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1 – 10 of over 2000Jason T. Cantrell, Sean Rohde, David Damiani, Rishi Gurnani, Luke DiSandro, Josh Anton, Andie Young, Alex Jerez, Douglas Steinbach, Calvin Kroese and Peter G. Ifju
This paper aims to present the methodology and results of the experimental characterization of three-dimensional (3D) printed acrylonitrile butadiene styrene (ABS) and…
Abstract
Purpose
This paper aims to present the methodology and results of the experimental characterization of three-dimensional (3D) printed acrylonitrile butadiene styrene (ABS) and polycarbonate (PC) parts utilizing digital image correlation (DIC).
Design/methodology/approach
Tensile and shear characterizations of ABS and PC 3D-printed parts were performed to determine the extent of anisotropy present in 3D-printed materials. Specimens were printed with varying raster ([+45/−45], [+30/−60], [+15/−75] and [0/90]) and build orientations (flat, on-edge and up-right) to determine the directional properties of the materials. Tensile and Iosipescu shear specimens were printed and loaded in a universal testing machine utilizing two-dimensional (2D) DIC to measure strain. The Poisson’s ratio, Young’s modulus, offset yield strength, tensile strength at yield, elongation at break, tensile stress at break and strain energy density were gathered for each tensile orientation combination. Shear modulus, offset yield strength and shear strength at yield values were collected for each shear combination.
Findings
Results indicated that raster and build orientations had negligible effects on the Young’s modulus or Poisson’s ratio in ABS tensile specimens. Shear modulus and shear offset yield strength varied by up to 33 per cent in ABS specimens, signifying that tensile properties are not indicative of shear properties. Raster orientation in the flat build samples reveals anisotropic behavior in PC specimens as the moduli and strengths varied by up to 20 per cent. Similar variations were observed in shear for PC. Changing the build orientation of PC specimens appeared to reveal a similar magnitude of variation in material properties.
Originality/value
This article tests tensile and shear specimens utilizing DIC, which has not been employed previously with 3D-printed specimens. The extensive shear testing conducted in this paper has not been previously attempted, and the results indicate the need for shear testing to understand the 3D-printed material behavior fully.
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Ryan R. Ford, Akhilesh Kumar Pal, Scott C.E. Brandon, Manjusri Misra and Amar K. Mohanty
The fused filament fabrication (FFF) process is an additive manufacturing technique used in engineering design. The mechanical properties of parts manufactured by FFF are…
Abstract
Purpose
The fused filament fabrication (FFF) process is an additive manufacturing technique used in engineering design. The mechanical properties of parts manufactured by FFF are influenced by the printing parameters. The mechanical properties of rigid thermoplastics for FFF are well defined, while thermoplastic elastomers (TPE) are uncommonly investigated. The purpose of this paper is to investigate the influence of extruder temperature, bed temperature and printing speed on the mechanical properties of a thermoplastic elastomer.
Design/methodology/approach
Regression models predicting mechanical properties as a function of extruder temperature, bed temperature and printing speed were developed. Tensile specimens were tested according to ASTM D638. A 3×3 full factorial analysis, consisting of 81 experiments and 27 printing conditions was performed, and models were developed in Minitab. Tensile tests verifying the models were conducted at two selected printing conditions to assess predictive capability.
Findings
Each mechanical property was significantly affected by at least two of the investigated FFF parameters, where printing speed and extruder temperature terms influenced all mechanical properties (p < 0.05). Notably, tensile modulus could be increased by 21%, from 200 to 244 MPa. Verification prints exhibited properties within 10% of the predictions. Not all properties could be maximized together, emphasizing the importance of understanding FFF parameter effects on mechanical properties when making design decisions.
Originality/value
This work developed a model to assess FFF parameter influence on mechanical properties of a previously unstudied thermoplastic elastomer and made property predictions within 10% accuracy.
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Chrysoula Pandelidi, Tobias Maconachie, Stuart Bateman, Ingomar Kelbassa, Sebastian Piegert, Martin Leary and Milan Brandt
Fused deposition modelling (FDM) is increasingly being explored as a commercial fabrication method due to its ability to produce net or near-net shape parts directly from a…
Abstract
Purpose
Fused deposition modelling (FDM) is increasingly being explored as a commercial fabrication method due to its ability to produce net or near-net shape parts directly from a computer-aided design model. Other benefits of technology compared to conventional manufacturing include lower cost for short runs, reduced product lead times and rapid product design. High-performance polymers such as polyetherimide, have the potential for FDM fabrication and their high-temperature capabilities provide the potential of expanding the applications of FDM parts in automotive and aerospace industries. However, their relatively high glass transition temperature (215 °C) causes challenges during manufacturing due to the requirement of high-temperature build chambers and controlled cooling rates. The purpose of this study is to investigate the mechanical properties of ULTEM 1010, an unfilled polyetherimide grade.
Design/methodology/approach
In this research, mechanical properties were evaluated through tensile and flexural tests. Analysis of variance was used to determine the significance of process parameters to the mechanical properties of the specimens, their main effects and interactions. The fractured surfaces were analysed by scanning electron microscopy and optical microscopy and porosity was assessed by X-ray microcomputed tomography.
Findings
A range of mean tensile and flexural strengths, 60–94 MPa and 62–151 MPa, respectively, were obtained highlighting the dependence of performance on process parameters and their interactions. The specimens were found to fracture in a brittle manner. The porosity of tensile samples was measured between 0.18% and 1.09% and that of flexural samples between 0.14% and 1.24% depending on the process parameters. The percentage porosity was found to not directly correlate with mechanical performance, rather the location of those pores in the sample.
Originality/value
This analysis quantifies the significance of the effect of each of the examined process parameters has on the mechanical performance of FDM-fabricated specimens. Further, it provides a better understanding of the effect process parameters and their interactions have on the mechanical properties and porosity of FDM-fabricated polyetherimide specimens. Additionally, the fracture surface of the tested specimens is qualitatively assessed.
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Lindsey Bass, Nicholas Alexander Meisel and Christopher B. Williams
Understanding how material jetting process parameters affect material properties can inform design and print orientation when manufacturing end-use components. This study aims to…
Abstract
Purpose
Understanding how material jetting process parameters affect material properties can inform design and print orientation when manufacturing end-use components. This study aims to explore the robustness of material properties in material jetted components to variations in processing environment and build orientation.
Design/methodology/approach
The authors characterized the properties of six different material gradients produced from preset “digital material” mixes of polypropylene-like (VeroWhitePlus) and elastomer-like (TangoBlackPlus) materials. Tensile stress, modulus of elasticity and elongation at break were analyzed for each material printed at three different build orientations. In a separate ten-week study, the authors investigated the effects of aging in different lighting conditions on material properties.
Findings
Specimens fabricated with their longest dimension along the direction of the print head travel (X-axis) tended to have the largest tensile strength, but trends in elastic modulus and elongation at break varied between the rigid and flexible photopolymers. The aging study showed that the ultimate tensile stress of VeroWhitePlus parts increased and the elongation decreased over time. Material properties were not significantly altered by lighting conditions.
Research limitations/implications
Many tensile specimens failed at the neck region, especially for the more elastomeric parts. It is hypothesized that this is due to the material jetting process approximating curves with a pixelated droplet arrangement, instead of curved contour as seen in other additive manufacturing processes. A new tensile specimen design that performs more consistently with elastomer-like materials should be considered. The aging component of this study is focused solely on polypropylene-like (VeroWhitePlus) material; additional research into the effects of aging on multiple composite materials is needed.
Originality/value
The study provides the first known description of orientation effects on the mechanical behavior of photopolymers containing varied concentrations of elastomeric (TangoBlackPlus) material. The aging study presents the first findings on how time affects parts made via material jetting.
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M. Balasubramanian, Thozhuvur Govindaraman Loganathan and R. Srimath
The purpose of this study is to understand the behavior of hybrid bio-composites under varied applications.
Abstract
Purpose
The purpose of this study is to understand the behavior of hybrid bio-composites under varied applications.
Design/methodology/approach
Fabrication methods and material characterization of various hybrid bio-composites are analyzed by studying the tensile, impact, flexural and hardness of the same. The natural fiber is a manufactured group of assembly of big or short bundles of fiber to produce one or more layers of flat sheets. The natural fiber-reinforced composite materials offer a wide range of properties that are suitable for many engineering-related fields like aerospace, automotive areas. The main characteristics of natural fiber composites are durability, low cost, low weight, high specific strength and equally good mechanical properties.
Findings
The tensile properties like tensile strength and tensile modulus of flax/hemp/sisal/Coir/Palmyra fiber-reinforced composites are majorly dependent on the chemical treatment and catalyst usage with fiber. The flexural properties of flax/hemp/sisal/coir/Palmyra are greatly dependent on fiber orientation and fiber length. Impact properties of flax/hemp/sisal/coir/Palmyra are depended on the fiber content, composition and orientation of various fibers.
Originality/value
This study is a review of various research work done on the natural fiber bio-composites exhibiting the factors to be considered for specific load conditions.
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Nastaran Mosleh, Soheil Dariushi and Masoud Esfandeh
In this paper, continuous glass tow preg-reinforced acrylonitrile butadiene styrene (ABS) composites were fabricated by using a 3D printing method, and the purpose of this study…
Abstract
Purpose
In this paper, continuous glass tow preg-reinforced acrylonitrile butadiene styrene (ABS) composites were fabricated by using a 3D printing method, and the purpose of this study is the investigation of the fiber preimpregnation effect on the mechanical behavior of these composites. In addition, a simple theoretical approach (mixture law), which considers the elastic behavior of reinforced composites and a numerical simulation method based on finite element method (FEM), was used to predict the tensile stress–strain behavior of ABS/glass tow preg composites in the elastic region.
Design/methodology/approach
Different groups of preimpregnated glass tows with various ABS amounts (named 2%, 10%, 20% and 30%) were prepared by the solution impregnation method. Then, preimpregnated glass tows (prepregs or tow-pregs) were fed into the printer head along with the polymeric ABS filament to print the composites. The tensile, flexural and short beam tests were conducted to evaluate the mechanical properties of the printed composites.
Findings
The first result of using tow-pregs instead of dry tows in continuous fiber 3D printing is much easier printing, printability improvement and the possibility of printing layers with low thickness, which can further increase the mechanical properties. The mechanical test results showed all of the glass prepregs improve strength and modulus in the tensile, three-point bending and short beam tests compared with neat ABS specimens, but statistical analysis showed that ABS weight percentage in the prepregs had no significant effect on the mechanical strength of composites except for the tensile modulus. Samples containing 2%-prepreg (minimum ABS amount in the tow-pregs) showed a significant improvement in tensile modulus. In the simulation section, good agreement is obtained between the model predictions and experimental tensile results. The results show that an acceptable deviation (14%) exists between the experimental and predicted value of elastic modulus by the numerical model.
Originality/value
To the best of the authors’ knowledge, this is the first study showing the effects of ABS weight percentage in prepregs on the mechanical properties of 3D printed continuous fiber-reinforced composites and predicting the mechanical behavior of 3D printed composites by numerical simulation method.
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Muneer Umar, Michael Ikpi Ofem, Auwal Sani Anwar and Abubakar Garba Salisu
This study aims to fabricate and study the effect of five cumulative graphite (G) and graphite nanoplatelets (GNP) filler loading composites by polymerising PA6 precursor; monomer…
Abstract
Purpose
This study aims to fabricate and study the effect of five cumulative graphite (G) and graphite nanoplatelets (GNP) filler loading composites by polymerising PA6 precursor; monomer epsilon caprolactam with the two carbons in situ while taking cognisance of the mixing effects (simultaneous stirring and sonication at varying amplitudes and duration). Different aspect ratios will be used to model the two streams of polymerisations.
Design/methodology/approach
High viscosity extrusion grade PA6 and synthetic G of less than 2 µm particle size were used as fillers. GNP and G are dried for 6 h in vacuum oven at 90°C. Prior to in situ polymerisation, probe sonication was applied to disperse fillers in molten ɛ-caprolactam, the PA6 monomer. Five carbon loadings were made, that is 5–25 Wt.% for G and 0.5–2.5 Wt.% for GNP composites. Two different sonification regimes were applied 20% sonication amplitude for 20 min (20/20) and 40% sonication amplitude for 10 min (40/10).
Findings
Better tensile properties were achieved using the 20/20 processing streams for both G and GNP. The G- and the GNP-based composites systems of the 20/20 processing stream had tensile modulus and yield strength retained or improved above the unfilled PA6 value. The highest modulus obtained in the 20/20 streams are 1,878 and 1,201 MPa, respectively, for GNP and G at the highest loading levels, while the 40/10 processing streams had 963 and 1,247 MPa, respectively, for the GNP and G.
Originality/value
To the best of the authors’ knowledge, nobody has ever used sonification amplitude to compare mechanical properties.
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Siti Faizah Mad Asasaari, King Jye Wong, Mohd Nasir Tamin and Mahzan Johar
This paper investigates the influence of moisture absorption on the mechanical properties of carbon/epoxy composites.
Abstract
Purpose
This paper investigates the influence of moisture absorption on the mechanical properties of carbon/epoxy composites.
Design/methodology/approach
Three types of specimens are prepared, which are for longitudinal, transverse and shear tests. Specimens are immersed in distilled water at 70°C for 1, 3 and 9 months. These correspond to the moisture content of 2.2, 3.8 and 5.3%.
Findings
Compared to the values at dry condition, the longitudinal modulus, shear modulus and Poisson's ratio are invariant with the moisture content. However, the transverse modulus, transverse strength and shear strength are sensitive to moisture attack. The maximum degradation is 33%, 76 and 33% for the three properties, respectively. It is also worth to note that the longitudinal tensile strength is stable at 1 and 9 months of immersion. However, at 3-months ageing period, there is only 67% of the longitudinal tensile strength retained.
Originality/value
The experimental results are fitted with a residual property model. Results show comparatively good fit, with a difference within 16% except the longitudinal tensile strength at 9-months immersion. This highlights that the model is not suitable to fit the experimental data with a fluctuated trend.
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Wei Chen, Qiuju Zhang, Ye Yuan, Xiaoyan Chen and Qinghao He
Continuous fiber reinforced thermoplastic composites (CFRTPCs) with great mechanical properties and green recyclability have been widely used in aerospace, transportation, sports…
Abstract
Purpose
Continuous fiber reinforced thermoplastic composites (CFRTPCs) with great mechanical properties and green recyclability have been widely used in aerospace, transportation, sports and leisure products, etc. However, the conventional molding technologies of CFRTPCs, with high cost and low efficiency, limit the property design and broad application of composite materials. The purpose of this paper is to study the effect of the 3D printing process on the integrated rapid manufacturing of CFRTPCs.
Design/methodology/approach
Tensile and flexural simulations and tests were performed on CFRTPCs. The effect of key process parameters on mechanical properties and molding qualities was evaluated individually and mutually to optimize the printing process. The micro morphologies of tensile and flexural breakages of the printed CFRTPCs were observed and analyzed to study the failure mechanism.
Findings
The results proved that the suitable process parameters for great printing qualities and mechanical properties included the glass hot bed with the microporous and solid glue coatings at 60°C and the nozzle temperature at 295°C. The best parameters of the nozzle temperature, layer thickness, feed rate and printing speed for the best elastic modulus and tensile strength were 285°C, 0.5 mm, 6.5r/min and 500 mm/min, respectively, whereas those for the smallest sectional porosity were 305°C, 0.6 mm, 5.5r/min and 550 mm/min, respectively.
Originality/value
This work promises a significant contribution to the improvement of the printing quality and mechanical properties of 3D printed CFRTPCs parts by the optimization of 3D printing processes.
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Pierandrea Dal Fabbro, Andrea La Gala, Willem Van De Steene, Dagmar R. D’hooge, Giovanni Lucchetta, Ludwig Cardon and Rudinei Fiorio
This study aims to evaluate and compare the macroscopic properties of commercial acrylonitrile-butadiene-styrene (ABS) processed by two different types of additive manufacturing…
Abstract
Purpose
This study aims to evaluate and compare the macroscopic properties of commercial acrylonitrile-butadiene-styrene (ABS) processed by two different types of additive manufacturing (AM) machines. The focus is also on the effect of multiple closed-loop recycling of ABS.
Design/methodology/approach
A conventional direct-drive, Cartesian-type machine and a Bowden, Delta-type machine with an infrared radiant heating system are used to manufacture test specimens molded in ABS. Afterward, multiple closed-loop recycling cycles are conducted, involving consecutive AM (four times) and recycling (three times). The rheological, mechanical, morphological and physicochemical properties are investigated.
Findings
The type of machine affects the quality of the produced parts. The machine containing an infrared radiant system in a temperature-controlled chamber produces parts showing higher mechanical properties and filling fraction, although it increases the yellowing. Closed-loop recycling of ABS for AM is applicable for at least two cycles, inducing a slight increase in tensile modulus (ca. 5%) and in tensile strength (ca. 13%) and a decrease in the impact strength (ca. 14%) and melt viscosity. An increase in the filling fraction of the AM parts promotes an increase in tensile strength and tensile modulus, although it does not influence the impact strength. Furthermore, multiple closed-loop recycling does not affect the overall chemical structure of ABS.
Practical implications
Controlling the environmental temperature and using infrared radiant heating during AM of ABS improves the quality of the produced parts. Closed-loop recycling of ABS used in AM is feasible up to at least two recycling steps, supporting the implementation of a circular economy for polymer-based AM.
Originality/value
This study shows original results regarding the assessment of the effect of different types of AM machines on the main end-use properties of ABS parts and the influence of multiple closed-loop recycling on the characteristics of ABS fabricated by the most suited AM machine with an infrared radiant heating system and a temperature-controlled environment.
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