Stochastic fracture of additively manufactured porous composites
Abstract Extrusion-based fused deposition modeling (FDM) introduces inter-bead pores into dense materials, which results in part-to-part mechanical property variations, i.e., low mechanical reliability. In addition, the internal structure of FDMed materials can be made porous intentionally to tailor...
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doaj-3f83fa067c3343efb4b048c393a3c9682020-12-08T06:21:13ZengNature Publishing GroupScientific Reports2045-23222018-10-018111210.1038/s41598-018-33863-4Stochastic fracture of additively manufactured porous compositesÖzgür Keleş0Eric H. Anderson1Jimmy Huynh2Jeff Gelb3Jouni Freund4Alp Karakoç5Chemical and Materials Engineering Department, San Jose State UniversityChemical and Materials Engineering Department, San Jose State UniversityChemical and Materials Engineering Department, San Jose State UniversityChemical and Materials Engineering Department, San Jose State UniversityDepartment of Mechanical Engineering, Aalto UniversityCivil and Environmental Engineering, University of CaliforniaAbstract Extrusion-based fused deposition modeling (FDM) introduces inter-bead pores into dense materials, which results in part-to-part mechanical property variations, i.e., low mechanical reliability. In addition, the internal structure of FDMed materials can be made porous intentionally to tailor mechanical properties, introduce functionality, reduce material consumption, or decrease production time. Despite these potential benefits, the effects of porosity on the mechanical reliability of FDMed composites are still unclear. Accordingly, we investigated the stochastic fracture of 241 FDMed short-carbon-fiber-reinforced-ABS with porosity ranging from 13 to 53 vol.% under tensile load. Weibull analysis was performed to quantify the variations in mechanical properties. We observed an increase in Weibull modulus of fracture/tensile strength for porosity higher than ~40 vol.% and a decrease in Weibull modulus of fracture strain for an increase in porosity from 25 to 53 vol.%. Micromechanics-based 2D simulations indicated that the mechanical reliability of FDMed composites depends on variations in bead strength and elastic modulus of beads. The change in raster orientation from 45°/−45° to 0° more than doubled the Weibull modulus. We identified five different types of pores via high-resolution X-ray computed tomography. A 22% and 48% decrease in carbon fiber length due to extrusion was revealed for two different regions of the filament.https://doi.org/10.1038/s41598-018-33863-4Stochastic FractureRaster OrientationFused Deposition Modeling (FDMed)Weibull ModulusFDMed Materials |
collection |
DOAJ |
language |
English |
format |
Article |
sources |
DOAJ |
author |
Özgür Keleş Eric H. Anderson Jimmy Huynh Jeff Gelb Jouni Freund Alp Karakoç |
spellingShingle |
Özgür Keleş Eric H. Anderson Jimmy Huynh Jeff Gelb Jouni Freund Alp Karakoç Stochastic fracture of additively manufactured porous composites Scientific Reports Stochastic Fracture Raster Orientation Fused Deposition Modeling (FDMed) Weibull Modulus FDMed Materials |
author_facet |
Özgür Keleş Eric H. Anderson Jimmy Huynh Jeff Gelb Jouni Freund Alp Karakoç |
author_sort |
Özgür Keleş |
title |
Stochastic fracture of additively manufactured porous composites |
title_short |
Stochastic fracture of additively manufactured porous composites |
title_full |
Stochastic fracture of additively manufactured porous composites |
title_fullStr |
Stochastic fracture of additively manufactured porous composites |
title_full_unstemmed |
Stochastic fracture of additively manufactured porous composites |
title_sort |
stochastic fracture of additively manufactured porous composites |
publisher |
Nature Publishing Group |
series |
Scientific Reports |
issn |
2045-2322 |
publishDate |
2018-10-01 |
description |
Abstract Extrusion-based fused deposition modeling (FDM) introduces inter-bead pores into dense materials, which results in part-to-part mechanical property variations, i.e., low mechanical reliability. In addition, the internal structure of FDMed materials can be made porous intentionally to tailor mechanical properties, introduce functionality, reduce material consumption, or decrease production time. Despite these potential benefits, the effects of porosity on the mechanical reliability of FDMed composites are still unclear. Accordingly, we investigated the stochastic fracture of 241 FDMed short-carbon-fiber-reinforced-ABS with porosity ranging from 13 to 53 vol.% under tensile load. Weibull analysis was performed to quantify the variations in mechanical properties. We observed an increase in Weibull modulus of fracture/tensile strength for porosity higher than ~40 vol.% and a decrease in Weibull modulus of fracture strain for an increase in porosity from 25 to 53 vol.%. Micromechanics-based 2D simulations indicated that the mechanical reliability of FDMed composites depends on variations in bead strength and elastic modulus of beads. The change in raster orientation from 45°/−45° to 0° more than doubled the Weibull modulus. We identified five different types of pores via high-resolution X-ray computed tomography. A 22% and 48% decrease in carbon fiber length due to extrusion was revealed for two different regions of the filament. |
topic |
Stochastic Fracture Raster Orientation Fused Deposition Modeling (FDMed) Weibull Modulus FDMed Materials |
url |
https://doi.org/10.1038/s41598-018-33863-4 |
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