Abstract
Material extrusion additive manufacturing is prone to introducing porosity within the structure due to the layer-by-layer construction using elliptical beads of material. This open porosity ultimately plays a role in determining the mechanical properties of printed parts. The shape, size, and amount of porosity within a printed part is influenced by a variety of factors, including nozzle diameter, infill percentage, layer height, raster orientation, and print speed. While several studies have investigated these and other parameters’ effects on mechanical performance and porosity, better understanding the interconnected relationships is crucial in balancing the various input parameters to achieve maximum strength. This work initially examined the influence of key print parameters (infill percentage and layer height) on the internal porosity of a printed Acrylonitrile Butadiene Styrene (ABS) part. Then, the print parameters and internal porosity were statistically correlated to final mechanical properties. Porosity was further classified as either open or closed to differentiate between connected voids in the mesostructure from isolated voids within the material itself. Mechanical performance increased with an increasing density and infill percentage, displaying a 224 % increase in elastic modulus and a 150 % increase in ultimate tensile strength. The contribution of layer height was found to be conditional upon the infill percentage.
| Original language | English |
|---|---|
| Article number | 103063 |
| Journal | Additive Manufacturing |
| Volume | 58 |
| DOIs | |
| State | Published - Oct 2022 |
Funding
Research sponsored by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Industrial Technologies Program , under contract DE-AC05-00OR22725 with UT-Battelle, LLC. This material was also based upon work supported by the National Science Foundation under Grant No. 2055529 and supported in part by Oak Ridge Institute for Science and Education through the Higher Education Research Experiences Program (HERE). Further thanks to the University of Tennessee – Knoxville Innovation & Collaboration Studio for their assistance. This manuscript has been authored in part by UT-Battelle, LLC under Contract No. DE-AC05–00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/ downloads/doe-public-access-plan). Research sponsored by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Industrial Technologies Program, under contract DE-AC05-00OR22725 with UT-Battelle, LLC. This material was also based upon work supported by the National Science Foundation under Grant No. 2055529 and supported in part by Oak Ridge Institute for Science and Education through the Higher Education Research Experiences Program (HERE). Further thanks to the University of Tennessee – Knoxville Innovation & Collaboration Studio for their assistance.
| Funders | Funder number |
|---|---|
| Office of Energy Efficiency and Renewable Energy, Industrial Technologies Program | DE-AC05-00OR22725 |
| National Science Foundation | 2055529 |
| U.S. Department of Energy | |
| Oak Ridge Institute for Science and Education | |
| University of Tennessee |
Keywords
- 3D Printing
- Extrusion
- Fused Filament Fabrication
- Mechanical Properties
- Porosity
