Polymeric composites with multi-functionality offer significant advantages over metals, including lightweight, high strength and stiffness, corrosion and fatigue resistance, etc. Additively manufactured composites draw intensive attention over the past decade due to that they exhibit the large potential to extend their applications from rapid prototyping to functional end-use components. Moreover, advances in additive manufacturing (AM) open new perspectives for the next generation of design and manufacturing of composites, which possess spatially digitalized and materialized arrangement of material/structure in a voxel-by-voxel manner. This review examines the work performed in this fast-growing field and elaborates its future perspectives and potentials. Specifically, the polymer AM processes incorporating different types of reinforcements are discussed in terms of mechanism, feedstocks, their advantages, and constraints. Then, the AM-driven designs for polymeric composites on multiscale and for multi-functional applications are emphasized. Further, emerging research topics including digital composites, intelligence/data-driven design approaches, and four-dimensional printing are further addressed with the careful analysis of existing gaps and future research trends. Finally, this review is concluded with an outlook on future research opportunities on AM-fabricated composites from design to fabrication. This review aims to provide a comprehensive guide to the stakeholders who want to utilize or develop an AM process for polymeric composites.

Additive manufacturing of polymeric composites from material processing to structural design

Additive manufacturing of continuous fiber reinforced polymer composites: Design opportunities and novel applications

In recent years, three-dimensional printing (3DP) technology has developed to include composite materials. Most of the development to date in this area has involved particulate or short fibre reinforced composites, whilst continuous fibre printing remains a relatively novel research area. This review paper focuses on the state-of-the-art of continuous fibre reinforced 3DP technology (CF-3DP). The materials and devices being used in the current studies are reviewed, and the different processing methods are discussed in detail. A thorough summary of the mechanical properties is provided. Despite improvements compared to 3D printed pure plastics, the performance of current continuous fibre 3D printed composites are not yet in a position to compete with conventionally processed composites due to defects and low fibre volume fraction. Finally, an overview of current potential applications are presented. However, challenges still remain in materials and process development. New design, modelling and analysis methods are needed before these novel composite structures can find their optimal applications.

pdf/material-extrusion-additive-manufacturing-of-continuous-57mjxpiavk.pdf

Material extrusion additive manufacturing of continuous fibre reinforced polymer matrix composites: A review and outlook

Continuous fiber reinforced polymer composites (CFRPC) have been widely used in the field of automobile, aircraft, and space due to light weight, high specific strength and modulus in comparison with metal as well as alloys. Innovation on 3D printing of CFRPCs opened a new era for the design and fabrication of complicated composite structure with high performance and low cost. 3D printing of CFRPCs provided an enabling technology to bridge the gaps between advanced materials and innovative structures. State-of-art has been reviewed according to the correlations of materials, structure, process, and performance as well as functions in 3D printing of CFRPCs. Typical applications and future perspective for 3D printing of CFRPCs were illustrated in order to grasp the opportunities and face the challenges, which need much more interdisciplinary researches covering the advanced materials, process and equipment, structural design, and final smart performance. 

3D Printing of Continuous Fiber Reinforced Polymer Composites: Development, Application, and Prospective

Three-dimensional (3D) printing is a potential rapid prototyping process that may replace traditional manufacturing processes to fabricate lightweight cellular structures with superior energy absorption performance. In the present work, continuous fiber reinforced composite honeycomb structures (CFRCHSs) with excellent shape memory properties were manufactured through a fused filament fabrication (FFF) technology, and their out-of-plane/in-plane compression behaviors and energy absorption characteristics were experimentally investigated. The results reveal that the failure process of the 3D printed CFRCHSs under in-plane loading is that the honeycomb cells collapse layer by layer along the loading direction，accompanied by the formation of a localized band. The crashworthiness analysis indicates that the 3D printed CFRCHSs outperform several competitive cellular topologies in the compression strength and specific energy absorption. A simplified analytical model for the in-plane compression strength of CFRCHSs was derived, and good agreement between measurements and predictions was observed. Additionally, the shape recovery tests demonstrate that the 3D printed CFRCHSs possess the potential as key elements of lightweight intelligent systems and adjustable energy absorbing devices.

Compression behavior and energy absorption of 3D printed continuous fiber reinforced composite honeycomb structures with shape memory effects

Continuous fiber-reinforced thermosetting polymer composites (CFRTPCs) were prepared via three-dimensional (3D) printing in this study. The entire process was divided into impregnation, printing, and curing stages. The impregnation stage ensured a tightly bonded interface and uniform distribution of fibers and resin. The printing stage solved the great conveying resistance and poor adhesion caused by the addition of continuous fibers. The curing stage aimed to preserve the shapes of the pre-formed samples and completed the polymerization and crosslinking reactions. An investigation into the experimental design focused on optimizing the parameters of the manufacturing process, wherein printing speed, printing space, printing thickness, curing pressure, and curing temperature were selected as target variables. Finally, 3D printed CFRTPC samples with 58 wt.% fiber content exhibited maximum flexural strength and modulus of 952.89 MPa and 74.05 GPa, respectively. Moreover, complex CFRTPC components were fabricated to demonstrate the feasibility and generality of the proposed technique. These results may broaden the potential use of 3D printed CFRTPCs in aerospace, defense, and automotive applications.

Investigation on process parameters of 3D printed continuous carbon fiber-reinforced thermosetting epoxy composites

Compressive strength and microstructural analysis of recycled coarse aggregate concrete treated with silica fume

Three-dimensional printing of continuous carbon fiber/epoxy composites (CCF/EPCs) is an emerging additive manufacturing technology for fiber-reinforced polymer composites and has wide application prospects. However, the 3D printing parameters and their relationship with the mechanical properties of the final printed samples have not been fully investigated in a computational and quantifiable way. This paper presents a sensitivity analysis (SA)-based parameter optimization framework for the 3D printing of CCF/EPCs. A surrogate model for a process parameter-mechanical property relationship was established by support vector regression (SVR) analysis of the experimental data on flexural strength and flexural modulus under different process parameters. An SA was then performed on the SVR surrogate model to calculate the importance of each individual 3D printing parameter on the mechanical properties of the printed samples. Based on the SA results, the optimal 3D printing parameters and the corresponding flexural strength and flexural modulus of the printed samples were predicted and verified by experiments. The results showed that the proposed framework can serve as a high-accuracy tool to optimize the 3D printing parameters for the additive manufacturing of CCF/EPCs.

https://www.mdpi.com/1996-1944/12/23/3961/pdf

A Sensitivity Analysis-Based Parameter Optimization Framework for 3D Printing of Continuous Carbon Fiber/Epoxy Composites.

Zirconium (Zr) hydrides threaten the reliability of fuel assembly and have repeatedly induced failures in cladding tubes and pressure vessels. Thus, they attract a broad range of research interests. For example, delayed hydride cracking induced a severe fracture and failure in a Zircaloy-2 pressure tube in 1983, causing the emergency shutdown of the Pickering nuclear reactor. Hydride has high hardness and very low toughness, and it tends to aggregate toward cooler or tensile regions, which initiates localized hydride precipitation and results in delayed hydride cracking. Notably, hydride reorientation under tensile stress substantially decreases the fracture toughness and increases the ductile-to-brittle transition temperature of Zr alloys, which reduces the safety of the long-term storage of spent nuclear fuel. Therefore, improving our knowledge of Zr hydrides is useful for effectively controlling hydride embrittlement in fuel assembly. The aim of this review is to reorganize the mechanisms of hydride nucleation and growth behaviors, hydride reorientation under external stress, and hydride-induced embrittlement. We revisit important examples of progress of research in this field and emphasize the key future aspects of research on Zr hydrides.

/pdf/mechanisms-of-hydride-nucleation-growth-reorientation-and-173yhmq4.pdf

Mechanisms of Hydride Nucleation, Growth, Reorientation, and Embrittlement in Zirconium: A Review

The land-use of organic fertilizers is considered as an important sustainable method for resource utilization, which may have an impact on the microplastic behaviors in the soil. Here, a 240-d dark culture experiment was conducted to reveal the degradation and biofilm characteristics of degradable and refractory granule microplastics in soil and soil-fertilizer systems. The results indicated that microplastics generally exhibited a weak weight loss as well as a specific etiolation on the surface after the culture, especially polyvinyl-chloride and polyhydroxyalkanoates (PHA). Increase in carbon-oxygen functional groups and the changes of oxygen/carbon ratios was noticed, which implied that oxidation and degradation occurred on the surface of microplastics during the cultural process. The changes were more intense on the degradable PHA, and the fertilized-soil treatment than those of the refractory microplastics and the pure soil. Moreover, the addition of organic fertilizers enriched the community diversity of bacterial biofilm on multiple microplastic surfaces. in this regard, the animal fertilizers provide a stronger effect than the plant fertilizers. Overall, the soil, fertilizer and microplastic types affected the community structure and diversity of bacterial biofilm. The outcomes of this study would provide a theoretical basis for the utilization of organic matters for agricultural soil applications. Organic fertilization is considered effective in improving the soil fertility. It may trigger microplastic degradation in the soil by introducing rich organic matters and microbial flora in soil. The study emphasizes that supplementation of organic fertilizers into the soil can promote the degradation of microplastics, by generating and increasing the number of oxygen-containing functional groups, and altering the microplastics unsaturation in the absence of light. The application of organic fertilizer into soil can significantly improve the aggregation of microorganisms on the surface of microplastics. In this regard, the soil, fertilizer or microplastic types affect the community structure of bacterial biofilm. 

Organic fertilizer facilitates the soil microplastic surface degradation and enriches the diversity of bacterial biofilm.

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