Effects of thermal process parameters on mechanical interlayer strength for additively manufactured Ultem 9085

Shelton, Travis E.; Willburn, Zane A.; Hartsfield, Carl R.; Cobb, Gregory R.; Cerri, Joshua T.; Kemnitz, Ryan A.

doi:10.1016/j.polymertesting.2019.106255

Cited by 34 publications

(14 citation statements)

References 9 publications

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“…Coogan and Kazmer [ 12 ] developed a healing model for predicting the bond strength of FFF parts, which depended on bonding strength estimated from wetting and reptation theory. Shelton et al [ 13 ] investigated the impact of thermal process, in particular, build chamber temperature, on the interlayer strength for ULTEM™ 9085 parts. It was found that higher the chamber temperature, the more consistent was the interlayer necking, which resulted in higher mechanical properties.…”

Section: Literature Reviewmentioning

confidence: 99%

The Effect of Annealing on Additive Manufactured ULTEM™ 9085 Mechanical Properties

Zhang

Moon

2021

Materials

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Fused filament fabrication (FFF) is increasingly adopted for direct manufacturing of end use parts in an aviation industry. However, the application of FFF technique is still restricted to manufacturing low criticality lightly loaded parts, due to poor mechanical performance. To alleviate the mechanical performance issue, thermal annealing process is frequently utilized. However, problems such as distortion issues and the need for jigs and fixtures limit the effectiveness of the thermal annealing process, especially for low volume complex FFF parts. In this research, a novel low temperature thermal annealing is proposed to address the limitations in conventional annealing. A modified orthogonal array design is applied to investigate the performance of ULTEM™ 9085 FFF coupons. Further, the coupons are annealed with specialized support structures, which are co-printed with the coupons during the manufacturing process. Once the annealing process is completed, multiscale characterizations are performed to identify the mechanical properties of the specimens. Geometrical measurement of post annealed specimens indicates an expansion in the layering direction, which indicates relief of thermal stresses. Moreover, annealed coupons show an improvement in tensile strength and reduction in strain concentration. Mesostructure and fracture surface analysis indicate an increase in ductility and enhanced coalescence. This research shows that the proposed annealing methodology can be applied to enhance the mechanical performance of FFF parts without significant distortion.

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Section: Literature Reviewmentioning

confidence: 99%

The Effect of Annealing on Additive Manufactured ULTEM™ 9085 Mechanical Properties

Zhang

Moon

2021

Materials

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“…Some studies (Garzon-Hernandez et al, 2020;Wu et al, 2018;Morales et al, 2018;Aliheidari et al, 2018) also put forward similar experimental conclusions, which supports the present experimental results. Other studies (Morales et al, 2018;Shelton et al, 2020;Costa et al, 2017) conducted thermal monitoring of the extruded materials and found that if the extrusion temperature is higher, the cooling time to glass transition will be longer. After the material is extruded from the nozzle, the extruded filament undergoes heat exchange with the environment, other filaments and the bedding, so it causes a decrease in the temperature of the fiber and an increase in the temperature of the other fibers.…”

Section: Resultsmentioning

confidence: 99%

Temperature-compensated constitutive model of fused filament fabrication 3D printed PLA materials with full extrusion temperatures

Zhu

Deng

Dai

et al. 2021

RPJ

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Purpose This study aims to focus on the effect of interlayer bonding and thermal decomposition on the mechanical properties of fused filament fabrication-printed polylactic acid specimens at high extrusion temperatures. Design/methodology/approach A printing process, that is simultaneous manufacturing of contour and specimen, is used to improve the printing accuracy at high extrusion temperatures. The effects of the extrusion temperature on the mechanical properties of the interlayer and intra-layer are evaluated via tensile experiments. In addition, the microstructure evolution affected by the extrusion temperature is observed using scanning electron microscopy. Findings The results show that the extrusion temperature can effectively improve the interlayer bonding property; however, the mechanical properties of the specimen for extrusion temperatures higher than 270°C may worsen owing to the thermal decomposition of the polylactic acid (PLA) material. The optimum extrusion temperature of PLA material in the three-dimensional (3D) printing process is recommended to be 250–270°C. Originality/value A temperature-compensated constitutive model for 3D printed PLA material under different extrusion temperatures is proposed. The present work facilitates the prediction of the mechanical properties of specimens at an extrusion temperature for different printing temperatures and different layers.

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“…3D printing of PEI needs high build surface temperature, up to 210 • C [30], and often an enclosed environment to reduce thermal stresses and improve layer bonding. Shelton and his colleagues [31] studied the effects of the chamber temperature up to 170 • C on the tensile properties of ULTEM™ 9085 specimens, concluding that for higher temperatures, the strength increases due to higher layer bonding and neck formation between adjacent filaments, which were evaluated by fractography. Higher envelope temperature also gave more consistent results with less variation between the produced specimens in the same condition.…”

Section: Effect Of Thermal Process Parametersmentioning

confidence: 99%

Extrusion Additive Manufacturing of PEI Pellets

Fabrizio

Strano

Farioli

et al. 2022

JMMP

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The simplest, most cost-efficient, and most widespread Additive Manufacturing (AM) technology is Extrusion Additive Manufacturing (EAM). Usually, EAM is performed with filament feedstock, but using pellets instead of filaments yields many benefits, including significantly lower cost and a wider choice of materials. High-performance polymers offer high strength even when produced with AM technique, allowing to produce near-net-shape functional parts. The production of these materials in filament form is still limited and expensive; therefore, in this paper, the possibility of producing AM components with engineering polymers from pellets will be thoroughly investigated. In this work, the effectiveness of a specially designed AM machine for printing high-performance materials in pellet form was tested. The material chosen for the investigation is PEI 1000 which offers outstanding mechanical and thermal properties, giving the possibility to produce with EAM functional components. Sensitivity analyses have been carried out to define a process window in terms of thermal process parameters by observing different response variables. Using the process parameters in the specified range, the additive manufactured material has been mechanically tested, and its microstructure has been investigated, both in dried and undried conditions. Finally, a rapid tool for sheet metal forming has been produced.

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Effects of thermal process parameters on mechanical interlayer strength for additively manufactured Ultem 9085

Cited by 34 publications

References 9 publications

The Effect of Annealing on Additive Manufactured ULTEM™ 9085 Mechanical Properties

The Effect of Annealing on Additive Manufactured ULTEM™ 9085 Mechanical Properties

Temperature-compensated constitutive model of fused filament fabrication 3D printed PLA materials with full extrusion temperatures

Extrusion Additive Manufacturing of PEI Pellets

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