Effect of Powder Loading and Binder Materials on Mechanical Properties in Iron-ABS Injection Molding Process

Abstract

This paper presents the development of a new polymer matrix composite (PMC) feedstock material by the injection molding machine. The material consists of iron powder filled in an acrylonitrile butadiene styrene (ABS) and surfactant powder (binder) material. In this study, the effect of powder loading and binder content on the mechanical properties was investigated experimentally. The detailed formulations of compounding ratio by Brabender Mixer and injection molding machine of the sample specimen was used with various combinations of the new PMC material. Based on the result obtained, it was found that, higher powder loading of iron filler affected the hardness, tensile and flexural strength of PMC material. With 32% iron powder loading in ABS composites increase the flexural force, maximum stress and force of PMC material through an injection molding process.

Development of rapid tooling using fused deposition modeling: a review

“…A new polymer matrix composite (PMC) feedstock material consists of iron powder filled in an ABS and surfactant powder (binder) material was investigated experimentally. The effect of higher powder loading of iron filler affected the hardness, tensile and flexural strength of PMC material (Sa’ude et al , 2013a, 2013b). The tensile properties of polycarbonate (PC) material used in the FDM systems have been affected by the FDM process parameters such as air gap, raster width and raster angle.…”

“…The CAD-based RT selection process for a given injection mould requirement was evaluated to identifying critical features that could be modified to improve manufacturability, better quality, lower cost and shorter lead time (Nagahanumaiah et al , 2008). Various researchers (Nikzad et al , 2011; Sa’ude et al , 2013a) focused on the development of new polymeric-based material to cater applications in injection moulding process. The development and testing of a new metal–polymer composite material for use in FDM process increases the application range of RT in injection moulding process (Massod and Song, 2004).…”

“…The volume percentages of all constituents are shown in Table IV. Sa’ude et al (2013a) focused on the development of proper formulation and mixing procedure for constituent materials for obtaining strong, flexible, smooth and conductive feedstock filament for FDM and will be used for tools and dies manufacturing. The ABS material is binder material, iron metal in powder form is filler material and surfactant was added for homogenous dispersion.…”

“…Gray et al (1998) studied the tensile modulus and strength of thermoplastic composite material for FDM according to ASTM D638-87b. Mechanical properties of reinforced polymeric composite material was effected by the proportions of constituents and shape of filler particles (Masood and Song, 2004; Nikzad et al , 2011; Sa’ude et al , 2013a). John and Adam (2013) analysed fatigue characterization of ABS plus (P 430) and ABS (P 400) materials specimens, fabricated on FDM with nine print orientations, according to UNI EN ISO 527-1 (1997) and found that both materials lose ductility during fabrication.…”

Melt Flow Behavior of Polymer Matrix Extrusion for Fused Deposition Modeling (FDM)

“…Normally, the FDM machine involved with either acrylonitrile butadiene styrene (ABS) plastic material [1,2,3,4,5,6,7] material. Currently, the most common polymer matrix composites(PMC) material used in FDM are ABS-Iron [1,7,8,9]. The RP technology was used to fabricate the desired product, and the machine parameters were control by the FDM software.…”