Mechanical Properties and Tension-Tension Fatigue Behavior of a Novel Additively Manufactured Polymer Matrix Composite at Room and Elevated Temperature

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Abstract:

The tension-tension fatigue behavior of a novel additively manufactured (AM) carbon fiber reinforced polymer matrix composite was studied. This novel material system consists of T1100 carbon fibers, and a UV photocured resin developed by Continuous Composites and Sartomer. Tensile properties and tension-tension fatigue were investigated for the 0/90 fiber orientation as well as for the 45 fiber orientation. Specimens with 0/90 fiber orientation were tested at ambient laboratory temperature (23 C) and at elevated temperature (150 C), while the specimens with the 45 fiber orientation were tested only at ambient laboratory temperature. Tension-tension fatigue testing was carried out with a frequency of 1 Hz, and a ratio of minimum to maximum stress of R=0.1. Fatigue runout was defined as 200,000 cycles. Results obtained for the AM composite in this study were compared to the results obtained in previous studies for traditionally manufactured (TM) aerospace-grade carbon fiber/resin composite systems. The tension-tension fatigue performance of the additively manufactured material system with 0/90 fiber orientation was somewhat worse than that of the traditionally manufactured aerospace-grade composites with 0/90 fiber orientation at room temperature. The additively manufactured material system 45 fiber orientation exhibited better tension-tension fatigue performance than the 45 aerospace-grade composite. The AM composite exhibited considerable degree of specimen-to-specimen variability, and consequently considerable data scatter. Before and after testing the AM composite specimens were imaged using X-Ray Computed Tomography in order to gain insight into how the unique microstructure produced by this novel fabrication method impacts mechanical behavior. The additive manufacturing process shows considerable promise for rapid and cost-effective fabrication of composite parts.

Author(s):
Harber, Grayson M
Author Organization(s):
AIR FORCE INSTITUTE OF TECHNOLOGY WRIGHT-PATTERSON AFB OH
Funding Organization(s):
Air Force Research Laboratory, Wright-Patterson Air Force Base , OH
Document Type:
Technical Report/Master's Thesis
Publication Date:
2022 Jul 20
Pagination:
117

Security Markings

DOCUMENT & CONTEXTUAL SUMMARY

Distribution Code:
A - Approved For Public Release
Distribution Statement: Public Release

RECORD

Collection: TRECMS
Identifying Numbers
Report Number(s):
AFIT-ENY-MS-22-S-119
Subject Terms
Modernization Areas:
Microelectronics
Communities of Interest:
Space
Descriptor(s):
materials science, additive manufacturing, polymer matrix composites, materials processing, x-ray computed tomography, mechanics, materials laboratories, materials testing, composite materials, fiber reinforced polymers, mechanical working, tensile strength, air force, fabrication, fiber reinforced composites, manufacturing, modulus of elasticity
Keyword(s):
Composite, Additive Manufacturing, Carbon Fiber
Creation Date:
2022 Oct 03
Update Date:
2022 Dec 06