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Title: Controlling substrate temperature with infrared heating to improve mechanical properties of large-scale printed parts

Journal Article · · Additive Manufacturing
ORCiD logo [1]; ORCiD logo [1]; ORCiD logo [1];  [2]; ORCiD logo [1]; ORCiD logo [3]
  1. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility
  2. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility; Univ. of Tennessee, Knoxville, TN (United States)
  3. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility; Univ. of Tennessee, Knoxville, TN (United States); Purdue Univ., West Lafayette, IN (United States)
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Additively manufactured parts made with polymer extrusion techniques can be 50-75% weaker in the z-direction (across layers) than in the x- and y-directions. This has been attributed to poor mobility of polymer chains and a low degree of entanglement across a cold deposition interface. This is particularly a challenge when printing large-scale parts, such as with the Big Area Additive Manufacturing (BAAM) system, because layer times can exceed several minutes. The current work presents a method for controlling the temperature of the substrate material on the BAAM just prior to deposition using infrared heating lamps. Additionally, long layer times were simulated by actively cooling the material following deposition of each layer. The effect of substrate temperature on the z-direction mechanical properties of 20% carbon fiber reinforced acrylonitrile butadiene styrene (ABS) was measured for an initial temperature ranging from 50 °C to 150 °C and a preheated temperature ranging from 150 °C to 220 °C. Infrared preheating proved to be very effective when applied to substrates that had cooled considerably, almost doubling the tensile strength and increasing the fracture toughness by a factor of 7x.

Research Organization:
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Sponsoring Organization:
USDOE Office of Energy Efficiency and Renewable Energy (EERE)
Grant/Contract Number:
AC05-00OR22725
OSTI ID:
1606965
Journal Information:
Additive Manufacturing, Journal Name: Additive Manufacturing Journal Issue: C Vol. 33; ISSN 2214-8604
Publisher:
ElsevierCopyright Statement
Country of Publication:
United States
Language:
English

References (11)

Fracture Surface Analysis of 3D-Printed Tensile Specimens of Novel ABS-Based Materials journal March 2014
An in-process laser localized pre-deposition heating approach to inter-layer bond strengthening in extrusion based polymer additive manufacturing journal October 2016
On reducing anisotropy in 3D printed polymers via ionizing radiation journal November 2014
Anisotropic material properties of fused deposition modeling ABS journal October 2002
Effect of processing conditions on the bonding quality of FDM polymer filaments journal March 2008
A review of melt extrusion additive manufacturing processes: I. Process design and modeling journal April 2014
Structure and mechanical behavior of Big Area Additive Manufacturing (BAAM) materials journal January 2017
Welding of 3D-printed carbon nanotube–polymer composites by locally induced microwave heating journal June 2017
The importance of carbon fiber to polymer additive manufacturing journal September 2014
Additive manufacturing of materials: Opportunities and challenges journal November 2015
Big Area Additive Manufacturing and Hardware-in-the-Loop for Rapid Vehicle Powertrain Prototyping: A Case Study on the Development of a 3-D-Printed Shelby Cobra conference April 2016

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Related Subjects

36 MATERIALS SCIENCE
Additive Manufacturing
Fracture toughness
Infrared heating
Large-scale printing
Mechanical properties
Tensile strength