TY - JOUR
T1 - Influence of Extrusion Parameters on the Mechanical Properties of Slow Crystallizing Carbon Fiber-Reinforced PAEK in Large Format Additive Manufacturing
AU - Consul, Patrick
AU - Feuchtgruber, Matthias
AU - Bauer, Bernhard
AU - Drechsler, Klaus
N1 - Publisher Copyright:
© 2024 by the authors.
PY - 2024/8
Y1 - 2024/8
N2 - 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.
AB - 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.
KW - additive manufacturing
KW - high-performance polymers
KW - material extrusion
KW - PAEK
UR - http://www.scopus.com/inward/record.url?scp=85202438747&partnerID=8YFLogxK
U2 - 10.3390/polym16162364
DO - 10.3390/polym16162364
M3 - Article
AN - SCOPUS:85202438747
SN - 2073-4360
VL - 16
JO - Polymers
JF - Polymers
IS - 16
M1 - 2364
ER -