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Additive Manufacturing of Syntactic Foams: Part 1: Development, Properties, and Recycling Potential of Filaments

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Abstract

This work focuses on developing filaments of high-density polyethylene (HDPE) and their hollow particle-filled syntactic foams for commercial three-dimensional (3D) printers based on fused filament fabrication technology. Hollow fly-ash cenospheres were blended by 40 wt.% in a HDPE matrix to produce syntactic foam (HDPE40) filaments. Further, the recycling potential was studied by pelletizing the filaments again to extrude twice (2×) and three times (3×). The filaments were tensile tested at 10−4 s−1, 10−3 s−1, and 10−2 s−1 strain rates. HDPE40 filaments show an increasing trend in modulus and strength with the strain rate. Higher density and modulus were noticed for 2× filaments compared to 1× filaments because of the crushing of some cenospheres in the extrusion cycle. However, 2× and 3× filament densities are nearly the same, showing potential for recycling them. The filaments show better properties than the same materials processed by conventional injection molding. Micro-CT scans show a uniform dispersion of cenospheres in all filaments.

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Acknowledgements

Mrityunjay Doddamani acknowledges the Department of Science and Technology, India, Grant DST/TSG/AMT/2015/394/G, and Visiting Scientist Fellowship Grant VSP 17-7-001 by the US Office of Naval research—Global (Program manager: Dr. Ramesh Kolar) to visit NYU for this work. Nikhil Gupta acknowledges the Office of Naval Research Grant N00014-10-1-0988. The views expressed in this article are those of authors, not of funding agencies.

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Authors and Affiliations

  1. Composite Materials and Mechanics Laboratory, Mechanical and Aerospace Engineering Department, Tandon School of Engineering, New York University, Brooklyn, NY, 11201, USA

    Ashish Kumar Singh, Brooks Saltonstall & Nikhil Gupta

  2. Advanced Manufacturing Laboratory, Department of Mechanical Engineering, National Institute of Technology Karnataka, Surathkal, India

    Balu Patil & Mrityunjay Doddamani

  3. Institut für Maschinenwesen, Technische Universität Clausthal, Clausthal-Zellerfeld, Germany

    Niklas Hoffmann

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  1. Ashish Kumar Singh
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  2. Balu Patil
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  3. Niklas Hoffmann
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  4. Brooks Saltonstall
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  5. Mrityunjay Doddamani
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  6. Nikhil Gupta
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Correspondence to Nikhil Gupta.

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Singh, A.K., Patil, B., Hoffmann, N. et al. Additive Manufacturing of Syntactic Foams: Part 1: Development, Properties, and Recycling Potential of Filaments. JOM 70, 303–309 (2018). https://doi.org/10.1007/s11837-017-2734-7

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  • DOI: https://doi.org/10.1007/s11837-017-2734-7

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