Material Extrusion additive manufacturing (MEX) represents the most widely implemented form of additive manufacturing due to its high performance-cost ratio and robustness. Being an extrusion process in its essence, this process enables the free form fabrication of a wide range of thermoplastic materials. However, in most typical MEX processes, only amorphous polymers are being used as feedstock material owing to their smaller dimensional shrinkage during cooling and well-stablished process/structure/property (P/S/P) relationship. Semi-crystalline polymers, with their crystalline nature, possess unique properties such as enhanced mechanical properties and improved chemical resistance. However, due to the inherent processing challenges in MEX of semi-crystalline polymers, the P/S/P relationships are much less established, thus limits the application of semi-crystalline polymers in MEX.
The overall aim of this thesis is to advance the understanding of P/S/P relationship of semi-crystalline polymers in MEX. This is accomplished through both experimental and simulation-based research. With a typical commodity semi-crystalline polymer, Poly (ethylene terephthalate) (PET), selected as the benchmark material.
First, we experimentally explored the MEX printing of both neat and glass fiber (GF) reinforced recycled PET (rPET). Excellent MEX printability were shown for both neat and composite materials, with GF reinforced parts showing a significant improved mechanical property. Notably, a gradient of crystallinity induced by a different toolpathing time was highlighted.
In the second project, to further investigate the impact of MEX parameter on crystallinity and mechanical properties, a series of benchmark parts were printed with neat PET and analyzed. The effect of part design and MEX parameter on thermal history during printing was revealed though a comparative analysis of IR thermography. Subsequent Raman spectroscopy and mechanical test indicated that crystallinity developed during the MEX process can adversely affects the interlayer adhesion.
In the third project, a 3D heat transfer model was developed to simulate and understand the thermal history of MEX feedstock material during printing, this model is then thoroughly validated against the experimental IR thermography data. While good prediction accuracy was shown for some scenarios, the research identified and discussed several unreported challenges that significantly affect the model's prediction performance in certain conditions.
In the fourth project, we employed a non-isothermal crystallization model to directly predict the development of crystallinity based on given temperature profiles, whether monitored experimentally or predicted by the heat transfer model. The research documented notable discrepancies between the model's predictions and actual crystallinity measurements, and the potential source of the error was addressed.
In summary, this thesis explored the MEX printing of semi-crystalline polymer and its fiber reinforced composite. The influence of MEX parameters and part designs on the printed part's thermal history, crystallinity and mechanical performance was then thoroughly investigated. A heat transfer model and a non-isothermal crystallization model were constructed and employed. With rigorous validation against experimental data, previously unreported challenges in MEX thermal and crystallization modeling was highlighted. Overall, this thesis deepens the understanding of current semi-crystalline polymer's P/S/P relationship in MEX, and offers insights for the optimization and future research in the field of both experiment and simulation of MEX. / Doctor of Philosophy / Material extrusion additive manufacturing (MEX), also known as fused filament fabrication (FFF), is a popular form of 3D printing known for its cost-effectiveness and versatility in creating objects from plastic materials. Traditionally, MEX utilizes amorphous polymers because they are less prone to shrinkage and thus easier to print. However, semi-crystalline polymers, offer enhanced strength and chemicals resistance, yet they pose significant challenges in printing due to a limited understanding of their process/structure/property (P/S/P) relationships in MEX.
This research aims to improve our understanding of P/S/P relationships of semi-crystalline polymers in MEX. The study utilizes a typical semi-crystalline polymer, Poly (ethylene terephthalate) (PET), as the benchmark material.
The study begins with the exploration of the MEX printing of recycled PET (rPET) and its glass fiber composite, finding that with appropriate MEX parameters, both feedstocks are highly printable, and the incorporation of glass fibers substantially increased the strength of the printed parts.
Subsequently, a comprehensive investigation regarding the intricate relationship between crystallinity development, mechanical properties, and the MEX printing process is conducted. Our research revealed that the MEX process and the design of the part both considerably affect the crystallinity of the final part, thereby influencing its mechanical properties.
In the third chapter, a 3D heat transfer model is constructed to better understand and predict the temperature evolution of materials during MEX printing. Most importantly, the modeling results are rigorously validated against experimental data, showing promising results. However, it also reveals challenges in precisely predicting the temperature of parts under certain conditions.
The research then evaluates the applicability of Nakamura non-isothermal crystallization model for MEX printing scenarios. It is found that this model underestimates crystallinity in MEX, primarily because it does not account for shear-induced crystallization, a critical factor in the process. This finding underscores the necessity for more advanced models that can effectively capture the complex dynamics of MEX.
In summary, this dissertation significantly enhances our understanding of the behavior of semi-crystalline polymers in MEX printing. It sheds light on the complex relationship between the printing process, the structure of the material, and the final properties of the printed object. This work not only advances our knowledge in 3D printing but also paves the way for more sophisticated modeling approaches, optimizing the MEX process and expanding its potential applications.
| Identifer | oai:union.ndltd.org:VTETD/oai:vtechworks.lib.vt.edu:10919/118414 |
| Date | 14 March 2024 |
| Creators | Lin, Yifeng |
| Contributors | Materials Science and Engineering, Williams, Christopher Bryant, Bortner, Michael J., Whittington, Abby Rebecca, Davis, Richey M. |
| Publisher | Virginia Tech |
| Source Sets | Virginia Tech Theses and Dissertation |
| Language | English |
| Detected Language | English |
| Type | Dissertation |
| Format | ETD, application/pdf, application/pdf |
| Rights | In Copyright, http://rightsstatements.org/vocab/InC/1.0/ |
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