One of the fundamental issues in the Fused Filament Fabrication (FFF) additive manufacturing process lies in the mechanical property anisotropy where the strength of the FFF-3D printed part in the build-direction can be significantly lower than that in other directions. The physical phenomenon that governs this issue is the coupled effect of macroscopic thermal mechanical issues associated with the thermal history of the interface, and the microscopic effect of the polymer microstructure and mass transfer across interfaces. In this study it was found that the use of 34.4 kHz ultrasonic vibrations during FFF-3D printing results in an increase of up to 10% in the interlayer adhesion in Acrylonitrile Butadiene Styrene (ABS), comparing the printing in identical thermal conditions to that in conventional FFF printing. This increase in the interlayer adhesion strength is attributed to the increase in polymer reptation due to ultrasonic vibration-induced relaxation of the polymer chains from secondary interactions in the interface regions.
more »
« less
Anisotropy in Additively Manufactured Concrete Specimens under Compressive Loading—Quantification of the Effects of Layer Height and Fiber Reinforcement
This paper analyzes the effect of print layer heights and loading direction on the compressive response of plain and fiber-reinforced (steel or basalt fiber) 3D printed concrete. Slabs with three different layer heights (6, 13, and 20 mm) are printed, and extracted cubes are subjected to compression (i) along the direction of printing, (ii) along the direction of layer build-up, and (iii) perpendicular to the above two directions. Digital image correlation (DIC) is used as a non-contact means to acquire the strain profiles. While the 3D printed specimens show lower strengths, as compared to cast specimens, when tested in all three directions, this effect can be reduced through the use of fiber reinforcement. Peak stress and peak strain-based anisotropy coefficients, which are linearly related, are used to characterize and quantify the directional dependence of peak stress and strain. Interface-parallel cracking is found to be the major failure mechanism, and anisotropy coefficients increase with an increase in layer height, which is attributable to the increasing significance of interfacial defects. Thus, orienting the weaker interfaces appropriately, through changes in printing direction, or strengthening them through material modifications (such as fiber reinforcement) or process changes (lower layer height, enables attainment of near-isotropy in 3D printed concrete elements.
more »
« less
- Award ID(s):
- 2020095
- PAR ID:
- 10482368
- Publisher / Repository:
- MDPI
- Date Published:
- Journal Name:
- Materials
- Volume:
- 16
- Issue:
- 15
- ISSN:
- 1996-1944
- Page Range / eLocation ID:
- 5488
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
More Like this
-
-
We designed and characterized a 3D printed acoustic shear wave polarization rotator (PR) based on the specific nature of the fused-deposition-modeling printing process. The principle of the PR is based on rotation of the polarization axis of a shear wave due to the gradual change in orientation of the axis of anisotropy along the direction of wave propagation of a printed layered structure. The component of the shear modulus parallel to the infilled lines within each layer is significantly higher than that in the perpendicular direction. As the PR was printing, a small angle between neighboring layers was introduced, resulting in a 3D helicoidal pattern of distribution of the axes of anisotropy. The polarization of the propagating shear wave follows this pattern leading to the rotation of the polarization axis by a desirable angle. The total rotation angle can be tuned by the number of printed layers. The fabricated [Formula: see text] rotators demonstrate high performance that can be improved by changing the infill fraction settings.more » « less
-
null (Ed.)Abstract Pellet-based extrusion deposition of carbon fiber-reinforced composites at high material deposition rates has recently gained much attention due to its applications in large-scale additive manufacturing. The mechanical and physical properties of large-volume components largely depend on their reinforcing fiber length. However, very few studies have been done thus far to have a direct comparison of additively fabricated composites reinforced with different carbon fiber lengths. In this study, a new additive manufacturing (AM) approach to fabricate long fiber-reinforced polymer (LFRP) was first proposed. A pellet-based extrusion deposition method was implemented, which directly used thermoplastic pellets and continuous fiber tows as feedstock materials. Discontinuous long carbon fibers, with an average fiber length of 20.1 mm, were successfully incorporated into printed LFRP samples. The printed LFRP samples were compared with short fiber-reinforced polymer (SFRP) and continuous fiber-reinforced polymer (CFRP) counterparts through mechanical tests and microstructural analyses. The carbon fiber dispersion, distribution of carbon fiber length and orientation, and fiber wetting were studied. As expected, a steady increase in flexural strength was observed with increasing fiber length. The carbon fibers were highly oriented along the printing direction. A more uniformly distributed discontinuous fiber reinforcement was found within printed SFRP and LFRP samples. Due to decreased fiber impregnation time and lowered impregnation rate, the printed CFRP samples showed a lower degree of impregnation and worse fiber wetting conditions. The feasibility of the proposed AM methods was further demonstrated by fabricating large-volume components with complex geometries.more » « less
-
Abstract Composites play progressively significant roles across a spectrum of applications involving high‐performance materials and products within industries such as aerospace, naval, automotive, construction, missiles, and defense technology. Notably, oriented fiber composites have garnered substantial attention due to their advantageous attributes like a high strength‐to‐weight ratio and controlled anisotropy. Nonetheless, challenges persist in uneven fiber alignment, fiber clustering within the matrix material, and constraints on fiber volume, impeding the mass production of oriented fiber‐reinforced composites. In this study, we present a novel approach to 3D printing of uniformly aligned short fiber reinforcement in a composite of heavily loaded carbon and nylon. Capitalizing on the additive manufacturing potential of rapidity and precision, the extrusion process induces carbon fiber (CF) alignments in filaments via shear forces. The 3D‐printed structures that were created displayed impressive potential for customization. They consistently demonstrated improved mechanical and thermal properties when compared to the original nylon structures. Our methodology for producing uniformly dispersed and aligned short fiber reinforcement in polymer composites promises to propel the advancement of design and manufacturing for high‐performance composite materials and components.more » « less
-
Magnetic Field Assisted Additive Manufacturing (MFAAM), 3D printing in a magnetic field, has the potential to fabricate high magnetic strength anisotropic bonded magnets. Here, 10, 35, and 54 wt% strontium ferrite bonded magnets using polyamide 12 binder were developed by twin screw compounding process and then printed via MFAAM samples in zero, and in 0.5 Tesla (H parallel to the print direction and print bed). The hysteresis curves were measured using a MicroSense EZ9 Vibrating Sample Magnetometer (VSM) for 3 different mount orientations of the sample on the sample holder to explore the magnetic anisotropy. The samples printed in zero field exhibited a weak anisotropy with an easy axis perpendicular to the print direction. This anisotropy is caused by the effect of shear flow on the orientation of the magnetic platelets in the 3D printer head. For the MFAAM samples, the S values are largest along the print bed normal. This anisotropy is caused by the field. The alignment of the magnetic particles happens when the molten suspension is in the extruder. When the material is printed, it is folded over on the print bed and its easy axis rotates 90° parallel to the print bed normally. Little realignment of the particles happens after it is printed, suggesting a sharp drop in temperature once the composite touches the print bed, indicating that field-induced effects in the nozzle dominate the anisotropy of MFAAM deposited samples.more » « less
An official website of the United States government

