Rheological Behavior and Dynamic Mechanical Properties for Interpretation of Layer Adhesion in FDM 3D Printing.

Commercial filaments of poly(lactic acid) (PLA) composites with particulate filler, carbon fiber, and copper powder with different contents were fabricated by FDM 3D printing in XZ-direction at bed temperatures of 45 °C and 60 °C. The effects of additives and bed temperatures on layer adhesion, fracture behavior, and mechanical performance of the PLA composites 3D printing were evaluated. Rheological properties informed viscous nature of all filaments and interface bonding in the PLA composites, which improved printability and dimensional stability of the 3D printing. Crystallinity of the PLA composites 3D printing increased with increasing bed temperature resulting in an improvement of storage modulus, tensile, and flexural properties. On the contrary, the ductility of the 3D printing was raised when printed at low bed temperature. Dynamic mechanical properties, the degree of entanglement, the adhesion factor, the effectiveness coefficient, the reinforcing efficiency factor, and the Cole-Cole analysis were used to understand the layer adhesion, and the interfacial interaction of the composites as compared to the compression molded sheets. SEM images revealed good adhesion between the additives and the PLA matrix. However, the additives induced faster solidification and showed larger voids in the 3D printing, which indicated lower layer adhesion as compared to neat PLA. It can be noted that the combination of the additives and the optimized 3D printing conditions would be obtain superior mechanical performance even layer adhesion has been restricted.

Relating Amorphous Structure to the Tear Strength of Polylactic Acid Films.

Compared with polyolefins that are used as single-use plastics, polylactic acid (PLA) has a lower tear strength in films. The relationship between the tear strength and the higher-order structure of films was investigated using PLA films that absorbed moisture at 30 °C and 95% relative humidity (RH) or that had been annealed under reduced pressure conditions. Although the mobile amorphous (MAm) amount did not change under high humidity, the film became brittle due to enthalpy relaxation. The crystallization by annealing also caused embrittlement, and the MAm amount decreased to 10%. The displacement until tearing is lowered from 2.5 to 0.5 mm in both cases. However, in situ retardation measurements revealed that there was a significant difference in the fracture morphology of the torn tip. When crystallized, the molecular chains and crystals are oriented in the tensile direction of the film, and a fragmented structure is observed in the ligament. Embrittlement due to enthalpy relaxation caused a weak orientation perpendicular to the tensile direction of the film, and cracks occurs along with this orientation.

Experimental Investigation and Numerical Simulation of a Self-Wiping Corotating Parallel Octa-Screw Extruder.

An octa-screw extruder (OSE) is equipment for pelletizing, blending, and mixing polymers and composites. In this study, the degree of resin filling, residence time distribution (RTD) of molten resin, and temperature profile in the octa-screw extruder were evaluated both experimentally and numerically. An intermeshing corotating parallel octa-screw kneading extruder was used for the experiments. For the comparison study, the results obtained from this extruder were compared with the twin-screw extruder. High-density polyethylene was selected as the material for extrusion. Meanwhile, a numerical code, based on a 2.5 D finite element method derived from the Hele-Shaw flow model, was developed to simulate the octa-screw extrusion process. The empirical outcomes suggest that octa-screw extrusion exhibited a narrower RTD of the molten resin compared with the twin-screw extrusion, suggesting better extrudate quality. The octa-screw extrusion also showed a lower temperature profile than twin-screw extrusion. The results of the simulation were also found to be in good agreement with experimental measurements. Experimental and numerical investigations of an OSE enable detailed comprehension and visualization of resin distribution in the entire length of the OSE, thus providing advantages in terms of process optimization.

Changes in Crystal Structure and Accelerated Hydrolytic Degradation of Polylactic Acid in High Humidity.

Highly crystallized polylactic acid (PLA) is suitable for industrial applications due to its stiffness, heat resistance, and dimensional stability. However, crystal lamellae in PLA products might delay PLA decomposition in the environment. This study clarifies how the initial crystal structure influences the hydrolytic degradation of PLA under accelerated conditions. Crystallized PLA was prepared by annealing amorphous PLA at a specific temperature under reduced pressure. Specimens with varied crystal structure were kept at 70 °C and in a relative humidity (RH) of 95% for a specific time. Changes in crystal structure were analyzed using differential calorimetry and wide-angle X-lay diffraction. The molecular weight (MW) was measured with gel permeation chromatography. The crystallinity of the amorphous PLA became the same as that of the initially annealed PLA within one hour at 70 °C and 95% RH. The MW of the amorphous PLA decreased faster even though the crystallinity was similar during the accelerated degradation. The low MW chains of the amorphous PLA tended to decrease faster, although changes in the MW distribution suggested random scission of the molecular chains for initially crystallized PLA. The concentrations of chain ends and impurities, which catalyze hydrolysis, in the amorphous region were considered to be different in the initial crystallization. The crystallinity alone does not determine the speed of hydrolysis.

Improvement of Interlayer Adhesion and Heat Resistance of Biodegradable Ternary Blend Composite 3D Printing.

Poly(lactic acid) (PLA) filaments have been the most used in fused deposition modeling (FDM) 3D printing. The filaments, based on PLA, are continuing to be developed to overcome brittleness, low heat resistance, and obtain superior mechanical performance in 3D printing. From our previous study, the binary blend composites from PLA and poly(butylene adipate-co-terephthalate) (PBAT) with nano talc (PLA/PBAT/nano talc) at 70/30/10 showed an improvement in toughness and printability in FDM 3D printing. Nevertheless, interlayer adhesion, anisotropic characteristics, and heat resistance have been promoted for further application in FDM 3D printing. In this study, binary and ternary blend composites from PLA/PBAT and poly(butylene succinate) (PBS) with nano talc were prepared at a ratio of PLA 70 wt. % and blending with PBAT or PBS at 30 wt. % and nano talc at 10 wt. %. The materials were compounded via a twin-screw extruder and applied to the filament using a capillary rheometer. PLA/PBAT/PBS/nano talc blend composites were printed using FDM 3D printing. Thermal analysis, viscosity, interlayer adhesion, mechanical properties, and dimensional accuracy of binary and ternary blend composite 3D prints were investigated. The incorporation of of PBS-enhanced crystallinity of the blend composite 3D prints resulted in an improvement to mechanical properties, heat resistance, and anisotropic characteristics. Flexibility of the blend composites was obtained by presentation of PBAT. It should be noted that the core-shell morphology of the ternary blend influenced the reduction of volume shrinkage, which obtained good surface roughness and dimensional accuracy in the ternary blend composite 3D printing.

Segmented Polyurethane Elastomers with Mechanochromic and Self-Strengthening Functions.

Mechanochromic elastomers that exhibit force-induced cross-linking reactions in the bulk state are introduced. The synthesis of segmented polyurethanes (SPUs) that contain difluorenylsuccinonitrile (DFSN) moieties in the main chain and methacryloyl groups in the side chains was carried out. DFSN was selected as the mechanophore because it dissociates under mechanical stimuli to form pink cyanofluorene (CF) radicals, which can also initiate the radical polymerization of methacrylate monomers. The obtained elastomers generated CF radicals and changed color by compression or extension; they also became insoluble due to the mechanically induced cross-linking reactions. Additionally, an SPU containing diphenylmethane units also exhibited highly sensitive mechanofluorescence. To the best of our knowledge, this is the first report to demonstrate damage detection ability and changes in the mechanical properties of bulk elastomers induced by simple compression or extension.

Effect of Layer Directions on Internal Structures and Tensile Properties of 17-4PH Stainless Steel Parts Fabricated by Fused Deposition of Metals.

17-4PH stainless steel specimens were fabricated by fused deposition of metals (FDMet) technology, which combines 17-4PH particles with an organic binder. FDMet promises a low-cost additive manufacturing process. The present research aims to clarify the influence of layer directions in the 3D printing process on the mechanical and shrinkage properties of as-sintered and as-aged specimens. All specimens (the as-sintered and as-aged specimens printed in three layer directions) exhibited high relative density (97.5-98%). The highest ultimate strengths (880 and 1140 MPa in the as-sintered and as-aged specimens, respectively) were obtained when the layer direction was perpendicular to the tensile direction. Conversely, the specimens printed with their layer direction parallel to the tensile direction presented a low ultimate strength and low strain at breakage. The fact that the specimens with their layer direction parallel to the tensile direction presented a low ultimate strength and low strain at breakage is a usual behavior of parts obtained by means of FDM. The SEM images revealed oriented binder domains in the printed parts and oriented voids in the sintered parts. It was assumed that large binder domains in the filament were oriented perpendicular to the layer directions during the fused deposition modeling printing, and remained as oriented voids after sintering. Stress concentration in the oriented void defects was likely responsible for the poor tensile properties of these specimens.

Effect of Melt-Compounding Protocol on Self-Aggregation and Percolation in a Ternary Composite.

A ternary composite of poly(lactic acid) (PLA), poly(caprolactone) (PCL), and carbon black (CB) shows the PCL-induced CB self-aggregation and percolation formation when the amount of the PCL phase as the secondary phase is as small as the amount of CB. Furthermore, when the drop size of the PCL phase becomes smaller, the ternary composite forms a percolation of high order structure, resulting in a remarkable enhancement of the electrical conductivity (~4 × 10-2 S/m with 4 wt.% CB). To further control the percolation structure, the composite fabrication is controlled by splitting a typical single-step mixing process into two steps, focusing on the dispersion of the secondary PCL phase and the CB particles separately. Under the single-step mixing protocol, the ternary composite shows a structure with greater CB aggregation in the form of a high aspect ratio and large aggregates (aggregate perimeter~aggregate size 0.7). Meanwhile, the two-step mixing process causes the CB aggregates to expand and create a higher structure (aggregate perimeter~aggregate size 0.8). The reduced size of the secondary phase under a mixing condition with high shear force prior to the addition of CB provides a larger interfacial area for CB to diffuse into the PCL phase during the subsequent mixing step, resulting in a further expansion of CB aggregation throughout the composite. The particle percolation of such a high order structure is attributed to high storage modulus (G'), high Young's modulus, high dielectric loss (ε″), and negative-positive switching of dielectric constant at high frequency (of 103 Hz) of composite.

Physical and Morphological Properties of Tough and Transparent PMMA-Based Blends Modified with Polyrotaxane.

We prepared several novel, tough, and transparent poly(methyl methacrylate) (PMMA) blends modified with polyrotaxane (PR) and evaluated their physical properties and morphologies. A styrene/methyl methacrylate/maleic anhydride (SMM) copolymer that was miscible with PMMA was used as a reactive compatibilizer to enhance interfacial adhesion between the matrix resin and PR. A twin-screw melt-kneading extruder was used to prepare the polymer blends, and their thermal, morphological, optical, and mechanical properties were characterized. The effect of PR was evaluated by analyzing the deformation behavior of the blends in notched three-point bending tests. A PMMA/PR blend was immiscible and appeared to be a phase-separated system. However, when SMM was added as a compatibilizer, PR was partially miscible and did not form observable PR domains. Viscosity increased, and the glass transition temperature (Tg) of the matrix resin decreased. The surface hardness of a PMMA/SMM/PR blend was only 15% lower than that of PMMA. A 2.5-fold increase in elongation at breakage was observed, and the tensile strength and Young's modulus decreased by 16%. The PMMA/SMM/PR blend had 60% higher impact strength than PMMA in notched Charpy impact test, which indicated that the balance between stiffness and ductility was excellent. PR served as a starting point for plastic deformation in the PMMA/SMM/PR blend. We found that PR could initiate void and craze formation, even when it was finely dispersed at the nanoscale. The stress-relieving effect of PR was effective when it was tightly bound at the interfaces. The materials obtained in this study are expected to make a significant contribution to reducing the weight of the products by applying them as a replacement for glass.

Influence of the Layer Directions on the Properties of 316L Stainless Steel Parts Fabricated through Fused Deposition of Metals.

Metal specimens were fabricated via the fused deposition of metals (FDMet) technique with a filament composed of the 316L stainless steel particles and an organic binder. This process was adopted due to its potential as a low-cost additive manufacturing process. The objective of this study is to investigate the influence of the processing conditions-layer directions and layer thicknesses-on the mechanical and shrinkage properties of the metal components. The specimens were printed in three different layer directions. The highest ultimate strength of 453 MPa and strain at break of 48% were obtained in the specimen printed with the layer direction perpendicular to the tensile direction. On the other hand, the specimen printed in the layer direction parallel to the tensile direction exhibited poor mechanical properties. The reason for the anisotropy of the properties was investigated through systematic SEM observations. The observations revealed the presence of segregated binder domains in the filaments. It was deduced that the binder domain was oriented in the direction perpendicular to that of the layer and remained as oriented voids even after sintering. The voids oriented perpendicular to the tensile direction act as defects that could cause stress concentration, thus resulting in poor mechanical properties.

Morphology, Thermal and Mechanical Properties of Co-Continuous Porous Structure of PLA/PVA Blends by Phase Separation.

Poly (lactic acid) (PLA) was blended with poly (vinyl alcohol) (PVA) in the composition of 70/30 (L7V3), 60/40 (L6V4), and 50/50 (L5V5) wt.%. L7V3 exhibits a sea-island morphology, while L6V4 and L5V5 show co-continuous phase morphologies. These polymers exhibited a solitary glass transition temperature, which obeyed the Fox equation. Thereafter, the blends were made porous by an etching process in hot water (35 °C) for 0-7 days, to remove PVA. The maximum etched PVA content of L7V3, L6V4, and L5V5 was 0.5%, 13.4%, and 36.1%, respectively; hence, L5V5 exhibited a co-continuous porous morphology with the porosity of 43.4%, the degree of swelling of 47.5%, and the pore size of 2 µm. The degree of crystallinity of PLA, exposed PLA, and L7V3 showed an insignificant change. L5V5, having the highest porosity, demonstrated the highest increase in the degree of crystallinity of approximately two times, because water induced the crystallization of PLA. The high porosity of L5V5 exhibited an excellent absorption property by increasing absorption energy more than two times, as obtained by micro indention. It had the maximum indentation depth more than 250 µm. Flexural and tensile properties considerably decreased with an increase in the porosity.