Additive Manufacturing of Syntactic Foams: Part 2: Specimen Printing and Mechanical Property Characterization

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

doi:10.1007/s11837-017-2731-x

Additive Manufacturing of Syntactic Foams: Part 2: Specimen Printing and Mechanical Property Characterization

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

Mechanical and Aerospace Engineering

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

Abstract

High-density polyethylene (HDPE) and its fly ash cenosphere-filled syntactic foam filaments have been recently developed. These filaments are used for three-dimensional (3D) printing using a commercial printer. The developed syntactic foam filament (HDPE40) contains 40 wt.% cenospheres in the HDPE matrix. Printing parameters for HDPE and HDPE40 were optimized for use in widely available commercial printers, and specimens were three-dimensionally (3D) printed for tensile testing at strain rate of 10⁻³ s⁻¹. Process optimization resulted in smooth operation of the 3D printer without nozzle clogging or cenosphere fracture during the printing process. Characterization results revealed that the tensile modulus values of 3D-printed HDPE and HDPE40 specimens were higher than those of injection-molded specimens, while the tensile strength was comparable, but the fracture strain and density were lower.

Original language	English (US)
Pages (from-to)	1-5
Number of pages	5
Journal	JOM
Volume	70
Issue number	3
DOIs	https://doi.org/10.1007/s11837-017-2731-x
State	Accepted/In press - Jan 16 2018

ASJC Scopus subject areas

Materials Science(all)
Engineering(all)

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title = "Additive Manufacturing of Syntactic Foams: Part 2: Specimen Printing and Mechanical Property Characterization",

abstract = "High-density polyethylene (HDPE) and its fly ash cenosphere-filled syntactic foam filaments have been recently developed. These filaments are used for three-dimensional (3D) printing using a commercial printer. The developed syntactic foam filament (HDPE40) contains 40 wt.% cenospheres in the HDPE matrix. Printing parameters for HDPE and HDPE40 were optimized for use in widely available commercial printers, and specimens were three-dimensionally (3D) printed for tensile testing at strain rate of 10−3 s−1. Process optimization resulted in smooth operation of the 3D printer without nozzle clogging or cenosphere fracture during the printing process. Characterization results revealed that the tensile modulus values of 3D-printed HDPE and HDPE40 specimens were higher than those of injection-molded specimens, while the tensile strength was comparable, but the fracture strain and density were lower.",

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AU - Singh, Ashish Kumar

AU - Saltonstall, Brooks

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AU - Hoffmann, Niklas

AU - Doddamani, Mrityunjay

AU - Gupta, Nikhil

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