Fused filament fabrication (FFF) is the most widely used additive manufacturing (AM) technology for printing thermoplastic materials, among them the ABS. A significant problem of 3D-printed parts manufactured by AM-FFF is the anisotropy of their mechanical properties. Thus, it is of great importance to understand the impact of the build strategy of the mechanical properties and failure mechanisms of AM-FFF ABS components. This research aims, at least partly, to fill this gap by studying the structure and mechanical behavior by performing fracture surface analysis of AM-FFF ABS specimens under the three-point bend test. For this purpose, three build orientations (flat, on-edge and upright), each built at 0°/90° and -45°/+45° raster angles and oblique printed samples (0°, 15°, 30°, 45°, 60°, and 75°) built at -45°/+45° raster angles were prepared. The results revealed that the build direction with the lowest density, the flexural modulus of elasticity, flexural strength, and deflection was in the upright direction for both 0°/90° and -45°/+45° raster orientations. Overall, two main failure modes were observed for the tested specimens: (1) inter-layer/inter-raster bond failure, which is the main contributor to failure of all upright samples and (2) intra-layer/trans-raster failure, which is the main contributor to failure of flat and on-edge specimens printed at -45°/+45° raster orientation. The results of the oblique printed samples demonstrate that a single crack initiation can transform into a few inter-laminar and intra-laminar fracture surfaces due to competing stress fields and structural gradients
Fused filament fabrication (FFF) technique is one of the most frequently used additive manufacturing (AM) technologies for printing ABS and many other thermoplastic materials. The anisotropy of the mechanical properties of 3D-printed parts manufactured by FFF technology is still of major concern when using this technique. Thus, the component’s orientation, build strategy and printing parameters affect the mechanical properties, and failure mechanisms are of crucial importance. This research aims to partly fill this gap by studying the structure and mechanical behavior of FFF-ABS specimens, and by performing fracture surface analysis by the three-point bend flexural test. A series of tests were conducted to determine the flexural properties of tilted specimens at 0°, 15°, 30°, 45°, 60° and 75° inclination angles relative to the machine platform. The work describes manufacture method of the specimens, experimental procedures, and outcomes from the mechanical and structural characterizations of the FFF-ABS specimens. Overall, two main failure modes were observed for the tested specimens: (1) inter-layer/ inter-raster bond failure (typical for upright specimens) and (2) intra-layer/trans-raster failure (typical for on-edge specimens). A mixed inter-layer/ intra-layer mode was found for the specimens tilted in-between the 15o and 60o range.
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