(181r) 3D Printing Carbon-Carbon Composites for Multifunctional Properties

Multifunctional composites refer to materials that exhibit multiple functionalities or properties often beyond the capabilities of traditional single-phase materials. In that sense, carbon-carbon (C-C) composites, are considered advanced composites with excellent properties and functionalities such as high strength, thermal conductivity, electrical conductivity, and many more including exception resilience to temperatures as high as 1500°C. These composites can sometimes outperform many ceramic, metal, or alloy composites. Primarily made up of a carbon-rich matrix and a carbon reinforcement (pre-carburization) with highly tunable properties with the choices of materials and nanoparticle arrangement. But conventional manufacturing or the current state-of-the-art manufacturing such as the performance yarn method are expensive, labor-intensive, and does not have the capability to produce complex and intricate shapes and structures. However, the advent of additive manufacturing (AM) technologies presents promising avenues for enhancing C-C composite manufacturing efficiency and affordability. Through the innovative multiphase direct ink writing (MDIW) 3D printing, this research explores the tailored fabrication of C-C composites with carbide and graphite reinforcements, exhibiting enhanced multifunctional properties. The MDIW 3D printing has a unique nozzle with the ability to use two polymer or nanocomposite inks as feedstocks, allowing for reinforcing the composite with both graphite (G_np) and silicon carbide (SiC) nanopowders simultaneously. Through thorough rheological and curing analysis, the green parts of C-C composites were fabricated in a few minutes followed by a carefully programmed carburization process that produced C-C composites with minimum to no deformation or warpage. The resulting C-C composites underwent rigorous thermal, electrical, and mechanical property tests, demonstrating their suitability for high-temperature applications up to 1000°C. This simplified manufacturing approach reduces costs, production time, and material wastage, making C-C composites more accessible for diverse applications.