Investigating the Effects of Annealing on the Mechanical Properties of FFF-Printed Thermoplastics

Fused filament fabrication (FFF) is a cost-effective additive manufacturing method that makes use of thermoplastics to produce customised products. However, there are several limitations associated with FFF that are adversely affecting its growth including variety of materials, rough surface finish and poor mechanical properties. This has resulted in the development of metal-infused thermoplastics that can provide better properties. Furthermore, FFF-printed parts can be subjected to post-processes to improve their surface finish and mechanical properties. This work takes into consideration two commonly used polymeric materials, i.e., ABS (acrylonitrile butadiene styrene) and PLA (polylactic acid) and compares the results with two metal-infused thermoplastics i.e., copper-enhanced PLA and aluminium-enhanced ASA (acrylonitrile styrene acrylate). The four different materials were subjected to a post-process called annealing to enhance their mechanical properties. The effect of annealing on these four materials was investigated through dimensional analysis, ultrasonic testing, tensile testing, microstructural analysis and hardness testing. The results showed that annealing affects the materials differently. However, a correlation among ultrasonic testing, tensile testing and microstructural analysis was observed for all the materials based on their crystallinity. It was found that the semi-crystalline materials (i.e., PLA and copper enhanced PLA) showed a considerable increase in tensile strength post-annealing. However, the amorphous materials (ABS and aluminium-enhanced ASA) showed a comparatively lower increase in tensile strength, demonstrating that they were less receptive to annealing. These results were supported by higher transmission times and a high percentage of voids in the amorphous materials. The highest hardness values were observed for the ASA material and the lowest for the ABS material. This work provides a good comparison for the metal-infused thermoplastics and their applicability with the commonly used PLA and ABS materials

Investigating the Effects of Ironing Parameters on the Dimensional Accuracy, Surface Roughness, and Hardness of FFF-Printed Thermoplastics

Ironing is a useful feature for parts made by fused filament fabrication (FFF), as it can smooth out surfaces using heat and extruding a small amount of material. Like any other processing parameter for FFF, ironing also requires optimisation to ensure a smooth surface can be achieved with limited adverse effects on the other features of the printed part. Even with such a beneficial use case, ironing is still considered experimental and, therefore, this study aims to investigate its effects on dimensional accuracy, surface roughness, and the hardness of two commonly used amorphous thermoplastics, i.e., ABS (acrylonitrile butadiene styrene) and ASA (acrylonitrile styrene acrylate). An extensive comparative analysis has been provided where parts have been manufactured using a low-cost, desktop-based 3D printer, with the two materials at three different ironing line spacings (0.1 mm, 0.2 mm, 0.3 mm), three different ironing flows (10%, 20%, 30%), and three different ironing speeds (50 mm/s, 100 mm/s, 150 mm/s). The study focuses on evaluating the effects of these different ironing parameters and determining the optimal combination for bespoke product requirements. The results showed that ASA was more adversely affected by the changes in ironing parameters compared to ABS. However, the different ironing parameters were proven to improve the smoothness as well as hardness of the parts, compared to the un-ironed samples of ABS and ASA. This work provides a good comparison between two popular amorphous materials and offers ways to leverage ironing parameters to achieve dimensional accuracy, optimal surface finish, and better hardness values

Experimental Analysis of Plastic-Based Composites Made by Composite Plastic Manufacturing

The significance of composites cannot be overstated in the manufacturing sector due to their unique properties and high strength-to-weight ratio. The use of thermoplastics for composites manufacturing is also gaining attention due to their availability, ease of operation, and affordability. However, the current methods for plastic-based composites are limited due to the requirements of long curing times and pre- and post-treatment, thereby resulting in longer lead times for the desired product. These methods also limit the freedom to operate with different forms of materials. Therefore, a new manufacturing process for plastic-based composites is required to overcome such limitations. This research presents a new manufacturing process to produce high-quality plastic-based composites with bespoke properties for engineering applications. The process is referred to as Composite Plastic Manufacturing (CPM) and is based on the principle of fused filament fabrication (FFF) equipped with a heat chamber. The process integrates two material extrusion additive manufacturing technologies, i.e., filament and syringe extrusion. The paper presents the principle of the process, both in theory and in practice, along with the methodology and materials used to manufacture plastic composites. Various composites have been manufactured using the CPM process with thermally activated materials and tested according to British and International standards. Polylactic Acid (PLA) has been interlaced with different thermally activated materials such as graphene-carbon hybrid paste, heat cure epoxy paste, and graphene epoxy paste. The process is validated through a comparative experimental analysis involving tests such as ultrasonic, tensile, microstructural, and hardness to demonstrate its capabilities. The results have been compared with commercially available materials (PLA and Graphene-enhanced PLA) as well as literature to establish the superiority of the CPM process. The CPM composites showed an increase of up to 10.4% in their tensile strength (54 MPa) and 8% in their hardness values (81 HD) when compared to commercially available PLA material. The composites manufactured by CPM have also shown strong bonding between the layers of PLA and thermally activated materials; thus, highlighting the effectiveness of the process. Furthermore, the composites showed a significant increase of up to 29.8% in their tensile strength and 24.6% in their hardness values when compared to commercially available Graphene-enhanced PLA material. The results show that the CPM process is capable of manufacturing superior quality plastic composites and can be used to produce products with bespoke properties

Investigating the Influence of Material Extrusion Rates and Line Widths on FFF-Printed Graphene-Enhanced PLA

Fused filament fabrication (FFF) is a widely used additive manufacturing process that can produce parts from thermoplastics. Its ease of operation and wide variety of materials make it a popular choice for manufacturing. To leverage such benefits, the commonly used thermoplastics (e.g., PLA and ABS) are impregnated with nanoparticles, short or continuous fibers, and other additives. The addition of graphene nanoplatelets to PLA makes for a high-quality filament possessing enhanced mechanical, electrical, and thermal properties. Even with the advancement in materials, the optimisation of the process parameter remains the most complex aspect for FFF. Therefore, this study investigates the influence of two under-researched and overlooked processing parameters (material extrusion rates and line widths) on commercially available graphene-enhanced PLA (GPLA). Nine different material extrusion rates (70% to 150%) and five different line widths (0.2 mm to 1 mm) were used to manufacture GPLA specimens using a low-cost, desktop-based 3D printer, as per British and international standards. The study analyses the influence of these two processing parameters on mass, dimensional accuracy, surface texture, and mechanical properties of GPLA specimens. A non-destructive test has also been conducted and correlated with three-point flexural test to establish its applicability in evaluating flexural properties of GPLA. The results how that small line widths provide more accuracy with longer print times whereas large line widths offer more strength with shorter printing times. Increase in material extrusion rates adversely affect the surface finish and hardness but positively influence the flexural strength of GPLA specimens. The study shows that the manipulation of material extrusion rates and line widths can help designers in understanding the limitations of the default printing settings (100% material extrusion rate and 0.4 mm line width) on most desktop 3D printers and identifying the optimal combination to achieve desired properties using the FFF process

Non-Destructive and Destructive Testing to Analyse the Effects of Processing Parameters on the Tensile and Flexural Properties of FFF-Printed Graphene-Enhanced PLA

The significance of non-destructive testing (NDT) methods cannot be overstated as they help to evaluate the properties of a material without damaging/fracturing it. However, their applicability is dependent on their ability to provide reliable correlation with destructive tests such as tensile and flexural. This correlation becomes more problematic when the material is not homogeneous, such is the case with parts manufactured using a popular additive manufacturing process termed as fused filament fabrication (FFF). This process also requires optimisation of its parameters to achieve desired results. Therefore, this study aims to investigate the effects of four different nozzle temperatures, print bed temperatures, and print speeds on FFF-printed Haydale’s Synergy Graphene Enhanced Super Tough PLA through three non-destructive (ultrasonic, hardness, strain) and two destructive (tensile, flexural) testing methods. Samples were manufactured using Anet® ET4 Pro 3D printer and evaluated as per British and International standards. Two non-destructive tests, i.e., ultrasonic and hardness have been associated with evaluating the tensile properties of the manufactured parts. These results were correlated with destructive tensile testing and showed good agreement. The NDT method of strain measurement showed a very good correlation with the destructive three-point flexural test and was able to provide a reliable evaluation of flexural properties as a function of all three processing parameters. The results presented in this work highlight the importance of NDT methods and how they can be used to evaluate different properties of a material

Contribution of two-photon and excited state absorption in 'axial-bonding' type hybrid porphyrin arrays under resonant electronic excitation

Two-photon absorption (2PA) and excited state absorption (ESA) properties of 'axial-bonding' type hybrid porphyrin arrays are investigated in the picosecond regime under single-photon resonant excitation condition. A crossover from reverse saturable absorption (RSA) to saturable absorption (SA) and back to RSA is observed with the increase of excitation intensity. In the corresponding intensity ranges, third- and fifth-order phase conjugate signals from degenerate four wave mixing are observed. These observations are explained using rate equations for population densities in a three-level energy scheme. At higher intensities, 2PA is found to be dominant contributor to nonlinear absorption compared to ESA

Enhanced optical limiting and nonlinear absorption properties of azoarene-appended phosphorus (V) tetratolylporphyrins

Optical limiting performance, third-order nonlinearity X(3), and nonlinear absorption properties have been investigated in a new class of azoarene phosphorus (V) porphyrins with charge transfer (CT) states. The introduction of axial azoarene groups into the phosphorus porphyrin structure is found to reduce the limiting threshold by a factor of 2 and lead to a rise in the second hyperpolarizability by 1 order of magnitude in the picosecond time regime and by 2 orders of magnitude in the nanosecond regime. The experimental data show reverse saturation of absorption in the nanosecond time regime and a saturation of the nonlinear absorption above a fluence of 0.5 J/cm2 in the picosecond regime. The presence of the CT state reduces saturation of excited-state absorption (ESA) in the S1 → Sn transition through the S1 → CT transition. Faster CT → T1 transition increases the ESA from T1 → Tn states in the nanosecond regime. A self-consistent theoretical analysis based on rate equations is used to estimate the high-lying excited-state lifetimes and absorption cross sections from the experimental results

Nonlinear absorption properties of 'axial-bonding' type tin(IV) tetratolylporphyrin based hybrid porphyrin arrays

The nonlinear absorption properties of 'axial-bonding' type hybrid porphyrin arrays based on a tin(IV) tetratolylporphyrin (SnTTP) scaffold are studied with picosecond and nanosecond pulses. The effect of different central metal atoms substituted adjacent to the tin(IV) porphyrin in the oligomer structure is discussed. In the picosecond regime the lifetimes of the excited singlet states and two-photon absorption (TPA) processes dominate leading to interesting switching of nonlinear absorption behaviour. The TPA cross-section (σTPA) is found to be as high as 396 × 10-46 cm4 s photon-1 molecule-1, for an oligomer with Sn and Ni porphyrin macrocycles. However, in the nanosecond regime the optical limiting performance has increased considerably with increasing number of porphyrins in the array and excited state absorption is found to play a major role

Poboljšan postupak sinteze nekih novih 1,3-diaril-2-propen-1-ona koristeći PEG-400 kao reciklirajuće otapalo i njihovo antimikrobno vrednovanje

A simple and convenient route is described for the synthesis of novel hetero 1,3-diaryl-2-propen-1-ones (chalcones) by using recyclable poly PEG-400 as an alternative reaction solvent. The reaction is clean with excellent yield, shorter reaction time and reduces the use of volatile organic compounds (VOCs). All the synthesized compounds were evaluated for their antimicrobial activities against several pathogenic representatives.Opisana je jednostavna i pogodna metoda sinteze novih hetero 1,3-diaril-2-propen-1-ona (kalkona) koristeći poli(etilenglikol) (PEG-400) kao alternativno otapalo. Reakcija je jednoznačna, a uporaba hlapljivih organskih otapala je smanjena. Iskorištenja na produktima su visoka, a reakcijska vremena kraća. Svi sintetizirani spojevi testirani su na antimikrobno djelovanje na nekoliko patogenih mikroorganizama