The mechanical properties of additive manufactured laser powder-bed fusion (L-PBF) AlSi10Mg specimens, built with the chessboard building strategy and followed by three thermal treatments, were evaluated using standard mechanical testing in tension. Metallography and fractography tests were conducted to reveal the microstructure and connect them to the properties in various stages of the research. A strong relationship between hatching strategy, build direction and loading direction was found and it was concluded that the mechanical properties of the alloy in the modified T5 (200 o C) thermal condition are similar to the as-built condition for the concept strategy. The mechanical properties are similar albeit the differences found in the fracture faces of X and Z specimens. The similarity of the mechanical properties in the X and Z directions also suggests that the additively manufacturing (AM) L-PBF process yields fairly homogenous mechanical properties of AlSi10Mg (excluding the T5 treated alloy). The mechanical properties and the microstructure obtained were compared to an equivalent alloy AM L-PBF manufactured using an EOS© system with a different hatching strategy. The three different thermal conditions, employed in this research, provided insight into the mechanical behavior under different strategies. Understanding these changes in mechanical properties, as a result of these thermal conditions, allows for tailoring AM parts for engineering applications having various requirements. The onset of the elastic-plastic deformation and the possible effects of the hatching strategy on the elastic-plastic deformation and the strain hardening behavior were also discussed.
The Fused Filament Fabrication (FFF) method is one of the most important additive manufacturing (AM) technologies. This technology is used today with various kinds of thermoplastic materials, including ABS. The present study deals with the flexural strength and axial deflection of ABS specimens versus relative density, to observe the influence of build-orientations, build model and microscopic level defects of these properties. In this study, the mechanical and structural characterization of AM-FFF ABS material was studied by CAD modelling of different orientations, three point bending mechanical testing, visual testing, and multifocal light microscopy observation, including fractography analysis. To that end, three different standard building orientations (Flat, On Edge and Upright) were printed, and each was built in two different angle orientations (-45o/+45o and 0°/90o). Based on the three point bending testing results, it was found that the specimen with the highest flexural strength was not necessarily the one with the highest deflection. It was also observed that On Edge 0/+90o orientations showed a relatively larger flexural strength difference in comparison to other building orientations (Flat and Upright). When the mechanical properties achieved from a bending test next to the building platform were compared to the properties far from the building platform, only a slight difference was found, which means that the flexural strength difference results from the building strategy and it is not related to the specific bending surface. Based on fractography observation, there is a major difference in the mechanical properties and fracture surface appearance, when the samples are bent between the layers (Upright orientation) or when the samples are bent through the layers (Flat and On Edge orientation).
One of the most important Additive Manufacturing (AM) technologies is the Fused Deposition Modeling (FDM) technology, suitable for various engineering applications which is currently used with many types of thermoplastic materials including ABS. AM-FDM printed ABS possesses an inherent capacity for property modifications as a function of printing parameters. The main goals of this study were to characterize experimentally the mechanical and structural properties of printed ABS specimens; as well as to reach an expression that will allow us to estimate the strength of the AM-FDM printed ABS for different printing parameters, prior to the printing process. In this experimental study, the mechanical and structural characterization of AM-FDM ABS material was performed by visual non-destructive testing inspection, mechanical testing, and light microscopy (LM) investigation. The three-point bend flexural test results revealed the mechanical properties as well as the fracture surface, according to build-on (coupon) specimens' dimensions and build-strategies. The results of this study provide preliminary quantitative estimates for the mechanical significant properties, as a function of some AM-FDM process variables for the ABS material. Parameter coefficients were defined to calculate the estimated strength of the printed ABS. They are chosen according to the desired printing parameters, and then multiplied by the highest average strength achieved for the X or Z direction bending tests specimens to achieve the estimated strength. The parameter coefficients were used to estimate the flexural strength of AM-FDM ABS specimens pertaining to a different R&D project; a decent agreement between the experimental data and the calculated results was obtained.
Fused Deposition Modelling (FDM) is one of the most important Additive Manufacturing (AM) technologies. This is a technology suitable for various engineering applications and currently used with many types of thermoplastic materials including Acrylonitrile Butadiene Styrene (ABS). AM-FDM printed ABS possesses an inherent capacity for property modifications as a function of printing parameters. The main goal of the present ongoing research project is to estimate the strength of the AM-FDM printed ABS for varying printing process parameters. In the present study, the mechanical and structural characterizations of AM-FDM ABS were evaluated by light microscopy and mechanical testing. Three-point bend flexural test results revealed the mechanical properties as well as the fracture behaviour according to the dimensions and printing strategies of the build-on specimens. An innovative transmitted-light microscopy experimental method was developed and utilized to investigate the crack propagation behaviour under bending.
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