Hybrid fused filament fabrication for manufacturing of Al microfilm reinforced PLA structures
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TECHNICAL PAPER
Hybrid fused filament fabrication for manufacturing of Al microfilm reinforced PLA structures Ranvijay Kumar1 · Jasgurpreet Singh Chohan2 · Raman Kumar2 · Aniket Yadav2 · Piyush2 · Narinder Singh3 Received: 13 March 2020 / Accepted: 13 August 2020 / Published online: 19 August 2020 © The Brazilian Society of Mechanical Sciences and Engineering 2020
Abstract The quality of 3D printed thermoplastic structures mainly depends upon the various aspects of deposition pattern, processing conditions, and layer bonding. The incomplete layer-to-layer adhesion during the additive manufacturing process is the most critical issue since thermoplastics are bad heat conductors. In this study, aluminum (Al) microfilms have been deposited to promote the adhesion between the additive layers. The composite structures (as per ASTM D 695) of polylactic acid thermoplastic were manufactured by fused filament fabrication (FFF) process and consecutively reinforced with Al spray. The composite structures were subjected to compressive loading to investigate the influence of input process variables like; in-between microfilm layers (1–5 layers), bed temperature (60–100 °C), and infill percentage (40–100%). The results of the study suggested that using microfilm in-between additive layers is a promising technique for improving the compressive properties. The compressive strength has been observed maximum by performing FFF with 3 layers of Al microfilm, 70% of infill percentage, and 100 °C bed temperature. The results are supported by scanning electron microscopy, energydispersive spectroscopy, and differential scanning calorimeter analysis. An optimization study was successfully conducted using the analytic hierarchy process, which predicted the optimum parameter settings based on the relative importance of each response variable. Keywords Al microfilm · PLA · Hybrid FFF · Compressive strength · Reinforced structures
1 Introduction AM is a digital fabrication processes through which parts having complex shapes can be formed at lower cost and time as compared to conventional manufacturing techniques [1]. AM is gaining popularity due to its application in almost every sector for preparing prototypes in engineering [2], the biomedical industry [3], electronic industry [4], and ceramic industry [5] and educational models [6]. The AM techniques are classified under seven broad categories, i.e., material Technical Editor: Zilda de Castro Silveira. * Ranvijay Kumar [email protected] 1
University Centre for Research and Development, Chandigarh University, Mohali, India
2
Department of Mechanical Engineering, Chandigarh University, Mohali, India
3
Department of Civil Engineering, University of Salerno, Salerno, Italy
extrusion [7], binder jetting, directed energy deposition [8], material jetting, powder bed fusion, sheet lamination [9], and vat photopolymerization as per ASTM F2792-12a [10]. FFF is one of the most economical and popular material extrusion techniques due to material flexibility, portability, and ea
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