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Significant advances have been made in the past decade concerning silicon carbide fiber manufacturing methods resulting in near-stoichiometric small-diameter fibers that meet the property requirements for most of the ceramic matrix composites (CMC) and nuclear applications. The manufacturing cost, however, remained prohibitively high, preventing the use of it in different applications requiring much lower cost. Silicon carbide (SiC) fiber reinforced CMC is dominated by the cost of SiC fiber which comprises more than 50 % of the finished part cost. This article provides insight into the SiC fiber manufacturing costs and highlights the need for an alternative SiC fiber precursor and manufacturing method. Analysis of the existing polycarbosilane (PCS)-based SiC fiber manufacturing shows that the crosslinking (curing) and raw material preparation steps are high-cost steps that need lower cost options. Alternative SiC fiber precursor should be sought for lowering the cost of SiC fibers. [ABSTRACT FROM AUTHOR]

Recycled carbon fiber has historically proven challenging to integrate into composite manufacturing due in no small part to the low-density, randomly oriented, discontinuous fiber format that results from typical recycling. Discontinuous fiber requires the use of alternative technologies than those traditionally applied to continuous fiber (e.g., hand lay-up, winding). Extrusion compounding is one such applicable technology, but material transfer into the system requires alternative feeding equipment or the use of an altered procedure as trialed in this research. In this study, an injection molding compound for automotive applications was prepared with recycled carbon fiber and compared against an existing commercial compound. Input fibers and molded compound were evaluated for mechanical performance, while relevant variables such as compounded fiber alignment and aspect ratio were compared to the existing baseline material to confirm a like-for-like composite material structure. Analysis indicates that recycled fiber performs similarly to virgin fiber reinforcement, demonstrating that recycled fiber may be a viable drop-in replacement for short-fiber discontinuous applications. [ABSTRACT FROM AUTHOR]

Large format additive manufacturing (LFAM) necessitates the use of short fiber thermoplastic composites, such as carbon fiber filled acrylonitrile butadiene styrene, to enable printing. Currently, when LFAM parts are machined into their final shape, the machining scrap (i.e., small flake like particles and offcuts) is landfilled. Previous studies have demonstrated the viability of recycling end-of-life LFAM parts by shredding and optionally re-compounding the material back into pellets. However, there is little understanding of the value and performance of recycled material made from LFAM machining scrap, which if pursued could motivate more broad recycling of this waste stream. In this study, recycled in-process machining scrap is explored as an LFAM feedstock source. Herein, it is found that the primary degradation mechanism of the recycled material is significant fiber length attrition during surface machining. While this fiber attrition negatively impacts the mechanical performance of the material in the print direction, it seems that the changes in processing behaviors and print quality, namely the surface roughness of the printed structure associated with shorter fiber lengths, is beneficial to interlayer adhesion. The tensile strength and elastic modulus of the recycled material, in the print direction, decreased 11% and 31% respectively compared to the pristine material. However, in the layer-wise direction it was found that the recycled material exhibited no significant change in elastic modulus and a significant 21% increase in tensile strength – a surprising result. This work indicates that machining waste could be a viable material stream for recycled LFAM feedstock materials. [Display omitted] [ABSTRACT FROM AUTHOR]

Carbon fiber filled acrylonitrile butadiene styrene (CF-ABS) is an emerging 3-D printable, recyclable thermoplastic composite. A popular application for CF-ABS is printed molds using large scale additive manufacturing (AM) processes produced for a variety of composites end-users. Other applications have not been fully realized as CF-ABS currently has a higher cost than other polymer composite feedstocks. The cost of CF-ABS could be greatly reduced if recycled CF-ABS material was accepted and utilized industrially, which would further expand its application space. The impacts of mechanical recycling on the properties and performance of CF-ABS after AM or other processes are not yet fully understood. As such, most AM CF-ABS is discarded as waste after use. In this work, AM CF-ABS molds used for concrete castings were recycled using an industrial shredder/granulator system. The granulate was then used as feedstock for large area AM to print test specimens. The elastic moduli in the printing direction and transverse to printing direction after mechanical recycling were found to decrease by 25% and 10%, respectively, most likely caused by reductions in the fiber content and polymer molecular weight. It was found that a significant portion of carbon fiber is lost during mechanical recycling through dust generation, while the thermomechanical extrusion during printing caused the polymer degradation. Although the mechanical performance of CF-ABS was reduced after recycling, the recycled feedstock retained properties for reuse as printed molds using large area AM or another suitable application. [Display omitted] [ABSTRACT FROM AUTHOR]

As the flexibility, efficiency, and application space of additive manufacturing continues to grow, many have begun to investigate more sustainable feedstocks as well as options for the end of life of additively manufactured parts. This study examines the effects of mechanical recycling on additively manufactured parts from bio-based feedstock. Articles were printed on the Big Area Additive Manufacturing (BAAM) system at the Oak Ridge National Laboratory using poly (lactic acid)/wood flour (PLA/WF) pellets. These parts were shredded and granulated, and the granulate was fed directly back into the BAAM system for re-printing, skipping the costly and energy-intensive steps of extrusion and pelletization. The chemical, mechanical, thermal, and rheological changes to PLA/WF before and after recycling were investigated. Additionally, the energy savings from directly printing granulate on the BAAM system without extrusion and pelletization is reported. It is shown that PLA/WF is an excellent candidate for recycling of large format additively manufactured parts, and value of these parts can be reclaimed while saving cost and energy through mechanical recycling. [ABSTRACT FROM AUTHOR]

Cellulose nanomaterials (CNMs) naturally exist in plant biomass. The success of extraction of CNMs opened up a new era of using plant biomass for innovative industrial applications. Because CNMs are abundant, renewable, biodegradable, transparent, light weight and low in cost, they are ideal materials for large volume applications such as packaging, automotive, building and infrastructure. In many potential application areas, CNM-enabled products appear in a composite form, mostly polymer composites. The industrial-scale manufacturing of CNM/thermoplastic composites remains as a set of unsolved problems for academia and industry. A prime challenge in applications is the nanoscale dispersion of CNMs in thermoplastic matrices during melt processing. Both bench-scale and pilot-scale studies have been conducted to solve the dispersion issue of CNMs. In this article, research related to the dispersion of CNMs in thermoplastic matrices during melt processing were critically reviewed. All research papers were classified into three groups: chemically-aided dispersion, physically-aided dispersion and mechanically-aided dispersion. Numerous factors affect the CNM dispersion and the mechanical performance of its nanocomposites. There are material-related factors, including CNM types and forms, polymer matrices, surface modification, coupling agents, etc. Extrusion processing parameters also play a significant role, covering screw rotation speed, extrusion barrel temperature settings and screw design. In addition, the material-related factors interact with the processing-related factors. Understanding all factors and their interactions are important for moving CNM nanocomposites research a step further towards industrial-relevant production, which is the final ambitious goal of this manuscript. Image 1 [ABSTRACT FROM AUTHOR]

Demands for reducing energy consumption and environmental impacts are the major driving factors for the development of natural fiber–reinforced composites (NFRCs) in many sectors. Compared with synthesized fiber, natural fiber provides several advantages in terms of biodegradability, light weight, low price, life-cycle superiority, and satisfactory mechanical properties. However, the inherent features of plant-based natural fibers have presented challenges to the development and application of NFRCs, such as variable fiber quality, limited mechanical properties, water absorption, low thermal stability, incompatibility with hydrophobic matrices, and propensity to agglomeration. Substantial research has recently been conducted to address these challenges for improved performance of NFRCs and their applications. This article reviews the recent advancements of plant-based NFRCs, focusing on strategies and breakthroughs in enhancing the NFRCs' performance, including fiber modification, fiber hybridization, lignocellulosic fillers incorporation, conventional processing techniques, additive manufacturing (3D printing), and new fiber source exploration. The sustainability of plant-based NFRCs using life-cycle assessment and the burgeoning applications of NFRCs with emphasis on the automotive industry are also discussed. [ABSTRACT FROM AUTHOR]

Advanced biocomposites reinforced by abundant biomass-derived fillers can add a revenue stream to enhance the economic viability of biofuel production chains and the energy efficiency of the composite industry. However, the low stiffness of biopolymers limits their use in structural applications. Poplar fibers (mesh size: <180 μm, Populus spp.), an abundant waste from the wood industry, were used as bio-filler to fabricate high-performance biocomposites based on polylactic acid (PLA), in which the poplar fibers were modified by an amino acid (l -lysine). As a benefit of the amino acid treatment, the tensile Young's moduli of the lysine/poplar/PLA composites increased by up to 68% with the addition of a small amount of lysine, compared with neat PLA. At the same time, the tensile strength, failure strain, and Young's modulus of the poplar/PLA composites all increased after adding only 0.1 wt % of lysine. It has been observed that the lysine content has a significant effect on the decomposition temperature, complex viscosity, storage modulus, crystallization temperature, and crystallinity of composites. The fracture surfaces of the composites with an optimum lysine content had fewer voids and were more compact compared with composites without any lysine. The pores on the surfaces of poplar fibers became more available for the penetration of PLA molecules as a result of lysine addition. Therefore, this study presents a facile method for reinforcing biocomposites with extremely low-cost and environmentally friendly biofillers. Image 1 • A small amount of amino acid improved the fiber/PLA interfacial adhesion. • Poplar/PLA composites with 0.1 wt% lysine exhibited best tensile strength and modulus. • Poplar/PLA composites with 0.1 wt% lysine exhibited superior rheology for 3D printing. • A proposed mechanism in composites: chain extension, cross-linking, and degradation. [ABSTRACT FROM AUTHOR]

For the successful transition of additive manufacturing (AM) from prototyping to manufacturing of structural load bearing parts, feedstock systems with improved mechanical properties are needed. In terms of sustainability and environmental impact, selection of biobased renewable alternatives instead of petroleum-based options is important. Nanocellulose, which gives plants and trees their structural integrity, can offer significant improvements in the mechanical properties of AM polymers, provided that the right fibril morphology, dispersion and adhesion are achieved. In this study, although the interfacial adhesion between the hydrophilic cellulose nanofibrils (CNFs) and the hydrophobic polylactate matrix was not strong, and the optimal dispersion in individual fibril level was not attained, dramatic improvements in mechanical properties of neat polymer were achieved (up to 80% tensile strength increase, up to 200% elastic modulus increase). An interlocking reinforcing mechanism in which CNF bundles act as "microsponges" was proposed and supported by high resolution electron microscopy images, x-ray computed chromatography scans and thermal and dynamic mechanical behavior. Additively manufactured samples showed significantly higher elastic modulus (7.12 GPa vs. 6.57 GPa at 30 wt % CNF content) and dramatically improved storage modulus (1.72 GPa vs. 0.9 GPa at 30 wt % CNF content) in the printing direction compared to compression molded samples. In conclusion, preparation and 3D-printing of a 100% biobased renewable feedstock material with substantial mechanical property improvements were successfully demonstrated, which can open up new window of opportunities in the AM industry. [ABSTRACT FROM AUTHOR]