A novel metal matrix composite freeform fabrication approach, fiber traction printing (FTP), is demonstrated through controlling the wetting behavior between fibers and the matrix. This process utilizes the fiber bundle to control the cross-sectional shape of the liquid metal, shaping it from circular to rectangular which is more precise. The FTP process could resolve manufacturing difficulties in the complex structure of continuous fiber reinforced metal matrix composites. The printing of the first layer monofilament is discussed in detail, and the effects of the fibrous coating thickness on the mechanical properties and microstructures of the composite are also investigated in this paper. The composite material prepared by the FTP process has a tensile strength of 235.2 MPa, which is close to that of composites fabricated by conventional processes. The complex structures are printed to demonstrate the advantages and innovations of this approach. Moreover, the FTP method is suited to other material systems with good wettability, such as modified carbon fiber, surfactants, and aluminum alloys.
A novel metal matrix composite freeform fabrication approach, fiber traction printing (FTP), is demonstrated through controlling the wetting behavior between fibers and the matrix. This process utilizes the fiber bundle to control the cross-sectional shape of the liquid metal, shaping it from circular to rectangular which is more precise. The FTP process could resolve manufacturing difficulties in the complex structure of continuous fiber reinforced metal matrix composites. The printing of the first layer monofilament is discussed in detail, and the effects of the fibrous coating thickness on the mechanical properties and microstructures of the composite are also investigated in this paper. The composite material prepared by the FTP process has a tensile strength of 235.2 MPa, which is close to that of composites fabricated by conventional processes. The complex structures are printed to demonstrate the advantages and innovations of this approach. Moreover, the FTP method is suited to other material systems with good wettability, such as modified carbon fiber, surfactants, and aluminum alloys.
[1] K Lu. The future of metals. Science, 2010, 328(5976): 319–320.
[2] H A Hegab. Design for additive manufacturing of composite materials and potential alloys: A review. Manufacturing Review, 2016, 3: 1–17
[3] A Dey, K M Pandey. Characterization of fly ash and its reinforcement effect on metal matrix composites: A review. Reviews on Advanced Materials Science, 2016, 44(2): 168–181.
[4] K Shirvanimoghaddam, S U Hamim, M KarbalaeiAkbari, et al. Carbon fiber reinforced metal matrix composites: Fabrication processes and properties. Composites Part A: Applied Science and Manufacturing, 2017, 92: 70–96.
[5] T B Sercombe, X Li. Selective laser melting of aluminium and aluminium metal matrix composites: review. Materials Technology, 2016, 31(2): 77–85.
[6] B V Ramnath, C Elanchezhian, R M Annamalai, et al. Aluminium metal matrix composites - A review. Reviews on Advanced Materials Science, 2014, 38(1): 55–60.
[7] S Attar, M Nagaral, H N Reddappa, et al. A review on particulate reinforced aluminum metal matrix composites. Journal of Emerging Technologies and Innovative Research, 2015, 2(2): 225–229.
[8] J Singh. Fabrication characteristics and tribological behavior of Al/SiC/Gr hybrid aluminum matrix composites: A review. Friction, 2016, 4(3): 191–207.
[9] S S Sidhu, A Batish, S Kumar. Fabrication and electrical discharge machining of metal-matrix composites: A review. Journal of Reinforced Plastics and Composites, 2013, 32(17): 1310–1320.
[10] S Liu, Y Li, N Li. A novel free-hanging 3D printing method for continuous carbon fiber reinforced thermoplastic lattice truss core structures. Materials & Design, 2018, 137: 235–244.
[11] Y Ming, Y Duan, B Wang, et al. A novel route to fabricate high-performance 3D printed continuous fiber-reinforced thermosetting polymer composites. Materials, 2019, 12(9): 1369.
[12] Dichen L, Jiankang H, Xiaoyong T, et al. Additive manufacturing: integrated fabrication of macro/microstructures. Journal of Mechanical Engineering, 2013, 49(06): 129–135. (in Chinese)
[13] D Herzog, V Seyda, E Wycisk, et al. Additive manufacturing of metals. ActaMaterialia, 2016, 117: 371–392.
[14] H Warren-Forward, P Cardew, B Smith, et al. A comparison of dose savings of lead and lightweight aprons for shielding of 99m-Technetium radiation. Radiation Protection Dosimetry, 2007, 124(2): 89–96.
[15] J X Wen, W N Wang, Q Guo, et al. Gamma-ray radiation on magneto-optical property of Pb-doped silica fiber. Journal of Inorganic Materials, 2018, 33(4): 416–420.
[16] M Kurudirek. Effective atomic number, energy loss and radiation damage studies in some materials commonly used in nuclear applications for heavy charged particles such as H, C, Mg, Fe, Te, Pb and U. Radiation Physics and Chemistry, 2016, 122: 15–23.
[17] J Mireles, H C Kim, I H Lee, et al. Development of a fused deposition modeling system for low melting temperature metal alloys. Journal of Electronic Packaging, 2013, 135(1).
[18] C T Ho. Wear of carbon fibre-reinforced tin-lead alloy composites. Journal of Materials Science Letters, 1997, 16: 1767–1770.
[19] C T Ho. Nickel- and copper-coated carbon fibre reinforced tin-lead alloy composites. Journal of Materials Science, 1996, 31(21): 5781–5786.
[20] C T Ho. Carbon-fiber-reinforced tin-lead alloy composites. Journal of Materials Research, 1994, 9(8): 2144–2147.
[21] C T Ho, D D L Chung. Carbon-fiber reinforced tin-lead alloy as a low thermal-expansion solder preform. Journal of Materials Research, 1990, 5(6): 1266–1270.
[22] K C Mills, Y C Su. Review of surface tension data for metallic elements and alloys: Part 1 - Pure metals. International Materials Reviews, 2006, 51(6): 329–351.
[23] J Bico, B Roman, L Moulin, et al. Elastocapillary coalescence in wet hair. Nature, 2004, 432(7018): 690.
[24] R Cunningham, S P Narra, T Ozturk, et al. Evaluating the effect of processing parameters on porosity in electron beam melted Ti-6Al-4V via synchrotron X-ray microtomography. JOM, 2016, 68(3): 765–771.
[25] C C Yang, X Y Tian, T F Liu, et al. 3D printing for continuous fiber reinforced thermoplastic composites: mechanism and performance. Rapid Prototyping Journal, 2017, 23(1): 209–215.
[26] X Y Tian, T F Liu, C C Yang, et al. Interface and performance of 3D printed continuous carbon fiber reinforced PLA composites. Composites Part a-Applied Science and Manufacturing, 2016, 88: 198–205.
[27] X Y Tian, T F Liu, Q R Wang, et al. Recycling and remanufacturing of 3D printed continuous carbon fiber reinforced PLA composites. Journal of Cleaner Production, 2017, 142: 1609–1618.
[28] Z Hou, X Tian, Z J hang, et al. 3D printed continuous fibre reinforced composite corrugated structure. Composite Structures, 2018, 184: 1005–1010.
[29] M Luo, X Tian, W Zhu, et al. Controllable interlayer shear strength and crystallinity of PEEK components by laser-assisted material extrusion. Journal of Materials Research, 2018, 33(11): 1632–1641.
[30] X Wang, M Jiang, Z W Zhou, et al. 3D printing of polymer matrix composites: A review and prospective. Composites Part B-Engineering, 2017, 110: 442–458.
