TY - JOUR
T1 - Thermal history based prediction of interlayer bond strength in parts manufactured by material extrusion additive manufacturing
AU - Mahmoud, Youmna
AU - Lyu, Jiaqi
AU - Akhavan, Javid
AU - Xu, Ke
AU - Manoochehri, Souran
N1 - Publisher Copyright:
© 2023, The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature.
PY - 2023/6
Y1 - 2023/6
N2 - Material extrusion additive manufacturing, also known as fused filament fabrication (FFF), is currently one of the most widely used technologies. Although promising, the technology is prone to several defects including poor surface quality, low dimensional accuracy, and inadequate mechanical performance caused by weak bonds between successively deposited layers. Studies have shown that bonding between filaments forms above the material’s glass transition temperature which makes it essential to study the thermal history of the printing process. Since interlayer bonding is thermally driven, this study has focused on the development of a regression model to predict the average interlayer bonding strength of a part using the thermal history of the printed layers and the process parameter settings. The process parameters studied are deposition temperature, print speed, and layer thickness. This study relies on using finite element analysis (FEA) to obtain the part’s thermal history and scanning electron microscopy (SEM) to evaluate the bond quality by performing microstructure analysis. The average interlayer bond strength was assessed by measuring the interlayer bond widths and average weld times of all layers in a printed part. The weld time is the time that the temperature of an extruded filament stays above the glass transition temperature when reheated by an adjacent layer. This study includes experimental validation of the developed predictive models to estimate the average weld time and average bond strength of thin wall samples. Results show that the average bond strength is most significantly influenced by two key variables—the average weld time and layer thickness.
AB - Material extrusion additive manufacturing, also known as fused filament fabrication (FFF), is currently one of the most widely used technologies. Although promising, the technology is prone to several defects including poor surface quality, low dimensional accuracy, and inadequate mechanical performance caused by weak bonds between successively deposited layers. Studies have shown that bonding between filaments forms above the material’s glass transition temperature which makes it essential to study the thermal history of the printing process. Since interlayer bonding is thermally driven, this study has focused on the development of a regression model to predict the average interlayer bonding strength of a part using the thermal history of the printed layers and the process parameter settings. The process parameters studied are deposition temperature, print speed, and layer thickness. This study relies on using finite element analysis (FEA) to obtain the part’s thermal history and scanning electron microscopy (SEM) to evaluate the bond quality by performing microstructure analysis. The average interlayer bond strength was assessed by measuring the interlayer bond widths and average weld times of all layers in a printed part. The weld time is the time that the temperature of an extruded filament stays above the glass transition temperature when reheated by an adjacent layer. This study includes experimental validation of the developed predictive models to estimate the average weld time and average bond strength of thin wall samples. Results show that the average bond strength is most significantly influenced by two key variables—the average weld time and layer thickness.
KW - Additive manufacturing
KW - Finite element analysis
KW - Fused filament fabrication
KW - Heat transfer
KW - Infrared camera
KW - Interlayer bonding strength
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U2 - 10.1007/s00170-023-11364-7
DO - 10.1007/s00170-023-11364-7
M3 - Article
AN - SCOPUS:85152465738
SN - 0268-3768
VL - 126
SP - 3813
EP - 3829
JO - International Journal of Advanced Manufacturing Technology
JF - International Journal of Advanced Manufacturing Technology
IS - 9-10
ER -