Process optimization and stochastic modeling of void contents and mechanical properties in additively manufactured composites

Papon, Easir Arafat; Haque, A.; Mulani, Sameer B.

doi:10.1016/j.compositesb.2019.107325

Cited by 54 publications

(29 citation statements)

References 61 publications

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“…The cross-section of the horizontal parts manufactured in experiments 1, 3 and 5 was analysed using optical microscopy ( Figure 8 ). It was observed that the cross-section of the samples of experiments 1 (room temperature) and 3 (50 °C) showed triangular macroporosity (voids) with sharp edges at interstitial sites, typical from FDM [ 27 , 28 ], with average sizes, standard deviations and maximum values of 57 ± 8 and 70 µm, respectively. There were no significant differences between both experiments in the size and distribution of these voids, which may indicate that the temperature jump was not enough to observe an effect in these types of defects.…”

Section: Resultsmentioning

confidence: 99%

Influence of Build Orientation, Chamber Temperature and Infill Pattern on Mechanical Properties of 316L Parts Manufactured by Bound Metal Deposition

Gabilondo¹,

Cearsolo²,

Arrue³

et al. 2022

Materials

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Bound Metal Deposition (BMD) is an alternative to the most common additive manufacturing (AM) technology for metal parts, Powder Bed Fusion (PBF), since the equipment used is more affordable and there are no risks due to exposure to loose powder and lasers or beams. However, the mechanical properties of parts manufactured by BMD are generally lower than those of PBF, making it necessary to study the process parameters to improve their performance. The aim of this work was to analyse the effect of different process parameters on the mechanical properties of 316L parts manufactured by BMD based on a set of specially designed experiments. The methodology followed in this research was thus based on the manufacturing of a series of samples with variations of the build orientation, infill pattern and chamber temperature followed by subsequent characterization and analysis. The microstructural analysis showed that voids were formed as a consequence of the air gaps generated between rasters during printing. It was observed that the characteristics of these macropores had a significant effect on the mechanical properties. The location, distribution and shape of these macropores depended on the alignment of rasters in each of the conditions, which varied with build orientation and infill pattern. Regarding the build orientation, horizontal parts exhibited lower porosity and considerably higher ultimate tensile strengths (UTS), approximately 160 MPa higher, than vertical samples. With respect to the infill pattern, horizontal parts with a concentric infill pattern showed triangular voids and a total porosity higher than 5%. However, samples with line infill patterns presented elongated macropores and a total porosity lower than 5%, properties that resulted in an improvement in UTS of 20 MPa, approximately. Overall, the results presented here offer a better comprehension of the effect of the BMD process parameters on mechanical properties and serve as a guideline for future work.

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Section: Resultsmentioning

confidence: 99%

Influence of Build Orientation, Chamber Temperature and Infill Pattern on Mechanical Properties of 316L Parts Manufactured by Bound Metal Deposition

Gabilondo¹,

Cearsolo²,

Arrue³

et al. 2022

Materials

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“…Recently, research effort is being directed to uncertainty quantification and stochastic modelling (UQSM) of mechanical, geometrical and dimensional properties of structures produced from additive manufacturing [34][35][36]. Typically, trial-and-error is employed to get high quality products, which constitutes a major hurdle for this kind of manufacturing process [37].…”

Section: Manufacturing Variability On the Periodic Designmentioning

confidence: 99%

Uncertainties in the attenuation performance of a multi-frequency metastructure from additive manufacturing

Fabro

Meng

Chronopoulos

2020

Mechanical Systems and Signal Processing

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Additive manufacturing has been used to propose several designs of phononic crystals and metamaterials due to the low cost to produce complex geometrical features. However, like any other manufacturing process, it can introduce material and geometrical variability in the nominal design and therefore affect the structural dynamic performance. Locally resonant metamaterials are typically designed such that the distributed resonators have the same natural frequency or, in the case of rainbow metastructures, a well-defined spatial profile. In this work, the effects of the break of periodicity caused by additive manufacturing variability on the attenuation performance of a multi-frequency metastructure is investigated. First, an experimental investigation on the manufacturing tolerances of test samples produced from a Selective Laser Sintering process are assessed and variability levels are used to propose a random field model for the metastructure. Subsequently, the stochastic model is used to investigate the vibration suppression performance of broadband multi-frequency metastructures. An analytical model based on a transfer matrix approach is used to calculate transfer receptance due to a point time harmonic force in a finite length metastructure, which is composed of evenly spaced nonsymmetric resonators attached to a beam with Π-shaped cross-section. This design creates a multifrequency metastructure, i.e. band gaps in more than one frequency band. Individual samples of the random fields are used to show that the mistuned resonators can change the vibration attenuation performance of the metastructure and that even small levels of variability, given by less than 1% for the masse and less than 3% for the Young's modulus can have a significant effect on the overall vibration attenuation performance of the metastructure when considered together. It is also shown that different spatial profiles can have a significant effect on the vibration attenuation performance in both band gaps. Therefore, the modelling of the uncertainty metastructures has to take into account the spatial correlation of the properties of the metastructure resonators. The obtained results are expected to be useful for further robust design in mass produced industrial applications.

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“…Material and process induced variations in FFF processed composites. 182 Reproduced with permission.…”

Section: Future Needs In Fffmentioning

confidence: 99%

“…However, the study fails to give any general guideline for the process parameters of any random two-phase system. Recently, Papon et al 182 studied the effects of process-induced variabilities on dimensional accuracy, void contents, and mechanical properties of CF/PLA composite in a multi-scale manner. The effects of dominant process parameters like solidification rate, print temperature, platform temperature, and print speed were analyzed from single bead to multi-layer end-product.…”

Section: Process Parameters Optimizationmentioning

confidence: 99%

Review on process model, structure-property relationship of composites and future needs in fused filament fabrication

Papon

Haque

2020

Journal of Reinforced Plastics and Composites

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This paper presents the state-of-the-art of additive manufacturing of composites for processing functional, load-bearing components. A general overview of different additive manufacturing methods is provided, and specific attention is focused on fused filament fabrication-based composites processing. Different process modeling strategies are summarized, and key aspects of these models are discussed. Significant results such as thermal and fluid flow characteristics, effects of nozzle geometry on melt flow, fiber orientation, bead spreading, and solidification, the formation of residual stresses, and deformation behavior are discussed from computational modeling perspective. The scientific advancement, model limitations, and future modeling needs are prescribed reviewing the current works. A general overview of material development in nano-micro-macro-scale reinforcement is also presented. Different length-scales of reinforcement has its own challenges and promises. The continuous fiber reinforcement has a great potential for being the next-generation composites manufacturing technology. However, the challenges in reducing the void content, better bonding between the fiber–matrix, and layer-layer adhesion, and process uncertainty are some of the key areas yet to advance. Based on the current limitations on computational modeling, materials development, and process modeling studies, future research needs and recommendations are provided.

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Process optimization and stochastic modeling of void contents and mechanical properties in additively manufactured composites

Cited by 54 publications

References 61 publications

Influence of Build Orientation, Chamber Temperature and Infill Pattern on Mechanical Properties of 316L Parts Manufactured by Bound Metal Deposition

Influence of Build Orientation, Chamber Temperature and Infill Pattern on Mechanical Properties of 316L Parts Manufactured by Bound Metal Deposition

Uncertainties in the attenuation performance of a multi-frequency metastructure from additive manufacturing

Review on process model, structure-property relationship of composites and future needs in fused filament fabrication

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