连续纤维增强聚合物复合材料增材制造工艺研究进展

邢悦; 何鹏飞; 李竞龙; 王荣; 陈永雄; 梁秀兵

doi:10.13801/j.cnki.fhclxb.20230224.001

连续纤维增强聚合物复合材料增材制造工艺研究进展

doi: 10.13801/j.cnki.fhclxb.20230224.001

军事科学院国防科技创新研究院，北京 100071

详细信息

通讯作者:
梁秀兵，博士，研究员，博士生导师，研究方向为极端环境新材料　E-mail: liangxb_d@163.com

中图分类号: V258；TB332
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- 文章访问数: 255
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- 被引次数: 0
出版历程
- 收稿日期: 2022-12-07
- 修回日期: 2023-01-19
- 录用日期: 2023-02-19
- 网络出版日期: 2023-02-27

Additive manufacturing for continuous fiber-reinforced polymer composites: A review on processing technique

National Innovation Institute of Defense Technology, Academy of Military Sciences, Beijing 100071, China

摘要

摘要: 近年来，连续纤维增强聚合物复合材料的相关研究已成为材料领域的关注热点，相比于金属、陶瓷等结构材料，其具有更高的设计性、比强度、断裂韧性、疲劳寿命和耐腐蚀特性，在航空航天、轨道交通、风电能源、机械工业等领域具有广阔的应用前景。连续纤维增强聚合物复合材料与增材制造技术的有机结合对于高端装备的轻量化、结构功能一体化制造具有重要意义。文针对连续纤维复材增材制造过程中的挤出与浸渍方式、打印温度、辅助工艺、打印速度、打印间距、几何构建方式等工艺研究的国内外最新进展情况进行了全面的综述，着重论述了各工艺参数对成形件性能的影响，并对目前面临的挑战和未来发展进行展望。1CFRPCs增材制造的要素及应用领域
- 连续纤维增强聚合物复合材料 /
- 增材制造 /
- 工艺参数 /
- 力学性能
Abstract: Compared with metal, ceramic or other structural materials, continuous fiber-reinforced polymer composites can offer significant advantage for their excellent design tailorability, mechanical properties, fracture toughness, good resistance to corrosion and fatigue, and are widely used in aerospace, transportation, energy, machinery and other fields. The organic combination of continuous fiber-reinforced polymer composites and additive manufacturing technology has the potential to promote new revolution for weight saving and structure-function integrated manufacturing of high-end equipment. This paper reviewed the recent research progress of extrusion and impregnation methods, printing temperature, auxiliary process, printing speed, printing spacing and geometric construction methods in additive manufacturing of continuous fiber composites. The influence of various process parameters on properties of the formed parts was emphatically discussed. Finally, the present challenges and future development directions have been prospected for reference.
- continuous fiber reinforced polymer composites /
- additive manufacturing /
- process parameter /
- mechanical property

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图 1 连续纤维增强聚合物复合材料(CFRPCs)增材制造的要素及应用领域

Figure 1. Element and application fields of additive manufacturing for continuousfiber reinforced polymer composites (CFRPCs)

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图 2 CFRPCs打印头原理示意图：(a) 共挤出方式；(b) 双挤出方式^[17]

Figure 2. Mechanism of CFRPCs printer: (a) Co-extrusion process; (b) Dua-extrusion process^[17]

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图 3 CFRPCs增材制造主要共挤出方式示意图^[49]

Figure 3. Schematic diagram of main co-extrusion methods for additive manufacturing of CFRPCs^[49]

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图 4 (a) 连续纤维在线浸渍增材制造工艺示意图；(b) 打印过程实物图^[7]

Figure 4. (a) Schematic of the 3D printer head using in-nozzle impregnation; (b) Photograph of the 3D printing process^[7]

FRTP—Fiber-reinforced thermoplastic

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图 5 (a) 离线浸渍后连续纤维增材制造示意图^[56]；(b) 溶液预浸渍碳纤维束示意图^[57]；(c) 连续纤维浸渍工艺线示意图^[58]；(d) 基于微螺杆原位挤压的连续纤维增强复合材料增材制造原理图^[59]；(e) 预浸渍连续纤维复合材料截面图^[63]

Figure 5. (a) Schematic of the 3D printer head using of pre-impregnated continuous fiber composite filament^[56]; (b) Schematic of surface preparation^[57]; (c) Schematic image of the CFRTP filament impregnation line^[58]; (d) Schematic of micro-screw in-situ extrusion based 3D printed continuous fiber reinforced composites^[59]; (e) Schematic of interface enhancement mechanism^[63]

PVA—Polyvinyl alcohol; l—Length; h—Height; α—Angle; w—Width; L—Layer thickness; H—Hatch spacing; D—Die diameter; θ—Angle; PA6—Polyamides 6; PA845H—Polyamides 845H; CFRTP—Continuous fifiber reinforced thermoplastic

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图 6 (a) 打印温度对CCF/PLA复合材料制件弯曲性能的影响；((b)、(d)) 180℃成形件的断裂截面微观形貌；((c)、(e)) 240℃成形件的断裂截面微观形貌；((f)、(g)) 180℃与240℃成形件的断裂截面宏观形貌^[53]

Figure 6. (a) Influence of temperature in liquefier on the flexural strength and modulus of the 3D printed CCF/PLA composites; ((b), (d)) Microstructures of fractured cross section with temperature in the printing head of 180℃; ((c), (e)) Microstructures of fractured cross section with temperature in the printing head of 240℃; ((f), (g)) Fracture pattern with temperature in the printing head of 180℃ and 240℃, respectively^[53]

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图 7 (a) 不同打印温度下玻纤/PLA复材样条实物图^[64]；(b) 2×2线材截面传热分析图(1、2为已沉积层，3为正在沉积单丝，4为后续即将沉积位置)^[65]

Figure 7. (a) Photograph of CGF/PLA in different printing temperatures^[64]; (b) Heat transfer analysis for a two-by-two bead geometry(1,2-printed, 3-printing, 4-may print)^[65]

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图 8 CCF/PEEK复合材料增材成形过程中：(a) 层间温度差导致结合弱示意图；(b) 无激光辅助预热层间键合示意图；(c) 有激光辅助预热层间键合示意图^[69]

Figure 8. 3D printed CCF/PEEK composites: (a) Diagram of weak interlayer bonding because of low temperature of printed layer; (b) Diagram of interlayer bonding during extrusion without laser assistance; (c) Diagram of interlayer bonding during extrusion with laser assistance^[69]

T_g—Glass transition temperature

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图 9 (a) 激光辅助加热工艺^[70]；(b) 等离子体辅助浸渍工艺^[71]；(c) 微波辅助加热工艺^[73]；(d) 热压实辊辅助工艺^[75]

Figure 9. (a) Schematic illustration of the laser-assisted printer system^[70]; (b) Plasma-assisted preparation of CCF^[71]; (c) Schematic diagram of the 3D microwave printing process^[73]; (d) Schematic image of the 3D compaction printer head^[75]

CCFRP—Continuous carbon fiber reinforced plastics

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图 10 (a) CGF/PLA复材在不同打印速度下成形的力学强度和试样实物图^[79]；(b) 上浆碳纤维(SCF)/PA复材在不同打印速度下成形的弯曲性能和试样实物图^[63]；(c)复材在不同打印速度下成形的弯曲性能和内部结构微观形貌^[60]

Figure 10. (a) Effect of printing speed on the properties of printed CGF/PLA composites and printed samples^[79]; (b) Effect of printing speed on the flexural properties of printed sized carbon fiber (SCF)/PA composites and printed samples^[63]; (c) Effect of printing speed on the flexural properties of printed composites and micro morphology of internal structures after curing^[60]

VCF/PA6—Virgin carbon fiber (VCF) reinforced PA6; E70—Feed rate of filament (70 mm/min); V—Printing speed

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图 11 (a)纤维取向排列示意图^[69]；CCF/PLA弯曲强度与工艺参数关系的三维曲面图(b)与数据表(c)^[87]

Figure 11. (a) Diagram of fibre orientation^[69]; 3D surface graphs (b) and data table (c) of relationship between flexural strength and printing parameters (printing temperature, printing speed, and layer thickness)^[87]

D—Inner line spacing; H—Thickness between adjacent layers

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图 12 (a) 打印喷嘴结构图；(b) CGF/PLA复材经不同内径喷嘴(1.0 mm、1.2 mm、1.5 mm、2.0 mm)成形的力学强度； CGF/PLA复材在不同层厚条件下成形的力学强度(c)与断裂截面SEM图像(d)^[79]

Figure 12. (a) Scheme of the nozzle and its internal structure; (b) Mechanical strength of printed CGF/PLA composites with different nozzle diameters (1.0 mm, 1.2 mm, 1.5 mm, 2.0 mm); (c) Mechanical strength of printed CGF/PLA composites with different layer thickness; (d) SEM of fractured cross section^[79]

b—Nozzle edge width; d—Nozzle diameter

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图 13 (a) 复合材料增材成形构建方向示意图^[90]；(b) 螺栓连接件打印路径优化示意图^[98]；(c) L型托架样件拓扑结构与打印路径优化过程及仿真示意图^[103]；(d) 不同芯型夹层结构实物图^[26]；(e) 超轻承重结构件实物图^[108]；(f) 独立式网架构件实物图^[111]

Figure 13. (a) Scheme of CFRPCs printing orientation^[90]; (b) Schematic for the optimization of the fiber trajectories^[98]; (c) Graphical summary of the topology and fiber paths design for L-shaped bracket CFRPCs^[103]; (d) Photos of various printed core shapes^[26]; (e) Photos of ultralightweight load-bearing structures^[108]; (f) Photos of printed free-standing lattice truss^[111]

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表 1 连续纤维复材增材制造典型材料及其性能特征^{[18, 21, 31, 39-41]}

Table 1. Materials used for continuous filament fabrication and properties^{[18, 21, 31, 39-41]}

Material	Property
Matrix	Density/ (g·cm⁻³)	Printing temperature/℃	Tensile modulus/GPa	Flexural modulus/GPa
PA	1.1	235-260	0.94	0.84
PLA	1.25	190-210	2.02	2.392
ABS	1.04	210-250	0.998	1.9
PP	0.92	230-260	1.1-1.6	1.2-1.6
PEEK	1.3	360-450	3.5-3.9	3.7-4.0
Continuous fiber	Density/ (g·cm⁻³)	Diameter/ cm (Number of mono filaments, diameter)	Tensile modulus/GPa	Flexural modulus/GPa
Carbon (CCF)	1.4/1.3	0.4(1000, 0.01)	54	51
Glass (CGF)	1.5	0.3(1000, 0.01)	21	22
Kevlar (CKF)	1.2	0.3(1000, 0.012)	27	26
Notes: PA—Polyamides; PLA—Polylactic acid; ABS—Acrylonitrile-butadiene-styrene copolymer; PP—Polypropylene; PEEK—Polyether ether ketone; CCF—Continuous carbon fiber; CGF—Continuous glass fiber; CKF—Continuous Kevlar fiber.

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