This work studies high-performance laminate composite materials made of graphite and poly(ether-ether-ketone) (PEEK). The main objective was to enhance graphite's inherent properties by the addition of PEEK to produce materials with improved thermal and mechanical stability for high-performance applications. The composites were fabricated using a hot press method at a temperature below 310 °C. The newly formed materials were then subjected to various tests, including Scanning Electron Microscopy, Thermogravimetric Analysis, mechanical properties tests, nanoindentation tests, and X-Ray Diffraction to assess their structural, thermal, and mechanical properties. Our findings showed a substantial interfacial interaction between PEEK and graphite, indicating successful composite formation. Both three-layered PEEK/graphite/PEEK (PGP) and five-layered PEEK/graphite/PEEK/graphite/PEEK (PG)₂P composites exhibited superior thermal stability at high temperatures compared to neat PEEK. Moreover, our mechanical tests demonstrated a 172% increase in ultimate tensile strength of PGP compared to neat graphite. Additionally, nanoindentation tests confirmed an increase in both Young's modulus and hardness of composites. Furthermore, XRD analysis revealed a 35.5% increase in crystallinity in the fabricated composites compared to pristine PEEK. These findings significantly contribute to the field of high-performance composite materials, confirming that the hot pressing of PEEK and graphite sheets results in enhanced thermal and mechanical properties.

Poly(ether-ether-ketone) (PEEK) is a high-performance thermoplastic with excellent mechanical strength, thermal stability, and chemical resistance, making it attractive for applications like biomedical implants and prostheses. However, neat PEEK suffers from a high friction coefficient and pronounced wear in sliding contacts. In this work, composites of PEEK with Cobalt-Chromium (CoCr) alloy powder were fabricated by centrifugal powder compaction and vacuum sintering. Four composite compositions, with weight percentages of 10%, 20%, 30%, and 40% of CoCr, were produced. Scanning electron microscopy analysis confirmed uniform dispersion of CoCr particles within the PEEK matrix. Differential scanning calorimetry and thermogravimetric analysis showed that CoCr addition did not significantly alter PEEK’s melting temperature or thermal stability. Microhardness increased with filler loading, with the 40% CoCr composite achieving a 40% hardness improvement over neat PEEK. Ball-on-disk tests against steel revealed that all composites exhibited significantly reduced wear loss by 84% compared to neat PEEK, while maintaining a friction coefficient typical for PEEK-steel contacts. Overall, the PEEK/CoCr composites demonstrate enhanced hardness and wear resistance while retaining PEEK’s favorable thermal properties, suggesting their potential for applications requiring better tribological performance than unfilled PEEK.

The present study investigates the flow characteristics of fly ash-based (FA) geopolymers reinforced with polypropylene (PP) fibers during the extrusion process in three-dimensional printing. By applying the Herschel–Bulkley rheological model, this research provides a sound theoretical basis to understand the flow behavior of these materials under various conditions. The Herschel–Bulkley model describes the relationship between shear stress and the shear rate in non-Newtonian fluids, capturing yield stress and flow consistency. A combination of experimental and numerical techniques based on the Finite-Element Method (FEM) in COMSOL has been used in this study. The results of both experimental and simulation approaches are compared to examine the material behavior during extrusion. The experimental results indicate that PP fiber content significantly affects the rheological properties. Mixtures with high fiber content encountered issues such as high static yield. However, mixtures with moderate fiber content showed smoother extrusion processes, suggesting an optimal fiber addition range that balances mechanical properties and extrudability. The numerical simulations generally agreed with the experimental data up to a certain fiber content level, beyond which more complex interactions necessitate further model refinements. The investigation identified a 0.25% to 0.5% fiber content range that enhances performance without complicating the extrusion process, facilitating the production of properly printed structures.

The present study drops the line for the flow characteristics of fly ash-based (FA) geopolymers reinforced with polypropylene (PP) fibers undergoing the extrusion process during three-dimensional printing. Applying to the Herschel-Bulkley rheological model the research is ready with the sound theoretical basis which is used to understand the flow behavior of these materials under various conditions. A combination of experimental and numerical techniques that are based on the Finite Element Method (FEM) in COMSOL has been used in this study. The results of both the experimental and simulation approaches are then compared and the behavior of the material during extrusion is then examined. The experimental results proved PP fiber content has significant effects on rheological properties. The experiments on mixes which are either devoid of fibers or possess a high content of fiber, encountered problems like a high static yield stress and material segregation. Mixes with fibers of moderate content showed smoother extrusion processes, which means that a suitable range of fiber addition exists for the fibers that optimally balance the mechanical properties and extrudability. Numerical simulations typically agreed with experimental data for fiber contents up until it reached a certain level but not above, suggesting the existence of more complex interactions inside the fibers and the necessity for the subsequent model refinements. The investigation outlines a 0.25% and 0.5% fiber content range that leads to enhanced performance without bringing the extrusion process to greater complications and further making the production of proper, architecturally printed structures possible.

This study investigates the application of centrifugal force for the compaction of metal powder. Previous studies using the centrifugal force for manufacturing the green bodies were focused on fine powders with narrow particle size distribution or binary mixtures. This study explores the particle packing of multi-sized powder. Aluminum alloy powder with a particle size less than 100 µm and polymer binder were admixed and compacted in the centrifugal casting with ranging magnitudes of centripetal acceleration. Three different centrifugal forces were tested: 700, 1800, and 3700 G. The microstructure of the green bodies was then observed on the SEM micrographs. The obtained green bodies had high packing densities ranging from 62 to 69%. The packing density and median particle size increase at the positions further away from the center of rotation of the centrifuge with an increase of centrifugal force. The effect of centrifugal force on the segregation of particles was investigated through the quasi-binary segregation index. The segregation phenomena was not observed at 700 G, but clear particle segregation was found at higher centrifugal forces. The increase of the centrifugal force resulted in higher segregation with finer particles moving to the inner part of the spinning mold, with a significant change in the size of particles located closer to the center of rotation. Overall, the centrifugal process was found to produce highly compacted green bodies while yielding a segregation effect due to wide particle size distribution.