Thermoplastic Materials for the Metal Replacement of Non-Structural Components in Marine Engines

Bertagna, Serena; Braidotti, Luca; Laurini, Erik; Marinò, Alberto; Pricl, Sabrina; Bucci, Vittorio

doi:10.3390/app12178766

Cited by 6 publications

(3 citation statements)

References 26 publications

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“…Thus, the resulting composite structure is more practical for various industrial applications that require good elastic properties of the components that should be lighter than common metallic parts. These aspects fit the current trends in the automotive industry [33][34][35].…”

Section: Discussionsupporting

confidence: 65%

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Recycled PET Composites Reinforced with Stainless Steel Lattice Structures Made by AM

Rusu,

Balc,

Moldovan

et al. 2023

Polymers

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Polyethylene terephthalate (PET) recycling is one of the most important environmental issues, assuring a cleaner environment and reducing the carbon footprint of technological products, taking into account the quantities used year by year. The recycling possibilities depend on the quality of the collected material and on the targeted product. Current research aims to increase recycling quantities by putting together recycled PET in an innovative way as a filler for the additive manufactured metallic lattice structure. Starting from the structures mentioned above, a new range of composite materials was created: IPC (interpenetrating phase composites), materials with a complex architecture in which a solid phase, the reinforcement, is uniquely combined with the other phase, heated to the temperature of melting. The lattice structure was modeled by the intersection of two rings using Solid Works, which generates the lattice structure, which was further produced by an additive manufacturing technique from 316L stainless steel. The compressive strength shows low values for recycled PET, of about 26 MPa, while the stainless-steel lattice structure has about 47 MPa. Recycled PET molding into the lattice structure increases its compressive strength at 53 MPa. The Young’s moduli are influenced by the recycled PET reinforcement by an increase from about 1400 MPa for the bare lattice structure to about 1750 MPa for the reinforced structure. This sustains the idea that recycled PET improves the composite elastic behavior due to its superior Young’s modulus of about 1570 MPa, acting synergically with the stainless-steel lattice structure. The morphology was investigated with SEM microscopy, revealing the binding ability of recycled PET to the 316L surface, assuring a coherent composite. The failure was also investigated using SEM microscopy, revealing that the microstructural unevenness may act as a local tensor, which promotes the interfacial failure within local de-laminations that weakens the composite, which finally breaks.

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Section: Discussionsupporting

confidence: 65%

“…We have considered replacing the metallic parts with lightweight structures produced through SLM and substituting the polymeric parts with recycled PET. Using lighter parts for the moving ensembles fits the current trends due to energy saving strategies [31][32][33].…”

Section: Resultsmentioning

confidence: 99%

Recycled PET Composites Reinforced with Stainless Steel Lattice Structures Made by AM

Rusu,

Balc,

Moldovan

et al. 2023

Polymers

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show abstract

“…Thus, PA6 must be modified to satisfy the industrial application requirements. Although PA6 is a semicrystalline polymer, it can be considerably toughened − by blending it with an elastomer. − The macroscopic properties of polymer blends depend on several key parameters, especially the blend composition; size, shape, and distribution of dispersed particles; and interfacial adhesion between the dispersed phase and matrix.…”

Section: Introductionmentioning

confidence: 99%

Enhanced Compatibility, Morphology, and Low-Temperature Toughness of Polyamide 6/Poly(dimethylsiloxane)/Epoxidized Silicone Rubber Composites

Zhang

Yang

et al. 2023

Ind. Eng. Chem. Res.

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Epoxidized silicone rubber with an epoxy content of 5% (ESR-5) was introduced to improve the compatibility of the polyamide 6 (PA6)/poly(dimethylsiloxane) (PDMS) composite. The effects of the ESR-5 on the molecular structure, interfacial morphology, and toughness and thermal properties of the PA6/PDMS composite were investigated using nuclear magnetic resonance (NMR) spectroscopy, Fourier transform infrared (FT-IR) spectroscopy, differential scanning calorimetry (DSC), scanning electron microscopy (SEM), atomic force microscopy (AFM), and dynamic thermomechanical analysis (DMA). The FT-IR spectra and torque rheological testing confirmed the reaction between the epoxy group of ESR-5 and the carboxyl group at the end of PA6. The AFM and SEM images confirmed that the ESR-5 altered the interfacial thickness and remarkably decreased the average size of the dispersed rubber particles, which enhanced the interfacial compatibility. At a rubber content of 20% by weight in PA6/PDMS composites, the optimum impact strength at −60 °C, which is 469% higher than pure PA6, was obtained with an ESR-5 content of 50% in rubber phase.

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Effect of annealing treatment and infill percentage on 3D-printed PEEK samples by Fused Filament Fabrication

Lannunziata,

Colucci,

Minetola

et al. 2024

Int J Adv Manuf Technol

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A strategy that is gaining momentum in several industrial sectors is metal replacement, which aims to find suitable alternatives for replacing metal components with lighter ones. One possible solution is represented by high-performance polymers (HPP), which are a family of materials with improved thermo-mechanical and functional properties, compared to commodity plastics. Additive manufacturing (AM) is revolutionizing the industrial world due to its high design freedom, dimensional accuracy, and shortened total production time. Thus, combining the use of HPP with AM technologies could lead to innovative results, which could offer new metal replacement solutions through redesign and new material properties. However, HPPs have some manufacturing limitations, for example, they require high processing temperatures, and some of them are subject to significant warping and deformation phenomena. This aspect is particularly significant for semi-crystalline polymers, as in the case of poly(ether-ether-ketone) (PEEK), which is affected by thermal gradients during 3D printing. In this research, an investigation was carried out on the Fused Filament Fabrication (FFF) of different 3D printed PEEK samples, evaluating the effect on final properties not only of various infill percentages (30%, 50%, 70%, and 100%) but also of two different heating treatments. In this regard, a traditional annealing in oven, post 3D printing, was compared to a direct annealing approach, performed during FFF. The mechanical performance of the samples was characterized through tensile and compression tests along with the thermal properties and the thermal stability. In addition, for all different cases, energy consumption was measured, to provide an indication of the sustainability of the presented approaches. The findings suggest that the direct annealing solution holds promise and merits further investigation to bridge knowledge gaps in this domain. This research contributed to advance the understanding of PEEK 3D printing by FFF and played a vital role in the practical implementation of metal replacement as a sustainable strategy across various industrial applications.

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Thermoplastic Materials for the Metal Replacement of Non-Structural Components in Marine Engines

Cited by 6 publications

References 26 publications

Recycled PET Composites Reinforced with Stainless Steel Lattice Structures Made by AM

Recycled PET Composites Reinforced with Stainless Steel Lattice Structures Made by AM

Enhanced Compatibility, Morphology, and Low-Temperature Toughness of Polyamide 6/Poly(dimethylsiloxane)/Epoxidized Silicone Rubber Composites

Effect of annealing treatment and infill percentage on 3D-printed PEEK samples by Fused Filament Fabrication

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