Process optimization of continuous aramid fiber reinforced PA12 filaments and printed composites

Abstract A multi‐stage fiber spreading process for the preparation of high‐performance continuous aramid fiber reinforced nylon 12 (CAF/PA12) composites was proposed in this paper. The effects of spreading rod crown radius, spreading rod axis height and traction speed on fiber impregnation effect and filaments properties were investigated. The fiber volume fraction of the prepared filament was approximately 30%. And the maximum tensile strength and modulus of the filaments were 839.89 MPa and 41.35 GPa, which were 34.36% and 34.30% higher than unspreading filaments, respectively. The influences of printing process parameters such as printing temperature, the combination of layer thickness and printing spacing on the transverse tensile properties of the specimens were studied. Printed specimens reached a transverse tensile strength and tensile modulus of 13.988 MPa and 1.293 GPa, respectively. The influences on low velocity impact properties of the specimens were also investigated in terms of impact energy and printing stacking sequences. Results revealed that the impact threshold energy of orthotropic ([0/90/0/90]₂) specimens was 50 J. Quasi‐isotropic ([0/45/90/−45]₂) specimens exhibited the superior impact resistance with an impact load of 4.939 kN. Macro‐ and micro‐matrix crack, surface buckling, fiber fracture and delamination were the main failure modes of the specimens. Highlights A novel thermoplastic composite filament forming process was proposed, and the filament forming equipment was designed and manufactured. Continuous aramid fiber‐reinforced PA12 filaments with about 30% fiber content were prepared by orthogonal tests under different forming process conditions, which showed maximum tensile properties of 839.89 MPa and 41.35 GPa, respectively. Spreading multiplication was positively related to filament tensile properties, which was major affected by the axial height of the spreading rod. Transverse tensile strength (13.988 MPa tensile strength and 1.293 GPa tensile modulus) of printed specimens was investigated under different printing parameters. Fiber orientation had a significant effect on the low‐velocity impact properties. Micro‐ and macro‐matrix crack, surface buckling, fiber fracture and delamination were the main failure modes of the low‐velocity impact specimens.