3D printed carbon fiber reinforced carbon as an energy efficient alternative to graphite for EFAS tooling

• Published in: Composites. Part B, Engineering Engineering, 2024-08, Vol.283, p.111679, Article 111679
• Main Authors: Preston, Arin S., Gorman, Andrew J., Matthews, Austin C., Rufner, Jorgen F.
• Format: Article
• Language: English
• Subjects: A. carbon–carbon composites (CCC'S); B. Electrical properties; B. Thermal properties; C-C; Carbon Fiber Reinfocred Carbon; E. Sintering; Electric Field Assisted Sintering (EFAS); Field Assisted Sintering Technique (FAST); MATERIALS SCIENCE; Spark Plasma Sintering (SPS)
• ISSN: 1359-8368
• DOI: 10.1016/j.compositesb.2024.111679

As Electric Field Assisted Sintering (EFAS) gains more industrial acceptance and use, it becomes more important to develop more efficient means to implement this technology. To this aim, 3D printed continuous carbon fiber reinforced carbon (CCC) was manufactured and fabricated into tooling for EFAS systems as an alternative to traditional graphite tooling. The impact of fiber orientation on the thermal and electrical properties of the CCC was characterized. Sample material was sintered in Tokai G535 graphite tooling, under common processing conditions and compared with CCC tooling. There was nearly 50 % energy savings compared to graphite while maintaining equivalent sample density and microstructure plus keeping ram temperatures 39 % cooler. This is due to spatial control of generated heat and thermal diffusivity within the molds, by means of fiber orientation anisotropy. Finite element modeling of the tooling design supported the experimental results as well as displays the effect of optimization of this 3D printed CCC material. [Display omitted] •Carbon Fiber Reinforced Carbon as tooling for Electric Field Assisted Sintering.•Reduced power requirements for similar heating compared to graphite.•Greater strength enables less material to be used in die walls.•Sintered sample quality is comparable to sintering by graphite tooling.•3D printing of carbon fiber enables tailorable heat profiles.