Novel procedure for laboratory scale production of composite functional filaments for additive manufacturing

Díaz-García, Álvaro; Law, Jia Yan; Cota, Agustín; Bellido-Correa, A.; Ramírez‐Rico, J.; Schäfer, R.; Franco, V.

doi:10.1016/j.mtcomm.2020.101049

Cited by 18 publications

(16 citation statements)

References 33 publications

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“…Several Fe-based magnetic materials produced by additive manufacturing have been studied owing to their wide range of potential applicability in the energy area [38][39][40][41][42][43][44]. Additive manufacturing of amorphous Fe-based magnetic materials is focused on within this review paper.…”

Section: Additive Manufacturing Of Amorphous Fe-based Magnetic Alloysmentioning

confidence: 99%

Laser Additive Manufacturing of Fe-Based Magnetic Amorphous Alloys

Ozden

Morley

2021

Magnetochemistry

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Fe-based amorphous materials offer new opportunities for magnetic sensors, actuators, and magnetostrictive transducers due to their high saturation magnetostriction (λs = 20–40 ppm) and low coercive field compared with polycrystalline Fe-based alloys, which have high magnetostriction but large coercive fields and Co-based amorphous alloys with small magnetostriction (λs = −3 to −5 ppm). Additive layer manufacturing (ALM) offers a new fabrication technique for more complex net-shaping designs. This paper reviews the two different ALM techniques that have been used to fabricate Fe-based amorphous magnetic materials, including the structural and magnetic properties. Selective laser melting (SLM)—a powder-bed fusion technique—and laser-engineered net shaping (LENS)—a directed energy deposition method—have both been utilised to fabricate amorphous alloys, owing to their high availability and low cost within the literature. Two different scanning strategies have been introduced by using the SLM technique. The first strategy is a double-scanning strategy, which gives rise to maximum relative density of 96% and corresponding magnetic saturation of 1.22 T. It also improved the glassy phase content by an order of magnitude of 47%, as well as improving magnetic properties (decreasing coercivity to 1591.5 A/m and increasing magnetic permeability to around 100 at 100 Hz). The second is a novel scanning strategy, which involves two-step melting: preliminary laser melting and short pulse amorphisation. This increased the amorphous phase fraction to a value of up to 89.6%, and relative density up to 94.1%, and lowered coercivity to 238 A/m. On the other hand, the LENS technique has not been utilised as much as SLM in the production of amorphous alloys owing to its lower geometric accuracy (0.25 mm) and lower surface quality, despite its benefits such as providing superior mechanical properties, controlled composition and microstructure. As a result, it has been commonly used for large parts with low complexity and for repairing them, limiting the production of amorphous alloys because of the size limitation. This paper provides a comprehensive review of these techniques for Fe-based amorphous magnetic materials.

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Section: Additive Manufacturing Of Amorphous Fe-based Magnetic Alloysmentioning

confidence: 99%

Laser Additive Manufacturing of Fe-Based Magnetic Amorphous Alloys

Ozden

Morley

2021

Magnetochemistry

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“…However, in a twin-screw extruder, the combination of temperature and the mechanical rotation of the screws in the melting zone of the extruder (Fig 1a), should disperse the J o u r n a l P r e -p r o o f agglomerated particles within the polymer 20 . Further work is required to better understand the cause of particle agglomeration of Bioglass in PDLGA during processing.…”

Section: Filament Processingmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

“…For composite filaments, good homogeneity and dispersion of incorporated filler particles is required to achieve good printability 20 . Filaments can be pre-fabricated using a range of techniques including hot melt or single/twin-screw extrusion [20][21][22][23] , or some 3D printers melt the polymers directly in a one-step process 24 . Twin-screw extrusion has been reported to produce a more homogeneous distribution of ceramics particles within the polymer matrix in composite filaments than comparator techniques 25 However, caution should be taken when selecting a suitable filament/scaffold fabrication method as they can cause thermally induced degradation, which could affect their clinical performance.…”

Section: Introductionmentioning

confidence: 99%

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Filament extrusion of bioresorbable PDLGA for additive manufacturing utilising diatom biosilica to inhibit process-induced thermal degradation

Han

Buchanan

Julius

et al. 2021

Journal of the Mechanical Behavior of Biomedical Materials

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“…The FDM method has been widely used as an additive manufacturing process. This method is based on melting polymer filaments in a liquefier followed by layer-by-layer addition of the melted filaments (Diaz-Garcia et al, 2020). Most of the materials used in this method are thermoplastics such as acrylonitrile butadiene styrene (ABS) and poly-lactic acid (PLA) which have the lowest price, highest accessibility and ability to be printed layer by layer (Attolico et al, 2019;Cerda-Avila et al, 2020).…”

Section: Introductionmentioning

confidence: 99%

Experimental study on tensile strength of copper microparticles filled polymer composites printed by fused deposition modelling process

Adibi

Hashemi

2021

RPJ

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Purpose The purpose of this paper is to investigate the variables of the fused deposition modelling (FDM) process and improve their effect on the mechanical properties of acrylonitrile butadiene styrene (ABS) components reinforced with copper microparticles. Design/methodology/approach In the experimental approach, after drying the ABS granule, it was mixed with copper microparticles (at concentrations of 5%, 8% and 10%) in a single screw extruder to fabricate pure ABS and composite filaments. Then, by making the components by the FDM process, the tensile strength of the parts was determined through tensile strength tests. Taguchi DOE method was used to design the experiments in which nozzle temperature, filling pattern and layer thickness were the design variables. The analysis of variance (ANOVA) and signal-to-noise analysis were conducted to determine the effectiveness of each FDM process parameter on the ultimate tensile strength of printed samples. Following that, the main effect analysis was used to optimize each process parameter for pure ABS and its composite at different copper contents. Findings The study allows the layer thickness and filling pattern had the highest effects on the ultimate tensile strength of the printed materials (pure and composite) in the FDM process. Moreover, the results show that the ultimate tensile strength of the ABS composite containing 5% copper was nearly 12.3% higher than the pure ABS part. According to validation tests, the maximum error of experiments was about 0.96%. Originality/value In this paper, the effect of copper microparticles (as filling agent) was investigated on the ultimate tensile strength of printed ABS material during the FDM process.

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Novel procedure for laboratory scale production of composite functional filaments for additive manufacturing

Cited by 18 publications

References 33 publications

Laser Additive Manufacturing of Fe-Based Magnetic Amorphous Alloys

Laser Additive Manufacturing of Fe-Based Magnetic Amorphous Alloys

Filament extrusion of bioresorbable PDLGA for additive manufacturing utilising diatom biosilica to inhibit process-induced thermal degradation

Experimental study on tensile strength of copper microparticles filled polymer composites printed by fused deposition modelling process

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