A numerical study on the packing quality of fibre/polymer composite powder for powder bed fusion additive manufacturing

Tan, Pengfei; Shen, Fei; Tey, Wei Shian; Zhou, Kun

doi:10.1080/17452759.2021.1922965

Cited by 45 publications

(11 citation statements)

References 52 publications

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“…The orientation mechanism is the shear flow induced by the recoater. Numerical models have been used to understand the flow dynamics in the recoating/packing process, and also the formation of voids [ 51 ]. In many cases, the fibre orientation is low.…”

Section: Discussionmentioning

confidence: 99%

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Thermal Conductivity and Mechanical Properties of Polymer Composites with Hexagonal Boron Nitride—A Comparison of Three Processing Methods: Injection Moulding, Powder Bed Fusion and Casting

et al. 2023

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Materials providing heat dissipation and electrical insulation are required for many electronic and medical devices. Polymer composites with hexagonal boron nitride (hBN) may fulfil such requirements. The focus of this study is to compare composites with hBN fabricated by injection moulding (IM), powder bed fusion (PBF) and casting. The specimens were characterised by measuring thermal conductivity, tensile properties, hardness and hBN particle orientation. A thermoplastic polyurethane (TPU) was selected as the matrix for IM and PBF, and an epoxy was the matrix for casting. The maximum filler weight fractions were 65%, 55% and 40% for IM, casting and PBF, respectively. The highest thermal conductivity (2.1 W/m∙K) was measured for an IM specimen with 65 wt% hBN. However, cast specimens had the highest thermal conductivity for a given hBN fraction. The orientation of hBN platelets in the specimens was characterised by X-ray diffraction and compared with numerical simulations. The measured thermal conductivities were discussed by comparing them with four models from the literature (the effective medium approximation model, the Ordóñez-Miranda model, the Sun model, and the Lewis-Nielsen model). These models predicted quite different thermal conductivities vs. filler fraction. Adding hBN increased the hardness and tensile modulus, and the tensile strength at high hBN fractions. The strength had a minimum as the function of filler fraction, while the strain at break decreased. These trends can be explained by two mechanisms which occur when adding hBN: reinforcement and embrittlement.

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Section: Discussionmentioning

confidence: 99%

“…When increasing the temperature, the mismatch will result in an increase in the distance between adjacent filler platelets in thermal pathways, and may also induce gaps between platelets and matrix. Both effects will reduce the conductivity of the composite [ 51 , 54 ].…”

Section: Discussionmentioning

confidence: 99%

Thermal Conductivity and Mechanical Properties of Polymer Composites with Hexagonal Boron Nitride—A Comparison of Three Processing Methods: Injection Moulding, Powder Bed Fusion and Casting

et al. 2023

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“…However, the available models have not yet sufficiently simulated the entire sintering process. Furthermore, previous reports using DEM 24,25,33 for sintering and the related processes indicate that the inhomogeneity in compacts must be focused on to realize a better-sintered body. Therefore, a specific and appropriate simulation method should be selected for particular purposes.…”

Section: Introductionmentioning

confidence: 99%

Distortion prediction during sintering using Monte Carlo method implemented with virtual springs

Matsuda

2022

Int J Ceramic Engine & Sci

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A computational simulation for sintering based on the Monte Carlo (MC) method implemented with a virtual spring was developed to predict the shrinkage and deformation of compacts. Conventional MC models do not sufficiently consider the local strain of the cells. The proposed model considered the local strain using a virtual spring in each cell. The model linked with the finite element method enables direct calculation of the deformation of the powder compacts. The results indicate that the distortion tendency of the simulations agreed with the experimental results of the sintering of Al2O3 powder compacts. Furthermore, the results indicate the potential of the model to predict the stress distribution in a microstructure during sintering.

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“…should be optimized for powder packing density, which has to be constant in the different layers that constitute the part. The powder packing state was studied also for composite material powders [6], where (at least) two different classes of particles are present: matrix and reinforcement, which in the case of fibers is characterized by a very different aspect ratio compared to the matrix. [6] reported also a detrimental effect of high recoating speed on packing density from DEM simulations, which is also influenced by layer thickness and content of fibers.…”

Section: Introductionmentioning

confidence: 99%

“…The powder packing state was studied also for composite material powders [6], where (at least) two different classes of particles are present: matrix and reinforcement, which in the case of fibers is characterized by a very different aspect ratio compared to the matrix. [6] reported also a detrimental effect of high recoating speed on packing density from DEM simulations, which is also influenced by layer thickness and content of fibers. [7] reported a detrimental effect of recoating speed on packing density, and even on final part quality and mechanical properties, showing e.g.…”

Section: Introductionmentioning

confidence: 99%

In-Situ Monitoring of Powder Bed Fusion of Polymers Using Laser Profilometry

Sillani¹,

MacDonald

Villela³

et al. 2022

SSRN Journal

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A numerical study on the packing quality of fibre/polymer composite powder for powder bed fusion additive manufacturing

Cited by 45 publications

References 52 publications

Thermal Conductivity and Mechanical Properties of Polymer Composites with Hexagonal Boron Nitride—A Comparison of Three Processing Methods: Injection Moulding, Powder Bed Fusion and Casting

Thermal Conductivity and Mechanical Properties of Polymer Composites with Hexagonal Boron Nitride—A Comparison of Three Processing Methods: Injection Moulding, Powder Bed Fusion and Casting

Distortion prediction during sintering using Monte Carlo method implemented with virtual springs

In-Situ Monitoring of Powder Bed Fusion of Polymers Using Laser Profilometry

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