Coal polymer composites prepared by fused deposition modeling (FDM) 3D printing

Zhang, Shuyang; Rehman, Muhammad Zia ur; Bhagia, Samarthya; Meng, Xianzhi; Meyer, Harry M.; Wang, Hsin; Köehler, Michael; Akhtar, Kalsoom; Harper, David P.; Ragauskas, Arthur J.

doi:10.1007/s10853-022-07276-8

Cited by 8 publications

(5 citation statements)

References 47 publications

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“…These results are in agreement with previously published literature regarding the reinforcing effect of carbon and coal fillers in polyamide-based composite materials. 17,50 Enhanced UTS for the PA12-based composites could be attributed to improved interfacial bonding between coal and PA12, leading to an efficient load transfer from the polymer to the coal particle. Molecular simulations (Section 3.2.3.)…”

Section: Resultsmentioning

confidence: 99%

“…Leveraging the composite’s benefits via alternative manufacturing processes such as AM provides the opportunity to further expand the technology to new applications and industries including composite tooling and additive house construction. While Zhang et al successfully demonstrated the processing of PA12 CPC filaments filled with up to 20 wt % anthracite and 50 wt % lignite coals, common FDM plastics, such as PLA and PETG, and other widely available and inexpensive plastics, such as HDPE, were not explored . The performance and economic benefits of CPC materials can be further compounded by leveraging AM.…”

Section: Introductionmentioning

confidence: 99%

“…While Zhang et al successfully demonstrated the processing of PA12 CPC filaments filled with up to 20 wt % anthracite and 50 wt % lignite coals, common FDM plastics, such as PLA and PETG, and other widely available and inexpensive plastics, such as HDPE, were not explored. 17 The performance and economic benefits of CPC materials can be further compounded by leveraging AM. Developing CPC filaments with high coal filler contents and characterizing their mechanical performance provide the opportunity to create sustainable and economically viable feedstocks for 3D printing tooling and structural components.…”

Section: Introductionmentioning

confidence: 99%

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3D Printing of Sustainable Coal Polymer Composites: Study of Processing, Mechanical Performance, and Atomistic Matrix–Filler Interaction

Veley,

Ugwumadu,

Trembly

et al. 2023

ACS Appl. Polym. Mater.

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Bituminous coal was utilized as a particulate filler in polymer-based composites to fabricate standard 1.75 mm coal-plastic composite filaments for material extrusion 3D printing. The composites were formulated by incorporating Pittsburgh No. 8 coal into polylactic acid, polyethylene terephthalate glycol, high-density polyethylene, and polyamide-12 resins with loadings ranging from 20 to 70 wt %. Coal-plastic composite filaments were extruded and printed by using the same processing parameters as the respective neat plastics. The introduction of coal ameliorated the warping problem of 3D printed high-density polyethylene, allowing for additive manufacturing of an inexpensive and widely available thermoplastic. The mechanical properties of the 3D printed composites were characterized and compared to those of composites fabricated using traditional compression molding. Microscopy of as-fractured samples revealed that particle pull-out and particle fracture were the predominant modes of composite failure. Tensile and flexural moduli as well as hardness had direct proportionality with increasing coal content, while flexural strength, tensile strength, and impact resistance decreased for most composite formulations. Interestingly, polyamide-based composites demonstrated greater maximum tensile and flexural strengths than unfilled plastic. Investigation of composite interfacial chemistry via molecular dynamics simulations and Fourier-transform spectroscopy revealed beneficial hydrogen bonding interactions between coal and polyamide-12, while no chemical reactions were evident for the other polymers investigated.

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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3D Printing of Sustainable Coal Polymer Composites: Study of Processing, Mechanical Performance, and Atomistic Matrix–Filler Interaction

Veley,

Ugwumadu,

Trembly

et al. 2023

ACS Appl. Polym. Mater.

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“…However, the process has some shortcomings that limit its broader functional applications. For example, FDM 3D-printed parts have weaker mechanical properties and are prone to delamination between layers, leading to premature failure compared to parts made through traditional plastic injection molding [ 22 , 23 , 24 ]. These weaknesses may be due to the low strength of the filaments used and/or the FDM process itself [ 25 , 26 , 27 ].…”

Section: Introductionmentioning

confidence: 99%

Various FDM Mechanisms Used in the Fabrication of Continuous-Fiber Reinforced Composites: A Review

Karimi,

Rahmatabadi,

Baghani

2024

Polymers

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Fused Deposition Modeling (FDM) is an additive manufacturing technology that has emerged as a promising technique for fabricating 3D printed polymers. It has gained attention recently due to its ease of use, efficiency, low cost, and safety. However, 3D-printed FDM components lack sufficient strength compared to those made using conventional manufacturing methods. This low strength can be mainly attributed to high porosity and low sinterability of layers and then to the characteristics of the polymer used in the FDM process or the FDM process itself. Regarding polymer characteristics, there are two main types of reinforcing fibers: discontinuous (short) and continuous. Continuous-fiber reinforced composites are becoming popular in various industries due to their excellent mechanical properties. Since continuous reinforcing fibers have a more positive effect on increasing the strength of printed parts, this article focuses primarily on continuous long fibers. In addition to polymer characteristics, different mechanisms have been developed and introduced to address the issue of insufficient strength in 3D-printed FDM parts. This article comprehensively explains two main FDM mechanisms: in-situ fusion and ex-situ prepreg. It also provides relevant examples of these mechanisms using different reinforcing elements. Additionally, some other less frequently utilized mechanisms are discussed. Each mechanism has its own advantages and disadvantages, indicating that further development and modification are needed to increase the strength of 3D-printed FDM parts to be comparable to those produced using traditional methods.

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“…Notably, coal exhibits a high filler loading capacity, allowing for the customization of composites based on specific application requirements. Moreover, the pre- and postprocessing costs associated with coal are comparatively lower than those of other nanoparticle processing methods, making it an appealing raw material for composite production. − …”

Section: Introductionmentioning

confidence: 99%

Ink-Based Additive Manufacturing of a Polymer/Coal Composite: A Non-Traditional Reinforcement

Sundaravadivelan,

Ravichandran,

Dmochowska

et al. 2024

ACS Appl. Eng. Mater.

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Coal, a crucial natural resource traditionally employed for generating carbonrich materials and powering global industries, has faced escalating scrutiny due to its adverse environmental impacts outweighing its utility in the contemporary world. In response to the worldwide shift toward sustainability, the United States alone has witnessed an approximate 50% reduction in coal consumption. Nevertheless, the ample availability of coal has spurred interest in identifying alternative sustainable applications. This research delves into the feasibility of utilizing coal as a nonconventional carbon-rich reinforcement in direct ink writing (DIW)-based 3D printing techniques. Our investigation here involves a thermosetting resin serving as a matrix, incorporating pulverized coal (250 μm in size) and carbon black as the reinforcement and a viscosity modifier, respectively. The ink formulation is meticulously designed to exhibit shear-thinning behavior essential for DIW 3D printing, ensuring uniform and continuous printing. Mechanical properties are assessed through the 3D printing of ASTM standard specimens to validate the reinforcing impact. Remarkably, the study reveals that a 2 wt % coal concentration in the ink leads to a substantial improvement in both tensile and flexural properties, resulting in enhancements of 35 and 12.5%, respectively. Additionally, the research demonstrates the printability of various geometries with coal as reinforcement, opening up new possibilities for coal utilization while pursuing more sustainable manufacturing and applications.

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Coal polymer composites prepared by fused deposition modeling (FDM) 3D printing

Cited by 8 publications

References 47 publications

3D Printing of Sustainable Coal Polymer Composites: Study of Processing, Mechanical Performance, and Atomistic Matrix–Filler Interaction

3D Printing of Sustainable Coal Polymer Composites: Study of Processing, Mechanical Performance, and Atomistic Matrix–Filler Interaction

Various FDM Mechanisms Used in the Fabrication of Continuous-Fiber Reinforced Composites: A Review

Ink-Based Additive Manufacturing of a Polymer/Coal Composite: A Non-Traditional Reinforcement

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