Systematic experimental exploration was carried out for the additive manufacturing process of continuous carbon fiber reinforced metal matrix composites. Results show that the molten metal matrix and the carbon fiber could be well infiltrated and compounded during the printing process after surface modification of the carbon fiber. The wire feeding speed had a great influence on the surface quality, path width and fiber volume fraction of a single deposition path. When the wire feeding speed was 4 mm/s, the surface quality of the single deposition path was good, the deposition path width was about 1.5 mm, and the volume fraction of carbon fiber was about 3.43%. The overlap rate of the deposition path had a great impact on the surface quality of the printed single layer. When the overlap rate was 50%, the surface quality of the printed single layer was relatively good. The additive manufacturing of continuous carbon fiber reinforced metal matrix composite thin-walled parts and tensile samples were realized based on the optimized experimental parameters. The carbon fiber in the thin-walled part formed a good combination with the metal matrix, and the continuous carbon fiber played a significant role in enhancing the tensile strength of the composite material.
Fig.1Principle of additive manufacturing process of continuous carbon fiber reinforced metal matrix composites
Fig.2Schematic diagram of overlap region formed between two adjacent trajectories
Fig.3Experimental results of surface modification of carbon fiber and its impregnation and composite with metal matrix
Fig.4Change of mass loss rate of copper-plated carbon fiber after cooling and heating cycles
Fig.5Morphology of single deposition path of composite material obtained under different wire feeding speed conditions
Fig.6Cross-section morphology of single deposition path
Fig.7Variation curve of width of single deposition path and its fiber volume fraction under different wire feeding speeds
Fig.8Surface topography of printed monolayers under different overlap ratios
Fig.9Continuous carbon fiber reinforced metal matrix composite thin-walled parts formed by additive manufacturing
Fig.10Micro morphology of combination of carbon fiber and metal matrix inside thin-walled parts
Fig.11Photographs of deposition molding, machining and breaking samples
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