Annealing of isotropic nylon-6,6

Mechanical Analysis of Parameter Variations in Large-Scale Extrusion Additive Manufacturing of Thermoplastic Composites

Large structural parts manufactured by Extrusion Additive Manufacturing (EAM) are limited by strong anisotropy due to insufficient bond formation and reduced molecular entanglement along the layer interface. To understand the correlation between process and material parameters and to enable digital modeling of EAM, the effect of different substrate temperatures and layer heights on tensile strength was investigated. A simple testing methodology for pelletized carbon fiber-filled polyamide 6 was developed. Tensile tests were performed in a full factorial Design of Experiments (DoE) to determine the tensile properties. For bulk simulation, the nominal strength and modulus were also determined based on contact width obtained by optical microscopy. The results demonstrated high anisotropy, with the maximum transverse tensile strength reaching only 27% of the corresponding longitudinal results and the transverse tensile modulus reaching only 20% of its longitudinal value. The effects of varying layer height were less significant than varying substrate temperature. The results support the hypothesis that sufficient transverse tensile strength is achieved between the extrapolated crystallization onset and melt temperature. The methodology of this study can be used as a benchmark method to qualify new thermoplastic polymers for EAM processes and to determine optimal process parameters for improved fusion bonding.

Electromagnetic Interference Shield of Highly Thermal-Conducting, Light-Weight, and Flexible Electrospun Nylon 66 Nanofiber-Silver Multi-Layer Film

A light-weight, flexible electromagnetic interference (EMI) shield was prepared by creating a layer-structured metal-polymer composite film consisting of electrospun nylon 66 nanofibers with silver films. The EMI shielding effectiveness (SE), specific SE, and absolute SE of the composite were as high as 60.6 dB, 67.9 dB cm³/g, and 6792 dB cm²/g in the X- and K_u-bands, respectively. Numerical and analytical calculations suggest that the energy of EM waves is predominantly absorbed by inter-layer multiple reflections. Because the absorbed EM energy is dissipated as heat, the thermal conductivity of absorption-dominant EMI shields is highly significant. Measured thermal conductivity of the composite was found to be 4.17 Wm⁻¹K⁻¹ at room temperature, which is higher than that of bulk nylon 66 by a factor of 16.7. The morphology and crystallinity of the composite were examined using scanning electron microscopy and differential scanning calorimetry, respectively. The enhancement of thermal conductivity was attributed to an increase in crystallinity of the nanofibers, which occurred during the electrospinning and subsequent hot pressing, and to the high thermal conductivity of the deposited silver films. The contribution of each fabrication process to the increase in thermal conductivity was investigated by measuring the thermal conductivity values after each fabrication process.