Browsing by Author "Das, Arit"
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- Customized blends of polypropylene for extrusion based additive manufacturingDas, Arit; Shanmugham, Nishanth; Bortner, Michael J. (Wiley, 2022-11)Filament-based material extrusion (MatEx) additive manufacturing has garnered great interest due to its simplicity, customizability, and cost-effectiveness. However, MatEx of semicrystalline polymers is still largely relegated to prototyping applications. Major issues involving volumetric shrinkage and warpage of the printed parts must be addressed in order to employ them for printing functional parts. Moreover, the crystallization behavior and rheology of the polymer are dependent on the MatEx processing conditions. In the current work, the printability of blends of isotactic polypropylene with a soft, low crystallinity propylene based homopolymer is evaluated. Addition of the homopolymer resulted in an increase in the crystallization window of the blends by similar to 6 degrees C that had a profound impact on the interlayer adhesion and residual stress state. The shear-dependent melt flow behavior inside the printing nozzle as well as the interlayer chain diffusion and interlayer welding on the print bed were investigated. Rheological characterizations also indicate sufficient dispersion and miscibility of the homopolymer in the neat polypropylene matrix. The incorporation of the homopolymer as an additive significantly improved the dimensional accuracy of the printed parts through better dissipation of the entrapped residual stresses during MatEx. Moreover, the degree of mechanical anisotropy of the parts was significantly lower than that obtained using many 3D printable grade polymers. The findings from this study can be leveraged in toolpath planning, process parameter optimization, and new feedstock development, highlighting current limitations as well as providing valuable insights into necessary processing modifications in order to enable MatEx of next generation semicrystalline polymers.
- Material Extrusion based Additive Manufacturing of Semicrystalline Polymers: Correlating Rheology with Print PropertiesDas, Arit (Virginia Tech, 2022-09-09)Filament-based material extrusion (MatEx) additive manufacturing has garnered huge interest in both academic and industrial communities. Moreover, there is an increasing need to expand the material catalog for MatEx to produce end use parts for a wide variety of functional applications. Current approaches towards MatEx of semicrystalline thermoplastics are in their nascent stage with fiber reinforcements being one of the most common techniques. MatEx of commodity semicrystalline thermoplastics has been investigated but most of the current methods are extremely material and machine specific. The goal of this dissertation is to enable MatEx of semicrystalline polymers with mechanical properties approaching that of injection molded parts. Tailored molecular architectures of blends that can control the crystallization kinetics from the melt state are investigated. By modifying the crystallization time window, the time during which chain diffusion can occur across the deposited layers is prolonged, which allows for a stronger bond between layers. Such differences in the crystallization process impact the z-axis adhesion and residual stress state, which directly affect mechanical properties and warpage in the printed parts. The impact of blend composition on polymer chain diffusion, crystallization profiles, and print properties resulting from the repeated non-uniform thermal history in filament based MatEx is studied. The melt flow behaviour is characterized using rheology and its effect on the interlayer adhesion of printed parts and print precision is explored. The extent of polymer chain re-entanglement post deposition on the printer bed is quantitatively determined using interrupted shear rheology protocols. Tensile bars are printed and mechanically characterized to analyze the tensile performance of the printed parts. Correlating the rheological findings with the mechanical performance of the printed parts provides valuable insights into the complex interlayer welding process during MatEx and is critical to improving existing machine designs and feedstocks in order to achieve printed parts with properties approaching their injection molded counterparts. The results will be essential in identifying optimal processing conditions to maximize material specific printed part performance as well as highlight the associated limitations to enable MatEx of next generation materials.