Consul Patrick, Feuchtgruber Matthias, Bauer Bernhard, Drechsler Klaus
Chair of Carbon Composites, Department of Aerospace and Geodesy, Technical University of Munich, 85748 Garching, Germany.
Polymers (Basel). 2024 Aug 21;16(16):2364. doi: 10.3390/polym16162364.
Additive Manufacturing (AM) enables the automated production of complex geometries with low waste and lead time, notably through Material Extrusion (MEX). This study explores Large Format Additive Manufacturing (LFAM) with carbon fiber-reinforced polyaryletherketones (PAEK), particularly a slow crystallizing grade by Victrex. The research investigates how extrusion parameters affect the mechanical properties of the printed parts. Key parameters include line width, layer height, layer time, and extrusion temperature, analyzed through a series of controlled experiments. Thermal history during printing, including cooling rates and substrate temperatures, was monitored using thermocouples and infrared cameras. The crystallization behavior of PAEK was replicated in a Differential Scanning Calorimetry (DSC) setup. Mechanical properties were evaluated using three-point bending tests to analyze the impact of thermal conditions at the deposition interface on interlayer bonding and overall part strength. The study suggests aggregated metrics, enthalpy deposition rate and shear rate under the nozzle, that should be maximized to enhance mechanical performance. The findings show that the common practice of setting fixed layer times falls short of ensuring repeatable part quality.
增材制造（AM）能够以低浪费和短交付周期自动生产复杂几何形状的部件，特别是通过材料挤出（MEX）工艺。本研究探索了采用碳纤维增强聚芳醚酮（PAEK）的大幅面增材制造（LFAM），尤其是威格斯公司生产的一种结晶缓慢的牌号。该研究调查了挤出参数如何影响打印部件的机械性能。关键参数包括线宽、层高、层打印时间和挤出温度，并通过一系列控制实验进行分析。打印过程中的热历史，包括冷却速率和基板温度，使用热电偶和红外热像仪进行监测。PAEK的结晶行为在差示扫描量热法（DSC）装置中进行复现。使用三点弯曲试验评估机械性能，以分析沉积界面处的热条件对层间粘结和整体部件强度的影响。该研究提出了综合指标，即喷嘴下方的焓沉积速率和剪切速率，应将其最大化以提高机械性能。研究结果表明，设定固定层打印时间的常规做法不足以确保部件质量的可重复性。
