Multiscale porosity characterization in additively manufactured polymer nanocomposites using micro-computed tomography

Satapathy, Yashas; Nikitin, Viktor; Hana, John; Venkatesan, Karthik Rajan; Tran, Felix; Chen, Si; Shevchenko, Pavel; De Carlo, Francesco; Kettimuthu, Rajkumar; Zekriardehani, Shahab; Mapkar, Javed; Krishnamurthy, Ajay; Tekawade, Aniket

doi:10.1016/j.addma.2024.104199

Multiscale porosity characterization in additively manufactured polymer nanocomposites using micro-computed tomography

Journal Article · Sat May 11 00:00:00 EDT 2024 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2024.104199· OSTI ID:2566191

^[1]; ^[2]; ^[3]; Venkatesan, Karthik Rajan ^[3]; Tran, Felix ^[3]; Chen, Si ^[3]; Shevchenko, Pavel ^[2]; ^[2]; Kettimuthu, Rajkumar ^[1]; Zekriardehani, Shahab ^[3]; Mapkar, Javed ^[3]; ^[3]; ^[1]

Argonne National Laboratory (ANL), Argonne, IL (United States)
Argonne National Laboratory (ANL), Argonne, IL (United States). Advanced Photon Source (APS)
Eaton Research Laboratory, Southfield, MI (United States)

Extrusion-based additive manufacturing (AM) of polymer composites exhibits complex thermally driven phenomena that introduce severe discontinuities in the internal structure across length scales, especially voids or porosity. This study utilizes a high-throughput porosity characterization technique to analyze large datasets from numerous micro-computed tomography (mu CT) scans to capture the influence of AM print parameters on the size, shape, and location of porosity across multiple print layers (up to a few cm) on fused granular fabrication (FGF) printers. The materials investigated include nanocomposite formulations based on commercially relevant nylon-12 and polyether ketone ketone (PEKK) materials comprising nano- or micro- sized fillers. The estimated global porosity follows an inverse linear correlation against the bulk density of the printed samples. Increasing the extrusion multiplier (EM) and the nozzle temperature while decreasing the print speeds reduces the global porosity. Outlier analyses (local porosity morphology) show that faster print speeds and higher extrusion rates result in long, slender inter-layer voids, while lower nozzle temperatures lead to large, symmetrical, inter-bead voids (at the bead junction). Lack of active chamber temperature increases inter-layer and intra-bead voids with a two-fold increase in global porosity. Overall, the micro filler-reinforced composites exhibit higher global porosity than nanofiller-reinforced composites, which is attributed to the increased mismatch in the thermal expansion coefficient between the filler and the polymers used in the study.

View Accepted Manuscript (DOE)

Research Organization:: Argonne National Laboratory (ANL), Argonne, IL (United States)

Sponsoring Organization:: USDOE Office of Science (SC), Basic Energy Sciences (BES); United States Army Corps of Engineers, Engineering Research and Development Center (USACE-ERDC)

Grant/Contract Number:: AC02-06CH11357

OSTI ID:: 2566191

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Vol. 86; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

References (32)

An Overview on 3D Printing of Structured Porous Materials and Their Applications Gao, Yuanyuan; Lalevée, Jacques; Simon‐Masseron, Angélique Advanced Materials Technologies, Vol. 8, Issue 17 https://doi.org/10.1002/admt.202300377	journal	July 2023
High-resolution non-invasive 3D imaging of paint microstructure by synchrotron-based X-ray laminography Reischig, Péter; Helfen, Lukas; Wallert, Arie Applied Physics A, Vol. 111, Issue 4 https://doi.org/10.1007/s00339-013-7687-2	journal	April 2013
Analysis of the Manufacturing Porosity in Fused Filament Fabricated Onyx/Long Fiber Reinforced Composites Using X-Ray Computed Tomography Pace, Francesco; Stamopoulos, Antonios G.; Eckl, Michael Journal of Nondestructive Evaluation, Vol. 42, Issue 4 https://doi.org/10.1007/s10921-023-01000-5	journal	September 2023
Effect of Printing Velocity on the Microscopic Void Distribution of 3D-Printed Short-Fiber-Reinforced Composites Luo, Hui; Yang, Haoming; Xi, Li Journal of Failure Analysis and Prevention, Vol. 22, Issue 3 https://doi.org/10.1007/s11668-022-01399-5	journal	April 2022
In situ 3-D observation of early strain localization during failure of thin Al alloy (2198) sheet Morgeneyer, Thilo F.; Taillandier-Thomas, Thibault; Helfen, Lukas Acta Materialia, Vol. 69 https://doi.org/10.1016/j.actamat.2014.01.033	journal	May 2014
Characterisation of void and fiber distribution in 3D printed carbon-fiber/PEEK using X-ray computed tomography Sommacal, S.; Matschinski, A.; Drechsler, K. Composites Part A: Applied Science and Manufacturing, Vol. 149 https://doi.org/10.1016/j.compositesa.2021.106487	journal	October 2021
Analytical study on the 3D-printed structure and mechanical properties of basalt fiber-reinforced PLA composites using X-ray microscopy Yu, Siwon; Hwang, Yun Hyeong; Hwang, Jun Yeon Composites Science and Technology, Vol. 175 https://doi.org/10.1016/j.compscitech.2019.03.005	journal	May 2019
Interlayer fusion bonding of semi-crystalline polymer composites in extrusion deposition additive manufacturing Barocio, Eduardo; Brenken, Bastian; Favaloro, Anthony Composites Science and Technology, Vol. 230 https://doi.org/10.1016/j.compscitech.2022.109334	journal	November 2022
Extrusion-based additive manufacturing technologies: State of the art and future perspectives Altıparmak, Sadettin Cem; Yardley, Victoria A.; Shi, Zhusheng Journal of Manufacturing Processes, Vol. 83 https://doi.org/10.1016/j.jmapro.2022.09.032	journal	November 2022
A review on voids of 3D printed parts by fused filament fabrication Tao, Yubo; Kong, Fangong; Li, Zelong Journal of Materials Research and Technology, Vol. 15 https://doi.org/10.1016/j.jmrt.2021.10.108	journal	November 2021
Performance analysis of image thresholding: Otsu technique Goh, Ta Yang; Basah, Shafriza Nisha; Yazid, Haniza Measurement, Vol. 114 https://doi.org/10.1016/j.measurement.2017.09.052	journal	January 2018
Three-dimensional imaging of integrated circuits with macro- to nanoscale zoom Holler, Mirko; Odstrcil, Michal; Guizar-Sicairos, Manuel Nature Electronics, Vol. 2, Issue 10 https://doi.org/10.1038/s41928-019-0309-z	journal	October 2019
Properties of multifunctional composite materials based on nanomaterials: a review Ali, Alamry; Andriyana, Andri RSC Advances, Vol. 10, Issue 28 https://doi.org/10.1039/C9RA10594H	journal	January 2020
High-resolution three-dimensional imaging of flat objects by synchrotron-radiation computed laminography Helfen, L.; Baumbach, T.; Mikulík, P. Applied Physics Letters, Vol. 86, Issue 7 https://doi.org/10.1063/1.1854735	journal	January 2005
On the implementation of computed laminography using synchrotron radiation Helfen, L.; Myagotin, A.; Mikulík, P. Review of Scientific Instruments, Vol. 82, Issue 6 https://doi.org/10.1063/1.3596566	journal	June 2011
Additive manufacturing and non-destructive testing of topology-optimised aluminium components Senck, Sascha; Happl, Michael; Reiter, Michael Nondestructive Testing and Evaluation, Vol. 35, Issue 3 https://doi.org/10.1080/10589759.2020.1774582	journal	June 2020
Laminographic imaging using synchrotron radiation – challenges and opportunities Helfen, Lukas; Xu, Feng; Suhonen, Heikki Journal of Physics: Conference Series, Vol. 425, Issue 19 https://doi.org/10.1088/1742-6596/425/19/192025	journal	March 2013
Effects of porosity on the mechanical properties of additively manufactured components: a critical review Al-Maharma, Ahmad Y.; Patil, Sandeep P.; Markert, Bernd Materials Research Express, Vol. 7, Issue 12 https://doi.org/10.1088/2053-1591/abcc5d	journal	December 2020
X-Ray Microcomputed Tomography in Additive Manufacturing: A Review of the Current Technology and Applications du Plessis, Anton; Yadroitsev, Igor; Yadroitsava, Ina 3D Printing and Additive Manufacturing, Vol. 5, Issue 3 https://doi.org/10.1089/3dp.2018.0060	journal	September 2018
Additive manufacturing of polymer-based structures by extrusion technologies Maguire, Alianna; Pottackal, Neethu; Saadi, M. A. S. R. Oxford Open Materials Science, Vol. 1, Issue 1 https://doi.org/10.1093/oxfmat/itaa004	journal	October 2020
Hard X-Ray Phase Tomography with Low-Brilliance Sources Pfeiffer, F.; Kottler, C.; Bunk, O. Physical Review Letters, Vol. 98, Issue 10 https://doi.org/10.1103/PhysRevLett.98.108105	journal	March 2007
Synchrotron radiation computed laminography for polymer composite failure studies Xu, Feng; Helfen, Lukas; Moffat, Andrew J. Journal of Synchrotron Radiation, Vol. 17, Issue 2 https://doi.org/10.1107/S0909049510001512	journal	January 2010
A New Iterative Triclass Thresholding Technique in Image Segmentation Cai, Hongmin; Yang, Zhong; Cao, Xinhua IEEE Transactions on Image Processing, Vol. 23, Issue 3 https://doi.org/10.1109/TIP.2014.2298981	journal	March 2014
Marching cubes: A high resolution 3D surface construction algorithm Lorensen, William E.; Cline, Harvey E. ACM SIGGRAPH Computer Graphics, Vol. 21, Issue 4 https://doi.org/10.1145/37402.37422	journal	August 1987
Evaluation of porosity effects on the mechanical properties of carbon fiber-reinforced plastic unidirectional laminates by X-ray computed tomography and mechanical testing Stamopoulos, Ag; Tserpes, Ki; Prucha, P. Journal of Composite Materials, Vol. 50, Issue 15 https://doi.org/10.1177/0021998315602049	journal	September 2015
Evolution of Manufacturing Defects of 3D-Printed Thermoplastic Composites with Processing Parameters: A Micro-CT Analysis Wu, Hantai; Chen, Xinyu; Xu, Shuaiheng Materials, Vol. 16, Issue 19 https://doi.org/10.3390/ma16196521	journal	September 2023
Multifunctional Hybrid Composites with Enhanced Mechanical and Thermal Properties Based on Polybenzoxazine and Chopped Kevlar/Carbon Hybrid Fibers Ghouti, Hamid Abdelhafid; Zegaoui, Abdeldjalil; Derradji, Mehdi Polymers, Vol. 10, Issue 12 https://doi.org/10.3390/polym10121308	journal	November 2018
Effect of Porosity on Mechanical Properties of 3D Printed Polymers: Experiments and Micromechanical Modeling Based on X-Ray Computed Tomography Analysis Wang, Xue; Zhao, Liping; Fuh, Jerry Ying Hsi Polymers, Vol. 11, Issue 7, p. 1154 https://doi.org/10.3390/polym11071154	journal	July 2019
Effect of Process Parameters on Void Distribution, Volume Fraction, and Sphericity within the Bead Microstructure of Large-Area Additive Manufacturing Polymer Composites Sayah, Neshat; Smith, Douglas E. Polymers, Vol. 14, Issue 23 https://doi.org/10.3390/polym14235107	journal	November 2022
Review on Hybrid Reinforced Polymer Matrix Composites with Nanocellulose, Nanomaterials, and Other Fibers Seydibeyoğlu, Mehmet Özgür; Dogru, Alperen; Wang, Jinwu Polymers, Vol. 15, Issue 4 https://doi.org/10.3390/polym15040984	journal	February 2023
Connected Component Labeling Using Components Neighbors-Scan Labeling Approach No authors listed Journal of Computer Science, Vol. 6, Issue 10 https://doi.org/10.3844/jcssp.2010.1099.1107	journal	October 2010
scikit-image: image processing in Python van der Walt, Stéfan; Schönberger, Johannes L.; Nunez-Iglesias, Juan PeerJ, Vol. 2 https://doi.org/10.7717/peerj.453	journal	January 2014

Similar Records

Rheological Characteristics of Fiber Reinforced Poly(Ether Ketone Ketone) (PEKK) for Melt Extrusion Additive Manufacturing

Conference · Mon May 01 00:00:00 EDT 2017 · OSTI ID:1474726

Mica filled polyetherketoneketones for material extrusion 3D printing

Journal Article · Sat Nov 20 19:00:00 EST 2021 · Additive Manufacturing · OSTI ID:1837634

Vacuum-assisted extrusion to reduce internal porosity in large-format additive manufacturing

Journal Article · Mon Dec 16 19:00:00 EST 2024 · Additive Manufacturing · OSTI ID:2491449

Related Subjects

36 MATERIALS SCIENCE
3D printing
Laminography
Nanocomposite
Polymer
Porosity
Reconstruction
Segmentation
X-ray Tomography

Multiscale porosity characterization in additively manufactured polymer nanocomposites using micro-computed tomography

Citation Formats

References (32)

Similar Records

Related Subjects