Metal spray layered hybrid additive manufacturing of PLA composite structures: Mechanical, thermal and morphological properties

Abstract

The fusion of additive layers is the primary concern, which affects the mechanical properties of the three-dimensional printed structures prepared by material extrusion-based additive manufacturing (MEAM) process. To promote the fusion and strength between the thermoplastic layers during MEAM process, the metal spray in between the additive layers is used as a novel approach. In this study, aluminium (Al) spray has been deposited in between the polylactic acid structures to enhance the bonding of the additive layers. The methodology includes deposition of 1, 3 and 5 Al spray layers at periodic time intervals with varying infill percentage (40%, 70% and 100%) and bed temperature (60°C, 80°C and 100°C). The structures have been subjected to flexural testing for investigation of the role of each input process parameter followed by fracture morphology analysis through scanning electron microscopy and energy-dispersive spectroscopy. The results of the study suggested that the maximum flexural strength is possible with five spray layers, 70% infill and 100°C bed temperature.

Metal and Polymer Based Composites Manufactured Using Additive Manufacturing—A Brief Review

“…Yangetal. [36] studied the volumetric energy density (Ev), mechanical strength, and densification behavior of the bioglass polymeric composite. On the surface of the composite, the presence of a larger amount of liquid was found, which was responsible for the discontinuous surface and poor lifetime of the polymeric composite [37][38][39].…”