Additive manufacturing of short and continuous carbon fiber reinforced ceramic matrix composites by fused filament fabrication
FREUDENBERG W. 1, WICH F. 1, BEST J. 1, LANGHOF N. 1, SCHAFFÖNER S. 1
1 University of Bayreuth, Bayreuth, Germany
Ceramic matrix composites (CMC) are conventionally fabricated by multi-stage processes, finishing with a final subtractive step. Additive manufacturing (AM) of CMC facilitates a cost reduced manufacturing process because cutting machining waste is avoided. On the other hand, it is possible to place the fibers in load direction for an optimized mechanical performance. To fabricate carbon fiber reinforced ceramic matrix composites by additive manufacturing, fused filament fabrication (FFF) technology for short fiber reinforcement (< 250 µm) and the micro automated fiber placement (µAFP) technology for continuous fiber reinforcement were used. Due to the FFF and the µAFP method, it is necessary to use thermoplastic filaments and tapes, respectively. Therefore (“CF-PEEK”) filaments and endless fiber tapes with thermoplastic polyetheretherketone (PEEK) as the matrix and C-precursor were processed, fabricating carbon fiber reinforced polymers (CFRP) in a first step. In order to prevent a re-melting of the as-printed CFRPs during pyrolysis at 1000 °C in N2 ensuring the freedom of design and complex parts, a prior crosslinking step below the melting temperature was introduced to stabilize and crosslink the CFRP. The finalized near net shape and complex CMC parts were obtained by liquid silicon infiltration process (LSI). The effect of the different fiber length due to both used methods and raw materials were investigated with regard to the mechanical properties and the microstructure.