高性能聚芳醚酮及其复合材料粉末床熔融成形的现状与挑战
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摘要
粉末床熔融成形是增材制造技术中的一种,以聚合物及其复合粉末为原材料,可用于特种工程塑料聚芳醚酮及其复合材料的增材制造,无需任何工装和模具即可完成复杂结构制件的直接成形,为航空航天、汽车工业领域内对制件结构优化和快速开发提供了一种解决方案。介绍了粉末床熔融成形聚芳醚酮及其复合材料的国内外研究现状,从成形系统、原材料、成形工艺以及碳纤维增强聚芳醚酮复合材料增强机理与性能等几个方面展开了论述,并对粉末床熔融成形聚芳醚酮及其复合材料面临的挑战进行了分析。
Powder Bed Fusion, which is a kind of Additive Manufacturing processes, uses the polymer powder and its composite powder as raw material. It could directly fabricate the polyaryletherketone(PAEK) and its composites with high mechanical performance. By this technology, the parts with complex geometries could be prepared without any tooling or molding process, which provides a solution for structure optimization design and rapid development for high performance composite parts in the aerospace and automobile industry. In this paper, research status of the powder bed fusion of polyaryletherketone and its composites at home and abroad were introduced. The powder bed fusion system for PAEK, raw materials, process parameters, the enhanced PAEK composites and mechanical performances were discussed. At last, the challenges about the application of this technology were analyzed.
Powder Bed Fusion, which is a kind of Additive Manufacturing processes, uses the polymer powder and its composite powder as raw material. It could directly fabricate the polyaryletherketone(PAEK) and its composites with high mechanical performance. By this technology, the parts with complex geometries could be prepared without any tooling or molding process, which provides a solution for structure optimization design and rapid development for high performance composite parts in the aerospace and automobile industry. In this paper, research status of the powder bed fusion of polyaryletherketone and its composites at home and abroad were introduced. The powder bed fusion system for PAEK, raw materials, process parameters, the enhanced PAEK composites and mechanical performances were discussed. At last, the challenges about the application of this technology were analyzed.
引文
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[5]SUTTON A T,KRIEWALL C S,LEU M C,et al.Powder Characterisation Techniques and Effects of Powder Characteristics on Part Properties in Powder-bed Fusion Processes[J].Virtual and Physical Prototyping,2017,12(1):3-29.
[6]KRUTH J P,WANG X,LAOUI T,et al.Lasers and Materials in Selective Laser Sintering[J].Assembly Automation,2003,23(4):357-371.
[7]SCHMID M,AMADO A,WEGENER K.Polymer Powders for Selective Laser Sintering(SLS)[C]//AIPConference Proceedings,AIP Publishing LLC,2015.
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[9]?ERCER A P B V.Influence of SLS Processing Parameters According to the New Mathematical Model on Flexural Properties[J].Rapid Prototyping Journal,2016,22(2):258-268.
[10]GOODRIDGE R D,TUCK C J,HAGUE R J M.Laser Sintering of Polyamides and Other Polymers[J].Progress in Materials Science,2012,57(2):229-267.
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[12]HARSHA A P,TEWARI U S.Tribo Performance of Polyaryletherketone Composites[J].Polymer Testing,2002,21(6):697-709.
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[14]REGIS M,BELLARE A,PASCOLINI T,et al.Characterization of Thermally Annealed PEEK and CFR-PEEKComposites:Structure-properties Relationships[J].Polymer Degradation and Stability,2017,136:121-130.
[15]RASHEVA Z,ZHANG G,BURKHART T.A Correlation Between the Tribological and Mechanical Properties of Short Carbon Fibers Reinforced PEEK Materials with Different Fiber Orientations[J].Tribology International,2010,43(8):1430-1437.
[16]STEINBERG E L,RATH E,SHLAIFER A,et al.Carbon Fiber Reinforced PEEK Optima-A Composite Material Biomechanical Properties and Wear/Debris Characteristics of CF-PEEK Composites for Orthopedic Trauma Implants[J].Journal of the Mechanical Behavior of Biomedical Materials,2013,17:221-228.
[17]PARK S Y,CHOI H S,CHOI W J,et al.Effect of Vacuum Thermal Cyclic Exposures on Unidirectional Carbon Fiber/Epoxy Composites for Low Earth Orbit Space Applications[J].Composites Part B:Engineering,2012,43(2):726-738.
[18]EOS.EOS P 810-High-temperature Polymer Laser Sintering Solution for Serial Production of Demanding Composite Components[EB/OL].(2019-04-30)[2019-06-28].https://www.eos.info/systems_solutions/eos-p-810.
[19]BERRETTA S,WANG Y,DAVIES R,et al.Polymer Viscosity,Particle Coalescence and Mechanical Performance in High-temperature Laser Sintering[J].Journal of Materials Science,2016,51(10):4778-4794.
[20]PEYRE P,ROUCHAUSSE Y,DEFAUCHY D,et al.Experimental and Numerical Analysis of the Selective Laser Sintering(SLS)of PA12 and PEKKSemi-crystalline Polymers[J].Journal of Materials Processing Technology,2015,225:326-336.
[21]EOS.EOS P800-Additive Manufacturing System for Processing High Performance Polymers[EB/OL].(2019-01-30)[2019-06-28].https://www.eos.info/systems_solutions/plastic/systems_equipment/eosint_p_800.
[22]EOS.EOS PEEK HP3[EB/OL].(2018-11-22)[2019-06-28].https://eos.materialdatacenter.com/eo/en.
[23]NAZAROV A,SKORNYAKOV I,SHISHKOVSKY I.The Setup Design for Selective Laser Sintering of High-Temperature Polymer Materials with the Alignment Control System of Layer Deposition[J].Machines,2018,6(1):11.
[24]YAN M,TIAN X,PENG G,et al.High Temperature Rheological Behavior and Sintering Kinetics of CF/PEEK Composites during Selective Laser Sintering[J].Composites Science and Technology,2018,165:140-147.
[25]YAZDANI B,CHEN B,BENEDETTI L,et al.A New Method to Prepare Composite Powders Customized for High Temperature Laser Sintering[J].Composites Science and Technology,2018,167:243-250.
[26]BERRETTA S,GHITA O,EVANS K E.Morphology of Polymeric Powders in Laser Sintering(LS):From Polyamide to New PEEK Powders[J].European Polymer Journal,2014,59:218-229.
[27]WANG Y,JAMES E,GHITA O R.Glass Bead Filled Polyetherketone(PEK)Composite by High Temperature Laser Sintering(HT-LS)[J].Materials&Design,2015,83:545-551.
[28]WANG Y,ROUHOLAMIN D,DAVIES R,et al.Powder Characteristics,Microstructure and Properties of Graphite Platelet Reinforced Poly Ether Ether Ketone Composites in High Temperature Laser Sintering(HT-LS)[J].Materials&Design,2015,88:1310-1320.
[29]YAZDANI B,CHEN B,BENEDETTI L,et al.A New Method to Prepare Composite Powders Customized for High Temperature Laser Sintering[J].Composites Science and Technology,2018,167:243-250.
[30]CHEN B L,WANG Y,BERRETTA S,et al.Poly Aryl Ether Ketones(PAEKs)and Carbon-reinforced PAEKPowders for Laser Sintering[J].Journal of Materials Science,2017,52(10):6004-6019.
[31]CHEN B L,BERRETTA S,EVANS K,et al.A Primary Study into Graphene/Polyether Ether Ketone(PEEK)Nanocomposite for Laser Sintering[J].Applied Surface Science,2018,428:1018-1028.
[32]CHEN B,YAZDANI B,BENEDETTI L,et al.Fabrication of Nanocomposite Powders with a Core-shell Structure[J].Composites Science and Technology,2019(170):116-127.
[33]BERRETTA S,EVANS K E,GHITA O.Processability of PEEK,a New Polymer for High Temperature Laser Sintering(HT-LS)[J].European Polymer Journal,2015,68:243-266.
[34]BERRETTA S,EVANS K E,GHITA O R.Predicting Processing Parameters in High Temperature Laser Sintering(HT-LS)from Powder Properties[J].Journal of Materials Science,2016,51(10):4778-4794.
[35]GHITA O,JAMES E,DAVIES R,et al.High Temperature Laser Sintering(HT-LS):An Investigation into Mechanical Properties and Shrinkage Characteristics of Poly(Ether Ketone)(PEK)Structures[J].Materials&Design,2014,61:124-132.
[36]GHITA O,JAMES E,TRIMBLE R,et al.Physico-chemical Behaviour of Poly(Ether Ketone)(PEK)in High Temperature Laser Sintering(HT-LS)[J].Journal of Materials Processing Technology,2014,214(4):969-978.
[37]CHEN B,BERRETTA S,DAVIES R,et al.Characterisation of Carbon Fibre(Cf)-Poly Ether Ketone(PEK)Composite Powders for Laser Sintering[J].Polymer Testing,2019(76):65-72.
[38]FISCHER S,PFISTER A,GALITZ V,et al.AHigh-performance Material for Aerospace Applications:Development of Carbon Fiber Filled PEKK for Laser Sintering:The 26th Annual International Solid Freeform Fabrication Symposium-An Additive Manufacturing Conference[C].2016.
[39]Advanced Laser Materials.HT-23[EB/OL].(2019-07-04)[2019-07-04].https://alm-llc.com/portfolio-items/ht-23/.
[2]KRUTH J P,MERCELIS P,VAN V J.Binding Mechanisms in Selective Laser Sintering and Selective Laser Melting[J].Rapid Prototyping Journal,2005,11(1):26-36.
[3]KHAIRALLAH S A,ANDERSON A T,RUBENCHIKA,et al.Laser Powder-bed Fusion Additive Manufacturing:Physics of Complex Melt Flow and Formation Mechanisms of Pores,Spatter,and Denudation Zones[J]Acta Materialia,2016,108:36-45.
[4]MOWER T M,LONG M J.Mechanical Behavior of Additive Manufactured,Powder-bed Laser-fused Materials[J].Materials Science and Engineering:A,2016,651:198-213.
[5]SUTTON A T,KRIEWALL C S,LEU M C,et al.Powder Characterisation Techniques and Effects of Powder Characteristics on Part Properties in Powder-bed Fusion Processes[J].Virtual and Physical Prototyping,2017,12(1):3-29.
[6]KRUTH J P,WANG X,LAOUI T,et al.Lasers and Materials in Selective Laser Sintering[J].Assembly Automation,2003,23(4):357-371.
[7]SCHMID M,AMADO A,WEGENER K.Polymer Powders for Selective Laser Sintering(SLS)[C]//AIPConference Proceedings,AIP Publishing LLC,2015.
[8]YUAN S,SHEN F,CHUA C,et al.Polymeric Composites for Powder-based Additive Manufacturing:Materials and Applications[J].Progress in Polymer Science,2019,91:141-168.
[9]?ERCER A P B V.Influence of SLS Processing Parameters According to the New Mathematical Model on Flexural Properties[J].Rapid Prototyping Journal,2016,22(2):258-268.
[10]GOODRIDGE R D,TUCK C J,HAGUE R J M.Laser Sintering of Polyamides and Other Polymers[J].Progress in Materials Science,2012,57(2):229-267.
[11]SHARMA M,BIJWE J,M?DER E,et al.Strengthening of CF/PEEK Interface to Improve the Tribological Performance in Low Amplitude Oscillating Wear Mode[J].Wear,2013,301(1/2):735-739.
[12]HARSHA A P,TEWARI U S.Tribo Performance of Polyaryletherketone Composites[J].Polymer Testing,2002,21(6):697-709.
[13]MATTHEW T.BISHOP F E K P.Solubility and Properties of a Poly(Aryl Ether Ketone)in Strong Acids[J].Macromolecules,1985,18:86-93.
[14]REGIS M,BELLARE A,PASCOLINI T,et al.Characterization of Thermally Annealed PEEK and CFR-PEEKComposites:Structure-properties Relationships[J].Polymer Degradation and Stability,2017,136:121-130.
[15]RASHEVA Z,ZHANG G,BURKHART T.A Correlation Between the Tribological and Mechanical Properties of Short Carbon Fibers Reinforced PEEK Materials with Different Fiber Orientations[J].Tribology International,2010,43(8):1430-1437.
[16]STEINBERG E L,RATH E,SHLAIFER A,et al.Carbon Fiber Reinforced PEEK Optima-A Composite Material Biomechanical Properties and Wear/Debris Characteristics of CF-PEEK Composites for Orthopedic Trauma Implants[J].Journal of the Mechanical Behavior of Biomedical Materials,2013,17:221-228.
[17]PARK S Y,CHOI H S,CHOI W J,et al.Effect of Vacuum Thermal Cyclic Exposures on Unidirectional Carbon Fiber/Epoxy Composites for Low Earth Orbit Space Applications[J].Composites Part B:Engineering,2012,43(2):726-738.
[18]EOS.EOS P 810-High-temperature Polymer Laser Sintering Solution for Serial Production of Demanding Composite Components[EB/OL].(2019-04-30)[2019-06-28].https://www.eos.info/systems_solutions/eos-p-810.
[19]BERRETTA S,WANG Y,DAVIES R,et al.Polymer Viscosity,Particle Coalescence and Mechanical Performance in High-temperature Laser Sintering[J].Journal of Materials Science,2016,51(10):4778-4794.
[20]PEYRE P,ROUCHAUSSE Y,DEFAUCHY D,et al.Experimental and Numerical Analysis of the Selective Laser Sintering(SLS)of PA12 and PEKKSemi-crystalline Polymers[J].Journal of Materials Processing Technology,2015,225:326-336.
[21]EOS.EOS P800-Additive Manufacturing System for Processing High Performance Polymers[EB/OL].(2019-01-30)[2019-06-28].https://www.eos.info/systems_solutions/plastic/systems_equipment/eosint_p_800.
[22]EOS.EOS PEEK HP3[EB/OL].(2018-11-22)[2019-06-28].https://eos.materialdatacenter.com/eo/en.
[23]NAZAROV A,SKORNYAKOV I,SHISHKOVSKY I.The Setup Design for Selective Laser Sintering of High-Temperature Polymer Materials with the Alignment Control System of Layer Deposition[J].Machines,2018,6(1):11.
[24]YAN M,TIAN X,PENG G,et al.High Temperature Rheological Behavior and Sintering Kinetics of CF/PEEK Composites during Selective Laser Sintering[J].Composites Science and Technology,2018,165:140-147.
[25]YAZDANI B,CHEN B,BENEDETTI L,et al.A New Method to Prepare Composite Powders Customized for High Temperature Laser Sintering[J].Composites Science and Technology,2018,167:243-250.
[26]BERRETTA S,GHITA O,EVANS K E.Morphology of Polymeric Powders in Laser Sintering(LS):From Polyamide to New PEEK Powders[J].European Polymer Journal,2014,59:218-229.
[27]WANG Y,JAMES E,GHITA O R.Glass Bead Filled Polyetherketone(PEK)Composite by High Temperature Laser Sintering(HT-LS)[J].Materials&Design,2015,83:545-551.
[28]WANG Y,ROUHOLAMIN D,DAVIES R,et al.Powder Characteristics,Microstructure and Properties of Graphite Platelet Reinforced Poly Ether Ether Ketone Composites in High Temperature Laser Sintering(HT-LS)[J].Materials&Design,2015,88:1310-1320.
[29]YAZDANI B,CHEN B,BENEDETTI L,et al.A New Method to Prepare Composite Powders Customized for High Temperature Laser Sintering[J].Composites Science and Technology,2018,167:243-250.
[30]CHEN B L,WANG Y,BERRETTA S,et al.Poly Aryl Ether Ketones(PAEKs)and Carbon-reinforced PAEKPowders for Laser Sintering[J].Journal of Materials Science,2017,52(10):6004-6019.
[31]CHEN B L,BERRETTA S,EVANS K,et al.A Primary Study into Graphene/Polyether Ether Ketone(PEEK)Nanocomposite for Laser Sintering[J].Applied Surface Science,2018,428:1018-1028.
[32]CHEN B,YAZDANI B,BENEDETTI L,et al.Fabrication of Nanocomposite Powders with a Core-shell Structure[J].Composites Science and Technology,2019(170):116-127.
[33]BERRETTA S,EVANS K E,GHITA O.Processability of PEEK,a New Polymer for High Temperature Laser Sintering(HT-LS)[J].European Polymer Journal,2015,68:243-266.
[34]BERRETTA S,EVANS K E,GHITA O R.Predicting Processing Parameters in High Temperature Laser Sintering(HT-LS)from Powder Properties[J].Journal of Materials Science,2016,51(10):4778-4794.
[35]GHITA O,JAMES E,DAVIES R,et al.High Temperature Laser Sintering(HT-LS):An Investigation into Mechanical Properties and Shrinkage Characteristics of Poly(Ether Ketone)(PEK)Structures[J].Materials&Design,2014,61:124-132.
[36]GHITA O,JAMES E,TRIMBLE R,et al.Physico-chemical Behaviour of Poly(Ether Ketone)(PEK)in High Temperature Laser Sintering(HT-LS)[J].Journal of Materials Processing Technology,2014,214(4):969-978.
[37]CHEN B,BERRETTA S,DAVIES R,et al.Characterisation of Carbon Fibre(Cf)-Poly Ether Ketone(PEK)Composite Powders for Laser Sintering[J].Polymer Testing,2019(76):65-72.
[38]FISCHER S,PFISTER A,GALITZ V,et al.AHigh-performance Material for Aerospace Applications:Development of Carbon Fiber Filled PEKK for Laser Sintering:The 26th Annual International Solid Freeform Fabrication Symposium-An Additive Manufacturing Conference[C].2016.
[39]Advanced Laser Materials.HT-23[EB/OL].(2019-07-04)[2019-07-04].https://alm-llc.com/portfolio-items/ht-23/.