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Processing and modeling of 3D-printed mill scale strengthened acrylonitrile butadiene styrene composites

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Abstract

Mill scale (MS) strengthened acrylonitrile-butadiene-styrene (ABS) composite filaments were fabricated as an optional low-cost and sustainable feedstock material with enhanced strength using fused filament fabrication (FFF) technology. In the present study, the effects of the FFF printing parameters on the mechanical properties of the printed ABS/1.0 vol% MS composites were evaluated. Test specimens of the composite were fabricated at printing temperatures of 240–280 °C, printing speeds of 10–90 mm s−1, and infill densities of 25–100%. Tensile tests and Izod impact tests were conducted for the specimens printed under different printing conditions to examine their mechanical characteristics. Afterwards, macro- and microstructural observations of the fractured specimens were carried out. The average maximum stress and modulus of the printed specimens increased when the printing temperature was raised to 270 °C while decreasing the printing speed, with numerous air gaps and pores found in the cross-sectional microstructures after failure at low infill density. High surface roughness of the printed composites was observed by a 3D laser scanner when printing at high temperatures and speeds due to insufficient cooling. The printed composite microstructures were examined by X-ray micro-computed tomography (μCT), and showed homogeneously dense particle dispersion in the entire printed part. Representative volume element (RVE)-based modeling was carried out using real particle geometries from the μCT. RVE simulations predicted high local stress distributions around mill scale particles and air gaps in the printed samples.

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Acknowledgements

This research study was supported by King Mongkut’s University of Technology North Bangkok under contract no. KMUTNB-67-KNOW-05. The authors acknowledge the National Metal and Materials Technology Center (MTEC), Thailand, for providing facilities through the Biofunctional Materials and Devices Research Unit. We would like to thank Mr. Phachai Kungwankrai and Mr. Suksan Muengto for technical assistance in filament extrusion and 3D printing.

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Authors and Affiliations

  1. Department of Materials and Production Technology Engineering, Faculty of Engineering, King Mongkut’s University of Technology North Bangkok, Bangkok, 10800, Thailand

    Jennarong Tungtrongpairoj, Korbkaroon Doungkeaw & Peeraphat Suttipong

  2. Biofunctional Materials and Devices Research Group, National Metal and Materials Technology Center, 114 Thailand Science Park, Phahonyothin Road, Khlong Nueng, Khlong Luang, Pathum Thani, 12120, Thailand

    Boonlom Thavornyutikarn

  3. Center for Lightweight Materials, Design and Manufacturing, Department of Mechanical Engineering, Faculty of Engineering, King Mongkut’s University of Technology Thonburi, 126 Pracha Uthit Road, Bang Mod, Thung Khru, Bangkok, 10140, Thailand

    Vitoon Uthaisangsuk

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  1. Jennarong Tungtrongpairoj
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Contributions

Jennarong Tungtrongpairoj: conceptualization, experimental design, methodology, software, data curation, writing—original draft, visualization, investigation, software, validation, funding acquisition. Korbkaroon Doungkeaw: methodology, carrying out measurements and calculation. Boonlom Thavornyutikarn: experimental design, methodology, writing—review and editing. Peeraphat Suttipong: software, simulation. Vitoon Uthaisangsuk: writing—review and editing, investigation, supervision.

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Correspondence to Jennarong Tungtrongpairoj.

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Tungtrongpairoj, J., Doungkeaw, K., Thavornyutikarn, B. et al. Processing and modeling of 3D-printed mill scale strengthened acrylonitrile butadiene styrene composites. Int J Adv Manuf Technol 131, 1567–1586 (2024). https://doi.org/10.1007/s00170-024-13037-5

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