Appraisal of Mechanical and Tribological Performance of Onyx and Carbon Fiber Composites Produced Through Various Layering Approaches in Continuous Fused Filament Fabricated

Continuous fused filament fabrication (CFFF) is an additive manufacturing technology which enabled designers to easily create custom-built parts with complicated geometries and higher performance. The automobile industry’s primary goal is to reduce weight with generative designed components without compromising strength. Our current research is focused on the preparation of CFFF test samples using various forms of layering approaches, which include mark forged onyx matrix, onyx with a core of carbon fiber, onyx with a sub-surface of carbon fiber and sandwiched onyx and carbon fiber (alternating layers). These samples were printed using a combination of continuous onyx and carbon fiber composites and compared based on their mechanical and tribological properties. All materials had been tested for mechanical conduct such as hardness, impact, tensile and flexural strength and then tested with a tribometer under varying applied loads of 5–20 N and sliding velocities of 1–3 m/s. Finally, all test responses were recorded for further analysis. Fracture surface and worn surface morphology were also performed at the end. The outcome revealed that the sandwiched onyx and carbon fiber composites sample was mechanically stronger compared to the other test specimens. For shore D hardness number 13.24%, impact strength 41.18%, tensile strength 54.76%, and flexural strength 44.90% were improved in sandwiched onyx and carbon fiber than pure onyx matrix. Furthermore, with an increase in applied load and sliding velocity, the wear rate and friction coefficient also increase for all test specimens. The sandwiched onyx and carbon fiber composite sample had a lower rate of wear and friction. The fracture surface morphology showed more dimple formation on the fracture surface and slight worn surface, with an absence of micropores and cracks presented in the sandwiched onyx and carbon fiber composite sample. Considering these improvements, sandwiched onyx and carbon fiber composites could potentially offer a lightweight and strong alternative for automotive body panels such as doors and hoods contributing to overall vehicle performence, durability and safety.