Continuous Fiber-Reinforced Material Extrusion with Hybrid Composites of Carbon and Aramid Fibers

An existing challenge in the use of continuous fiber reinforcements in additively manufactured parts is the limited availability of suitable fiber materials. This leads to a reduced adaptability of the mechanical properties to the load case. The increased design freedom of additive manufacturing allows the flexible deposition of fiber strands at defined positions, so that even different fiber materials can be easily combined in a printed part. In this work, therefore, an approach is taken to combine carbon and aramid fibers in printed composite parts to investigate their effects on mechanical properties. For this purpose, tensile, flexural and impact tests were performed on printed composite parts made of carbon and aramid fibers in a nylon matrix with five different mixing ratios. The tests showed that the use of hybrid composites for additive manufacturing is a reasonable approach to adapt the mechanical properties to the loading case at hand. The experiments showed that increasing the aramid fiber content resulted in an increase in impact strength, but a decrease in tensile and flexural strength and a decrease in stiffness. Microstructural investigations of the fracture surfaces showed that debonding and delamination were the main failure mechanisms. Finally, Rule of Hybrid Mixture equations were applied to predict the mechanical properties at different mixture ratios. This resulted in predicted values that differed from the experimentally determined values by an average of 5.6%.