CN112706401B - 弱各向异性连续纤维增强聚合物复合材料及增材制造方法 - Google Patents
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Abstract
本发明公开了一种弱各向异性连续纤维增强聚合物复合材料及增材制造方法,采用正弦形密排基体铺设与穿插纤维路径优化提升增材制造技术,由此提高制备获得的连续纤维增强聚合物复合材料的强度及削弱复合材料性能的各向异性。本案利用聚合物基体的正弦形依次铺设,连续纤维穿插多道次基体的路径规划方法,获得高强、弱各向异性的一体化连续纤维增强聚合物复合材料复杂结构。本发明一方面解决了增材制造连续纤维增强聚合物复合材料界面连接单一、性能提升受限的问题,另一方面有效减弱了增材制造聚合物复合材料性能的各向异性。
Description
技术领域
本发明涉及一种用于连续纤维增强聚合物复合材料增材制造领域的高效制备技术,涉及一种弱各向异性连续纤维增强聚合物复合材料及增材制造方法,特别是涉及一种性能可调控的高强弱各向异性连续纤维增强聚合物复合材料的增材制备方法。
背景技术
由于轻质高强的优异性能,连续纤维增强聚合物复合材料被广泛应用于航空航天以及汽车领域。尤其是近年来,增材制造技术的飞速发展,为纤维增强复合材料的制备提供了更大的潜力。连续纤维,包括碳纤维、玻璃纤维、芳纶纤维等,具有比强度高,耐腐蚀性能好等诸多优势,是理想的增强材料,可大幅提升聚合物基体的综合性能。但是传统的制造方法限制了复合材料性能的进一步提升,无法完全发挥连续纤维的优势。主要存在两个问题,一是增材制造成形连续纤维增强复合材料性能存在明显的各向异性,二是连续纤维与基体结合界面薄弱,极大地削弱复合材料的性能。
增材制造的连续纤维增强聚合物复合材料中,对材料性能影响最大的为结合界面。结合界面属于复合材料中的薄弱环节,包括连续纤维与基体的结合界面及基体与基体的结合界面。由于现有增材制造技术中纤维与基体堆叠方向一致或制发生单点接触,导致在复合界面处产生较多的缺陷或弱连接,极易发生纤维抽出的现象,导致复合材料性能差。在增材制造连续纤维增强聚合物复合材料服役过程中,往往由于纤维与聚合物界面剥离抽出或基体层道间的剥离,导致材料失效。
连续纤维在复合材料内部处于张紧状态时才能发挥增强效果,由于增材制造过程中连续纤维束的铺设方向与基体铺陈方向单一,导致材料性能存在明显的各向异性。在单丝送进设备中,连续纤维束排列方向与基体一致,导致与之垂直方向性能最薄弱,严重降低材料的使用性能;在双丝或多丝送进设备中,实现了工艺多样性,连续纤维与基体的界面配合方式更加多样化,但连续纤维束与聚合物集体多数属于单点接触,材料的性能受到较大的影响。
此外,需要指出的是,现有3D打印制造聚合物及其复合材料均存在严重的性能各项异性的缺点,尤其是熔覆道连接间的结合强度较弱。
发明内容
本发明的目的是针对现有技术中的上述不足,提供一种弱各向异性连续纤维增强聚合物复合材料及增材制造方法。本发明可简单地通过3D打印过程中材料排布方式有效地弱化连续纤维增强复合材料3D打印样件中性能各项异性的问题,其结合3D打印技术,尤其是配合3D打印装置所具有的多头打印功能,实现了基体材料与增强纤维的路径穿插。
尤其是,本案的零件成形过程中材料的准备、参数设定等过程可以与传统3D打印方式类相同,因而,其可以基于现有的3D打印技术和生产系统进行打印。但与现有技术不同的是,本案通过成形路径的划分与打印过程中打印头多头协调配合实现基体与纤维的穿插密排分布,形成多重接触结构,因而,克服了现有技术中各项性能差异差的缺陷,由此减弱3D打印成形零件性能各项异性,最终获得的了弱各向异性连续纤维增强聚合物复合材料。
为了达到上述目的,本发明采用如下技术方案:
第一方面,本发明提出了一种弱各向异性连续纤维增强聚合物的制造方法,所述制造方法采用将:连续纤维通过3D打印穿插分布于基体材料上,其中,基体材料排布呈正弦曲线,以使得连续纤维以非直线的路径穿插分布于正弦形密排基体面上,使连续纤维与基体材料之间形成多重接触,最终获得弱各向异性连续纤维增强聚合物。
优选地,所述制造方法具体包括以下步骤:
步骤S1:建立打印制件三维模型,根据连续纤维增强聚合物复合材料制件的要求,使用计算机辅助软件建立三维模型实体,保存为模型处理软件可识别的文件格式;
步骤S2:确定增材制造过程参数;
步骤S3:数据模型处理,将步骤S1产生的模型处理软件可识别的文件格式导入到增材制造切片分层模型处理软件中,根据步骤S2确定的增材制造参数,规划制造路径;
步骤S4:根据步骤S3所规划的路径配合3D打印设备的多打印头,在基体材料上进行连续纤维的铺设,使连续纤维穿插分布于基体材料上,制备获得最终的弱各向异性连续纤维增强聚合物。
优选地,在所述步骤S2中,所述增材制造过程参数包括:基材加热温度为250℃,纤维头加热温度为250 ℃,打印层厚t为0.2mm,基材填充间距h为0.3mm,纤维填充间距d为0.8mm,打印速度为120mm/min。
优选地,在所述步骤S4中,打印设备的基板预热至80℃。
优选地,在所述步骤S4中,所述连续纤维的铺设方向与X方向平行,连续纤维的行走方向与X方向垂直,所述X方向为基材排布方向。
优选地,在所述步骤S4中,连续纤维采用张紧的方式穿插于基体材料上,而所制备的弱各向异性连续纤维增强聚合物的边缘采用宽幅轮廓填充方式。
第二方面,本发明提出了一种弱各向异性连续纤维增强聚合物,所述弱各向异性连续纤维增强聚合物采用上述的制造方法制备获得。
优选地,所述弱各向异性连续纤维增强聚合物的X方向抗拉强度为235Mpa,Y方向抗拉强度为145Mpa,各项异性强度差为36.96%。
优选地,所述基体材料包括ABS树脂、PLA树脂、PA-聚酰胺、PE-聚乙烯、PEEK-聚醚醚酮、短纤维增强热塑性树脂的一种或多种。
优选地,所述连续纤维材料包括碳纤维、玻璃纤维、耐高温玻璃纤维、芳纶纤维、凯夫拉纤维、陶瓷纤维的一种或多种。
较现有技术本发明的有益效果如下:
(1) 本发明相较于传统增材制造连续纤维增强复合材料技术,基材采用正弦形密排分布方式,可有效增加相邻沉积道间的接触面积,有效提升材料的性能。
(2) 本发明相对于传统的连续纤维增强复合材料增材制造,采用连续纤维穿插分布于正弦形基材上,一束纤维可同时穿插多道沉积基材,可实现连续纤维与基材之间的多点稳定接触,形成良好的结合界面,在充分发挥纤维的增强效应的同时单层沉积面内的各向异性得到改善。结合相邻层间的适当角度旋转,可有效改善整个制件的各项异性。
附图说明
通过阅读参照以下附图对非限制性实施例所作的详细描述,本发明的其它特征、目的和优点将会变得更明显:
图1是本发明所述的实现高强弱各项异性连续纤维增强复合材料的增材制造原理三维示意图;
图2是单层内基材与纤维穿插分布路径规划示意图;
图3进一步放大了图2的路径规划。
具体实施方式
下面结合具体实施例对本发明进行详细说明。以下实施例将有助于本领域的技术人员进一步理解本发明,但不以任何形式限制本发明。应当指出的是,对本领域的普通技术人员来说,在不脱离本发明构思的前提下,还可以做出若干变化和改进。这些都属于本发明的保护范围。
实施例1
图1是本发明所述的实现高强弱各项异性连续纤维增强复合材料的增材制造原理三维示意图。
本实施例的弱各向异性连续纤维增强聚合物复合材料的增材制造方法具体包括以下步骤:
1)建立打印制件三维模型:根据连续纤维增强聚合物复合材料制件的要求,使用计算机辅助软件建立三维模型实体,保存为模型处理软件可识别的文件格式,如stl格式,例如:采用计算机辅助绘图软件creo 2.0绘制100×100×50mm的三维模型,将三维模型导出为stl格式。
2)确定增材制造过程参数:连续纤维增强聚合物复合材料的成形性态主要取决于聚合物基材,选取加热区间高于聚合物基材1,该聚合物基材1小于增强相连续纤维束2(即连续纤维)的熔点。而增强连续纤维束2预先经过浸润处理,包覆与聚合物基材1具有良好浸润性的聚合物相。增材制造过程中聚合物基材1发生熔化,增强相连续纤维束2不发生熔化,增强相连续纤维束2表面包覆的聚合物浸润相发生熔化,最终形成界面的稳固连接,增强相连续纤维束2需在复合材料试件中始终保持张紧状态。并且,根据上述材料体系需求确定增材制造工艺参数。
例如:选取适当材料体系时,选择尼龙PA作为聚合物基材,增强连续纤维束2选择预浸润的连续碳纤维。尼龙基材的熔点为220℃,碳纤维的熔点为3500℃。选择制备温度为250℃,制备过程中聚合物基材1发生完全融化,以熔融态挤出成丝,增强连续纤维束2表面包覆层发生熔化,二者形成良好的界面结合且纤维在基体内部一直处于张紧状态。
3)数据模型处理:将步骤1)产生的三维格式文件导入到增材制造切片分层模型处理软件中,根据步骤2)确定的增材制造参数,t为单层厚度,h为基材沉积间距,d 为纤维铺设间距,A为基体材料排布正弦曲线的振幅,然后规划制造路径,生成正弦形密排分布基材铺设连续纤维穿插路径的复合材料的打印命令文件。单根纤维可穿插多条基体熔覆道,形成多重接触,增强相连续纤维束2(1)同时穿插基材熔覆道1(1)、1(2)、1(3)、1(4)、1(5)、1(6)、1(7)、1(8)。例如:基材加热温度为250℃,纤维头加热温度为250℃,打印层厚t为0.2mm,基材填充间距h为0.3mm,纤维填充间距d为0.8mm,打印速度为120mm/min。
此外,参考图1可以看出,相邻层间旋转一定的角度,试件边缘采用宽幅轮廓填充的方式,轮廓宽度为2A。最终将模型导出为设备可识别的文件格式。
其中,参照图2和图3,填充路径中基材采用正弦形密排分布,连续碳纤维采用张紧的穿插于及基材的分布方式;制件边缘(图2中附图标记3所示意的位置)采用宽幅轮廓填充方式。
而参考图2可以看出,轮廓填充层数为6;相邻层间填充角度发生变化,本实施案例中优选45°递增的方式,参照图1,第n层与第n+1层之间依次旋转45°。最终生成包含参数与路径规划的可被设备可识别的文件格式。
4) 增材制造:对增材制造设备进行调整设置,将步骤3)产生的文件格式导入设备,通过设备多打印头之间的运动配合,最终制备得到弱各向异性的增材制造连续纤维增强聚合物制件。其中,产生的文件格式导入设备,通过设备多打印头之间的运动配合,最终制备得到弱各向异性的增材制造连续纤维增强聚合物制件。
设置设备参数,设备基板预热到80℃,将步骤3)产生的文件导入设备,使纤维铺设方向与X方向平行,最终制备得到高强弱各向异性的连续碳纤维增强尼龙复合材料制件。
在本实施方式中,采用传统材料铺设方法制备的连续纤维增强复合材料X方向抗拉强度为220Mpa,Y方向抗拉强度为103Mpa;通过本发明制备的试样经检测试样X方向抗拉强度为235Mpa,Y方向抗拉强度为145Mpa。各项异性强度差由原来的53.18%降低为36.96%。
本发明中基材采用正弦形密排分布方式,可有效增加相邻沉积道间的接触面积,有效提升材料的性能。采用连续纤维穿插分布于正弦形密排分布基材上,一束纤维可同时穿插多道沉积基材,可实现连续纤维与基材之间的多点稳定接触,形成良好的结合界面,在充分发挥纤维的增强效应的同时单层沉积面内的各向异性得到改善。结合相邻层间的适当角度旋转,可有效改善制件的各项异性。
需要说明的是,本发明的保护范围中现有技术部分并不局限于本申请文件所给出的实施例,所有不与本发明的方案相矛盾的现有技术,包括但不局限于在先专利文献、在先公开出版物,在先公开使用等等,都可纳入本发明的保护范围。
此外,本案中各技术特征的组合方式并不限本案权利要求中所记载的组合方式或是具体实施例所记载的组合方式,本案记载的所有技术特征可以以任何方式进行自由组合或结合,除非相互之间产生矛盾。
以上对本发明的具体实施例进行了描述。需要理解的是,本发明并不局限于上述特定实施方式,本领域技术人员可以在权利要求的范围内做出各种变化或修改,这并不影响本发明的实质内容。在不冲突的情况下,本申请的实施例和实施例中的特征可以任意相互组合。
Claims (10)
1.一种弱各向异性连续纤维增强聚合物的制造方法,其特征在于,所述制造方法采用将:连续纤维通过3D打印穿插分布于基体材料上,其中,基体材料排布呈正弦曲线,以使得连续纤维以非直线的路径穿插分布于正弦形密排基体材料面上,使连续纤维与基体材料之间形成多重接触,最终获得弱各向异性连续纤维增强聚合物;
采用连续纤维穿插分布于正弦形基材上,一束纤维同时穿插多道沉积基材,实现连续纤维与基材之间的多点稳定接触。
2.根据权利要求1所述的弱各向异性连续纤维增强聚合物的制造方法,其特征在于,所述制造方法具体包括以下步骤:
步骤S1:建立打印制件三维模型,根据连续纤维增强聚合物复合材料制件的要求,使用计算机辅助软件建立三维模型实体,保存为模型处理软件可识别的文件格式;
步骤S2:确定增材制造过程参数;
步骤S3:数据模型处理,将步骤S1产生的模型处理软件可识别的文件格式导入到增材制造切片分层模型处理软件中,根据步骤S2确定的增材制造参数,规划制造路径;
步骤S4:根据步骤S3所规划的路径配合3D打印设备的多打印头,在基体材料上进行连续纤维的铺设,使连续纤维穿插分布于基体材料上,制备获得最终的弱各向异性连续纤维增强聚合物。
3.根据权利要求2所述的弱各向异性连续纤维增强聚合物的制造方法,其特征在于,在所述步骤S2中,所述增材制造过程参数包括:基材加热温度为250℃,纤维头加热温度为250℃,打印层厚t为0.2mm,基材填充间距h为0.3mm,纤维填充间距d为0.8mm,打印速度为120mm/min。
4.根据权利要求2所述的弱各向异性连续纤维增强聚合物的制造方法,其特征在于,在所述步骤S4中,打印设备的基板预热至80℃。
5.根据权利要求2所述的弱各向异性连续纤维增强聚合物的制造方法,其特征在于,在所述步骤S4中,所述连续纤维的铺设方向与X方向平行,连续纤维的穿插方向与X方向垂直,所述X方向为基材排布方向。
6.根据权利要求2所述的弱各向异性连续纤维增强聚合物的制造方法,其特征在于,在所述步骤S4中,连续纤维采用张紧的方式穿插于基体材料上,而所制备的弱各向异性连续纤维增强聚合物的边缘采用宽幅轮廓填充方式。
7.一种弱各向异性连续纤维增强聚合物,其特征在于,所述弱各向异性连续纤维增强聚合物采用如权利要求1-6中任意一项所述的制造方法制备获得。
8.根据权利要求7所述的弱各向异性连续纤维增强聚合物,其特征在于,所述弱各向异性连续纤维增强聚合物的X方向抗拉强度为235Mpa,Y方向抗拉强度为145Mpa,各项异性强度差为36.96%。
9.根据权利要求7所述的弱各向异性连续纤维增强聚合物,其特征在于,所述基体材料包括ABS树脂、PLA树脂、PA-聚酰胺、PE-聚乙烯、PEEK-聚醚醚酮、短纤维增强热塑性树脂的一种或多种。
10.根据权利要求7所述的弱各向异性连续纤维增强聚合物,其特征在于,所述连续纤维材料包括碳纤维、玻璃纤维、芳纶纤维、凯夫拉纤维、陶瓷纤维的一种或多种。
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