Affordable commercial desktop 3-D printers and filaments have introduced additive manufacturing to all disciplines of science and engineering. With rapid innovations in 3-D printing technology and new filament materials, material vendors are offering specialty multifunctional metal-reinforced polymers with unique properties. Studies are necessary to understand the effects of filament composition, metal reinforcements, and print parameters on microstructure and mechanical behavior. In this study, densities, metal vol%, metal cross-sectional area %, and microstructure of various metal-reinforced Polylactic Acid (PLA) filaments were characterized by multiple methods. Comparisons are made between polymer microstructures before and after printing, and the effect of printing on the metal-polymer interface adhesion has been demonstrated. Tensile response and fracture toughness as a function of metal vol% and print height was determined. Tensile and fracture toughness tests show that PLA filaments containing approximately 36 vol% of bronze or copper particles significantly reduce mechanical properties. The mechanical response of PLA with 12 and 18 vol% of magnetic iron and stainless steel particles, respectively, is similar to that of pure PLA with a slight decrease in ultimate tensile strength and fracture toughness. These results show the potential for tailoring the concentration of metal reinforcements to provide multi-functionality without sacrificing mechanical properties.
Fused filament fabrication (FFF) systems utilize a wide variety of commercially available filaments, including Acrylonitrile Butadiene Styrene (ABS), as well as their variants. However, the effect of filament composition, reinforcements (chopped fibers and nanotubes), and 3-D printing variables on the microstructure and thermomechanical behavior is not well understood, and systematic studies are needed. In this work, different types of ABS materials with and without carbon fiber and carbon nanotube reinforcements were printed with multiple print layer heights. The microstructure, elastic behavior, tensile behavior, and fracture toughness of 3-D printed materials were characterized. ABS material systems printed at a low print layer height of 0.1 mm outperformed those printed at a larger height of 0.2 mm. Carbon nanotube reinforcements result in significant improvement in the strength and elastic modulus of ABS materials. Printed coupons of ABS with carbon nanotubes achieve an ultimate strength of 34.18 MPa, while a premium grade ABS coupon achieved 28.75 MPa when printed with the same print layer heights. Samples of ABS with chopped carbon fiber show an ultimate strength of 27.25 MPa, due primarily to the significant porosity present in the filament. Elastic moduli and fracture toughness measured using dynamic and mechanical methods show similar trends as a function of layer height. The effects of different materials, reinforcements, and printing parameters on the microstructure and mechanical properties are discussed in detail.
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