TY - JOUR
T1 - Additive Manufacturing of Syntactic Foams
T2 - Part 1: Development, Properties, and Recycling Potential of Filaments
AU - Singh, Ashish Kumar
AU - Patil, Balu
AU - Hoffmann, Niklas
AU - Saltonstall, Brooks
AU - Doddamani, Mrityunjay
AU - Gupta, Nikhil
N1 - Funding Information:
Mrityunjay Doddamani acknowledges the Department of Science and Technology, India, Grant DST/ TSG/AMT/2015/394/G, and Visiting Scientist Fellowship Grant VSP 17-7-001 by the US Office of Naval research—Global (Program manager: Dr. Ra-mesh Kolar) to visit NYU for this work. Nikhil Gupta acknowledges the Office of Naval Research Grant N00014-10-1-0988. The views expressed in this article are those of authors, not of funding agencies.
Publisher Copyright:
© 2018, The Minerals, Metals & Materials Society.
PY - 2018/1/24
Y1 - 2018/1/24
N2 - This work focuses on developing filaments of high-density polyethylene (HDPE) and their hollow particle-filled syntactic foams for commercial three-dimensional (3D) printers based on fused filament fabrication technology. Hollow fly-ash cenospheres were blended by 40 wt.% in a HDPE matrix to produce syntactic foam (HDPE40) filaments. Further, the recycling potential was studied by pelletizing the filaments again to extrude twice (2×) and three times (3×). The filaments were tensile tested at 10−4 s−1, 10−3 s−1, and 10−2 s−1 strain rates. HDPE40 filaments show an increasing trend in modulus and strength with the strain rate. Higher density and modulus were noticed for 2× filaments compared to 1× filaments because of the crushing of some cenospheres in the extrusion cycle. However, 2× and 3× filament densities are nearly the same, showing potential for recycling them. The filaments show better properties than the same materials processed by conventional injection molding. Micro-CT scans show a uniform dispersion of cenospheres in all filaments.
AB - This work focuses on developing filaments of high-density polyethylene (HDPE) and their hollow particle-filled syntactic foams for commercial three-dimensional (3D) printers based on fused filament fabrication technology. Hollow fly-ash cenospheres were blended by 40 wt.% in a HDPE matrix to produce syntactic foam (HDPE40) filaments. Further, the recycling potential was studied by pelletizing the filaments again to extrude twice (2×) and three times (3×). The filaments were tensile tested at 10−4 s−1, 10−3 s−1, and 10−2 s−1 strain rates. HDPE40 filaments show an increasing trend in modulus and strength with the strain rate. Higher density and modulus were noticed for 2× filaments compared to 1× filaments because of the crushing of some cenospheres in the extrusion cycle. However, 2× and 3× filament densities are nearly the same, showing potential for recycling them. The filaments show better properties than the same materials processed by conventional injection molding. Micro-CT scans show a uniform dispersion of cenospheres in all filaments.
UR - http://www.scopus.com/inward/record.url?scp=85040935719&partnerID=8YFLogxK
UR - http://www.scopus.com/inward/citedby.url?scp=85040935719&partnerID=8YFLogxK
U2 - 10.1007/s11837-017-2734-7
DO - 10.1007/s11837-017-2734-7
M3 - Article
AN - SCOPUS:85040935719
SN - 1047-4838
VL - 70
SP - 1
EP - 8
JO - JOM
JF - JOM
IS - 3
ER -