1
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Laurenzi S, Zaccardi F, Toto E, Santonicola MG, Botti S, Scalia T. Fused Filament Fabrication of Polyethylene/Graphene Composites for In-Space Manufacturing. MATERIALS (BASEL, SWITZERLAND) 2024; 17:1888. [PMID: 38673245 PMCID: PMC11052346 DOI: 10.3390/ma17081888] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 03/14/2024] [Revised: 04/08/2024] [Accepted: 04/16/2024] [Indexed: 04/28/2024]
Abstract
Graphene-based composite materials are highly sought after for space applications due to their ability to encompass various properties, such as electrical conductivity, thermal resistance, and radiation shielding. This versatility allows for the creation of multifunctional components that can serve various purposes in space. Three-dimensional (3D) printing of composite materials in space offers a versatile and efficient means of manufacturing components, tools, and structures that are tailored to the unique challenges and requirements of space missions. In this work, we aim to develop 3D-printed composites made of medium-density polyethylene (MDPE) matrix and exfoliated graphene nanoplatelets (xGnP) as filler, using fused filament fabrication (FFF). Our research focuses on the challenges associated with the FFF process for fabricating MDPE/xGnP materials, particularly by optimizing filament extrusion and assessing the resulting material properties and space environmental compatibility. Firstly, we optimize the extrusion process, and use the MDPE/xGnP filaments to fabricate 3D-printed samples after defining the FFF parameters. We employ differential scanning calorimetry (DSC) to assess the melting properties and crystallization degree of the extruded filaments and 3D-printed samples, providing insights into the relationship between these properties and the characteristics of the initial powders. Electrical and tensile tests are carried out to evaluate the material properties after successfully mitigating challenges, such as warping and inadequate adhesion, to build plates during the printing process. Finally, we subject the 3D-printed composites to outgassing tests under exposure to the AM0 solar spectrum to evaluate their space environmental suitability. The results of this work demonstrate the capability of the FFF-based process to efficiently manufacture components made of MDPE/xGnP composites, providing optimized parameters for their potential in-space fabrication.
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Affiliation(s)
- Susanna Laurenzi
- Department of Astronautical Electrical and Energy Engineering, Sapienza University of Rome, Via Salaria 851-881, 00138 Rome, Italy;
| | - Federica Zaccardi
- Department of Astronautical Electrical and Energy Engineering, Sapienza University of Rome, Via Salaria 851-881, 00138 Rome, Italy;
| | - Elisa Toto
- Department of Chemical Engineering Materials Environment, Sapienza University of Rome, Via del Castro Laurenziano 7, 00161 Rome, Italy; (E.T.); (M.G.S.)
| | - Maria Gabriella Santonicola
- Department of Chemical Engineering Materials Environment, Sapienza University of Rome, Via del Castro Laurenziano 7, 00161 Rome, Italy; (E.T.); (M.G.S.)
| | - Sabina Botti
- Photonics Micro- and Nano-Structures Laboratory, Division of Physical Technologies and Security, Nuclear Department, ENEA C.R. Frascati, Via E. Fermi 45, 00044 Frascati, Italy;
| | - Tanya Scalia
- Italian Space Agency, Via del Politecnico s.n.c., 00133 Rome, Italy;
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2
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Muhammad A, Srivastava R, Koutroumanis N, Semitekolos D, Chiavazzo E, Pappas PN, Galiotis C, Asinari P, Charitidis CA, Fasano M. Mesoscopic Modeling and Experimental Validation of Thermal and Mechanical Properties of Polypropylene Nanocomposites Reinforced By Graphene-Based Fillers. Macromolecules 2023; 56:9969-9982. [PMID: 38161324 PMCID: PMC10753874 DOI: 10.1021/acs.macromol.3c01529] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/01/2023] [Revised: 10/19/2023] [Accepted: 11/22/2023] [Indexed: 01/03/2024]
Abstract
The development of nanocomposites relies on structure-property relations, which necessitate multiscale modeling approaches. This study presents a modeling framework that exploits mesoscopic models to predict the thermal and mechanical properties of nanocomposites starting from their molecular structure. In detail, mesoscopic models of polypropylene (PP)- and graphene-based nanofillers (graphene (Gr), graphene oxide (GO), and reduced graphene oxide (rGO)) are considered. The newly developed mesoscopic model for the PP/Gr nanocomposite provides mechanistic information on the thermal and mechanical properties at the filler-matrix interface, which can then be exploited to enhance the prediction accuracy of traditional continuum simulations by calibrating the thermal and mechanical properties of the filler-matrix interface. Once validated through a dedicated experimental campaign, this multiscale model demonstrates that with the modest addition of nanofillers (up to 2 wt %), the Young's modulus and thermal conductivity show up to 35 and 25% enhancement, respectively, whereas the Poisson's ratio slightly decreases. Among the different combinations tested, the PP/Gr nanocomposite shows the best mechanical properties, whereas PP/rGO demonstrates the best thermal conductivity. This validated mesoscopic model can contribute to the development of smart materials with enhanced mechanical and thermal properties based on polypropylene, especially for mechanical, energy storage, and sensing applications.
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Affiliation(s)
- Atta Muhammad
- Department
of Energy, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129, Torino, Italy
- Department
of Mechanical Engineering, Mehran University
of Engineering and Technology, SZAB Campus, 66020 Khairpur Mir’s, Sindh, Pakistan
| | - Rajat Srivastava
- Department
of Energy, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129, Torino, Italy
- Department
of Engineering for Innovation, University
of Salento, Piazza Tancredi
7, 73100, Lecce, Italy
| | - Nikolaos Koutroumanis
- Foundation
of Research and Technology-Hellas, Institute
of Chemical Engineering Sciences, Stadioustr Rion26504, Patras, Greece
| | - Dionisis Semitekolos
- School
of Chemical Engineering, National Technical
University of Athens, 9 Heroon Polytechniou, 15780 Athens, Greece
| | - Eliodoro Chiavazzo
- Department
of Energy, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129, Torino, Italy
| | - Panagiotis-Nektarios Pappas
- Foundation
of Research and Technology-Hellas, Institute
of Chemical Engineering Sciences, Stadioustr Rion26504, Patras, Greece
| | - Costas Galiotis
- Foundation
of Research and Technology-Hellas, Institute
of Chemical Engineering Sciences, Stadioustr Rion26504, Patras, Greece
- Department
of Chemical Engineering, University of Patras, 1 Caratheodory26504 Patras, Greece
| | - Pietro Asinari
- Department
of Energy, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129, Torino, Italy
- Istituto
Nazionale di Ricerca Metrologica, Strada delle Cacce 91, 10135 Torino, Italy
| | - Costas A. Charitidis
- School
of Chemical Engineering, National Technical
University of Athens, 9 Heroon Polytechniou, 15780 Athens, Greece
| | - Matteo Fasano
- Department
of Energy, Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129, Torino, Italy
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3
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Slonov A, Musov I, Zhansitov A, Khashirov A, Tlupov A, Musov K, Rzhevskaya E, Fomicheva I, Potapov A, Khashirova S. Investigation of the Properties of Polyethylene and Ethylene-Vinyl Acetate Copolymer Blends for 3D Printing Applications. Polymers (Basel) 2023; 15:4129. [PMID: 37896371 PMCID: PMC10610766 DOI: 10.3390/polym15204129] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/28/2023] [Revised: 10/15/2023] [Accepted: 10/16/2023] [Indexed: 10/29/2023] Open
Abstract
3D printing of polyolefins, such as polyethylene (PE) and polypropylene (PP), is of great practical interest due to the combination of high properties of these materials. However, the use of these materials in 3D printing is associated with many problems due to their high rate of crystallization, which causes shrinkage and warpage of the printed object. In this regard, blends of PE and ethylene-vinyl acetate copolymer (EVA) of various compositions were investigated for 3D printing. It was found that with an increase in the concentration of EVA, an increase in the pseudoplastic effect and amorphization of PE occurs. It has been shown that with an increase in the EVA content, the degree of crystallinity of PE decreases slightly (by 11% at a content of 80% EVA); however, a significant decrease in the rate of crystallization of PE is observed (by 87.5% at the same EVA concentration). It was found that PE and EVA are completely compatible in the amorphous phase and partially compatible in the crystalline phase, which leads to a slight decrease in the melting point of PE. The introduction of EVA also leads to a significant increase in impact strength: the maximum value is achieved at a 50/50 ratio, which is five times the value of the initial PE and two times the value of the initial EVA. At the same time, it was revealed that EVA leads to a gradual decrease in the elastic modulus and strength of PE, the change of which generally obeys the additivity rule. The resulting printing filaments are characterized by a certain ovality due to their shrinkage, which decreases with increasing EVA content and reaches a minimum value at a PE/EVA ratio of 30/70. This composition also demonstrates the lowest shrinkage of the printed sample and higher processability during printing.
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Affiliation(s)
- Azamat Slonov
- Laboratory of Technology of Polymer Materials and Composites, Tula State University, Prospekt Lenina 92, 300012 Tula, Russia
- Progressive Materials and Additive Technologies Center, Kabardino-Balkarian State University Named after H.M. Berbekov, St. Chernyshevsky, 173, 360004 Nalchik, Russia
| | - Ismel Musov
- Laboratory of Technology of Polymer Materials and Composites, Tula State University, Prospekt Lenina 92, 300012 Tula, Russia
- Progressive Materials and Additive Technologies Center, Kabardino-Balkarian State University Named after H.M. Berbekov, St. Chernyshevsky, 173, 360004 Nalchik, Russia
| | - Azamat Zhansitov
- Laboratory of Technology of Polymer Materials and Composites, Tula State University, Prospekt Lenina 92, 300012 Tula, Russia
- Progressive Materials and Additive Technologies Center, Kabardino-Balkarian State University Named after H.M. Berbekov, St. Chernyshevsky, 173, 360004 Nalchik, Russia
| | - Azamat Khashirov
- Laboratory of Technology of Polymer Materials and Composites, Tula State University, Prospekt Lenina 92, 300012 Tula, Russia
- Progressive Materials and Additive Technologies Center, Kabardino-Balkarian State University Named after H.M. Berbekov, St. Chernyshevsky, 173, 360004 Nalchik, Russia
| | - Aslanbek Tlupov
- Progressive Materials and Additive Technologies Center, Kabardino-Balkarian State University Named after H.M. Berbekov, St. Chernyshevsky, 173, 360004 Nalchik, Russia
| | - Khasan Musov
- Progressive Materials and Additive Technologies Center, Kabardino-Balkarian State University Named after H.M. Berbekov, St. Chernyshevsky, 173, 360004 Nalchik, Russia
| | - Elena Rzhevskaya
- Progressive Materials and Additive Technologies Center, Kabardino-Balkarian State University Named after H.M. Berbekov, St. Chernyshevsky, 173, 360004 Nalchik, Russia
| | - Irina Fomicheva
- Laboratory of Technology of Polymer Materials and Composites, Tula State University, Prospekt Lenina 92, 300012 Tula, Russia
| | - Andrey Potapov
- Laboratory of Technology of Polymer Materials and Composites, Tula State University, Prospekt Lenina 92, 300012 Tula, Russia
| | - Svetlana Khashirova
- Laboratory of Technology of Polymer Materials and Composites, Tula State University, Prospekt Lenina 92, 300012 Tula, Russia
- Progressive Materials and Additive Technologies Center, Kabardino-Balkarian State University Named after H.M. Berbekov, St. Chernyshevsky, 173, 360004 Nalchik, Russia
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4
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Montoya-Ospina MC, Zeng J, Tan X, Osswald TA. Material Extrusion Additive Manufacturing with Polyethylene Vitrimers. Polymers (Basel) 2023; 15:polym15061332. [PMID: 36987113 PMCID: PMC10058395 DOI: 10.3390/polym15061332] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/10/2023] [Revised: 03/03/2023] [Accepted: 03/05/2023] [Indexed: 03/09/2023] Open
Abstract
Polyethylene (PE) is one of the most widely used polymers in conventional polymer manufacturing processes. However, it remains a challenge to use PE in extrusion-based additive manufacturing (AM). Some of the challenges that this material presents include low self-adhesion and shrinkage during the printing process. These two issues lead to higher mechanical anisotropy when compared to other materials, along with poor dimensional accuracy and warpage. Vitrimers are a new class of polymers that have a dynamic crosslinked network, allowing the material to be healed and reprocessed. Prior studies on polyolefin vitrimers suggest that the crosslinks reduce the degree of crystallinity and increase the dimensional stability at elevated temperatures. In this study, high-density polyethylene (HDPE) and HDPE vitrimers (HDPE-V) were successfully processed using a screw-assisted 3D printer. It was demonstrated that HDPE-V were able to reduce shrinkage during the printing process. This shows that 3D printing with HDPE-V will provide better dimensional stability when compared to regular HDPE. Furthermore, after an annealing process, 3D-printed HDPE-V samples showed a decrease in mechanical anisotropy. This annealing process was only possible in HDPE-V due to their superior dimensional stability at elevated temperatures, with minimal deformation above melting temperature.
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5
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Molecular Pathways for Polymer Degradation during Conventional Processing, Additive Manufacturing, and Mechanical Recycling. Molecules 2023; 28:molecules28052344. [PMID: 36903589 PMCID: PMC10004996 DOI: 10.3390/molecules28052344] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/20/2023] [Revised: 02/20/2023] [Accepted: 02/28/2023] [Indexed: 03/06/2023] Open
Abstract
The assessment of the extent of degradation of polymer molecules during processing via conventional (e.g., extrusion and injection molding) and emerging (e.g., additive manufacturing; AM) techniques is important for both the final polymer material performance with respect to technical specifications and the material circularity. In this contribution, the most relevant (thermal, thermo-mechanical, thermal-oxidative, hydrolysis) degradation mechanisms of polymer materials during processing are discussed, addressing conventional extrusion-based manufacturing, including mechanical recycling, and AM. An overview is given of the most important experimental characterization techniques, and it is explained how these can be connected with modeling tools. Case studies are incorporated, dealing with polyesters, styrene-based materials, and polyolefins, as well as the typical AM polymers. Guidelines are formulated in view of a better molecular scale driven degradation control.
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6
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Wu Y, Ding G, Zhu Y, Wang Y, Liu R, Sun Y. Preparation of Highly Stable Polymer Microstructure with Enhanced Adhesion Strength by Pushpin-like Nano/Microstructure Array. Polymers (Basel) 2023; 15:polym15041015. [PMID: 36850298 PMCID: PMC9966650 DOI: 10.3390/polym15041015] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/22/2022] [Revised: 02/13/2023] [Accepted: 02/15/2023] [Indexed: 02/22/2023] Open
Abstract
This polymer microstructure expands more available application, which is a milestone for the development of micro-electro-mechanical system devices towards intelligence and multifunction. Poor interface bonding between the polymer and Si or metal is a particular problem, which restricts the application and promotion of polymer materials. In this study, a transition strengthening layer is proposed to obtain a highly stable polymer microstructure by enhancing the interfacial adhesion strength. The transition strengthening layer is activated by a pushpin-like nano/microstructure array with micromachining technology. Given its good graphical qualities and compatibility, epoxy negative photoresist SU-8 is applied to evaluate the strengthened capabilities of the pushpin-like nano/microstructure array. The microstructure of SU-8 is prepared by the same processes, and then the adhesion strength between the SU-8 microstructure and various activated substrates is tested by the thrust tester. It was determined that SU-8 with an activated pushpin-like microstructure array possessed a highly stable adhesion ability, and its adhesion strength increased from 6.51 MPa to 15.42 MPa. With its ultrahigh stable adhesion ability, it has been applied in fabricating three typical microstructures (hollow square microstructure, gradually increasing adjacent periodic microstructure, and slender strip microstructures) and large-area SU-8 microstructures to evaluate the feasibility of the transition strengthening layer and repeatability and universality of the microfabrication processes. The drifting and gluing phenomenon are avoided by this method compared with the traditional design. The proposed pushpin-like nano/microstructure array is promising in enhancing the stability of polymer microstructures with a substrate.
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Affiliation(s)
- Yongjin Wu
- National Key Laboratory of Science and Technology on Micro/Nano Fabrication, Shanghai Jiao Tong University, Shanghai 200240, China
- School of Electronic Information and Electrical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
| | - Guifu Ding
- National Key Laboratory of Science and Technology on Micro/Nano Fabrication, Shanghai Jiao Tong University, Shanghai 200240, China
| | - Yuan Zhu
- National Key Laboratory of Science and Technology on Micro/Nano Fabrication, Shanghai Jiao Tong University, Shanghai 200240, China
- School of Electronic Information and Electrical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
| | - Yan Wang
- National Key Laboratory of Science and Technology on Micro/Nano Fabrication, Shanghai Jiao Tong University, Shanghai 200240, China
| | - Rui Liu
- National Demonstration Center for Experimental Materials Science and Engineering Education, Jiangsu University of Science and Technology, Zhenjiang 212003, China
| | - Yunna Sun
- National Key Laboratory of Science and Technology on Micro/Nano Fabrication, Shanghai Jiao Tong University, Shanghai 200240, China
- Correspondence:
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7
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Influence of Binder Composition and Material Extrusion (MEX) Parameters on the 3D Printing of Highly Filled Copper Feedstocks. Polymers (Basel) 2022; 14:polym14224962. [PMID: 36433087 PMCID: PMC9692767 DOI: 10.3390/polym14224962] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/25/2022] [Revised: 11/06/2022] [Accepted: 11/11/2022] [Indexed: 11/18/2022] Open
Abstract
This work aims to better understand the type of thermoplastic binders required to produce highly loaded copper filaments that can be successfully printed via low-cost filament-based material extrusion (MEX). Compounding feedstock material with 55 vol.% of copper and three multi-component binder systems has been performed. The MEX behavior of these feedstocks was evaluated by depositing material at different speeds and appropriately selecting the extrusion temperature depending on the binder composition. The rest of the MEX parameters remained constant to evaluate the printing quality for the different feedstocks. Printable filaments were produced with low ovality and good surface quality. The filaments showed good dispersion of the powder and polymeric binder system in SEM analysis. The feedstock mechanical properties, i.e., the tensile strength of the filament, were sufficient to ensure proper feeding in the MEX machine. The viscosity of the feedstock systems at the adjusted printing temperatures lies in the range of 102-103 Pa·s at the shear rate of 100-1000 s-1, which appears to be sufficient to guarantee the correct flowability and continuous extrusion. The tensile properties vary greatly (e.g., ultimate tensile strength 3-9.8 MPa, elongation at break 1.5-40.5%), and the most fragile filament could not be reliably printed at higher speeds. Micrographs of the cross-section of printed parts revealed that as the printing speed increased, the porosity was minimized because the volumetric flow of the feedstock material increased, which can help to fill pores. This study offers new insights into the feedstock requirements needed to produce low-cost intricate copper components of high quality in a reliable and efficient manner. Such components can find many applications in the electronics, biomedical, and many other industries.
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8
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Optimizing System Reliability in Additive Manufacturing Using Physics-Informed Machine Learning. MACHINES 2022. [DOI: 10.3390/machines10070525] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 02/05/2023]
Abstract
Fused filament fabrication (FFF), an additive manufacturing process, is an emerging technology with issues in the uncertainty of mechanical properties and quality of printed parts. The consideration of all main and interaction effects when changing print parameters is not efficiently feasible, due to existing stochastic dependencies. To address this issue, a machine learning method is developed to increase reliability by optimizing input parameters and predicting system responses. A structure of artificial neural networks (ANN) is proposed that predicts a system response based on input parameters and observations of the system and similar systems. In this way, significant input parameters for a reliable system can be determined. The ANN structure is part of physics-informed machine learning and is pretrained with domain knowledge (DK) to require fewer observations for full training. This includes theoretical knowledge of idealized systems and measured data. New predictions for a system response can be made without retraining but by using further observations from the predicted system. Therefore, the predictions are available in real time, which is a precondition for the use in industrial environments. Finally, the application of the developed method to print bed adhesion in FFF and the increase in system reliability are discussed and evaluated.
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9
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Koffi A, Toubal L, Jin M, Koffi D, Döpper F, Schmidt H, Neuber C. Extrusion‐based
3D
printing with high‐density polyethylene Birch‐fiber composites. J Appl Polym Sci 2022. [DOI: 10.1002/app.51937] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/04/2023]
Affiliation(s)
- Agbelenko Koffi
- Institut d'Innovations en Écomatériaux, Écoproduits et Écoénergies (I2E3) Université du Québec à Trois‐Rivières Trois‐Rivières Quebec Canada
| | - Lotfi Toubal
- Institut d'Innovations en Écomatériaux, Écoproduits et Écoénergies (I2E3) Université du Québec à Trois‐Rivières Trois‐Rivières Quebec Canada
| | - Minde Jin
- Macromolecular Chemistry I University of Bayreuth Bayreuth Germany
- Bavaria Polymer Institute (BPI) University of Bayreuth Bayreuth Germany
| | - Demagna Koffi
- Institut d'Innovations en Écomatériaux, Écoproduits et Écoénergies (I2E3) Université du Québec à Trois‐Rivières Trois‐Rivières Quebec Canada
| | - Frank Döpper
- Chair Manufacturing and Remanufacturing Technology, Faculty of Engineering Science University of Bayreuth Bayreuth Germany
| | - Hans‐Werner Schmidt
- Macromolecular Chemistry I University of Bayreuth Bayreuth Germany
- Bavaria Polymer Institute (BPI) University of Bayreuth Bayreuth Germany
| | - Christian Neuber
- Macromolecular Chemistry I University of Bayreuth Bayreuth Germany
- Bavaria Polymer Institute (BPI) University of Bayreuth Bayreuth Germany
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Laumann D, Spiehl D, Dörsam E. Device for measuring part adhesion in FFF process. HARDWAREX 2022; 11:e00258. [PMID: 35509946 PMCID: PMC9058659 DOI: 10.1016/j.ohx.2022.e00258] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 11/10/2021] [Revised: 12/14/2021] [Accepted: 01/03/2022] [Indexed: 06/14/2023]
Abstract
The adhesion of parts to the build surface plays a central role in the Fused Filament Fabrication (FFF) process. Without sufficient adhesion, the part will deform (so called warping) due to thermal shrinkage, so that no defined geometries can be created. Nevertheless, there is no established method to measure the adhesion of printed parts and therefore it is not possible to targeted improve it. This article presents a measurement method based on the DIN EN 28510-1 standard and a corresponding test device which makes it possible to identify the optimum build surface for a filament and also to improve the process parameters in a targeted manner. The test device combines a FFF printer with a measuring unit so that all common filaments can be tested close to the process up to a processing temperature of 400 °C in the nozzle and around 150 °C on the build platform. The test device uses only open-source parts and software and costs about 1700€.
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11
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Optimization of Alumina Ceramics Corrosion Resistance in Nitric Acid. MATERIALS 2022; 15:ma15072579. [PMID: 35407911 PMCID: PMC9000651 DOI: 10.3390/ma15072579] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 03/12/2022] [Revised: 03/28/2022] [Accepted: 03/30/2022] [Indexed: 11/17/2022]
Abstract
The development of ceramic materials resistance in various aggressive media combined with required mechanical properties is of considerable importance for enabling the wider application of ceramics. The corrosion resistance of ceramic materials depends on their purity and microstructure, the kind of aggressive media used and the ambient temperature. Therefore, the corrosion resistance of alumina ceramics in aqueous HNO3 solutions of concentrations of 0.50 mol dm-3, 1.25 mol dm-3 and 2.00 mol dm-3 and different exposure times-up to 10 days-have been studied. The influence of temperature (25, 40 and 55 °C) was also monitored. The evaluation of Al2O3 ceramics corrosion resistance was based on the concentration measurements of eluted Al3+, Ca2+, Fe3+, Mg2+, Na+ and Si4+ ions obtained by inductively coupled plasma atomic emission spectrometry (ICP-AES), as well as density measurements of the investigated alumina ceramics. The response surface methodology (RSM) was used for the optimization of parameters within the experimental "sample-corrosive media" area. The exposure of alumina ceramics to aqueous HNO3 solutions was conducted according to the Box-Behnken design. After the regression functions were defined, conditions to achieve the maximum corrosion resistance of the sintered ceramics were determined by optimization within the experimental area.
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12
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Chaka KT. Fused deposition modeling of polypropylene-aluminium silicate dihydrate microcomposites. E-POLYMERS 2022. [DOI: 10.1515/epoly-2022-0014] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/24/2022]
Abstract
Abstract
Polypropylene (PP) undergoes fast crystallization and resulting in rigorous shrinkage when it is subjected to high temperature likewise of the fused deposition modeling (FDM) process. This research study focuses on the investigation of the processing parameters and factors that decrease the warpage of PP during the FDM process. Aluminium silicate dihydrate (K) microparticles of different ratios were melt blended with PP by a twin-screw extruder, and filaments of about 1.7 mm diameter were extruded in a single screw extruder. Then, the extruded filaments were used to fabricate the dumbbells structure through the FDM process. The effects of optimizing the fused deposition temperature, coating the chamber with thick papers/fabrics, and coating a printer bed with PP material were also investigated in this study. Scanning and transmission electron microscopy, differential scanning calorimetry, melt flow, and mechanical properties testing instruments are used to analyze the microparticles dispersion, crystallization, flow, and mechanical properties of resulting samples. Uniformly dispersed filler and increased printing chamber temperature result in an increase of crystallization temperature and improve the dimensional accuracy of fused deposited specimens. The fused deposited PP-K10 wt% composite showed an improvement of up to 32% in tensile modulus compared to the neat PP.
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Affiliation(s)
- Kilole Tesfaye Chaka
- Ethiopian Institute of Textile and Fashion Technology, Bahir Dar University , Bahir Dar , Ethiopia
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13
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Mechanical performance and supermolecular morphology of void free polypropylene manufactured by fused filament fabrication. J Appl Polym Sci 2021. [DOI: 10.1002/app.51409] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/07/2022]
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14
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Hejmady P, van Breemen LC, Anderson PD, Cardinaels R. A processing route to spherical polymer particles via controlled droplet retraction. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2021.04.058] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/13/2022]
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15
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Establishment of a Rotary Print Head to Effect Residual Stresses and Interlayer Bonding in an FLM-Process. JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING 2021. [DOI: 10.3390/jmmp5030082] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
Abstract
In fused layer modeling (FLM) manufacturing technology, there is an increased demand for semi-crystalline materials due to their favorable mechanical properties, such as high strength and toughness. The reasons for their limited use are process-related residual stresses and reduced interlayer bonding, resulting in component distortion, warping and poor strength. Addressing these problems, this paper presents the development and implementation of a rotary print head that enables local laser pre-deposition heating and forced air cooling in the 2.5-dimensional FLM process. Samples of polypropylene are fabricated to investigate the effects of the modified process on residual stresses and interlayer bonding. The investigations show that local laser pre-deposition heating can positively influence the interlayer bonding. In combination with a reduction of the extrusion temperature and additional cooling, it is possible to considerably reduce the residual stresses. The results of this research show that pre-deposition heating and forced air cooling significantly improve the processability of semi-crystalline thermoplastics in the FLM process.
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Koutsamanis I, Paudel A, Alva Zúñiga CP, Wiltschko L, Spoerk M. Novel polyester-based thermoplastic elastomers for 3D-printed long-acting drug delivery applications. J Control Release 2021; 335:290-305. [PMID: 34044092 DOI: 10.1016/j.jconrel.2021.05.030] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/29/2021] [Revised: 05/08/2021] [Accepted: 05/21/2021] [Indexed: 12/31/2022]
Abstract
To improve patient compliance and personalised drug delivery, long-acting drug delivery devices (LADDDs), such as implants and inserts, greatly benefit from a customisation in their shape through the emerging 3D-printing technology, since their production usually follows a one-size-fits-most approach. The use of 3D-printing for LADDDs, however, is mainly limited by the shortage of flawlessly 3D-printable, yet biocompatible materials. The present study tackles this issue by introducing a novel, non-biodegradable material, namely a polyester-based thermoplastic elastomer (TPC) - a multi-block copolymer containing alternating semi-crystalline polybutylene terephthalate hard segments and poly-ether-terephthalate amorphous soft segments. Next to a detailed description of the material's 3D-printability by mechanical, rheological and thermal analyses, which was found to be superior to that of conventional polymers (ethylene-vinyl acetates (EVA)), this study establishes the fundamental understandings of the interactions between progesterone (P4) and TPC and drug-releasing properties of TPC for the first time. P4-loaded LADDDs based on TPC, prepared via an elaborated solvent-immersion technique, enable the release of P4 at pharmacologically relevant rates, similar to those of marketed formulations based on EVA and silicones. Additionally, TPC demonstrated an exceptional 3D-printability for a wide selection of implant sizes and complex geometries.
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Affiliation(s)
- Ioannis Koutsamanis
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Amrit Paudel
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria; Institute of Process and Particle Engineering, Graz University of Technology, Inffeldgasse 13, 8010 Graz, Austria.
| | | | - Laura Wiltschko
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria
| | - Martin Spoerk
- Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria.
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Progress in MgCl2 supported Ziegler-Natta catalyzed polyolefin products and applications. JOURNAL OF POLYMER RESEARCH 2021. [DOI: 10.1007/s10965-021-02412-5] [Citation(s) in RCA: 11] [Impact Index Per Article: 3.7] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 02/07/2023]
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Gordeev EG, Ananikov VP. Widely accessible 3D printing technologies in chemistry, biochemistry and pharmaceutics: applications, materials and prospects. RUSSIAN CHEMICAL REVIEWS 2020. [DOI: 10.1070/rcr4980] [Citation(s) in RCA: 22] [Impact Index Per Article: 5.5] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/08/2022]
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Lamm ME, Wang L, Kishore V, Tekinalp H, Kunc V, Wang J, Gardner DJ, Ozcan S. Material Extrusion Additive Manufacturing of Wood and Lignocellulosic Filled Composites. Polymers (Basel) 2020; 12:E2115. [PMID: 32957494 PMCID: PMC7569778 DOI: 10.3390/polym12092115] [Citation(s) in RCA: 23] [Impact Index Per Article: 5.8] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/31/2020] [Revised: 09/14/2020] [Accepted: 09/15/2020] [Indexed: 12/30/2022] Open
Abstract
Wood and lignocellulosic-based material components are explored in this review as functional additives and reinforcements in composites for extrusion-based additive manufacturing (AM) or 3D printing. The motivation for using these sustainable alternatives in 3D printing includes enhancing material properties of the resulting printed parts, while providing a green alternative to carbon or glass filled polymer matrices, all at reduced material costs. Previous review articles on this topic have focused only on introducing the use of natural fillers with material extrusion AM and discussion of their subsequent material properties. This review not only discusses the present state of materials extrusion AM using natural filler-based composites but will also fill in the knowledge gap regarding state-of-the-art applications of these materials. Emphasis will also be placed on addressing the challenges associated with 3D printing using these materials, including use with large-scale manufacturing, while providing insight to overcome these issues in the future.
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Affiliation(s)
- Meghan E. Lamm
- Manufacturing Demonstration Facility, Energy and Transportation Science Division, Oak Ridge National Laboratory, 2350 Cherahala Boulevard, Knoxville, TN 37932, USA; (V.K.); (H.T.); (V.K.)
| | - Lu Wang
- Advanced Structures and Composites Center, University of Maine, 35 Flagstaff Road, Orono, ME 04469, USA; (L.W.); (D.J.G.)
- School of Forest Resources, University of Maine, 5755 Nutting Hall, Orono, ME 04469, USA
| | - Vidya Kishore
- Manufacturing Demonstration Facility, Energy and Transportation Science Division, Oak Ridge National Laboratory, 2350 Cherahala Boulevard, Knoxville, TN 37932, USA; (V.K.); (H.T.); (V.K.)
| | - Halil Tekinalp
- Manufacturing Demonstration Facility, Energy and Transportation Science Division, Oak Ridge National Laboratory, 2350 Cherahala Boulevard, Knoxville, TN 37932, USA; (V.K.); (H.T.); (V.K.)
| | - Vlastimil Kunc
- Manufacturing Demonstration Facility, Energy and Transportation Science Division, Oak Ridge National Laboratory, 2350 Cherahala Boulevard, Knoxville, TN 37932, USA; (V.K.); (H.T.); (V.K.)
| | - Jinwu Wang
- Forest Products Laboratory, U.S. Forest Service, 1 Gifford Pinchot Drive, Madison, WI 53726, USA;
| | - Douglas J. Gardner
- Advanced Structures and Composites Center, University of Maine, 35 Flagstaff Road, Orono, ME 04469, USA; (L.W.); (D.J.G.)
| | - Soydan Ozcan
- Manufacturing Demonstration Facility, Energy and Transportation Science Division, Oak Ridge National Laboratory, 2350 Cherahala Boulevard, Knoxville, TN 37932, USA; (V.K.); (H.T.); (V.K.)
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Fused Filament Fabricated Polypropylene Composite Reinforced by Aligned Glass Fibers. MATERIALS 2020; 13:ma13163442. [PMID: 32764235 PMCID: PMC7476032 DOI: 10.3390/ma13163442] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 06/24/2020] [Revised: 07/30/2020] [Accepted: 07/30/2020] [Indexed: 11/16/2022]
Abstract
3D printing using fused composite filament fabrication technique (FFF) allows prototyping and manufacturing of durable, lightweight, and customizable parts on demand. Such composites demonstrate significantly improved printability, due to the reduction of shrinkage and warping, alongside the enhancement of strength and rigidity. In this work, we use polypropylene filament reinforced by short glass fibers to demonstrate the effect of fiber orientation on mechanical tensile properties of the 3D printed specimens. The influence of the printed layer thickness and raster angle on final fiber orientations was investigated using X-ray micro-computed tomography. The best ultimate tensile strength of 57.4 MPa and elasticity modulus of 5.5 GPa were obtained with a 90° raster angle, versus 30.4 MPa and 2.5 GPa for samples with a criss-cross 45°, 135° raster angle, with the thinnest printed layer thickness of 0.1 mm.
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Estimation of the Adhesion Interface Performance in Aluminum-PLA Joints by Thermographic Monitoring of the Material Extrusion Process. MATERIALS 2020; 13:ma13153371. [PMID: 32751285 PMCID: PMC7435926 DOI: 10.3390/ma13153371] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 07/02/2020] [Revised: 07/24/2020] [Accepted: 07/27/2020] [Indexed: 11/17/2022]
Abstract
Using additive manufacturing to generate a polymer-metal structure offers the potential to achieve a complex customized polymer structure joined to a metal base of high stiffness and strength. A tool to evaluate the generated interface during the process is of fundamental interest, as the sequential deposition of the polymer as well as temperature gradients within the substrate lead to local variations in adhesion depending on the local processing conditions. On preheated aluminum substrates, 0.3 and 0.6 mm high traces of polylactic acid (PLA) were deposited. Based on differential scanning calorimetry (DSC) and rheometry measurements, the substrate temperature was varied in between 150 and 200 °C to identify an optimized manufacturing process. Decreasing the layer height and increasing the substrate temperature promoted wetting and improved the adhesion interface performance as measured in a single lap shear test (up to 7 MPa). Thermographic monitoring was conducted at an angle of 25° with respect to the substrate surface and allowed a thermal evaluation of the process at any position on the substrate. Based on the thermographic information acquired during the first second after extrusion and the preset shape of the polymer trace, the resulting wetting and shear strength were estimated.
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Abstract
Material extrusion (ME) systems offer end-users with a more affordable and accessible additive manufacturing (AM) technology compared to other processes in the market. ME is often used to quickly produce low-cost prototyping with the freedom of scalability where parts can be produced in different geometries, quantities and sizes. As the use of desktop ME machines has gained widespread adoption, this review paper discusses the key design strategies and considerations to produce high quality ME parts, as well as providing actional advice to aid end-users in quickly identifying and efficiently troubleshooting issues since current information is often fragmented and incomplete. The systemic issues and solutions concerning desktop ME processes discussed are not machine-specific, covering categories according to printer-associated, deposition-associated and print quality problems. The findings show that the majority of issues are associated with incorrect printer calibration and parameters, hardware, material, Computer Aided Design (CAD) model and/or slicing settings. A chart for an overview of ME troubleshooting is presented allowing designers and engineers to straightforwardly determine the possible contributing factors to a particular problem.
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Mechanical properties of polymeric implant materials produced by extrusion-based additive manufacturing. J Mech Behav Biomed Mater 2020; 104:103611. [DOI: 10.1016/j.jmbbm.2019.103611] [Citation(s) in RCA: 45] [Impact Index Per Article: 11.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/20/2019] [Revised: 12/13/2019] [Accepted: 12/30/2019] [Indexed: 01/08/2023]
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Spoerk M, Holzer C, Gonzalez‐Gutierrez J. Material extrusion‐based additive manufacturing of polypropylene: A review on how to improve dimensional inaccuracy and warpage. J Appl Polym Sci 2019. [DOI: 10.1002/app.48545] [Citation(s) in RCA: 88] [Impact Index Per Article: 17.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/12/2022]
Affiliation(s)
- Martin Spoerk
- Polymer ProcessingMontanuniversitaet Leoben, Otto Gloeckel‐Straße 2 Leoben 8700 Austria
| | - Clemens Holzer
- Polymer ProcessingMontanuniversitaet Leoben, Otto Gloeckel‐Straße 2 Leoben 8700 Austria
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Mechanical Recyclability of Polypropylene Composites Produced by Material Extrusion-Based Additive Manufacturing. Polymers (Basel) 2019; 11:polym11081318. [PMID: 31394766 PMCID: PMC6723500 DOI: 10.3390/polym11081318] [Citation(s) in RCA: 29] [Impact Index Per Article: 5.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/01/2019] [Revised: 08/02/2019] [Accepted: 08/05/2019] [Indexed: 11/22/2022] Open
Abstract
Due to a lack of long-term experience with burgeoning material extrusion-based additive manufacturing technology, also known as fused filament fabrication (FFF), considerable amounts of expensive material will continue to be wasted until a defect-free 3D-printed component can be finalized. In order to lead this advanced manufacturing technique toward cleaner production and to save costs, this study addresses the ability to remanufacture a wide range of commercially available filaments. Most of them either tend to degrade by chain scission or crosslinking. Only polypropylene (PP)-based filaments appear to be particularly thermally stable and therefore suitable for multiple remanufacturing sequences. As the extrusion step exerts the largest influence on the material in terms of temperature and shear load, this study focused on the morphological, rheological, thermal, processing, tensile, and impact properties of a promising PP composite in the course of multiple consecutive extrusions as well as the impact of additional heat stabilizers. Even after 15 consecutive filament extrusions, the stabilized additively manufactured PP composite revealed an unaltered morphology and therefore the same tensile and impact strength as the initial material. As the viscosity of the material of the 15th extrusion was nearly identical to that of the 1st extrusion sequence, the processability both in terms of extrusion and FFF was outstanding, despite the tremendous amount of shear and thermal stress that was undergone. The present work provides key insights into one possible step toward more sustainable production through FFF.
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Flores Ituarte I, Wiikinkoski O, Jansson A. Additive Manufacturing of Polypropylene: A Screening Design of Experiment Using Laser-Based Powder Bed Fusion. Polymers (Basel) 2018; 10:E1293. [PMID: 30961218 PMCID: PMC6401993 DOI: 10.3390/polym10121293] [Citation(s) in RCA: 16] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/02/2018] [Revised: 11/12/2018] [Accepted: 11/13/2018] [Indexed: 11/18/2022] Open
Abstract
The use of commodity polymers such as polypropylene (PP) is key to open new market segments and applications for the additive manufacturing industry. Technologies such as powder-bed fusion (PBF) can process PP powder; however, much is still to learn concerning process parameters for reliable manufacturing. This study focusses in the process⁻property relationships of PP using laser-based PBF. The research presents an overview of the intrinsic and the extrinsic characteristic of a commercial PP powder as well as fabrication of tensile specimens with varying process parameters to characterize tensile, elongation at break, and porosity properties. The impact of key process parameters, such as power and scanning speed, are systematically modified in a controlled design of experiment. The results were compared to the existing body of knowledge; the outcome is to present a process window and optimal process parameters for industrial use of PP. The computer tomography data revealed a highly porous structure inside specimens ranging between 8.46% and 10.08%, with porosity concentrated in the interlayer planes in the build direction. The results of the design of experiment for this commercial material show a narrow window of 0.122 ≥ Ev ≥ 0.138 J/mm³ led to increased mechanical properties while maintaining geometrical stability.
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Affiliation(s)
- Iñigo Flores Ituarte
- Department of Materials and Production, Section of Sustainable Production, Faculty of Engineering and Science, Aalborg University, Copenhagen 2450, Denmark.
| | - Olli Wiikinkoski
- Department of Mechanical Engineering, School of Engineering, Aalto University, Espoo 11000, Finland.
| | - Anton Jansson
- Department of Mechanical Engineering, Örebro University, Örebro 70182, Sweden.
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Yasin S, Sun D, Memon H, Zhu F, Jian H, Bin Y, Mingbo M, Hussain M. Optimization of Mechanical and Thermal Properties of iPP and LMPP Blend Fibres by Surface Response Methodology. Polymers (Basel) 2018; 10:E1135. [PMID: 30961060 PMCID: PMC6403866 DOI: 10.3390/polym10101135] [Citation(s) in RCA: 13] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/08/2018] [Revised: 09/25/2018] [Accepted: 10/10/2018] [Indexed: 11/16/2022] Open
Abstract
Optimization of the mechanical and thermal properties of isotactic polypropylene (iPP) homopolymer blended with relatively new low molecular low modulus polypropylene (LMPP) at different blend ratios was carried out via surface response methodology (RSM). Regression equations for the prediction of optimal conditions were achieved considering eight individual parameters: naming, elongation at break, tensile strength and elastic modulus, crystallization temperature (TC), first melting temperatures (TM1), heat fusion (Hf), crystallinity, and melt flow rate (MFR), which were measured as responses for the design of experiment (DOE). The adjusted and predicted correlation coefficient (R²) shows good agreement between the actual and the predicted values. To confirm the optimal values from the response model, supplementary experiments as a performance evaluation were conducted, posing better operational conditions. It has been confirmed that the RSM model was adequate to reflect the predicted optimization. The results suggest that the addition of LMPP into iPP could effectively enhance the functionality and processability of blend fibres if correctly proportioned.
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Affiliation(s)
- Sohail Yasin
- School of Textiles and Design, Heriot-Watt University, Galashiels TD1 3HF, UK.
| | - Danmei Sun
- School of Textiles and Design, Heriot-Watt University, Galashiels TD1 3HF, UK.
| | - Hafeezullah Memon
- Key Laboratory of Textile Science and Technology, Donghua University, Shanghai 201620, China.
| | - Feichao Zhu
- School of Materials and Textiles, Zhejiang Sci-Tech University, Hangzhou 310018, China.
| | - Han Jian
- School of Materials and Textiles, Zhejiang Sci-Tech University, Hangzhou 310018, China.
| | - Yu Bin
- School of Materials and Textiles, Zhejiang Sci-Tech University, Hangzhou 310018, China.
| | - Ma Mingbo
- School of Materials and Textiles, Zhejiang Sci-Tech University, Hangzhou 310018, China.
| | - Munir Hussain
- School of Materials and Textiles, Zhejiang Sci-Tech University, Hangzhou 310018, China.
- Department of Polymer Science and Engineering, Zhejiang University, Hangzhou 310027, China.
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Gonzalez-Gutierrez J, Cano S, Schuschnigg S, Kukla C, Sapkota J, Holzer C. Additive Manufacturing of Metallic and Ceramic Components by the Material Extrusion of Highly-Filled Polymers: A Review and Future Perspectives. MATERIALS (BASEL, SWITZERLAND) 2018; 11:E840. [PMID: 29783705 PMCID: PMC5978217 DOI: 10.3390/ma11050840] [Citation(s) in RCA: 88] [Impact Index Per Article: 14.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 04/26/2018] [Revised: 05/11/2018] [Accepted: 05/16/2018] [Indexed: 11/21/2022]
Abstract
Additive manufacturing (AM) is the fabrication of real three-dimensional objects from metals, ceramics, or plastics by adding material, usually as layers. There are several variants of AM; among them material extrusion (ME) is one of the most versatile and widely used. In MEAM, molten or viscous materials are pushed through an orifice and are selectively deposited as strands to form stacked layers and subsequently a three-dimensional object. The commonly used materials for MEAM are thermoplastic polymers and particulate composites; however, recently innovative formulations of highly-filled polymers (HP) with metals or ceramics have also been made available. MEAM with HP is an indirect process, which uses sacrificial polymeric binders to shape metallic and ceramic components. After removing the binder, the powder particles are fused together in a conventional sintering step. In this review the different types of MEAM techniques and relevant industrial approaches for the fabrication of metallic and ceramic components are described. The composition of certain HP binder systems and powders are presented; the methods of compounding and filament making HP are explained; the stages of shaping, debinding, and sintering are discussed; and finally a comparison of the parts produced via MEAM-HP with those produced via other manufacturing techniques is presented.
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Affiliation(s)
- Joamin Gonzalez-Gutierrez
- Polymer Processing, Department of Polymer Engineering and Science, Montanuniversitaet Leoben, Otto Gloeckel-Strasse 2, 8700 Leoben, Austria.
| | - Santiago Cano
- Polymer Processing, Department of Polymer Engineering and Science, Montanuniversitaet Leoben, Otto Gloeckel-Strasse 2, 8700 Leoben, Austria.
| | - Stephan Schuschnigg
- Polymer Processing, Department of Polymer Engineering and Science, Montanuniversitaet Leoben, Otto Gloeckel-Strasse 2, 8700 Leoben, Austria.
| | - Christian Kukla
- Industrial Liaison Department, Montanuniversitaet Leoben, Peter Tunner Strasse 27, 8700 Leoben, Austria.
| | - Janak Sapkota
- Polymer Processing, Department of Polymer Engineering and Science, Montanuniversitaet Leoben, Otto Gloeckel-Strasse 2, 8700 Leoben, Austria.
| | - Clemens Holzer
- Polymer Processing, Department of Polymer Engineering and Science, Montanuniversitaet Leoben, Otto Gloeckel-Strasse 2, 8700 Leoben, Austria.
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