CAREER: Additive Manufacturing of Polymer Composites via in-situ Polymerization

职业：通过原位聚合增材制造聚合物复合材料

• 批准号: 2239563
• 负责人: Mostafa Yourdkhani
• 金额: $ 66.55万
• 依托单位: Colorado State University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2023
• 资助国家: 美国
• 起止时间: 2023-05-01 至 2028-04-30
• 项目状态: 未结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2239563&HistoricalAwards=false
• 关键词: CAREER; Additive; Manufacturing; Polymer; Composites

Traditional manufacturing of fiber-reinforced polymer composites is slow, energy-inefficient, and labor-intensive. It requires using expensive molds that severely limit the flexibility in the design and fabrication of complex composite structures. Additive manufacturing provides a promising alternative for rapidly creating desired composite structures without needing molds; however, additive manufacturing of high-quality fiber-reinforced composites is challenging, mainly because it is difficult to mix the matrix polymer with solid fiber reinforcements uniformly prior to deposition and then rigidize them in place along the desired print path. This Faculty Early Career Development (CAREER) award will support fundamental research that will enable additive manufacturing of composites containing a high concentration of carbon fibers by instantaneously rigidizing the composite material during the printing process. If successful, this project will lay a theoretical foundation for rapid manufacturing of composites without molds or even in midair. This project will provide hands-on activities to encourage Colorado’s middle and high school students, particularly women and Hispanic/Latinx students, in STEM education. New courses and experiential activities will be developed to train the next generation of composites workforce.Current approaches for the additive manufacturing of continuous fiber-reinforced polymer composites are mainly focused on using thermoplastic polymers or photocurable resins as the matrix polymer of composites, which typically have poor mechanical properties and/or are hard to process with a high volume-fraction of fibers. This project will investigate the manufacturing science of a new composite additive manufacturing method based on in-situ thermal polymerization of the matrix resin of composites. Central to this project is a new composite manufacturing platform that uses a remote stimulus to locally heat the thermo-responsive liquid resin of the composite filament to instantaneously polymerize and rigidize the printed composite. This project will elucidate the intrinsic interplay between process parameters, spatiotemporal variations in material composition and properties, and multiscale performance of printed composites. The proposed research is expected to uncover the mechanisms of interface formation and bonding control between adjacent layers. Experimental and numerical studies will be used to understand the viscoelastic deformation behavior and fiber distribution within filaments along multilayered, curvilinear paths during the manufacturing process. Finally, a new sensing and control framework will be developed to determine multiscale physical and thermochemical properties of materials during the manufacturing process and update the processing parameters on the fly to manufacture high-quality complex composite structures.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

纤维增强聚合物复合材料的传统制造速度慢、能源效率低且劳动力密集，需要使用昂贵的模具，这严重限制了复杂复合材料结构设计和制造的灵活性，增材制造为快速制造所需的材料提供了一种有前景的替代方案。不需要模具的复合材料结构；然而，高质量纤维增强复合材料的增材制造具有挑战性，主要是因为很难在沉积之前将基体聚合物与固体纤维增强材料均匀混合，然后将它们沿着所需的打印固定到位该学院早期职业发展（职业）奖将支持基础研究，通过在打印过程中瞬间硬化复合材料来实现含有高浓度碳纤维的复合材料的增材制造。如果成功，该项目将奠定理论基础。无需模具甚至在空中快速制造复合材料 该项目将提供实践活动，鼓励科罗拉多州的中学生，特别是女性和西班牙裔/拉丁裔学生，将开发新的课程和体验活动。培训下一代复合材料劳动力。目前连续纤维增强聚合物复合材料的增材制造方法主要集中于使用热塑性聚合物或光固化树脂作为复合材料的基体聚合物，这些聚合物通常机械性能较差和/或难以制备该项目将研究基于复合材料基体树脂原位热聚合的新型复合材料增材制造方法的制造科学，该项目的核心是使用新的复合材料制造平台。远程刺激可局部加热复合材料长丝的热响应液体树脂，从而瞬间聚合和硬化打印复合材料。该项目将阐明工艺参数、材料成分和性能的时空变化以及打印复合材料的多尺度性能之间的内在相互作用。所提出的研究预计将揭示相邻层之间界面形成和粘合控制的机制，实验和数值研究将用于了解长丝内的粘弹性变形行为和纤维分布。最后，将开发一种新的传感和控制框架，以确定制造过程中材料的多尺度物理和热化学特性，并动态更新加工参数，以制造高质量的复杂复合材料结构。该奖项反映了 NSF 的法定使命，并通过使用基金会的智力价值和更广泛的影响审查标准进行评估，被认为值得支持。