Two‐stage annealing method for short carbon fiber‐reinforced nylon 6 in fused filament fabrication

Abstract The mechanical properties of short carbon fiber‐reinforced nylon 6 (CF‐PA6) components formed by fused filament fabrication (FFF) are significantly affected by the process parameters of additive manufacturing and heat treatment. In this study, the effects of printing speed, carbon fiber aspect ratio, and annealing temperature on fiber orientation were investigated by observation of single‐layer‐single‐fiber samples. Furthermore, a two‐stage annealing process was proposed to increase the tensile modulus of CF‐PA6 based on the correlation analysis results between the degree of fiber alignment and the variation of tensile modulus. According to the calculation of the Pearson correlation coefficient, the tensile modulus was highly correlated with the degree of fiber alignment under different printing speeds and fiber aspect ratios. The variation in tensile modulus and fiber orientation was also consistent when the annealing temperature was lower than the crystallization temperature. Conversely, the variation of tensile modulus and fiber orientation were opposite, as the annealing temperature was higher than the crystallization temperature because of the influence of crystallinity. Through increasing the degree of fiber alignment and crystallinity of the parts, the proposed two‐stage annealing method could increase the tensile modulus of the parts to 9.0 GPa, which was 16.81% higher than that of single‐temperature annealing. Highlights The effects of annealing temperature, carbon fiber aspect ratio and printing speed on fiber orientation were illustrated. The relationship between the degree of fiber alignment and the variation of tensile modulus was established. The proposed two‐stage annealing method, considering fiber orientation and crystallinity, significantly increased the tensile modulus of CF270‐PA6 parts from 7.7 to 9.0 GPa. The quantitative analysis of the fiber orientation is realized by the statistical analysis of the plane fiber orientation angle of the single‐layer‐single‐fiber sample.