Additive Manufacturing of Syntactic Foams: Part 1: Development, Properties, and Recycling Potential of Filaments

Ashish Kumar Singh; Balu Patil; Niklas Hoffmann; Brooks Saltonstall; Mrityunjay Doddamani; Nikhil Gupta

doi:10.1007/s11837-017-2734-7

Additive Manufacturing of Syntactic Foams: Part 1: Development, Properties, and Recycling Potential of Filaments

Ashish Kumar Singh, Balu Patil, Niklas Hoffmann, Brooks Saltonstall, Mrityunjay Doddamani, Nikhil Gupta

Mechanical and Aerospace Engineering

Research output: Contribution to journal › Article › peer-review

Abstract

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.

Original language	English (US)
Pages (from-to)	1-8
Number of pages	8
Journal	JOM
Volume	70
Issue number	3
DOIs	https://doi.org/10.1007/s11837-017-2734-7
State	Accepted/In press - Jan 24 2018

ASJC Scopus subject areas

Materials Science(all)
Engineering(all)

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10.1007/s11837-017-2734-7

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title = "Additive Manufacturing of Syntactic Foams: Part 1: Development, Properties, and Recycling Potential of Filaments",

abstract = "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.",

author = "Singh, {Ashish Kumar} and Balu Patil and Niklas Hoffmann and Brooks Saltonstall and Mrityunjay Doddamani and Nikhil Gupta",

note = "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: {\textcopyright} 2018, The Minerals, Metals & Materials Society.",

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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.

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Additive Manufacturing of Syntactic Foams: Part 1: Development, Properties, and Recycling Potential of Filaments

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