A comprehensive analysis and prediction of the effect of groove shape and volume fraction of multi-walled carbon nanotubes on the polymer 3D-printed parts in the friction stir welding process

Javadi, Mohammad Sadegh; Ehteshanfar, Mohammad Vahid; Adibi, Hamed

doi:10.1016/j.polymertesting.2022.107844

Cited by 13 publications

(10 citation statements)

References 44 publications

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“…The application of AM process ranges from manufacturing plastic toys to metal or concrete structures (Shkundalova et al , 2018). Fundamental material types, such as metals, polymers, ceramics and composites were used widely as feedstock filament materials in various 3D printing processes (Ngo et al , 2018; Javadi et al , 2023) in different specific applications. However, flexibility in the printing process, high economic feasibility and environment-friendly criteria lead to the vast use of polymer feedstock materials in the FDM, SLA and Poly-Jet processes (Ngo et al , 2018; Park and Fu, 2021).…”

Section: Introductionmentioning

confidence: 99%

Investigation into tensile behavior of 3D printed nylon-based low and high-volume fraction carbon fiber composite

Mishra

Jagadesh

2023

RPJ

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Purpose The tensile behavior of additively manufactured nylon-based carbon fiber-reinforced composites (CFRP) is an important criterion in aerospace and automobile structural design. So, this study aims to evaluate and validate the tensile stiffness of printed CFRP composites (low- and high-volume fraction fiber) using the volume average stiffness (VAS) model in consonance with experimental results. In specific, the tensile characterization of printed laminate composites is studied under the influence of raster orientations and process-induced defects. Design/methodology/approach CFRP composite laminates of low- and high-volume fraction carbon fiber of different raster orientations (0°, ± 45° and 0/90°) were fabricated using the continuous fiber 3D printing technique, and tensile characteristics of laminates were done on a universal testing machine with the crosshead speed of 2 mm/min. The induced fracture surface of laminates due to tensile load was examined using the scanning electron microscopy technique. Findings The VAS model can predict the tensile stiffness of printed CFRP composites with different raster orientations at an average prediction error of 5.94% and 10.58% for low- and high-volume fiber fractions, respectively. The unidirectional CFRP laminate composite with a high-volume fraction (50%) of carbon fiber showed 50.79% more tensile stiffness and 63.12% more tensile strength than the low-volume fraction (26%) unidirectional composite. Fiber pullout, fiber fracture and ply delamination are the major failure appearances observed in fracture surfaces of laminates under tensile load using scanning electron microscopy. Originality/value This investigation demonstrates the novel methodology to study specific tensile characteristics of low- and high-volume fraction 3D printed CFRP composite.

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Section: Introductionmentioning

confidence: 99%

Investigation into tensile behavior of 3D printed nylon-based low and high-volume fraction carbon fiber composite

Mishra

Jagadesh

2023

RPJ

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“…Referring to additive manufacturing (AM) is not expected to replace traditional fabrication processes but complement them as an essential step in the whole productive chain in future manufacturing systems. The layer-by-layer manufacturing route used in AM allows producing complex geometries with considerable flexibility (Javadi et al , 2023; Ehteshamfar et al , 2022). The metal-based AM methods are considered a suitable option at an industrial level, mainly to produce customizable components.…”

Section: Introductionmentioning

confidence: 99%

A novel optimization framework for minimizing the surface roughness while increasing the material processing rate in the SLM process of 316L stainless steel

La Fé-Perdomo,

Ramos-Grez,

Quiza

et al. 2023

RPJ

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Purpose 316 L stainless steel alloy is potentially the most used material in the selective laser melting (SLM) process because of its versatility and broad fields of applications (e.g. medical devices, tooling, automotive, etc.). That is why producing fully functional parts through optimal printing configuration is still a key issue to be addressed. This paper aims to present an entirely new framework for simultaneously reducing surface roughness (SR) while increasing the material processing rate in the SLM process of 316L stainless steel, keeping fundamental mechanical properties within their allowable range. Design/methodology/approach Considering the nonlinear relationship between the printing parameters and features analyzed in the entire experimental space, machine learning and statistical modeling methods were defined to describe the behavior of the selected variables in the as-built conditions. First, the Box–Behnken design was adopted and corresponding experimental planning was conducted to measure the required variables. Second, the relationship between the laser power, scanning speed, hatch distance, layer thickness and selected responses was modeled using empirical methods. Subsequently, three heuristic algorithms (nonsorting genetic algorithm, multi-objective particle swarm optimization and cross-entropy method) were used and compared to search for the Pareto solutions of the formulated multi-objective problem. Findings A minimum SR value of approximately 12.83 μm and a maximum material processing rate of 2.35 mm3/s were achieved. Finally, some verification experiments recommended by the decision-making system implemented strongly confirmed the reliability of the proposed optimization methodology by providing the ultimate part qualities and their mechanical properties nearly identical to those defined in the literature, with only approximately 10% of error at the maximum. Originality/value To the best of the authors’ knowledge, this is the first study dealing with an entirely different and more comprehensive approach for optimizing the 316 L SLM process, embedding it in a unique framework of mechanical and surface properties and material processing rate.

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“…3 Firstly, this process was employed for welding aluminum alloys, it has now been adapted for joining magnesium, titanium alloys, copper alloys, metal matrix composites, dissimilar metals and even polymeric materials. [4][5][6][7] The process of welding or joining two similar materials is a widely practiced technique, and numerous studies have been conducted on the joining of various material combinations such as ABS-ABS (acrylonitrile butadiene styrene), PA-PA (polyamide), LDPE-LDPE (low-density polyethylene), HDPE-HDPE (high-density polyethylene), and so forth. [8][9][10] However, the process of joining or welding two dissimilar thermoplastic materials proved to be more complex due to the distinct properties exhibited by each polymer, such as differences in melt flow index (MFI), melting point, molecular weight, and so on.…”

Section: Introductionmentioning

confidence: 99%

“…The main benefits of this technique are low‐cost, environmentally friendly and more efficient 3 . Firstly, this process was employed for welding aluminum alloys, it has now been adapted for joining magnesium, titanium alloys, copper alloys, metal matrix composites, dissimilar metals and even polymeric materials 4–7 . The process of welding or joining two similar materials is a widely practiced technique, and numerous studies have been conducted on the joining of various material combinations such as ABS‐ABS (acrylonitrile butadiene styrene), PA‐PA (polyamide), LDPE‐LDPE (low‐density polyethylene), HDPE‐HDPE (high‐density polyethylene), and so forth 8–10 .…”

Section: Introductionmentioning

confidence: 99%

Effect of process parameters on the mechanical behavior of additively manufactured and FSW joined PLA wood sheets

Koçar,

Anaç,

Palaniappan

et al. 2023

Polymer Composites

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Friction stir welding (FSW), a solid‐state joining method, is an innovative technique widely employed in the welding of thermoplastics, with broad application areas such as the automotive and aerospace industries. Due to its inherent advantages, including ease of processing, biodegradability, and printability, polylactic acid (PLA) and its derivatives are notably the most commonly used polymers in 3D printing. The limited print area of 3D printers necessitates post‐production joining processes. In this study, the weldability of plates obtained using PLA Wood filament through the FSW is evaluated. For this purpose, different pin geometries (triangle, square, and screw), feed rates (20, 40, and 60 mm/min), and tool rotation speeds (1250, 1750, and 2250 rpm) are employed. Visual inspections are conducted to determine the effects of process parameters on weld quality and to identify defects in the weld region. Temperature values are measured to investigate the influence of heat generated during the FSW process. Furthermore, after determining the highest weld strengths achieved for each pin geometry, the weldability of PLA Wood material with PLA‐CF and PLA Plus materials is investigated using these parameters. The results indicate that the highest weld quality for joining PLA Wood plates is achieved using the square pin geometry, 20 mm/min feed rate, and 1750 rpm with an efficiency of 74.5%. When welding PLA Wood with PLA‐CF and PLA Plus, high weld strengths are obtained using the same process parameters (square pin, 20 mm/min, and 1750 rpm).Highlights Friction stir welding process of 3D printed PLA Wood material. Friction stir welding process of dissimilar materials pairs. Effect of welding parameters on weld strength and hardness. Identifying the fracture surface images occurring in parts after friction stir welding. Examination of temperature generation during friction stir welding.

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A comprehensive analysis and prediction of the effect of groove shape and volume fraction of multi-walled carbon nanotubes on the polymer 3D-printed parts in the friction stir welding process

Cited by 13 publications

References 44 publications

Investigation into tensile behavior of 3D printed nylon-based low and high-volume fraction carbon fiber composite

Investigation into tensile behavior of 3D printed nylon-based low and high-volume fraction carbon fiber composite

A novel optimization framework for minimizing the surface roughness while increasing the material processing rate in the SLM process of 316L stainless steel

Effect of process parameters on the mechanical behavior of additively manufactured and FSW joined PLA wood sheets

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