SAMPE Journal - November/December 2021 - 41
Coupon Fabrication and Testing
Fabrication
Initial modeling and hand calculations predicted
that five plies of Hextool on each side of the AM
shell would be sufficient to restrain the thermal
expansion of the tool to a target range of less than
6 ppm/°C. Two coupon panels measuring 150 mm
by 150 mm were cut from a larger BAAM print.
After preparing the panel surfaces for bonding,
both panels were laminated with Hextool. One
panel was laminated with five plies and the other
was laminated with 6 plies. Both panels were cured
according the Hextool M81 datasheet6
.
PEI Tool
(as-printed)
Testing
After curing, holes were drilled into the four
corners of each coupon panel (Figure 2). Precision
metal dowels, measuring 4.5 mm in diameter, were
installed in the holes. A handheld caliper was used
to measure the distance between the dowels in the
x and y direction. After recording these values, the
panels were soaked in a 180°C oven until the panels
had reached steady state, as determined by an
attached thermocouple. The panels were removed
individually from the oven, and the distances
between the dowels were quickly measured again
while the panel was hot. This process was repeated
with a 150 mm by 150 mm BAAM print without
tooling prepreg as well. Once cool, the panels were
inspected for signs of delamination, but none were
found (Figure 3).
Using Equation 1, the CTE in the x and y
direction of each panel was calculated. These are
shown in Table 1.
Figure 4. Subscale tool model.
[1]
As can be seen, the CTE difference between
the x (cross-flow) and y (flow) direction is an order
of magnitude different in the as-printed panel.
This confirms the high anisotropy expected in the
AM shell that results from fiber alignment during
printing. The CTE in the cross-flow direction is
almost equivalent to the base polymer since there
is almost no carbon aligned to that direction.
After laminating with Hextool, the CTE in both
directions drop, but the cross-flow direction drops
significantly more at almost 90% since it had such
a high starting value as compared to the Hextool.
The panel with six plies of Hextool provides a CTE
in the flow direction of 2.4 ppm/°C and in the crossflow
direction of 5.4 ppm/°C. By comparison, invar
tooling exhibits a CTE of approximately 2 ppm/°C.
CLTE177C
ppm/C
Flow
x-flow
5.8
57.1
PEI Tool
(with 5 plies HexTool)
2.6
6.3
Table 1. CTE values for test panels.
PEI Tool
(with 6 plies HexTool)
2.4
5.4
Figure 3. Cross section of laminated test panel after thermal cycling.
Y-direction (in-flow) is into the page. X-direction (cross-flow) is labeled.
Figure 5. Both sections of right half of the subscale tool BAAM print. Red
lines denote cut lines after printing.
www. sampe.org
NOVEMBER/DECEMBER 2021
|
SAMPE JOURNAL |
41
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SAMPE Journal - November/December 2021
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