Friction Stir Welding Optimization of 3D-Printed Acrylonitrile Butadiene Styrene in Hybrid Additive Manufacturing

Vidakis, Nectarios; Petousis, Markos; Korlos, Apostolos; Mountakis, Nikolaos; Kechagias, John

doi:10.3390/polym14122474

Cited by 22 publications

(9 citation statements)

References 51 publications

(52 reference statements)

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“…Mechanical tests have shown effective enhancements in the tensile and flexural strengths of both nano- and micro-composite materials [ 51 ]. ABS has also been investigated in Hybrid Additive Manufacturing, combining MEX 3D printing and friction stir welding for manufacturing large parts [ 52 ], or MEX 3D printing and laser cutting for the improvement of the quality characteristics of the parts built with the process [ 53 ].…”

Section: Introductionmentioning

confidence: 99%

Mechanical Reinforcement of ABS with Optimized Nano Titanium Nitride Content for Material Extrusion 3D Printing

et al. 2023

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Acrylonitrile Butadiene Styrene (ABS) nanocomposites were developed using Material Extrusion (MEX) Additive Manufacturing (AM) and Fused Filament Fabrication (FFF) methods. A range of mechanical tests was conducted on the produced 3D-printed structures to investigate the effect of Titanium Nitride (TiN) nanoparticles on the mechanical response of thermoplastic polymers. Detailed morphological characterization of the produced filaments and 3D-printed specimens was carried out using Atomic Force Microscopy (AFM) and Scanning Electron Microscopy (SEM). High-magnification images revealed a direct impact of the TiN concentration on the surface characteristics of the nanocomposites, indicating a strong correlation with their mechanical performance. The chemical compositions of the raw and nanocomposite materials were thoroughly investigated by conducting Raman and Energy Dispersive Spectroscopy (EDS) measurements. Most of the mechanical properties were improved with the inclusion of TiN nanoparticles with a content of 6 wt. % to reach the optimum mechanical response overall. ABS/TiN 6 wt. % exhibits remarkable increases in flexural modulus of elasticity (42.3%) and toughness (54.0%) in comparison with pure ABS. The development of ABS/TiN nanocomposites with reinforced mechanical properties is a successful example that validates the feasibility and powerful abilities of MEX 3D printing in AM.

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Section: Introductionmentioning

confidence: 99%

Mechanical Reinforcement of ABS with Optimized Nano Titanium Nitride Content for Material Extrusion 3D Printing

et al. 2023

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“…The results showed that the pins with increased edges and a triangular shape demonstrated more pronounced heat generation, influencing the heat flux on polyethylene surfaces. Vidakis et al [10] examined the welding tool geometry, rotational speed, and travel speed for acrylonitrile butadiene styrene (ABS) fabricated with a material extrusion process [11]. Ma et al [12] investigated the impact of temperature on the mechanical characteristics of aluminum alloy joints via friction stir welding.…”

Section: Introductionmentioning

confidence: 99%

Enhancing the Weld Quality of Polylactic Acid Biomedical Materials Using Rotary Friction Welding

Kuo,

Liang,

Huang

et al. 2024

Polymers

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Polylactic acid (PLA) stands out as a biomaterial with immense potential, primarily owing to its innate biodegradability. Conventional methods for manufacturing PLA encompass injection molding or additive manufacturing (AM). Yet, the fabrication of sizable medical devices often necessitates fragmenting them into multiple components for printing, subsequently requiring reassembly to accommodate the constraints posed by the dimensions of the AM platform. Typically, laboratories resort to employing nuts and bolts for the assembly of printed components into expansive medical devices. Nonetheless, this conventional approach of jointing is susceptible to the inherent risk of bolts and nuts loosening or dislodging amid the reciprocating movements inherent to sizable medical apparatus. Hence, investigation into the joining techniques for integrating printed components into expansive medical devices has emerged as a critical focal point within the realm of research. The main objective is to enhance the joint strength of PLA polymer rods using rotary friction welding (RFW). The mean bending strength of welded components, fabricated under seven distinct rotational speeds, surpasses that of the underlying PLA substrate material. The average bending strength improvement rate of welding parts fabricated by RFW with three-stage transformation to 4000 rpm is about 41.94% compared with the average bending strength of PLA base material. The average surface hardness of the weld interface is about 1.25 to 3.80% higher than the average surface hardness of the PLA base material. The average surface hardness of the weld interface performed by RFW with variable rotational speed is higher than the average surface hardness of the weld interface performed at a fixed rotating friction speed. The temperature rise rate and maximum temperature recorded during RFW in the X-axis of the CNC turning machine at the outer edge of the welding part surpassed those observed in the internal temperature of the welding part. Remarkably, the proposed method in this study complies with the Sustainable Development Goals due to its high energy efficiency and low environmental pollution.

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“…Research is aiming to reduce the effects of these parameters on the quality of the 3D-printed parts by optimizing the 3D printing settings used [ 26 ]. At the same time, MEX 3D printing is combined with other manufacturing techniques in a hybrid additive manufacturing system to further increase the quality of the built parts [ 27 ] and expand the potential fields of application [ 28 ].…”

Section: Introductionmentioning

confidence: 99%

Optimizing the Rheological and Thermomechanical Response of Acrylonitrile Butadiene Styrene/Silicon Nitride Nanocomposites in Material Extrusion Additive Manufacturing

Petousis,

Michailidis,

Papadakis

et al. 2023

Nanomaterials

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The current research aimed to examine the thermomechanical properties of new nanocomposites in additive manufacturing (AM). Material extrusion (MEX) 3D printing was utilized to evolve acrylonitrile butadiene styrene (ABS) nanocomposites with silicon nitride nano-inclusions. Regarding the mechanical and thermal response, the fabricated 3D-printed samples were subjected to a course of standard tests, in view to evaluate the influence of the Si3N4 nanofiller content in the polymer matrix. The morphology and fractography of the fabricated filaments and samples were examined using scanning electron microscopy and atomic force microscopy. Moreover, Raman and energy dispersive spectroscopy tests were accomplished to evaluate the composition of the matrix polymer and nanomaterials. Silicon nitride nanoparticles were proved to induce a significant mechanical reinforcement in comparison with the polymer matrix without any additives or fillers. The optimal mechanical response was depicted to the grade ABS/Si3N4 4 wt. %. An impressive increase in flexural strength (30.3%) and flexural toughness (47.2%) was found. The results validate that these novel ABS nanocomposites with improved mechanical properties can be promising materials.

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Friction Stir Welding Optimization of 3D-Printed Acrylonitrile Butadiene Styrene in Hybrid Additive Manufacturing

Cited by 22 publications

References 51 publications

Mechanical Reinforcement of ABS with Optimized Nano Titanium Nitride Content for Material Extrusion 3D Printing

Mechanical Reinforcement of ABS with Optimized Nano Titanium Nitride Content for Material Extrusion 3D Printing

Enhancing the Weld Quality of Polylactic Acid Biomedical Materials Using Rotary Friction Welding

Optimizing the Rheological and Thermomechanical Response of Acrylonitrile Butadiene Styrene/Silicon Nitride Nanocomposites in Material Extrusion Additive Manufacturing

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