A study on additive manufacturing build parameters as bonded joint design factors

Bergonzi, Lorenzo; Pirondi, A.; Moroni, F.; Frascio, Mattia; Avalle, Massimiliano

doi:10.1080/00218464.2020.1862655

Cited by 18 publications

(6 citation statements)

References 42 publications

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“…The technique helps us to determine the extent to which the effect of an individual variable is a major component (Girden, 2023). In very simple terms, ANOVA helps us to evaluate the influence of each factor on the outputs, identify its interactions and estimate if the factor is significant (Bergonzi et al, 2021;Frascio et al, 2019;Ghani et al, 2004).…”

Section: Optimization Of the Parameters By Analysis Of Variancementioning

confidence: 99%

“…While diverse approaches have been recommended in the literature to mitigate the above drawbacks, information related to the build volume limitation and the necessity for suitable joining techniques for sub-assemblies is still ambiguous and incomplete (Favero et al , 2019; Leicht et al , 2020; Li et al , 2020; Luo et al , 2012; Song et al , 2015; Vanek et al , 2014). Conventional bonding techniques for 3D-printed parts involve the usage of adhesives, mechanical fasteners like rivets/bolts and mechanical interlocking methods, each one of them having their own limitations (Alexei Samimi, 2019; Bergonzi et al , 2021; Dilberoglu et al , 2018; Inaniwa et al , 2013; Tiwary et al , 2021; Zhou et al , 2014).…”

Section: Introductionmentioning

confidence: 99%

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Investigations on friction stir spot welding to overcome bed size limits of material extrusion (MEX) 3D printers

Tiwary,

Padmakumar,

Malik

2023

RPJ

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Purpose Material extrusion (MEX) 3D printers suffer from an intrinsic limitation of small size of the prints due to its restricted bed dimension. On the other hand, friction stir spot welding (FSSW) is gaining wide interest from automobile, airplane, off-road equipment manufacturers and even consumer electronics. This paper aims to explore the possibility of FSSW on Acrylonitrile Butadiene Styrene/Polylactic acid 3D-printed components to overcome the bed size limitation of MEX 3D printers. Design/methodology/approach Four different tool geometries (tapered cylindrical pin with/without concavity, pinless with/without concavity) were used to produce the joints. Three critical process parameters related to FSSW (tool rotational speed, plunge depth and dwell time) and two related to 3D printing (material combination and infill percentages) were investigated and optimized using the Taguchi L27 design of experiments. The influence of each welding parameter on the shear strength was evaluated by analysis of variance. Findings Results revealed that the infill percentage, a 3D printing parameter, had the maximum effect on the joint strength. The joints displayed pull nugget, cross nugget and substrate failure morphologies. The outcome resulted in the joint efficiency reaching up to 100.3%, better than that obtained by other competitive processes for 3D-printed thermoplastics. The results, when applied to weld a UAV wing, showed good strength and integrity. Further, grafting the joints with nylon micro-particles was also investigated, resulting in a detrimental effect on the strength. Originality/value To the best of the authors’ knowledge, this is the first study to demonstrate that the welding of dissimilar 3D-printed thermoplastics with/without microparticles is possible by FSSW, whilst the process parameters have a considerable consequence on the bond strength.

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Section: Optimization Of the Parameters By Analysis Of Variancementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Investigations on friction stir spot welding to overcome bed size limits of material extrusion (MEX) 3D printers

Tiwary,

Padmakumar,

Malik

2023

RPJ

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“…Nevertheless, the material grading distribution rules are not practical right now for production purposes. The implementation of fused deposition modeling (3D printing) to the adhesive joints is now promising for the production of a functionally graded adhesive layer [32][33][34][35]. Consequently, the practice of functionally graded adhesive is still in the development stage and needs many theoretical and experimental studies that consider all aspects of adhesive material and adhesive joint.…”

Section: Introductionmentioning

confidence: 99%

Thermal Stress Formation in a Functionally Graded Al2O3-Adhesive Single Lap Joint Subjected to a Uniform Temperature Field

Apalak

Reddy

2023

MCA

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This study investigates the strain and stress states in an aluminum single lap joint bonded with a functionally graded Al2O3 micro particle reinforced adhesive layer subjected to a uniform temperature field. Navier equations of elasticity theory were designated by considering the spatial derivatives of Lamé constants and the coefficient of thermal expansion for local material composition. The set of partial differential equations and mechanical boundary conditions for a two-dimensional model was reduced to a set of linear equations by means of the central finite difference approximation at each grid point of a discretized joint. The through-thickness Al2O3-adhesive composition was tailored by the functional grading concept, and the mechanical and thermal properties of local adhesive composition were predicted by Mori–Tanaka’s homogenization approach. The adherend–adhesive interfaces exhibited sharp discontinuous thermal stresses, whereas the discontinuous nature of thermal strains along bi-material interfaces can be moderated by the gradient power index, which controls the through-thickness variation of particle amount in the local adhesive composition. The free edges of the adhesive layer were also critical due to the occurrence of high normal and shear strains and stresses. The gradient power index can influence the distribution and levels of strain and stress components only for a sufficiently high volume fraction of particles. The grading direction of particles in the adhesive layer was not influential because the temperature field is uniform; namely, it can only upturn the low and high strain and stress regions so that the neat adhesive–adherend interface and the particle-rich adhesive–adherend interface can be relocated.

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“…Although it is a promising technique, the usage of this technique results in the modification of the material properties due to heat generation. 28 Further, the welded zone represents the weakest link in the whole structure leading to a catastrophic failure. Furthermore, it also asks for specific equipment and setup adding to the manufacturing costs.…”

Section: Introductionmentioning

confidence: 99%

“…One of the earliest investigations on comparing the joining techniques for AM parts was carried out by Espalin et al, 44 wherein various methods were sorted as per effectiveness of the strength including hot air welding, ultrasonic spot welding, solvent, and adhesive bonding. Numerous researchers including Bergonzi et al, 28 Frascio et al, 45 and Kovan et al 46,47 attempted to investigate the effect of FDM printing parameters including extruder temperature, raster angle, printing speed, layer thicknesses, and print orientation on the strength of the adhesively bonded parts. A remarkable finding was that improvement in the strength could be obtained by simply setting the FDM printers parameters properly.…”

Section: Introductionmentioning

confidence: 99%

Adhesive bonding of similar/dissimilar three-dimensional printed parts (ABS/PLA) considering joint design, surface treatments, and adhesive types

Tiwary

Padmakumar

Malik

2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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Three-dimensional printing (3D), a vital technological pillar of industry 4.0 suffers from an important bed size limitation, wherein it cannot print any part larger than its bed size. Unfortunately, research in this domain has not kept pace with the other limitations hindering the acceptability of fused deposition modeling (FDM)-3D printers. This paper investigates the adhesive joining of dissimilar 3D-printed parts made from usually preferred materials (Acrylonitrile Butadiene Styrene (ABS), Polylactic Acid (PLA)) having different geometric joint designs (lap, scarf, stepped) employing diverse adhesives (epoxy, cyanoacrylate, polyurathane-based) subjected to different surface treatments (sanding, vapor, plasma). The aim is two-fold: to enhance the joint strength making adhesive bonding a suitable solution for complex structural application, as well as to overcome the bed size limitation of commercially available 3D printers. The individual and combined effect of the parameters, prediction, and validation for tensile strength were realized by statistical tools (DOE and ANOVA). The results revealed the significance of the process parameters in the following order: material type, joint configuration, adhesive types, and surface pre-treatments. The preferred material turned out to be ABS + ABS, with stepped configuration, subjected to plasma treatment and bonded with Loctite adhesives giving a strong improvement in terms of performance. Finally, the model summary with R2 value of 95.6% implied that the experimentation was successful and could be easily reproduced on an industrial scale helping to attain high strength-less weight components even with smaller FDM-3D printers.

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A study on additive manufacturing build parameters as bonded joint design factors

Cited by 18 publications

References 42 publications

Investigations on friction stir spot welding to overcome bed size limits of material extrusion (MEX) 3D printers

Investigations on friction stir spot welding to overcome bed size limits of material extrusion (MEX) 3D printers

Thermal Stress Formation in a Functionally Graded Al2O3-Adhesive Single Lap Joint Subjected to a Uniform Temperature Field

Adhesive bonding of similar/dissimilar three-dimensional printed parts (ABS/PLA) considering joint design, surface treatments, and adhesive types

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