Powder bed fusion of poly(phenylene sulfide) at bed temperatures significantly below melting

Chatham, Camden A.; Long, Timothy Edward; Williams, Christopher B.

doi:10.1016/j.addma.2019.05.025

Cited by 20 publications

(21 citation statements)

References 35 publications

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“…Moreover, cryogenic milling [18,19], a melt emulsification process [20], co-extrusion [21], spray agglomeration, spray drying [22], or precipitation based processes [23][24][25] have been reported. Among the various researched materials for PBF are, e.g., polypropylene [26,27], polyethylene [28], polystyrene [29], polybutylene terephthalate [21], PAEKs [11,30,31], polyphenylene sulfide [32], and polylactide [19,25], to only name a few. Despite the good mechanical properties of POM, its high stiffness, high creep resistance, intrinsic whiteness, and low coefficient of friction, reports on PBF of POM are scarce, with only a patent application for POM PBF powders [33] and publications by Rietzel et al [34,35].…”

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confidence: 99%

Development of Polyoxymethylene Particles via the Solution-Dissolution Process and Application to the Powder Bed Fusion of Polymers

2020

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In this study, the development of a polyoxymethylene (POM) feedstock material for the powder bed fusion (PBF) of polymers is outlined. POM particles are obtained via liquid-liquid phase separation (LLPS) and precipitation, also known as the solution-dissolution process. In order to identify suitable POM solvent systems for LLPS and precipitation, in the first step, a solvent screening based on solubility parameters was performed, and acetophenone and triacetin were identified as the most promising suitable moderate solvents for POM. Cloud point curves were measured for both solvents to derive suitable temperature profiles and polymer concentrations for the solution-dissolution process. In the next step, important process parameters, namely POM concentration and stirring conditions, were studied to elucidate their effect on the product’s properties. The product particles obtained from both aforementioned solvents were characterized with regard to their morphology and size distribution, as well as their thermal properties (cf. the PBF processing window) and compared to a cryo-milled POM PBF feedstock. Both solvents allowed for precipitation of POM particles of an appropriate size distribution for PBF for polymer concentrations of at least up to 20 wt.%. Finally, a larger powder batch for application in the PBF process was produced by precipitation from the preferred solvent acetophenone. This POM powder was further analyzed concerning its flowability, Hausner ratio, and mass-specific surface area. Finally, test specimens, namely a complex gyroid body and a detailed ornament, were successfully manufactured from this feedstock powder showing appropriate bulk solid and thermal properties to demonstrate PBF processability. In summary, a processable and suitable POM PBF feedstock could be developed based on the non-mechanical solution dissolution process, which, to the authors’ best knowledge, has not been reported in previous studies.

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confidence: 99%

Development of Polyoxymethylene Particles via the Solution-Dissolution Process and Application to the Powder Bed Fusion of Polymers

2020

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“…[ 43 ] However, PBF‐grade PPS with values above 1.25 is consistent with prior reports of PBF printing PPS. [ 36 ] Also, PBF powder with avalanche angles between 40–60° have been reported as printable [ 16 ] ; therefore, these measurements should not be interpreted as adversely effecting recoating. Instead, these deviations from typical Hausner ratio guidelines should motivate further investigations using dynamic flowability measurements and understanding data from dynamic powder flow instruments relate to PBF printing.…”

Section: Resultsmentioning

confidence: 99%

“…The experimental PPS powder was aged from an as‐received state at three process‐relevant temperatures: 200, 230, and 278 °C. These temperatures were selected based on prior work published by the authors [ 36 ] where 278 °C was identified as the recommended bed‐temperature based on the first‐derivative method [ 9 ] and 230 °C was the bed temperature used in printing PPS on a PBF machine with standard temperature control. [ 36 ] While the hotter two temperatures represent PBF bed temperature ( T b ), the additional 200 °C temperature was selected to represent overflow powder that experiences a milder thermal load than that of cake powder.…”

Section: Methodsmentioning

confidence: 99%

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Ageing of PBF‐Grade Poly(Phenylene Sulfide) Powder and its Effect on Critical Printability Properties

Chatham

Das

Long

et al. 2021

Macro Materials & Eng

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Poly(phenylene sulfide) (PPS) is a high‐performance polymer suiting the needs of powder bed fusion (PBF) early‐adopter industries. Although there are many benefits to PBF's powder bed‐based, one drawback is thermal ageing of the powder not incorporated into printed parts. Ideally, unfused powder can be reused in future builds; however, it is unlikely that critical printability properties of the thermally aged powder will remain unchanged. Changes in properties lead to either limited reuse through a practice of mixing used and new powder, or elimination of all powder after each build. In this paper, the authors report effects of thermal ageing in simulated printing conditions on properties of PPS critical to PBF processing. PBF‐grade PPS powder is exposed to process‐mimicking conditions. Properties relevant to the three PBF manufacturing process sub‐functions are assessed for the aged powders. Single‐layer prints are made using aged powder to observe polymer‐PBF interactions ad machina. Significant and systematic deviations from the as‐received state of the powder are observed for thermal and coalescence related properties with increasing exposure time and temperature. These changes are interpreted both in terms of physical and chemical changes in PPS and in terms of how these changes may impact the PBF printing process.

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“…Polyphenylene sulfide (PPS) is one among the HPT material that offers many outstanding properties as well as poly‐ether‐ether‐ketone (PEEK), including superior thermal stability, high mechanical strength, and chemical resistance. [ 10–15 ]…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation and optimization of printing parameters of3Dprinted polyphenylene sulfide through response surface methodology

Magri

Mabrouk

Vaudreuil

et al. 2020

J of Applied Polymer Sci

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Today fused filament fabrication is one of the most widely used additive manufacturing techniques to manufacture high performance materials. This method entails a complexity associated with the selection of their appropriate manufacturing parameters. Due to the potential to replace poly-ether-etherketone in many engineering components, polyphenylene sulfide (PPS) was selected in this study as a base material for 3D printing. Using central composite design and response surface methodology (RSM), nozzle temperature (T), printing speed (S), and layer thickness (L) were systematically studied to optimize the output responses namely Young's modulus, tensile strength, and degree of crystallinity. The results showed that the layer thickness was the most influential printing parameter on Young's modulus and degree of crystallinity. According to RSM, the optimum factor levels were achieved at 338 C nozzle temperature, 30 mm/s printing speed, and 0.17 mm layer thickness. The optimized post printed PPS parts were then annealed at various temperatures to erase thermal residual stress generated during the printing process and to improve the degree of crystallinity of printed PPS's parts. Results showed that annealing parts at 200 C for 1 hr improved significantly the thermal, structural, and tensile properties of printed PPS's parts. K E Y W O R D S crystallization, glass transition, mechanical properties, thermal properties 1 | INTRODUCTION Fused deposition modeling (FDM), also called fused filament fabrication (FFF), is a very popular additive manufacturing (AM) technology for its simplicity and low investment costs. [1] It relies on the deposition of a liquefied thermoplastic polymer filament in a layer upon layer manner. The precise control of the extruder head enables direct fabrication of three-dimensional complex geometries from a computer-aided design (CAD) system. FFF often considers as a simple and efficient process to print commodity polymers, such as polylactic acid (PLA), acrylonitrile butadiene styrene, polycarbonate, and highdensity polyethylene due to their low cost and simple operation. [2-7] However, when applied to manufacture high performance thermoplastics (HPT), the FFF equipment faces a number of challenges to achieve optimized results for both material properties and part quality. Among these challenges, high melting temperature, large thermal expansion, and large temperature gradient are

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Powder bed fusion of poly(phenylene sulfide) at bed temperatures significantly below melting

Cited by 20 publications

References 35 publications

Development of Polyoxymethylene Particles via the Solution-Dissolution Process and Application to the Powder Bed Fusion of Polymers

Development of Polyoxymethylene Particles via the Solution-Dissolution Process and Application to the Powder Bed Fusion of Polymers

Ageing of PBF‐Grade Poly(Phenylene Sulfide) Powder and its Effect on Critical Printability Properties

Experimental investigation and optimization of printing parameters of3Dprinted polyphenylene sulfide through response surface methodology

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