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

Camden A. Chatham; Arit Das; Timothy E. Long; Michael J. Bortner; Christopher B. Williams

doi:10.1002/mame.202000599

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

Camden A. Chatham, Arit Das, Timothy E. Long, Michael J. Bortner, Christopher B. Williams

Research output: Contribution to journal › Article › peer-review

4 Scopus citations

Abstract

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.

Original language	English
Article number	2000599
Journal	Macromolecular Materials and Engineering
Volume	306
Issue number	3
DOIs	https://doi.org/10.1002/mame.202000599
State	Published - Mar 2021
Externally published	Yes

Funding

This work was funded by the Department of Energy's Kansas City National Security Campus, operated by Honeywell Federal Manufacturing & Technologies, LLC under contract number DE‐NA0002839. A.D. would like to acknowledge funding from the Adhesives and Sealants graduate research assistantship from the Macromolecules Innovation Institute (MII) at Virginia Tech. The authors would like to acknowledge Julia Pimentel with the DREAMS Lab at Virginia Tech for assistance in measurements associated with the powder recoating section, Glenn Spiering with the Moore Research Group at Virginia Tech for assistance in XRD measurements. In addition, the authors acknowledge MII for providing a collaborative infrastructure focused across the spectrum of topics in cutting‐edge polymer science and engineering research.

Keywords

additive manufacturing
high-performance polymers
material reuse
powder bed fusion
thermal ageing

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1002/mame.202000599

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abstract = "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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AB - 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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Ageing of PBF-Grade Poly(Phenylene Sulfide) Powder and its Effect on Critical Printability Properties

Abstract

Funding

Keywords

UN SDGs

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