RESUMEN
The development of multi-material filaments has enabled fused filament fabrication-based additive manufacturing to address demand for high-performance lightweight multifunctional components. In this study, polylactic acid (PLA) and acrylonitrile butadiene styrene based filaments with metallic reinforcements of magnetic iron (MI), stainless steel (SS), bronze (Br), copper (Cu), Bismuth (Bi), and Tungsten (W) were investigated to elucidate their complex processing-structure-property relationships. The microstructure of 3D-printed materials were characterized by microscopy and analyzed to determine the metal cross-sectional area percentage and the relationship between metal reinforcement, the polymer matrix, and porosity. Compression testing was conducted in directions parallel and perpendicular to the build direction in order to evaluate the effect of orientation and metal reinforcement on the mechanical properties. 3D-printed specimens experienced either fracture through print layers or layer-wise interfacial rupture for loads applied perpendicular and parallel to the print layers, respectively. A dependence of yield strength on loading orientation was observed for Br-PLA, Cu-PLA, SS-PLA, Bi-ABS, and W-ABS; however, MI-PLA and pure ABS specimens did not exhibit this sensitivity. Metal reinforcement also influenced the magnitude of compressive yield strength, with MI-PLA and SS-PLA demonstrating increased strength over Br-PLA and Cu-PLA, while ABS demonstrated increased strength over Bi-ABS and W-ABS. These results demonstrate the importance of considering orientation in printing and applications, the trade-off between various metallic reinforcements for added multifunctionality, and the potential of these tailored polymer composites for novel 3D-printed structures.
RESUMEN
The expansive utility of polymeric 3D-printing technologies and demand for high- performance lightweight structures has prompted the emergence of various carbon-reinforced polymer composite filaments. However, detailed characterization of the processing-microstructure-property relationships of these materials is still required to realize their full potential. In this study, acrylonitrile butadiene styrene (ABS) and two carbon-reinforced ABS variants, with either carbon nanotubes (CNT) or 5 wt.% chopped carbon fiber (CF), were designed in a bio-inspired honeycomb geometry. These structures were manufactured by fused filament fabrication (FFF) and investigated across a range of layer thicknesses and hexagonal (hex) sizes. Microscopy of material cross-sections was conducted to evaluate the relationship between print parameters and porosity. Analyses determined a trend of reduced porosity with lower print-layer heights and hex sizes compared to larger print-layer heights and hex sizes. Mechanical properties were evaluated through compression testing, with ABS specimens achieving higher compressive yield strength, while CNT-ABS achieved higher ultimate compressive strength due to the reduction in porosity and subsequent strengthening. A trend of decreasing strength with increasing hex size across all materials was supported by the negative correlation between porosity and increasing print-layer height and hex size. We elucidated the potential of honeycomb ABS, CNT-ABS, and ABS-5wt.% CF polymer composites for novel 3D-printed structures. These studies were supported by the development of a predictive classification and regression supervised machine learning model with 0.92 accuracy and a 0.96 coefficient of determination to help inform and guide design for targeted performance.
RESUMEN
Safe operation and health of structures relies on their ability to effectively dissipate undesired vibrations, which could otherwise significantly reduce the life-time of a structure due to fatigue loads or large deformations. To address this issue, nanoscale fillers, such as carbon nanotubes (CNTs), have been utilized to dissipate mechanical energy in polymer-based nanocomposites through filler-matrix interfacial friction by benefitting from their large interface area with the matrix. In this manuscript, for the first time, we experimentally investigate the effect of CNT alignment with respect to reach other and their orientation with respect to the loading direction on vibrational damping in nanocomposites. The matrix was polystyrene (PS). A new technique was developed to fabricate PS-CNT nanocomposites which allows for controlling the angle of CNTs with respect to the far-field loading direction (misalignment angle). Samples were subjected to dynamic mechanical analysis, and the damping of the samples were measured as the ratio of the loss to storage moduli versus CNT misalignment angle. Our results defied a notion that randomly oriented CNT nanocomposites can be approximated as a combination of matrix-CNT representative volume elements with randomly aligned CNTs. Instead, our results points to major contributions of stress concentration induced by each CNT in the matrix in proximity of other CNTs on vibrational damping. The stress fields around CNTs in PS-CNT nanocomposites were studied via finite element analysis. Our findings provide significant new insights not only on vibrational damping nanocomposites, but also on their failure modes and toughness, in relation to interface phenomena.