process parameters Range of values Other process parameters Layering thickness(H)/mm 0.14，0.17，0.20 S1.2，T280 Scan spacing(S)/mm 1.0，1.2，1.4 H0.17，T280 Print temperature(T)/℃ 270，280，290 H0.17，S1.2
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表 5 不同温度下PC熔融指数(MFR)
Table 5. Melt index of PC at different temperatures (MFR)
Temperature/℃ 250 270 290 MFR/(g/10 min) 5.13 10.20 25.63
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表 6 不同工艺参数的CCF/PC复合材料纤维含量
Table 6. Fiber content of CCF/PC composites with different process parameters
Process Parameters Fiber Content/vol% Constants/ mm Variables/ mm S 1.0 H 0.10 28.66 H 0.13 26.78 H 0.16 23.57 H 0.13 S 0.8 28.62 S 1.0 26.78 S 1.2 25.18
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表 7 不同工艺参数的CGF/PC复合材料纤维含量
Table 7. Fiber content of CGF/PC composites with different process parameters
Process Parameters Fiber Content/vol% Constants/ mm Variables/ mm S 1.2 H0.14 51.35 H0.17 46.87 H 0.20 43.93 H0.17 S 1.0 50.95 S 1.2 46.87 S 1.4 40.84
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表 8 不同工艺参数对应的CCF/PC复合材料孔隙率
Table 8. Porosity of CCF/PC composites corresponding to different process parameters
Process Parameters Porosity% Constants/mm Variables/mm S1.0 H 0.10 3.87 H 0.13 8.64 H 0.16 8.76 H 0.13 S 0.8 7.29 S 1.0 8.64 S 1.2 14.22
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表 9 不同工艺参数对应的CGF/PC复合材料孔隙率
Table 9. Porosity of CGF/PC composites corresponding to different process parameters
Process Parameters Porosity/% Constants/mm Variables/mm S 1.2 H 0.14 4.41 H 0.17 5.24 H 0.20 5.56 H 0.17 S 1.0 6.45 S 1.2 5.24 S 1.4 14.44
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