Improved Interlayer Performance of Short Carbon Fiber Reinforced Composites with Bio-Inspired Structured Interfaces

Abstract

The weak layer interfaces of 3D-printed short carbon fiber (SCF) reinforced polymer composites have remained an issue due to planar layer printing by traditional 3D printers. Recently, multi-axis 3D printing technology which can realize non-planar layer printing has been developed. This study’s aim was to evaluate and compare the bonding performance of non-planar interfaces produced by multi-axis 3D printing with that of planar interfaces. The tested non-planar interfaces were designed as bio-inspired structured interfaces (BISIs) based on microstructural interfacial elements in biological materials. The standard specimens with the 0°/90° and 0° infill line directions were printed by a robotic arm multi-axis 3D printer. Double cantilever beam (DCB) and end-notched flexure (ENF) tests were conducted to obtain Mode Ⅰ and Mode Ⅱ interlaminar toughness of SCF-reinforced composites. Test results showed that the critical energy release rates of the integrally formed BISI were significantly improved compared with the planar interface (PLAI) for both Mode I and Mode II delamination. In particular, the BISI with 0° infill line direction exhibited the greatest increase in critical energy release rate, and the damaged areas were spatially swept through the curved interfaces of the BISI with different infill line directions by scanning electron microscopy (SEM) and computed tomography (CT), which showed that the higher critical energy release rate was always accompanied with a larger damaged area. This work provides an in-depth investigation of the PLAI and BISI properties of SCF-reinforced composites, demonstrating the potential benefits of integrally formed BISI by multi-axis 3D printing and fostering new perspectives to enhance layer interfaces of 3D printed composites.

Keywords: Multi-axis 3D printing, Bio-inspired structured interface (BISI), Interfacial toughness, Short carbon fiber (SCF) reinforced composite