AddJoining: A novel additive manufacturing approach for layered metal-polymer hybrid structures

Falck, Rielson; Goushegir, Seyed M.; Santos, Jorge F. dos; Amancio‐Filho, Sergio T.

doi:10.1016/j.matlet.2018.01.021

Cited by 58 publications

(50 citation statements)

References 6 publications

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“…There are many benefits to using AM processes in manufacturing of end-user parts, including the ability to produce extremely complex geometry directly from digital models [8,9] and the freedom from formal tooling requirements [2,10]. Various AM methods can process a wide variety of polymer, metal, and ceramic materials; some hybrid processes have recently emerged [11][12][13][14][15] which can use more than one class of material in the same part and process.…”

Section: Introductionmentioning

confidence: 99%

Full-Density Fused Deposition Modeling Dimensional Error as a Function of Raster Angle and Build Orientation: Large Dataset for Eleven Materials

Messimer

Pereira

Patterson

et al. 2019

JMMP

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This paper describes the collection of a large dataset (6930 measurements) on dimensional error in the fused deposition modeling (FDM) additive manufacturing process for full-density parts. Three different print orientations were studied, as well as seven raster angles ( 0 ∘ , 15 ∘ , 30 ∘ , 45 ∘ , 60 ∘ , 75 ∘ , and 90 ∘ ) for the rectilinear infill pattern. All measurements were replicated ten times on ten different samples to ensure a comprehensive dataset. Eleven polymer materials were considered: acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), high-temperature PLA, wood-composite PLA, carbon-fiber-composite PLA, copper-composite PLA, aluminum-composite PLA, high-impact polystyrene (HIPS), polyethylene terephthalate glycol-enhanced (PETG), polycarbonate, and synthetic polyamide (nylon). The samples were ASTM-standard impact-testing samples, since this geometry allows the measurement of error on three different scales; the nominal dimensions were 3 . 25 mm thick, 63 . 5 mm long, and 12 . 7 mm wide. This dataset is intended to give engineers and product designers a basis for judging the accuracy and repeatability of the FDM process for use in manufacturing of end-user products.

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Section: Introductionmentioning

confidence: 99%

Full-Density Fused Deposition Modeling Dimensional Error as a Function of Raster Angle and Build Orientation: Large Dataset for Eleven Materials

Messimer

Pereira

Patterson

et al. 2019

JMMP

View full text Add to dashboard Cite

show abstract

“…Kumar et al [ 23 , 24 ] and Khan et al [ 25 , 26 ] used AM to create single lap joint (SLJ) geometries with tailored modulus in the bondline layer without additional joining, a process conceptually similar to that of AddJoining [ 12 ].…”

Section: Joint Design Strategies For Additive Manufacturingmentioning

confidence: 99%

“…Subsequent studies explored joint performance improvements using AM as a joining tool, the AddJoining process [ 12 , 13 ] with or without co-curing, and a voxel-oriented design [ 14 ] approach. A hybrid approach combining the first two solutions was also considered.…”

Section: Introductionmentioning

confidence: 99%

Review of Tailoring Methods for Joints with Additively Manufactured Adherends and Adhesives

et al. 2020

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This review aims to assess the current modelling and experimental achievements in the design for additive manufacturing of bonded joints, providing a summary of the current state of the art. To limit its scope, the document is focused only on polymeric additive manufacturing processes. As a result, this review paper contains a structured collection of the tailoring methods adopted for additively manufactured adherends and adhesives with the aim of maximizing bonded joint performance. The intent is, setting the state of the art, to produce an overview useful to identify the new opportunities provided by recent progresses in the design for additive manufacturing, additive manufacturing processes and materials’ developments.

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“…For the most common thermoplastics currently used in the ME process, Amancio-Filho et al [ 13 ] suggests substrate temperatures in between the extrusion, T e , and the crystallization temperature, T c , of the polymer to optimize the polymer–metal bonding. In their recent publications regarding the Addjoining ® process, Falck et al [ 14 , 15 ] applied a primer by spreading, e.g., an acrylonitrile butadiene styrene (ABS)-acetone solution onto the metal surface before the actual ME process is carried out. An improvement in single lap shear strength was observed for an increased extruder head velocity, primer thickness and decreased layer height [ 14 ].…”

Section: Introductionmentioning

confidence: 99%

“…An optimized local temperature management allows for an improvement of the adhesive (polymer layer to substrate) and cohesive (layer to layer) properties [ 5 , 6 , 7 , 13 , 14 , 15 , 17 , 18 , 19 , 20 ]. Thermography is suitable to evaluate the ME process in terms of local temperature distribution [ 18 , 19 , 21 , 22 ].…”

Section: Introductionmentioning

confidence: 99%

Estimation of the Adhesion Interface Performance in Aluminum-PLA Joints by Thermographic Monitoring of the Material Extrusion Process

et al. 2020

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Using additive manufacturing to generate a polymer–metal structure offers the potential to achieve a complex customized polymer structure joined to a metal base of high stiffness and strength. A tool to evaluate the generated interface during the process is of fundamental interest, as the sequential deposition of the polymer as well as temperature gradients within the substrate lead to local variations in adhesion depending on the local processing conditions. On preheated aluminum substrates, 0.3 and 0.6 mm high traces of polylactic acid (PLA) were deposited. Based on differential scanning calorimetry (DSC) and rheometry measurements, the substrate temperature was varied in between 150 and 200 °C to identify an optimized manufacturing process. Decreasing the layer height and increasing the substrate temperature promoted wetting and improved the adhesion interface performance as measured in a single lap shear test (up to 7 MPa). Thermographic monitoring was conducted at an angle of 25° with respect to the substrate surface and allowed a thermal evaluation of the process at any position on the substrate. Based on the thermographic information acquired during the first second after extrusion and the preset shape of the polymer trace, the resulting wetting and shear strength were estimated.

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AddJoining: A novel additive manufacturing approach for layered metal-polymer hybrid structures

Cited by 58 publications

References 6 publications

Full-Density Fused Deposition Modeling Dimensional Error as a Function of Raster Angle and Build Orientation: Large Dataset for Eleven Materials

Full-Density Fused Deposition Modeling Dimensional Error as a Function of Raster Angle and Build Orientation: Large Dataset for Eleven Materials

Review of Tailoring Methods for Joints with Additively Manufactured Adherends and Adhesives

Estimation of the Adhesion Interface Performance in Aluminum-PLA Joints by Thermographic Monitoring of the Material Extrusion Process

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