MSc candidate
Project: Improving interlayer adhesion for large scale additive manufacturing tooling of composites
nicolas.courion [at] mail.mcgill.ca (Mail)
Supervisor: Prof Pascal Hubert
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Large scale hybrid manufacturing techniques have recently revealed challenges in achieving sufficient interlayer bonding for tooling parts measuring meters in size. Studies show that excessive layer times lead to poor bonding adhesion. However, printing parameters of single screw extruders can be modified to minimize layer times and improve interlayer adhesion.
This research project aims to investigate the thermal history associated with different layer times. By identifying the layer time range at which the substrate temperature falls below the glass transition temperature (Tg), this study seeks to optimize printing parameters to avoid this critical range. The material at hand is carbon fiber reinforced polycarbonate.
This research will employ a FE heat transfer model to simulate conduction, convection and radiation in the printed parts. ASTM5045, Single-edge-notch bending (SENB) will be employed to calculate fracture toughness of interlayer bonds of different layer times. Variability within each layer time is analyzed through crack initiation topography using light profilometry, while digital image correlation is used to identify pre-fracture strain fields. The study will focus on identifying optimal printer deposition speed, screw RPM and layer time to obtain consistent high-quality parts.
The project is expected to produce design charts that enable the user to select appropriate printing parameters to ensure strong interlayer bonding. This will minimize the risk of delamination and void formation both after the subtractive step of the hybrid process and during the cyclic use of the composite tool.
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