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Embedding Carbon Fibers in a Steel Matrix Through Additive Manufacturing: A part of the World Class Material-project at Swerim AB
KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering.
KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering.
2019 (English)Independent thesis Basic level (degree of Bachelor), 10 credits / 15 HE creditsStudent thesis
Abstract [en]

In recent years, steel components manufactured through additive manufacturing have increased their popularity and commercial importance and carbon fiber reinforced polymers are widely used in today’s society. Yet there is no composite material combining the properties of steel and carbon fibers. This thesis work is a part of the World Class Material-project at Swerim AB where different methods for manufacturing a steel matrix carbon fiber composite are researched upon.

Two methods for additive manufacturing: selective laser melting and electron beam melting were used to evaluate the possibility of creating a steel matrix carbon fiber composite. The experiment with electron beam melting was conducted without powder and the two selective laser melting experiments were conducted with powder using fibers with organic and metal coating respectively. The main aspect evaluated was the survival of carbon fibers during processing.

The results showed no intact carbon fibers after processing organically sized fibers in either of the processes. In the selective laser melting experiment with organic coating, big voids were found where the fiber bundles had been placed, showing no infiltration of powder or molten metal into the bundle prior to fiber breakdown. The metal-coated fibers survived partially but showed poor infiltration of matrix material into the carbon fiber bundle. The methods used in this report were not found suitable for the manufacturing of steel matrix carbon fiber composites.

Abstract [sv]

De senaste åren har additiv tillverkning av stålkomponenter blivit alltmer populärt och kolfiberarmerade polymerer används i stor utsträckning i dagens samhälle. Trots det finns det i nuläget inget kompositmaterial som kombinerar stål och kolfiber. Detta kandidatexamensarbete har varit en del av World Class Material-projektet på Swerim AB, där olika metoder för tillverkning av en kolfiberkomposit med stålmatris undersöks.

Två additiva tillverkningsmetoder, selective laser melting (SLM) och electron beam melting (EBM), användes för att utvärdera möjligheten att med dessa tillverka en stål-och kolfiberkomposit. Testet i EBM genomfördes utan pulver och i testerna SLM med pulver där fibrerna i ena försöket hade kvar sin organiska ytbeläggning och en metallbeläggning i det andra försöket. Den huvudsakliga aspekten som undersöktes var kolfibrernas förmåga att klara tillverkningsmiljön.

Det förekom inga intakta kolfiber efter processen i försöken med EBM och SLM med den organiska ytbeläggningen. Beträffande SLM-försöket, påträffades även stora håligheter där kolfiber befunnit sig, vilket visade på en bristfällig impregnering av fibrerna innan deras nedbrytning. Fibrerna som var belagda med en metall överlevde framställningsprocessen i en större utsträckning, men impregnationen var fortfarande bristfällig.

Metoderna som undersöktes i denna rapport var sålunda inte lämpliga för att tillverka en kolfiberkomposit med stålmatris.

Place, publisher, year, edition, pages
2019. , p. 34
Series
TRITA-ITM-EX ; 2019:516
National Category
Composite Science and Engineering
Identifiers
URN: urn:nbn:se:kth:diva-254355OAI: oai:DiVA.org:kth-254355DiVA, id: diva2:1331189
External cooperation
Swerim AB
Educational program
Master of Science in Engineering - Materials Design and Engineering
Presentation
2019-05-15, Jernkontoret, Kungsträdgårdsgatan 10, Stockholm, 08:00 (English)
Supervisors
Examiners
Available from: 2019-07-10 Created: 2019-06-26 Last updated: 2019-07-10Bibliographically approved

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