RESUMEN
This paper explores the use of Discontinuous Aligned Fibre Filament (DcAFF), a novel discontinuous fibre reinforced thermoplastic filament for 3D printing, to produce structural complex parts. Compared to conventional composite manufacturing, 3D printing has great potential in steering fibres around small structural features. In this current study, the initial thin carbon fibre (CF)-poly(L-lactic acid) (PLA) tape, produced with the High Performance Discontinuous Fibre (HiPerDiF) technology, is now reshaped into a circular cross-section filament, the DcAFF, using a bespoke machine designed to be scalable to high production rates rather than using a labour-intensive manual moulding method as in previous work. The filaments are then fed to a general-purpose 3D printer. Tensile and open-hole tensile tests were considered in this paper for mechanical and processability of DcAFF. The 3D printed specimens fabricated with the DcAFF show superior tensile properties compared to other PLA-based 3D printed composites, even those containing continuous fibres. Curvilinear open-hole tensile test samples were fabricated to explore the processability and performances of such material in complex shapes. The mechanical performance of the produced specimens was benchmarked against conventionally laid-up specimens with a cut hole. Although the steered specimens produced have lower strength than the fully consolidated samples, the raster generated by the printing path has turned the failure mechanism of the composite from brittle to ductile.
RESUMEN
Sustainable fibre reinforced polymer composites have drawn significant attention in many industrial sectors as a means for overcoming issues with end-of-life regulations and other environmental concerns. Plant based natural fibres are considered to be the most suitable reinforcement for sustainable composites since they are typically from renewable resources, are cheap, and are biodegradable. In this study, a number of plant based natural fibres-curaua, flax, and jute fibres-are used to reinforce epoxy, poly(lactic acid) (PLA), and polypropylene (PP) matrices to form aligned discontinuous natural fibre reinforced composites (ADNFRC). The novel HiPerDiF (high performance discontinuous fibre) method is used to produce high performance ADNFRC. The tensile mechanical, fracture, and physical (density, porosity, water absorption, and fibre volume fraction) properties of these composites are reported. In terms of stiffness, epoxy and PP ADNFRC exhibit similar properties, but epoxy ADNFRC shows increased strength compared to PP ADNFRC. It was found that PLA ADNFRC had the poorest mechanical performance of the composites tested, due principally to the limits of the polymer matrix. Moreover, curaua, flax (French origin), and jute fibres are found to be promising reinforcements owing to their mechanical performance in epoxy and PP ADNFRC. However, only flax fibre with desirable fibre length is considered to be the best reinforcement constituent for future sustainable ADNFRC studies in terms of mechanical performance and current availability on the market, particularly for the UK and EU.
RESUMEN
Growing environmental concerns and stringent waste-flow regulations make the development of sustainable composites a current industrial necessity. Natural fibre reinforcements are derived from renewable resources and are both cheap and biodegradable. When they are produced using eco-friendly, low hazard processes, then they can be considered as a sustainable source of fibrous reinforcement. Furthermore, their specific mechanical properties are comparable to commonly used, non-environmentally friendly glass-fibres. In this study, four types of abundant natural fibres (jute, kenaf, curaua, and flax) are investigated as naturally-derived constituents for high performance composites. Physical, thermal, and mechanical properties of the natural fibres are examined to evaluate their suitability as discontinuous reinforcements whilst also generating a database for material selection. Single fibre tensile and microbond tests were performed to obtain stiffness, strength, elongation, and interfacial shear strength of the fibres with an epoxy resin. Moreover, the critical fibre lengths of the natural fibres, which are important for defining the mechanical performances of discontinuous and short fibre composites, were calculated for the purpose of possible processing of highly aligned discontinuous fibres. This study is informative regarding the selection of the type and length of natural fibres for the subsequent production of discontinuous fibre composites.
RESUMEN
Conventional composite materials reinforced with continuous fibres display high specific strength but have a number of drawbacks including: the elastic-brittle behaviour, difficulties in producing defect-free components of complex shape with high-volume automated manufacturing processes, and inherent lack of recyclability. Highly aligned, discontinuous fibre-reinforced composites (ADFRCs) are truly beneficial for mass production applications, with the potential to offer better formability and comparable mechanical properties with continuous fibre-reinforced composites. In previous publications, the High Performance Discontinuous Fibre (HiPerDiF) technology has been shown to offer the possibility to intimately hybridise different types of fibres, to achieve pseudo-ductile tensile behaviour, and remanufacture reclaimed fibres into high-performance recycled composites. However, to date, the work has been conducted with unidirectional (UD) laminates, which is of limited interest in engineering applications with mechanical stresses acting across many directions; this paper reports, for the first time, the mechanical behaviour of quasi-isotropic (QI) ADFRCs. When compared with randomly-oriented discontinuous fibre composites (RODFRCs), QI ADFRCs offer enhanced stiffness (+26%) and strength (+77%) with higher consistency, i.e., a reduction of the coefficient of variance from the 25% of RODFRCs to the 6% of ADFRCs. Furthermore, hybrid QI ADFRCs retain the pseudo-ductility tensile behaviour previously observed in unidirectional (UD) lay-up.
RESUMEN
We report the successful manufacture of short fibre reinforced polymer composites via the process of ultrasonic assembly. An ultrasonic device is developed allowing the manufacture of thin layers of anisotropic composite material. Strands of unidirectional reinforcement are, in response to the acoustic radiation force, shown to form inside various matrix media. The technique proves suitable for both photo-initiator and temperature controlled polymerisation mechanisms. A series of glass fibre reinforced composite samples constructed in this way are subjected to tensile loading and the stress-strain response is characterised. Structural anisotropy is clearly demonstrated, together with a 43% difference in failure stress between principal directions. The average stiffnesses of samples strained along the direction of fibre reinforcement and transversely across it were 17.66±0.63MPa and 16.36±0.48MPa, respectively.