Comparative Effects of Carbon Fiber Reinforcement on Polypropylene and Polylactic Acid Composites in Fused Deposition Modeling. | ||||
| JES. Journal of Engineering Sciences | ||||
| Article 9, Volume 53, Issue 1, January and February 2025, Page 25-44 PDF (1.68 MB) | ||||
| Document Type: Research Paper | ||||
| DOI: 10.21608/jesaun.2024.334433.1381 | ||||
 View on SCiNiTO | ||||
| Authors | ||||
Alhassan Abdelhafeez   1; Yasser Abdelrhman 2; M-Emad Soliman1; Shemy M. Ahmed1
| ||||
| 1Mechanical Design and Production Engineering Department, Faculty of Engineering, Assiut University, Assiut, 71515, Egypt | ||||
| 2Mechanical Design and Production Engineering Department - Faculty of Engineering - Assiut University, Department of Mechanical and Industrial Engineering, College of Engineering, Majmaah University, Al Majmaah, 11952, Saudi Arabia | ||||
| Abstract | ||||
| This study offers a comparative evaluation of the impact of carbon fiber reinforcement on polypropylene (PP) and polylactic acid (PLA) matrices, focusing on their application in fused deposition modeling (FDM). Composite filaments with varying micro carbon fiber (MCF) contents were fabricated for both matrices, with their mechanical, moisture absorption, and morphological properties thoroughly characterized. In PP composites, MCF addition significantly improved tensile and flexural strengths, achieving optimal enhancement at 9.09 wt%, where tensile and flexural strengths rose by 75% and 100%, respectively, compared to pure PP. Conversely, PLA composites showed slight strength increases at lower MCF contents (below 5 wt%) but experienced strength reductions as fiber content exceeded this threshold. However, both materials exhibited increased stiffness (elastic modulus) with rising MCF levels, though PLA achieved optimal strength at a lower fiber loading. Moisture absorption increased in both matrices as fiber content rose; PP showed a proportional increase, whereas PLA displayed more pronounced absorption due to inter- and intra-filament porosities. Optical microscopy (OM) highlighted further differences: PP retained fiber distribution and bonding over a wide range of MCF levels, while PLA showed strong fiber adhesion and ductile fracture behavior at lower MCF, shifting to brittle fracture and void formation at higher levels. Gaussian Process Regression (GPR) modeling corroborated these trends, identifying optimal MCF content as 9.09 wt% for PP and around 2.5 wt% for PLA. These findings provide guidance on selecting material and fiber loading for FDM applications, with each material achieving a unique balance of mechanical performance and moisture resistance. | ||||
| Keywords | ||||
| Carbon-fiber reinforced plastic; Fused deposition modeling; Mechanical properties; Hydrophilicity; Gaussian process regression | ||||
| References | ||||
|
[1] Shulga, E., Karamov, R., and Sergeichev, I. S., 2020, “Fused Filament Fabricated Polypropylene Composite Reinforced by Aligned Glass Fibers,” Materials (Basel). (13), pp. 3442–3451. [Online]. Available: https://www.mdpi.com/1996-1944/13/16/3442.
[2] Liu, J., Gaynor, A. T., Chen, S., Kang, Z., Suresh, K., Takezawa, A., Li, L., Kato, J., Tang, J., Wang, C. C. L., Cheng, L., Liang, X., and To, A. C., 2018, “Current and Future Trends in Topology Optimization for Additive Manufacturing,” Struct. Multidiscip. Optim. 57(6), pp. 2457–2483. https://doi.org/10.1007/s00158-018-1994-3.
[3] Heshmat, M., and Abdelrahman, Y., 2021, “Improving Surface Roughness of Polylactic Acid (PLA) Products Manufactured by 3D Printing Using a Novel Slurry Impact Technique,” Rapid Prototyp. J., 27(10), pp. 1791–1800. https://doi.org/10.1108/RPJ-09-2020-0227.
[4] Heshmat, M., Maher, I., and Abdelrahman, Y., 2023, “Surface Roughness Prediction of Polylactic Acid (PLA) Products Manufactured by 3D Printing and Post Processed Using a Slurry Impact Technique: ANFIS-Based Modeling,” Prog. Addit. Manuf., 8(2), pp. 87–98. https://doi.org/10.1007/s40964-022-00314-6.
[5] Romero, L. M., Esquivel, S. E., Montaño, M. C., Medina-Muñoz, C., Sánchez-Sanhueza, G. A., Palacio, D. A., Jaramillo, A. F., and Meléndrez, M. F., 2024, “Polypropylene with Clay–Filled for Fused Filament Fabrication: Comparative Study of the Mechanical Performance of Injected and 3d Printed Composite,” Int. J. Adv. Manuf. Technol., 130(9), pp. 4251–4262. https://doi.org/10.1007/s00170-023-12889-7.
[6] Saleh, M., Anwar, S., AlFaify, A. Y., Al-Ahmari, A. M., and Abd Elgawad, A. E. E., 2024, “Development of PLA/Recycled-Desized Carbon Fiber Composites for 3D Printing: Thermal, Mechanical, and Morphological Analyses,” J. Mater. Res. Technol., 29, pp. 2768–2780. https://doi.org/https://doi.org/10.1016/j.jmrt.2024.01.267.
[7] Li, J., Durandet, Y., Huang, X., Sun, G., and Ruan, D., 2022, “Additively Manufactured Fiber-Reinforced Composites: A Review of Mechanical Behavior and Opportunities,” J. Mater. Sci. Technol., 119, pp. 219–244. https://doi.org/https://doi.org/10.1016/j.jmst.2021.11.063.
[8] Dickson, A. N., Barry, J. N., McDonnell, K. A., and Dowling, D. P., 2017, “Fabrication of Continuous Carbon, Glass and Kevlar Fibre Reinforced Polymer Composites Using Additive Manufacturing,” Addit. Manuf., 16, pp. 146–152. https://doi.org/https://doi.org/10.1016/j.addma.2017.06.004.
[9] Durga Prasada Rao, V., Rajiv, P., and Navya Geethika, V., 2019, “Effect of Fused Deposition Modelling (FDM) Process Parameters on Tensile Strength of Carbon Fibre PLA,” Mater. Today, Proc., 18, pp. 2012–2018. https://doi.org/https://doi.org/10.1016/j.matpr.2019.06.009.
[10] Ismail, K. I., Yap, T. C., and Ahmed, R., 2022, “3D-Printed Fiber-Reinforced Polymer Composites by Fused Deposition Modelling (FDM): Fiber Length and Fiber Implementation Techniques,” Polymers (Basel). 14(21). https://doi.org/10.3390/polym14214659.
[11] Dickson, A. N., Abourayana, H. M., and Dowling, D. P., 2020, “3D Printing of Fibre-Reinforced Thermoplastic Composites Using Fused Filament Fabrication—A Review,” Polymers (Basel). 12(10). https://doi.org/10.3390/polym12102188.
[12] Prüß, H., and Vietor, T., 2015, “Design for Fiber-Reinforced Additive Manufacturing,” J. Mech. Des., 137(11), p. 111409. https://doi.org/10.1115/1.4030993.
[13] Ning, F., Cong, W., Qiu, J., Wei, J., and Wang, S., 2015, “Additive Manufacturing of Carbon Fiber Reinforced Thermoplastic Composites Using Fused Deposition Modeling,” Compos. Part B Eng., 80, pp. 369–378. https://doi.org/10.1016/j.compositesb.2015.06.013.
[14] Pollini, M., Mutua, J. M., Mbuya, T. O., and Ernest, K., 2021, “Recipe Development and Mechanical Characterization of Carbon Fibre Reinforced Recycled Polypropylene 3D Printing Filament,” Open J. Compos. Mater. 11(03), pp. 47–61. https://doi.org/10.4236/ojcm.2021.113005.
[15] Spork, M., Savandaiah, C., Arbeiter, F., Traxler, G., Cardon, L., Holzer, C., and Sapkota, J., 2018, “Anisotropic Properties of Oriented Short Carbon Fibre Filled Polypropylene Parts Fabricated by Extrusion-Based Additive Manufacturing,” Compos. Part an Appl. Sci. Manuf., 113, pp. 95–104. https://doi.org/https://doi.org/10.1016/j.compositesa.2018.06.018.
[16] Blok, L. G., Longana, M. L., Yu, H., and Woods, B. K. S., 2018, “An Investigation into 3D Printing of Fibre Reinforced Thermoplastic Composites,” Addit. Manuf., 22, pp. 176–186. https://doi.org/https://doi.org/10.1016/j.addma.2018.04.039.
[17] Thirugnanasamabandam, A., Subramaniyan, M., Prabhu, B., and Ramachandran, K., 2024, “Development and Comprehensive Investigation on PLA / Carbon Fiber Reinforced PLA Based Structurally Alternate Layered Polymer Composites,” J. Ind. Eng. Chem., (xxxx). https://doi.org/10.1016/j.jiec.2024.02.012.
[18] Papen, E. A., and Hague, A., 2019, “Fracture Toughness of Additively Manufactured Carbon Fiber Reinforced Composites,” Addit. Manuf., 26, pp. 41–52. https://doi.org/https://doi.org/10.1016/j.addma.2018.12.010.
[19] Plastic, T., “LynX Additive Manufacturing.” [Online]. Available: https://www.lynx-am.com/.
[20] “Eldawlia ICO.” [Online]. Available: https://www.eldawlia-ico.com/#home.
[21] Easycomposites, 2011, Carbiso Milled Carbon Fibre. [Online]. Available: http://www.elgcf.com/products/carbiso-milled-fibre.
[22] Taoufik Hachimia, Nassima Naboulsia, Fatima Majida, Rajae Rhanimb, I., and Mrania, H. R., 2021, “Design and Manufacturing of a 3D Printer Filaments Extruder,” IGF26 - 26th Int. Conf. Fract. Struct. Integr. 33. [Online]. Available: e behavior can be changed by adding other po.
[23] Hasib, A. G., Niauzorau, S., Xu, W., Niverty, S., Kublik, N., Williams, J., Chawla, N., Song, K., and Azeredo, B., 2021, “Rheology Scaling of Spherical Metal Powders Dispersed in Thermoplastics and Its Correlation to the Extrudability of Filaments for 3D Printing,” Addit. Manuf., 41, p. 101967. https://doi.org/https://doi.org/10.1016/j.addma.2021.101967.
[24] 2014, “ASTM D638-14. Standard Test Method for Tensile Properties of Plastics. West Conshohocken, PA, USA: ASTM International,” ASTM D638-14. [Online]. Available: https://www.astm.org/d0638-14.html.
[25] 2016, “ASTM D790-10 Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials,” ASTM D790-10. [Online]. Available: https://www.astm.org/d0790-10.html.
[26] 2022, “ASTM D570- 98 Standard Test Method for Water Absorption of Plastics,” ASTM, ASTM D570- 98, West Conshohocken, PA, USA. [Online]. Available: https://www.astm.org/standards/d570.
[27] Banjo, A. D., Agrawal, V., Auad, M. L., and Celestine, A.-D. N., 2022, “Moisture-Induced Changes in the Mechanical Behavior of 3D Printed Polymers,” Compos. Part C Open Access, 7, p. 100243. https://doi.org/https://doi.org/10.1016/j.jcomc.2022.100243.
[28] Saunders, R., Rawlings, A., Birnbaum, A., Iliopoulos, A., Michopoulos, J., Lagoudas, D., and Elwany, A., 2022, “Additive Manufacturing Melt Pool Prediction and Classification via Multifidelity Gaussian Process Surrogates,” Integr. Mater. Manuf. Innov., 11(4), pp. 497–515. https://doi.org/10.1007/s40192-022-00276-1.
[29] Arun Kumar DT, Kaushik V Prasad, and P S Raghavendra Rao, 2015, “Study of Mechanical Properties of Carbon Fiber Reinforced Polypropylene,” Int. J. Eng. Res., V4 (10), pp. 406–408. https://doi.org/10.17577/ijertv4is100500.
[30] Alkabbanie, R., Aktas, B., Demircan, G., and Yalcin, S., 2024, “Short Carbon Fiber-Reinforced PLA Composites: Influence of 3D-Printing Parameters on the Mechanical and Structural Properties,” Iran. Polym. J., 33(8), pp. 1065–1074. https://doi.org/10.1007/s13726-024-01315-8.
[31] Mohd Yasin, S. B., Terry, J. S., and Taylor, A. C., 2023, “Fracture and Mechanical Properties of an Impact Toughened Polypropylene Composite: Modification for Automotive Dashboard-Airbag Application,” RSC Adv., 13(39), pp. 27461–27475. https://doi.org/10.1039/D3RA04151D.
[32] Sodeifian, G., Ghaseminejad, S., and Yousefi, A., 2018, “Mechanical and Morphological Properties of Polypropylene/Short Glass Fiber /POE-g-MA Composite Manufactured by Fused Deposition Modeling (FDM) and CM Methods,” The 10th International Chemical Engineering Congress & Exhibition (IChEC 2018).
[33] Mastalygina, E. E., and Aleksanyan, K. V, 2024, “Recent Approaches to the Plasticization of Poly (Lactic Acid) (PLA) (A Review),” Polymers (Basel). 16(1). https://doi.org/10.3390/polym16010087. | ||||
|
Statistics Article View: 293 PDF Download: 302 |
||||
