Phenolic carbon fiber composite inks for the additive manufacturing of carbon/carbon (C/C)

Caitlyn M. Clarkson; Connor Wyckoff; William Costakis; Andrew Abbott; Andrew Schlup; James W. Kemp; Lisa M. Rueschhoff; Matthew B. Dickerson; Hilmar Koerner

doi:10.1016/j.addma.2024.104056

Phenolic carbon fiber composite inks for the additive manufacturing of carbon/carbon (C/C)

Caitlyn M. Clarkson, Connor Wyckoff, William Costakis, Andrew Abbott, Andrew Schlup, James W. Kemp, Lisa M. Rueschhoff, Matthew B. Dickerson, Hilmar Koerner

Research output: Contribution to journal › Article › peer-review

5 Scopus citations

Abstract

Additive manufacturing (AM) is a crucial development area for high temperature, inorganic and ceramic materials which, using conventional methods, are difficult to process into complex shapes. In particular, carbon/carbon (C/C) composites produced using AM techniques are underexplored compared to other ceramics and ceramic matrix composites. This work investigated and optimized the development of phenolic resin/carbon fiber inks for the material extrusion technique of direct ink writing (DIW) to form C/C composites. Utilizing recent advances in the material extrusion of ceramics, namely the DIW preceramic polymers and preceramic polymer-based suspensions or slurries, we were able to create C/C composites. AM processes can be used to obtain complex geometries and material extrusion processes also facilitate the alignment of high aspect ratio fillers, like carbon fiber, which affects material properties like strength or stiffness. Formulation of material extrusion inks from phenolic resole resin, pitch-based milled carbon fiber as a reinforcement, and a low-density carbon black filler is reported herein. The effects of carbon fiber content and filler, which was used to obtain a printable rheology and appreciable yield stress are discussed in the context of printability.

Original language	English
Article number	104056
Journal	Additive Manufacturing
Volume	83
DOIs	https://doi.org/10.1016/j.addma.2024.104056
State	Published - Mar 5 2024
Externally published	Yes

Funding

This research was conducted while Dr. Caitlyn Clarkson and Dr. William Costakis, Jr. held National Research Council (NRC) Research Associateship awards at the Air Force Research Laboratory. The authors acknowledge support from the Air Force Research Laboratory Materials & Manufacturing Directorate including core and laboratory director's funds. Research was performed by UES employees (Connor Wyckoff, Dr. Andrew Schlup, Dr. James W. Kemp) on site at AFRL/RX under contract FA8650-15-D-5230. We thank Mr. Randall Corns for operating the furnaces, Dr. HJ Kim, and Mr. Andrew Abbott for their helpful advice. We would also like to thank Dr. Ashley Hilmas and Bryant Burton for their support in the analysis of X-ray CT data. DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited, AFRL-2023-4601. This research was conducted while Dr. Caitlyn Clarkson and Dr. William Costakis, Jr. held National Research Council (NRC) Research Associateship awards at the Air Force Research Laboratory. The authors acknowledge support from the Air Force Research Laboratory Materials & Manufacturing Directorate including core and laboratory director’s funds. Research was performed by UES employees (Connor Wyckoff, Dr. Andrew Schlup, Dr. James W. Kemp) on site at AFRL/RX under contract FA8650-15-D-5230. We thank Mr. Randall Corns for operating the furnaces, Dr. HJ Kim, and Mr. Andrew Abbott for their helpful advice. We would also like to thank Dr. Ashley Hilmas and Bryant Burton for their support in the analysis of X-ray CT data. DISTRIBUTION STATEMENT A. Approved for public release: distribution unlimited, AFRL-2023-4601.

Keywords

Additive manufacturing
Carbon-fiber composite
Carbon/carbon
Direct ink writing
Phenolic

UN SDGs

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

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10.1016/j.addma.2024.104056

Cite this

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title = "Phenolic carbon fiber composite inks for the additive manufacturing of carbon/carbon (C/C)",

abstract = "Additive manufacturing (AM) is a crucial development area for high temperature, inorganic and ceramic materials which, using conventional methods, are difficult to process into complex shapes. In particular, carbon/carbon (C/C) composites produced using AM techniques are underexplored compared to other ceramics and ceramic matrix composites. This work investigated and optimized the development of phenolic resin/carbon fiber inks for the material extrusion technique of direct ink writing (DIW) to form C/C composites. Utilizing recent advances in the material extrusion of ceramics, namely the DIW preceramic polymers and preceramic polymer-based suspensions or slurries, we were able to create C/C composites. AM processes can be used to obtain complex geometries and material extrusion processes also facilitate the alignment of high aspect ratio fillers, like carbon fiber, which affects material properties like strength or stiffness. Formulation of material extrusion inks from phenolic resole resin, pitch-based milled carbon fiber as a reinforcement, and a low-density carbon black filler is reported herein. The effects of carbon fiber content and filler, which was used to obtain a printable rheology and appreciable yield stress are discussed in the context of printability.",

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AU - Schlup, Andrew

AU - Kemp, James W.

AU - Rueschhoff, Lisa M.

AU - Dickerson, Matthew B.

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AB - Additive manufacturing (AM) is a crucial development area for high temperature, inorganic and ceramic materials which, using conventional methods, are difficult to process into complex shapes. In particular, carbon/carbon (C/C) composites produced using AM techniques are underexplored compared to other ceramics and ceramic matrix composites. This work investigated and optimized the development of phenolic resin/carbon fiber inks for the material extrusion technique of direct ink writing (DIW) to form C/C composites. Utilizing recent advances in the material extrusion of ceramics, namely the DIW preceramic polymers and preceramic polymer-based suspensions or slurries, we were able to create C/C composites. AM processes can be used to obtain complex geometries and material extrusion processes also facilitate the alignment of high aspect ratio fillers, like carbon fiber, which affects material properties like strength or stiffness. Formulation of material extrusion inks from phenolic resole resin, pitch-based milled carbon fiber as a reinforcement, and a low-density carbon black filler is reported herein. The effects of carbon fiber content and filler, which was used to obtain a printable rheology and appreciable yield stress are discussed in the context of printability.

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Phenolic carbon fiber composite inks for the additive manufacturing of carbon/carbon (C/C)

Abstract

Funding

Keywords

UN SDGs

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