连续纤维复合材料增材随行热压增强技术研究

Enhancement of interlayer bonding in continuous carbon fiber composites via additive manufacturing with integrated in-situ compaction

  • 摘要: 连续纤维增材制造因具有高比强度、一体化成形及实现复杂构件绿色制造的显著优势,在航空航天、生物医学及新能源轻量化等领域得到广泛应用。然而,该技术制备的复合材料层间结合性能较差,因此提升材料层间性能成为关键挑战。针对连续碳纤维增强聚乳酸复合材料(continuous carbon fiber-reinforced polylactic acid, CCF/PLA)增材制造开发了具有随行热压功能的打印喷头。实际随行热压测试结果表明,基于该设计方案加工并优化的随行热压装置能够对打印构件进行有效压实,显著提升了增材制造复合材料的层间结合性能,在最优工艺参数(30 N和150 ℃)下,层间剪切强度提升了104.2%,达到16.95 MPa,且表面粗糙度降低至14.07 μm,为连续碳纤维增强复合材料3D打印技术的工艺改进及层间性能提升提供了实验依据。

     

    Abstract: Continuous fiber additive manufacturing has been widely applied in aerospace, biomedical, and energy-efficient lightweight industries owing to its advantages in fabricating complex components with high specific strength, integrated forming, and environmentally sustainable production. However, the relatively poor interlayer bonding performance of composites fabricated by this technology remains a critical limitation. To address this issue, an innovative printing nozzle integrated with in-situ compaction functionality was developed for continuous carbon fiber-reinforced polylactic acid (CCF/PLA) composites. Experimental validation demonstrated that the optimized hot-pressing device effectively enhanced interlayer consolidation during the additive manufacturing process. Under optimal process parameters (compaction force is 30 N, temperature is 150 ℃), the interlaminar shear strength of the composites was increased by 104.2%, reaching 16.95 MPa, while the surface roughness was reduced to 14.07 μm. Microstructural analysis revealed improved fiber-matrix adhesion and reduced interfacial voids. This study provides a practical framework for enhancing interlayer performance in 3D-printed continuous fiber composites, with implications for process optimization in high-performance applications.

     

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