Structure and Properties of Additive Manufactured Polymer Components (Woodhead Publishing Series in Composites Science and Engineering)

431 Pages·2020·13.759 MB·English

by  Klaus Friedrich (editor), Rolf Walter (editor)

Woodhead Publishing Series in Composites
Science and Engineering
Structure and Properties
of Additive Manufactured
Polymer Components
Edited by
Klaus Friedrich
Rolf Walter
Editor-in-Chief
Constantinos Soutis
Series Editor
Suresh G Advani
Ing. Habil. Bodo Fiedler
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Contributors
Laurent Adam e-Xstream engineering, a Hexagon/MSC Software company
Vladislav O. Aleksenko Lab. of Mechanics of Polymer Composite Materials, Institute
of Strength Physics and Materials Science, Tomsk, Russia
Eduardo Barocio Composites Manufacturing and Simulation Center, Purdue
University, West Lafayette, IN, United States
Svetlana A. Bochkareva Lab. of Mechanics of Polymer Composite Materials,
Institute of Strength Physics and Materials Science, Tomsk; Department
of Mechanics and Graphics, Tomsk State University of Control Systems and
Radioelectronics, Tomsk, Russia
Michael Bogdanor Composites Manufacturing and Simulation Center, Purdue
University, West Lafayette, IN, United States
Bastian Brenken CFK Valley e.V. Ottenbecker Damm 12, Stade, Germany
Dmitry G. Buslovich Lab. of Mechanics of Polymer Composite Materials, Institute
of Strength Physics and Materials Science, Tomsk; Department of Materials Science,
Engineering School of Advanced Manufacturing Technologies, National Research
Tomsk Polytechnic University, Tomsk, Russia
Li Chang Centre for Advanced Materials Technology, School of Aerospace,
Mechanical and Mechatronic Engineering, The University of Sydney, Sydney, NSW,
Australia
Issam Doghri e-Xstream engineering, a Hexagon/MSC Software company;
Université catholique de Louvain, institute of Mechanics, Materials and Civil
Engineering (iMMC), Louvain-la-Neuve, Belgium
Matthias Domm IVW, Kaiserslautern, Germany
Yuri V. Dontsov Lab. of Mechanics of Polymer Composite Materials, Institute of
Strength Physics and Materials Science, Tomsk; Department of Materials Science,
Engineering School of Advanced Manufacturing Technologies, National Research
Tomsk Polytechnic University, Tomsk, Russia
Sithiprumnea Dul Department of Industrial Engineering, University of Trento,
Trento, Italy
Luca Fambri Department of Industrial Engineering, University of Trento, Trento,
Italy
xiii
xiv Contributors
Anthony Favaloro Composites Manufacturing and Simulation Center, Purdue
University, West Lafayette, IN, United States
Guoxia Fei State Key Laboratory of Polymer Materials Engineering, Polymer
Research Institute, Sichuan University, Chengdu, China
Klaus Friedrich Institute for Composite Materials (IVW GmbH), Technical
University Kaiserslautern, Kaiserslautern, Germany
Xinpeng Gan State Key Laboratory of Polymer Materials Engineering, Polymer
Research Institute, Sichuan University, Chengdu, China
Julien Gardan ICD/LASMIS, University of Technology of Troyes, Troyes;
EPF, Engineering School, Rosieres-Pres-Troyes, France
Xia Gao Chongqing Institute of Green and Intelligent Technology,
Chinese Academy of Sciences, Chongqing; Chongqing Engineering
Research Center of Application Technology for 3D Printing, Chongqing, China
Mehrdad N. Ghasemi Nejhad Department of Mechanical Engineering, University of
Hawaii at Manoa, Honolulu, HI, United States
Yves Grohens University Bretagne Sud, Lorient, France
Martin Gurka Institute for Composite Materials (IVW GmbH), Technical University
Kaiserslautern, Kaiserslautern, Germany
Qinghao He Centre for Advanced Materials Technology, School of Aerospace,
Mechanical and Mechatronic Engineering, The University of Sydney, Sydney, NSW,
Australia
Jemy James International and Inter University Centre for Nanoscience and
Nanotechnology, Mahatma Gandhi University, Kottayam, Kerala, India; University
Bretagne Sud, Lorient, France
Xin Jia School of Chemistry and Chemical Engineering, Shihezi University, Shihezi,
China
Blessy Joseph International and Inter University Centre for Nanoscience and
Nanotechnology, Mahatma Gandhi University, Kottayam, Kerala, India
Nandakumar Kalarikkal International and Inter University Centre for Nanoscience
and Nanotechnology, Mahatma Gandhi University, Kottayam, Kerala, India
Lyudmila A. Kornienko Lab. of Mechanics of Polymer Composite Materials, Institute
of Strength Physics and Materials Science, Tomsk, Russia
Vlastimil Kunc Materials Science and Technology Division, Oak Ridge National
Laboratory, Oak Ridge, TN; School of Aeronautics and Astronautics, Purdue
University, West Lafayette, IN, United States
Marino Lavorgna Institute for Polymer, Composites and Biomaterials, National
Research Council of Italy, Portici, Italy
Contributors xv
Jing Li Chongqing Institute of Green and Intelligent Technology, Chinese Academy
of Sciences, Chongqing; Chongqing Engineering Research Center of Application
Technology for 3D Printing, Chongqing, China
Olivier Lietaer e-Xstream engineering, a Hexagon/MSC Software company
Peng Liu Saint-Gobain Research North America, Northborough, MA, United States
Boris A. Lyukshin Lab. of Mechanics of Polymer Composite Materials, Institute
of Strength Physics and Materials Science, Tomsk; Department of Mechanics and
Graphics, Tomsk State University of Control Systems and Radioelectronics, Tomsk,
Russia
Ziyan Man Centre for Advanced Materials Technology, School of Aerospace,
Mechanical and Mechatronic Engineering, The University of Sydney, Sydney, NSW,
Australia
Sylvain Mathieu e-Xstream engineering, a Hexagon/MSC Software company
Sergey V. Panin Lab. of Mechanics of Polymer Composite Materials, Institute of
Strength Physics and Materials Science, Tomsk; Department of Materials Science,
Engineering School of Advanced Manufacturing Technologies, National Research
Tomsk Polytechnic University, Tomsk, Russia
Alessandro Pegoretti Department of Industrial Engineering, University of Trento,
Trento, Italy
R. Byron Pipes Composites Manufacturing and Simulation Center, Purdue University,
West Lafayette, IN, United States
Ralf Selzer igus® GmbH, Köln, Germany
Sergey V. Shilko Lab. of Mechanics of Composites and Biopolymers, Belyi Institute
of Mechanics of Metal–Polymer Systems, National Academy of Sciences of Belarus,
Gomel, Belarus
Sabu Thomas International and Inter University Centre for Nanoscience and
Nanotechnology, Mahatma Gandhi University, Kottayam, Kerala, India
Rolf Walter Institute for Composite Materials (IVW GmbH), Technical University
Kaiserslautern, Kaiserslautern, Germany
Jinzhi Wang State Key Laboratory of Polymer Materials Engineering, Polymer
Research Institute, Sichuan University, Chengdu, China
Xiaolong Wang State Key Laboratory of Solid Lubrication, Lanzhou Institute of
Chemical Physics, Chinese Academy of Sciences, Lanzhou; School of Chemistry and
Chemical Engineering, Shihezi University, Shihezi; Yiwu R&D Centre for Functional
Materials, LICP, CAS, Yiwu, China
Zhanhua Wang State Key Laboratory of Polymer Materials Engineering, Polymer
Research Institute, Sichuan University, Chengdu, China
xvi Contributors
Hesheng Xia State Key Laboratory of Polymer Materials Engineering, Polymer
Research Institute, Sichuan University, Chengdu, China; Institute for Polymer,
Composites and Biomaterials, National Research Council of Italy, Portici, Italy
Lin Ye Centre for Advanced Materials Technology, School of Aerospace, Mechanical
and Mechatronic Engineering, The University of Sydney, Sydney, NSW, Australia
Ning Yu Chongqing Institute of Green and Intelligent Technology, Chinese Academy
of Sciences, Chongqing; Chongqing Engineering Research Center of Application
Technology for 3D Printing, Chongqing, China
A Zachary Trimble Department of Mechanical Engineering, University of Hawaii at
Manoa, Honolulu, HI, United States
Xiaoqin Zhang State Key Laboratory of Solid Lubrication, Lanzhou Institute of
Chemical Physics, Chinese Academy of Sciences, Lanzhou, China
Foreword
Additive manufacturing (or 3D printing) represents a brand-new bottom-up,
scalable fabrication technology applicable to metals, ceramics, polymers, and
composites. In the past decade, the topic has received increasing attention,
which in turn greatly promotes its development speed. Meanwhile, there is con-
sensus that its advantages over traditional methods include freedom of design,
customizability, rapid prototyping, construction of complex geometries and
structures of products, and waste minimization. Quite a few challenges in the
aerospace, automotive, electronic, biomedical, and construction industries may
thus be overcome by using this revolutionary technology. Unlike most cases
where technological study lags behind scientific exploration, industries have
been involved in the research and commercialization of additive manufacturing
soon after its emergence because of the obvious economic benefit and brilliant
prospects. Accordingly, the conversion of research outcomes into marketable
products is remarkably expedited.
Polymer composites have benefited from additive manufacturing and vice
versa. Numerous innovative techniques have been proposed and implemented
in recent years, so that 3D printed products, either particulate filled or continu-
ous fiber reinforced polymer composite objects are available now. The book
on “Structure and Properties of Additive Manufactured Polymer Components,”
edited by Professor Klaus Friedrich and Mr. Rolf Walter, timely reflects the key
achievements in this area in a systematic way from an important angle. In other
words, the book offers an in-depth discussion about structure and properties of
the products of additive manufacturing, which deals with the core issues of the
ultimate performance of products in practical applications.
As can be seen from the table of contents, the editors have worked out a
clear framework of writing on the basis of frequently used additive manufactur-
ing processes, which determines the application-oriented thread of the book.
The contributions by various experts are reasonably arranged forming a united
whole. In addition to the general survey of the state-of-the-art, polymer-based
nanocomposites, discontinuous and continuous fibers composites made by a
series of 3D printing approaches like selective laser sintering (SLS), fused fila-
ment fabrication (FFF), and droplet ink writing (DIW) are carefully investigated
in correlation to the feedstock materials and processing parameters. Further-
more, the relationships between strength, modulus, toughness, and tribological
xvii
xviii Foreword
properties and microstructures are revealed in terms of experimental studies and
mechanical simulations.
Having gone through the book, readers will have a comprehensive image
of the field, while new researchers might have ideas for creating new materials
or even new techniques based on 3D printing. Audience in both academic and
industrial communities will be provided with a grasp of the progress to date and
an insight into the future growth.
I knew Professor Klaus Friedrich in the early 1990s when he visited our
university, and in the middle of the 1990s, I worked with him as a visiting scien-
tist at the Institute for Composite Materials (IVW) in Kaiserslautern, Germany.
Professor Klaus Friedrich is a world-famous materials scientist specializing in
composites. The most valuable thing that I learned from him is his spirit of
continuous exploration and innovation, which keeps him active in the latest
academic frontiers including 3D printing. I met the other editor, Dipl.-Ing Rolf
Walter, during my first stay at the IVW. He has been a long-time collaborator
of Klaus since their time at the Technical University of Hamburg-Harburg. His
German engineering skills have left a deep impression on me. In particular,
Rolf has a lot of experience in electrical measuring techniques, design and con-
struction of prototype apparatuses, and polymer processing. His specialties are
extrusion compounding of tribologically optimized polymer composites, and
in the past few years he has gained a lot of knowledge in the field of additive
manufacturing of polymeric components. In this context, the combination of
the two editors ensures an excellent balance between theoretical analyses and
experimental results of the book.
I would like to thank the authors from different countries for their collective
efforts, which ensures a very high quality of the book. It is hoped that they will
keep on achieving great success in this exciting field in the future. Besides, I
also wish that the publisher would be very successful with this new book.
Guangzhou, China, 28 September, 2019 Professor Ming Qiu Zhang
Key Laboratory for Polymeric Composite and
Functional Materials of Ministry of Education
School of Chemistry
Sun Yat-sen University
Guangzhou, China
Preface
This book is dedicated to the structure–property relationships of additive manu-
factured (AM) components out of polymeric materials. The major focus is put
on materials science aspects, that is, how the quality of the polymer preforms
(feedstock) and the parameters of the AM method chosen affect the microstruc-
ture and properties of the final product (Fig. 1).
Individual chapters of authors from different parts of the globe are orga-
nized according to various major sub-headings. The “Introduction” part 1
summarizes those chapters that first give an overview on the principles of vari-
ous AM-methods. The chapter of the French scientist J. Gardan (University of
Technology of Troyes) on “Additive Manufacturing Technologies for Polymer
Composites: State of the Art and Future Trends” gives an overview of addi-
tive manufacturing technologies, with specific attention focused on components
made of polymer composites. Two important principles are used to make the
components, Material Extrusion and Vat Photopolymerization. New trends are
exposed to understand the chosen orientations through a few applications. A.
Pegoretti and his team from Trento, Italy, concentrates on the “Development of
New Nanocomposites for 3D Printing Applications.” In this chapter, the state of
the art of the use of polymeric nanocomposites in AM will be reviewed. Vari-
ous materials formulation and popular AM methods such as materials extrusion
(i.e., fused filament fabrication and liquid deposition modeling), selective laser
sintering and stereolithography will be discussed. Emphasis is paid to the per-
formances (mechanical, electrical, and thermal) of AM products obtained by
using nanocomposites and their prospective applications.
Part 2 deals with “Frequently Used Additive Manufacturing Process Cat-
egories” and focuses in the first sub-chapter 2.1 on “General Aspects. V. Kunc
and L. Peng from Oak Ridge National Laboratory and Saint Gobain Research
in North America report about the “Effect of 3D Printing Conditions on the
Micro-and Macro Structure and Properties of High Performance Thermoplas-
tic Composites.” The chapter provides research for understanding the physical
relationships between microstructure variables and macrostructure properties
of high-performance thermoplastic polymers. The development of interlayer
strength is discussed based on the theory of inter-diffusion and re-entanglement
of polymer chains at interfaces. Quantitative predictions of interfacial strength as
a function of processing temperature and contact time are presented. The second
half of the chapter outlined a set of printing conditions and their influence on
xix