Development of functionally graded material by fused deposition modelling assisted investment casting

Abstract Application of functionally graded materials (FGMs) in energy, aviation and nuclear industries has increased since the last decade due to potential reduction of in-plane and transverse through-the-thickness stresses, enhanced residual stress distribution, superior thermal properties, free from delamination, and reduced stress intensity factors. FGMs are categorized as an advanced class of composite materials where the two constituent materials are graded along the thickness direction. Absence of sharp change in material property in the interface layer eliminates the problem of delamination and debonding, which is a major concern for traditional composite material. In this work, PLA-ABS functionally graded material is manufactured using additive manufacturing techniques through fused deposition modeling (FDM) using Y-type extruder. X-ray computed tomography test is conducted to see the air void (generated during printing) distribution in the printed FGM. Tensile test (as per ISO-527standrad) is conducted to evaluate the Young’s Modulus of additive manufactured FGMs. Three different measuring positions are considered in the FGM specimens to check the effect of property change along the grading direction. Tensile test results of PLA-ABS FGM are compared with their individual constituents (ABS and PLA). Further, flexural vibration test is conducted to evaluate the natural frequency of printed FGM beam. Experimentally determined mechanical and dynamic characteristics in terms effective Young’s Modulus and natural frequency are analyzed and discussed.

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On the Optimal Design of Metal Matrix Composites as Functionally Graded Innovative Materials for Sensor Devices

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.826.45 ◽

2019 ◽

Vol 826 ◽

pp. 45-54

Author(s):

Narinder Singh ◽

Rupinder Singh ◽

Inderpreet Singh Ahuja ◽

Ilenia Farina

Keyword(s):

Metal Matrix Composites ◽

Investment Casting ◽

Metal Matrix ◽

Research Work ◽

Functionally Graded ◽

Fused Deposition Modelling ◽

Matrix Composites ◽

Fused Deposition ◽

Sensor Devices ◽

Innovative Materials

In the present work an effort has been made to prepare Al matrix composite by 3D printing assisted rapid investment casting (RIC). The RIC has been performed by using patterns prepared by fused deposition modelling (FDM). For preparation of 3D parts, a composite material reinforced with ceramic particles (SiC and Al2O3) has been used as filament wire. The main motive of this research work is to prepare metal matrix composites as functionally graded innovative materials (FGIM), via investment casting as functional prototypes which will have wear resistance properties of SiC and Al2O3 (especially in rapid tooling (RT) applications. The reinforcements in the RT (as functional prototype) have been ensured by SEM analysis. The potential of the analysed materials for the fabrication of novel sensor devices is highlighted. Also the functional prototypes were checked for process capability analysis for batch production

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Investigating the friction coefficient in functionally graded rapid prototyping of Al–Al2O3 composite prepared by fused deposition modelling

Assembly Automation ◽

10.1108/aa-06-2016-055 ◽

2017 ◽

Vol 37 (2) ◽

pp. 154-161

Author(s):

Rupinder Singh ◽

Sunpreet Singh

Keyword(s):

Friction Coefficient ◽

Rapid Prototyping ◽

Process Parameters ◽

Research Work ◽

Functionally Graded ◽

Fused Deposition Modelling ◽

Melt Flow ◽

Content Type ◽

Fused Deposition ◽

Graded Material

Purpose The present research work aims to study the friction coefficient in functionally graded rapid prototyping of Al–Al2O3 composite prepared via fused deposition modelling (FDM)-assisted investment casting (IC) process. The optimized settings of the process parameters (namely, filament proportion, volume of FDM pattern, density of FDM pattern, barrel finishing (BF) time, BF media weight and number of IC slurry layers) suggested in the present research work will help fabricate parts possessing higher frictional coefficient. Design/methodology/approach Initially, melt flow index (MFI) of two different proportions of Nylon6-Al–Al2O3 (to be used as an alternative FDM filament material) was tested on the melt flow indexer and matched with MFI of commercially used acrylonitrile–butadiene–styrene filament. After this, the selected proportions of Nylon6-Al–Al2O3 were prepared in the form of the FDM filament by using a single screw extruder. Further, this FDM filament has been used for developing sacrificial IC patterns in the existing FDM system which was barely finished to improve their surface finish. Castings developed were tested for their wear resistance properties on a pin-on-disc-type tribo-tester under dry conditions at sliding conditions to check their suitability as a frictional device for industrial applications. In the methodology part, Taguchi L18 orthogonal array was used to study the effect of selected process variables on the coefficient of friction (μ). Findings It has been found that filament proportion, volume of FDM pattern and density of FDM pattern have significantly affected the μ-values. Further, density of the FDM pattern was found to have 91.62 per cent contribution in obtaining μ-values. Scanning electron micrographs highlighted uniform distribution of Al2O3 particles in the Al-matrix at suggested optimized settings. Practical implications The present methodology shows the development of a functional graded material that consisted of surface reinforcement with Al2O3 particles, which could have applications for manufacturing friction surfaces such as clutch plates, brake drum, etc. Originality/value This paper describes the effect of process parameters on wear properties of the Al–Al2O3 composite developed as a functionally graded material by the FDM-based pattern in the IC process.

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