Characterization of micro-sandwich structures via direct ink writing epoxy based cores

Zane J. Smith, Demiana R. Barsoum, Zachariah L. Arwood, Dayakar Penumadu, Rigoberto C. Advincula

Research output: Contribution to journalArticlepeer-review

4 Scopus citations

Abstract

Sandwich structured (SS) composites demonstrate considerable flexural stiffness and high strength-to-weight ratios and can be tailored as functional materials. Historically they have been constrained to specific material types and geometry due to limitations in manufacturing methods. However, employing additive manufacturing (AM), specifically direct ink writing (DIW), can provide an alternative method for making SS composites with complex and controllable micro and mesostructures with multifunctionality targeted at desired mechanical, thermal, and electrical properties. DIW, an extrusion-based AM technique, uses a viscous and thixotropic ink with desired components that, once printed, is cured to obtain the final complex net shape parts. In this paper, a novel hybrid AM technique is employed to manufacture SS composite materials containing bisphenol A-based epoxy core and carbon fiber reinforced polymer (CFRP) face sheets that are fabricated via DIW and vacuum infusion process (VIP), respectfully. We demonstrate that the fabrication of these SS composites can be tailored from a thermosetting material, from which additives and/or various lattice structures can be manufactured to achieve enhanced and desirable mechanical integrity with functional properties. Surface topology and mechanical testing techniques are used to characterize the fabricated hybrid SS composites to study and assess mechanical stability. A rheo-kinetic cure model was developed for the core material to allow for additive manufacturing process requirements while ensuring complete cross-linking for the thermoset-based core material. Because of the ability to obtain relatively small core-thickness and controlled architecture, this method now allows for fabricating layered micro-sandwich structures for realizing further light-weighting in relevant applications.

Original languageEnglish
Pages (from-to)112-127
Number of pages16
JournalJournal of Sandwich Structures and Materials
Volume25
Issue number1
DOIs
StatePublished - Jan 2023
Externally publishedYes

Funding

The authors would like to thank other members of the Advincula Research Group (Department of Chemical and Biomechanical Engineering, University of Tennessee, Knoxville) and the Penumadu Research Group (Department of Civil and Environmental Engineering, University of Tennessee, Knoxville). Work (or part of this work) was conducted by ORNL’s Center for Nanophase Materials Sciences, which is a US Department of Energy Office of Science User Facility. The author(s) disclosed receipt of the following financial support for the research, authorship, and/or publication of this article: This work was supported by the DOE-EERE and Vehicle Technology Office. The author(s) disclosed receipt of the following financial support for the research, authorship, and/or publication of this article: This work was supported by the DOE-EERE and Vehicle Technology Office.

Keywords

  • additive manufacturing
  • direct ink writing
  • epoxy resin
  • hybrid manufacturing
  • sandwich structures

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