Manufacturing and characterization of continuous carbon fiber reinforced polyphenylene sulfide filaments via melt impregnation method

Abstract

The utilization of continuous fiber-reinforced thermoplastic composites (CFRTP)in additive manufacturing technology (AM) is envisioned to enable the productionof high-performance parts with enhanced mechanical properties. In the productionof CFRTP filaments, ensuring proper impregnation plays a crucial role in improv-ing the characteristics of the produced filament. Carbon fiber (CF) reinforced poly-phenylene sulfide (PPS) composites find applications in secondary aerospace parts,automotive structural parts, and chemical process applications. Continuous CF-reinforced PPS filaments enable the production of lightweight, high-performancepartswithmechanicalstrength,heat,and chemical resistance in AM. In the pre-sent study, continuous CF-reinforced PPS filaments were produced using the meltimpregnation method for use in fused deposition modeling technology. Filamentdiameter, geometrical evenness, and effective fiber impregnation are important cri-teria in filament production. An impregnation mold was designed and manufac-tured to provide impregnation. The influence of three different pin angles (56(omicron),70(omicron),and82(omicron)) on impregnation and mechanical properties has been investigated bydeveloping an impregnation die for CFRTP filament production. Tensile testing,fiber content analysis, optical microscopy, and scanning electron microscope analy-sis were performed on the produced filaments. Furthermore, increasing the pinangle leads to an increase in both the spreading and impregnation of fibers.