Characterization of Anisotropic Mechanical Properties of Polymer Composites Manufactured by a Hybrid Additive Manufacturing-Compression Molding Process using X-ray Computer Tomography

Deepak Kumar Pokkalla; Vipin Kumar; Eonyeon Jo; Ahmed Arabi Hassen; Ercan Cakmak; Shailesh P. Alwekar; Vlastimil Kunc; Uday Vaidya; Harsh K. Baid; Seokpum Kim

doi:10.1117/12.2614620

Characterization of Anisotropic Mechanical Properties of Polymer Composites Manufactured by a Hybrid Additive Manufacturing-Compression Molding Process using X-ray Computer Tomography

Deepak Kumar Pokkalla, Vipin Kumar, Eonyeon Jo, Ahmed Arabi Hassen, Ercan Cakmak, Shailesh P. Alwekar, Vlastimil Kunc, Uday Vaidya, Harsh K. Baid, Seokpum Kim

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

5 Scopus citations

Abstract

In this study, anisotropic stiffness tensors were reconstructed based on fiber orientation distributions obtained from X-ray computer tomography (xCT). A preform was manufactured via a big area additive manufacturing (BAAM) system with carbon fiber (CF) filled acrylonitrile butadiene styrene (ABS). The tailored preform from additive manufacturing (AM) was used in the compression molding (CM) process to produce a low-void high-performance thermoplastic composite panel. An xCT technique was employed to detect the fiber orientations in CF/ABS composites manufactured via three different methods: AM from BAAM, extrusion compression molding (ECM), and AM-CM. The anisotropic stiffness tensor was obtained from the composite panel manufactured via the three manufacturing methods (AM, ECM, and AM-CM). A micromechanics theory was used to obtain the orthotropic stiffness tensors of the composite panels and compared with the experimental values. The predicted stiffness tensors of AM and AM-CM composite panels were used to study the deformation characteristics of a steering wheel during airbag deployment by performing finite element analysis (FEA). The approach developed in this study can be utilized for evaluating high-performance composites.

Original language	English
Title of host publication	Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XVI
Editors	H. Felix Wu, Andrew L. Gyekenyesi, Peter J. Shull, Tzuyang Yu
Publisher	SPIE
ISBN (Electronic)	9781510649699
DOIs	https://doi.org/10.1117/12.2614620
State	Published - 2022
Event	Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XVI 2022 - Virtual, Online Duration: Apr 4 2022 → Apr 10 2022

Publication series

Name	Proceedings of SPIE - The International Society for Optical Engineering
Volume	12047
ISSN (Print)	0277-786X
ISSN (Electronic)	1996-756X

Conference

Conference	Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XVI 2022
City	Virtual, Online
Period	04/4/22 → 04/10/22

Funding

This research was supported by the DOE Office of Energy Efficiency and Renewable Energy (EERE), Advanced Manufacturing Office and used resources at the Manufacturing Demonstration Facility (MDF), a DOE-EERE User Facility at Oak Ridge National Laboratory. MCQ-Chopped software to characterize chopped fiber reinforced composite material properties was provided by AlphaSTAR Corporation. For large format additive manufacturing, the printing equipment was provided by Cincinnati Incorporated, a manufacturer of metal and additive manufacturing equipment, headquartered in Harrison, Ohio (www.e-ci.com). The printing material was provided by Techmar PM, a material design and manufacturing company headquartered in Clinton, TN. CT scan was performed at Zeiss facility at MDF. Authors thanks Dr. Pradeep Bhattad and Curtis Frederick for performing the CT scans. * This manuscript has been authored by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The published acknowledges the US government license to provide public access under the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan)

Funders	Funder number
DOE-EERE
U.S. Department of Energy
Advanced Manufacturing Office
Office of Energy Efficiency and Renewable Energy
Oak Ridge National Laboratory

Keywords

Additive Manufacturing
Extrusion Compression Molding
Fiber orientation distribution
Mechanical properties
Orientation tensor
Polymer composites
Porosity
Stiffness tensor

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

Access to Document

10.1117/12.2614620

Cite this

Pokkalla, D. K., Kumar, V., Jo, E., Hassen, A. A., Cakmak, E., Alwekar, S. P., Kunc, V., Vaidya, U., Baid, H. K., & Kim, S. (2022). Characterization of Anisotropic Mechanical Properties of Polymer Composites Manufactured by a Hybrid Additive Manufacturing-Compression Molding Process using X-ray Computer Tomography. In H. F. Wu, A. L. Gyekenyesi, P. J. Shull, & T. Yu (Eds.), Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XVI Article 120470V (Proceedings of SPIE - The International Society for Optical Engineering; Vol. 12047). SPIE. https://doi.org/10.1117/12.2614620

Pokkalla, Deepak Kumar ; Kumar, Vipin ; Jo, Eonyeon et al. / Characterization of Anisotropic Mechanical Properties of Polymer Composites Manufactured by a Hybrid Additive Manufacturing-Compression Molding Process using X-ray Computer Tomography. Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XVI. editor / H. Felix Wu ; Andrew L. Gyekenyesi ; Peter J. Shull ; Tzuyang Yu. SPIE, 2022. (Proceedings of SPIE - The International Society for Optical Engineering).

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title = "Characterization of Anisotropic Mechanical Properties of Polymer Composites Manufactured by a Hybrid Additive Manufacturing-Compression Molding Process using X-ray Computer Tomography",

abstract = "In this study, anisotropic stiffness tensors were reconstructed based on fiber orientation distributions obtained from X-ray computer tomography (xCT). A preform was manufactured via a big area additive manufacturing (BAAM) system with carbon fiber (CF) filled acrylonitrile butadiene styrene (ABS). The tailored preform from additive manufacturing (AM) was used in the compression molding (CM) process to produce a low-void high-performance thermoplastic composite panel. An xCT technique was employed to detect the fiber orientations in CF/ABS composites manufactured via three different methods: AM from BAAM, extrusion compression molding (ECM), and AM-CM. The anisotropic stiffness tensor was obtained from the composite panel manufactured via the three manufacturing methods (AM, ECM, and AM-CM). A micromechanics theory was used to obtain the orthotropic stiffness tensors of the composite panels and compared with the experimental values. The predicted stiffness tensors of AM and AM-CM composite panels were used to study the deformation characteristics of a steering wheel during airbag deployment by performing finite element analysis (FEA). The approach developed in this study can be utilized for evaluating high-performance composites.",

keywords = "Additive Manufacturing, Extrusion Compression Molding, Fiber orientation distribution, Mechanical properties, Orientation tensor, Polymer composites, Porosity, Stiffness tensor",

author = "Pokkalla, {Deepak Kumar} and Vipin Kumar and Eonyeon Jo and Hassen, {Ahmed Arabi} and Ercan Cakmak and Alwekar, {Shailesh P.} and Vlastimil Kunc and Uday Vaidya and Baid, {Harsh K.} and Seokpum Kim",

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year = "2022",

doi = "10.1117/12.2614620",

language = "English",

series = "Proceedings of SPIE - The International Society for Optical Engineering",

publisher = "SPIE",

editor = "Wu, {H. Felix} and Gyekenyesi, {Andrew L.} and Shull, {Peter J.} and Tzuyang Yu",

booktitle = "Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XVI",

}

Pokkalla, DK, Kumar, V, Jo, E, Hassen, AA , Cakmak, E, Alwekar, SP, Kunc, V, Vaidya, U, Baid, HK & Kim, S 2022, Characterization of Anisotropic Mechanical Properties of Polymer Composites Manufactured by a Hybrid Additive Manufacturing-Compression Molding Process using X-ray Computer Tomography. in HF Wu, AL Gyekenyesi, PJ Shull & T Yu (eds), Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XVI., 120470V, Proceedings of SPIE - The International Society for Optical Engineering, vol. 12047, SPIE, Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XVI 2022, Virtual, Online, 04/4/22. https://doi.org/10.1117/12.2614620

Characterization of Anisotropic Mechanical Properties of Polymer Composites Manufactured by a Hybrid Additive Manufacturing-Compression Molding Process using X-ray Computer Tomography. / Pokkalla, Deepak Kumar; Kumar, Vipin; Jo, Eonyeon et al.
Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XVI. ed. / H. Felix Wu; Andrew L. Gyekenyesi; Peter J. Shull; Tzuyang Yu. SPIE, 2022. 120470V (Proceedings of SPIE - The International Society for Optical Engineering; Vol. 12047).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

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AU - Hassen, Ahmed Arabi

AU - Cakmak, Ercan

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AB - In this study, anisotropic stiffness tensors were reconstructed based on fiber orientation distributions obtained from X-ray computer tomography (xCT). A preform was manufactured via a big area additive manufacturing (BAAM) system with carbon fiber (CF) filled acrylonitrile butadiene styrene (ABS). The tailored preform from additive manufacturing (AM) was used in the compression molding (CM) process to produce a low-void high-performance thermoplastic composite panel. An xCT technique was employed to detect the fiber orientations in CF/ABS composites manufactured via three different methods: AM from BAAM, extrusion compression molding (ECM), and AM-CM. The anisotropic stiffness tensor was obtained from the composite panel manufactured via the three manufacturing methods (AM, ECM, and AM-CM). A micromechanics theory was used to obtain the orthotropic stiffness tensors of the composite panels and compared with the experimental values. The predicted stiffness tensors of AM and AM-CM composite panels were used to study the deformation characteristics of a steering wheel during airbag deployment by performing finite element analysis (FEA). The approach developed in this study can be utilized for evaluating high-performance composites.

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KW - Mechanical properties

KW - Orientation tensor

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KW - Porosity

KW - Stiffness tensor

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Pokkalla DK, Kumar V, Jo E, Hassen AA , Cakmak E, Alwekar SP et al. Characterization of Anisotropic Mechanical Properties of Polymer Composites Manufactured by a Hybrid Additive Manufacturing-Compression Molding Process using X-ray Computer Tomography. In Wu HF, Gyekenyesi AL, Shull PJ, Yu T, editors, Nondestructive Characterization and Monitoring of Advanced Materials, Aerospace, Civil Infrastructure, and Transportation XVI. SPIE. 2022. 120470V. (Proceedings of SPIE - The International Society for Optical Engineering). doi: 10.1117/12.2614620

Characterization of Anisotropic Mechanical Properties of Polymer Composites Manufactured by a Hybrid Additive Manufacturing-Compression Molding Process using X-ray Computer Tomography

Abstract

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Funding

Keywords

UN SDGs

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