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Fiber orientation and porosity in large-format extrusion process: The role of processing parameters
Controlling fiber orientation and porosity in short-fiber thermoplastic composites is important for enhancing mechanical, electrical and thermal properties in large-format additive manufacturing. This study employs a factorial design of experiments (DoE) to assess the effects of nozzle diameter (5.08 mm–10.16 mm), temperature (230–250 °C), and extruder screw speed (150–280 rpm) on flow rate, shear rate, porosity, fiber orientation, fiber length and tensile strength in 20 % carbon fiber-filled acrylonitrile butadiene styrene. ANOVA results show that screw speed significantly impacts flow rate, while nozzle diameter and temperature have lesser effects. Shear rate increases with smaller nozzles and higher speeds. Porosity decreases from 5.58 % with a 10.16 mm nozzle to 3.11 % with a 5.08 mm nozzle at 150 rpm due to increased shear rates, which induce shear thinning, reducing viscosity and facilitating gas escape. Larger nozzles (10.16 mm) produce larger, more heterogeneous pores, while smaller nozzles (5.08 mm) yield smaller, uniform pores. Beads produced with the 5.08 mm nozzle exhibit longer fiber lengths due to reduced residence time, lower shear stress, and better alignment. Fiber orientation improves with smaller nozzles due to higher shear rates but decreases with higher screw speeds (280 rpm) due to shorter residence times. The highest fiber alignment (A xx ∼ 0.65) and low porosity (∼3%) were achieved with a 5.08 mm nozzle at 150 rpm, while equivalent additive manufacturing-compression molding samples exhibited better tensile strength (∼93 MPa) under these conditions. In conclusion, these findings emphasize the importance of optimizing processing parameters to enhance fiber alignment and reduce porosity for improved mechanical performance.
Extrusion-based additive manufacturing of functionally graded ceramics
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Effect of corrosion behavior of cast and extruded ZK60 magnesium alloys processed via friction extrusion
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High dose ion irradiation response of large strain extrusion machined ultrafine grain HT-9 steel
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A synergistic approach to improve the cellulose nanofibril dispersion in poly(lactic acid) composites as feedstocks for extrusion-based additive manufacturing
Hybrid fiber-reinforced polymer composites (HFRPs) are multifunctional materials that bear more than one characteristic benefit. In this study, hybrid cellulose fibers, e.g., pulp fiber (PF) and cellulose nanofibril (CNF), were used for reinforcing poly(lactic acid) (PLA). A synergistic approach was applied to disperse CNF. The low-surface-tension solvent (ethanol), together with PF templating, assisted the dispersion of CNF in PLA. The HFRP achieved a higher tensile strength (∼70 MPa, 29% increase from PLA) and modulus (∼7 GPa, 46% increase from PLA), as well as a higher heat deflection temperature (∼60℃, 6℃ increase compared to neat PLA), compared to single-reinforcement FRPs. Additionally, the formulation was demonstrated to be potentially suitable for large-scale additive manufacturing.
Thermo-mechanical recycling via ultrahigh-speed extrusion of film-grade recycled LDPE and injection molding
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Bimetallic Zeolitic Imidazole Frameworks for Improved Stability and Performance of Intrusion–Extrusion Energy Applications
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Effects of soybean 7S protein on the quality and digestibility of dry rice noodles under twin‐screw extrusion process
Summary Starch and protein are important components of food, the mixed system formed between them (complexes, gels, mixtures, etc.) can improve the physical and chemical properties of starch and protein, and its potential application in the food industry has also attracted widespread attention. In this study, indica rice flour and soybean 7S protein (β‐Conglycinin) were used as the experimental materials to explore the effect of soybean 7S protein addition on the quality and digestibility of rice noodles. Aims to develop rice noodles with high protein and low GI, so that people can take care of their health while satisfying their appetites. The results showed that with the increase of soybean 7S protein addition, the starch digestibility decreased, resulting in the estimated glycaemic index (eGI) and glycaemic load (GL) decreasing. However, the cooking loss rate and breakage rate of rice noodles gradually increased, the water absorption first increased and then decreased, and the taste of rice noodles is acceptable when the 7S protein addition amount is within 9%. The interaction between starch and soybean 7S protein was mediated by weak interactions such as hydrogen bonds and hydrophobic forces indicated by Fourier transform infrared spectroscopy (FTIR) and X‐ray diffraction (XRD).
Ballistic characterization of additively manufactured extrusion deposited thermoplastic composite plates
Additive manufacturing (AM) is rapidly emerging in high performance applications such as army ground vehicles, automotive and transportation. However, the response of AM parts/components to extreme loading such as high velocity impacts is less studied. In this work, the performance under ballistic impact of AM panels is evaluated using a medium velocity gas gun, generating projectile velocities up to 400 m/s. The preferential print orientation properties are considered in order to evaluate whether the panels exhibit isotropic or anisotropic behavior under impact. Surface morphology is investigated by milling the beads smooth on samples and comparing the impact on as-printed samples to those that are smoothed. The effect of nickel chromium micron (nichrome) wire embedded in the AM panels (during print) of polycarbonate-carbon fiber (PC-CF) and polycarbonate-glass fiber (PC-GF) are explored. Thermoplastic polyurethane-acrylonitrile butadiene styrene/carbon fiber (TPU-ABS/CF), Acrylonitrile butadiene styrene-carbon-fiber (ABS-CF) AM samples absorbed >50% of the impact energy. The ballistic performance was noted to be in the following order – ABS-CF > TPU-ABS/CF > PC. Scanning electron microscopy (SEM) was conducted to study the interface between the nichrome wire and the polymer-fiber matrix. This work is the first of its kind exploring into the capabilities of AM panels as ballistic materials. This study leads the way for developing AM panels that are easily manufactured and exhibit superior ballistic resistance.
Design Guidelines for Material Extrusion Based Additive Manufacturing: Generation of Rules for Ceramics and Comparison to Polymer Standards
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In Situ Process Monitoring of Direct Ink Write Material Extrusion Additive Manufacturing
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Electroplated Laser-Powder Bed Fusion and Bound Powder Extrusion Additive Manufactured 17-4 Stainless Steel
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Extrusion Models for Viscoelastic Fluids
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Electroplated Laser-Powder Bed Fusion and Bound Powder Extrusion Additive Manufactured 17-4 Stainless Steel
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