Variability analysis of ABS solid fuel manufactured by fused deposition modeling for hybrid rocket motors

2021 ◽  
Vol 15 (2) ◽  
pp. 8029-8041
Author(s):  
Jose Alejandro Urrego ◽  
Fabio Arturo Rojas ◽  
Jaime Roberto Muñoz
Keyword(s):  
Combustion Chamber ◽  
Solid Fuel ◽  
Fused Deposition Modeling ◽  
Rocket Engine ◽  
Acrylonitrile Butadiene Styrene ◽  
Hybrid Rocket ◽  
Rocket Motors ◽  
Fused Deposition ◽  
Manufacture Process ◽  
Direct Digital Manufacturing

The process of fused deposition material (FDM) was used to manufacture propellant grains of Acrylonitrile Butadiene Styrene (ABS) as novel rocket fuel grain, with three types of geometry in the burning port. These solid fuel grains were used to measure the typical characteristics of combustion in rocket motors such as thrust and pressure inside the combustion chamber, seeking to obtain preliminary characteristics of operation and analyze the effect of combustion port geometry on pressure and thrust, using Multivariate Analysis of Variance (MANOVA) as statistical method. Two of the three geometries were manufactured with a helical-finocyl configuration, specially designed to be fabricated by Direct Digital Manufacturing (DDM), the other one was a straight-bore geometry also by DDM. This characterization experiment was performed on a static hybrid rocket engine, designed to inject 99.98% pure nitrous oxide into a combustion chamber with capacity to withstand 6.9 MPa of pressure, with an easy-to-exchange nozzle, avoiding erosive behavior in the throat. Statistical analyses made with the ABS fuel grains, suggest a significant effect on rocket motor pressure and thrust, due to helical geometric changes made to the combustion port of solid fuel grains made by FDM manufacture process.

scholarly journals Carbon Nanotube-Based Composite Filaments for 3D Printing of Structural and Conductive Elements

2021 ◽  
Vol 11 (3) ◽  
pp. 1272
Author(s):  
Bartłomiej Podsiadły ◽  
Piotr Matuszewski ◽  
Andrzej Skalski ◽  
Marcin Słoma
Keyword(s):  
Carbon Nanotubes ◽  
Fused Deposition Modeling ◽  
Supply Voltage ◽  
Acrylonitrile Butadiene Styrene ◽  
Structural Elements ◽  
Filling Fraction ◽  
Fused Deposition ◽  
Structural Electronics ◽  
Measured Sample ◽  
Deposition Modeling

In this publication, we describe the process of fabrication and the analysis of the properties of nanocomposite filaments based on carbon nanotubes and acrylonitrile butadiene styrene (ABS) polymer for fused deposition modeling (FDM) additive manufacturing. Polymer granulate was mixed and extruded with a filling fraction of 0.99, 1.96, 4.76, 9.09 wt.% of CNTs (carbon nanotubes) to fabricate composite filaments with a diameter of 1.75 mm. Detailed mechanical and electrical investigations of printed test samples were performed. The results demonstrate that CNT content has a significant influence on mechanical properties and electrical conductivity of printed samples. Printed samples obtained from high CNT content composites exhibited an improvement in the tensile strength by 12.6%. Measurements of nanocomposites’ electrical properties exhibited non-linear relation between the supply voltage and measured sample resistivity. This effect can be attributed to the semiconductor nature of the CNT functional phase and the occurrence of a tunnelling effect in percolation network. Detailed I–V characteristics related to the amount of CNTs in the composite and the supply voltage influence are also presented. At a constant voltage value, the average resistivity of the printed elements is 2.5 Ωm for 4.76 wt.% CNT and 0.15 Ωm for 9.09 wt.% CNT, respectively. These results demonstrate that ABS/CNT composites are a promising functional material for FDM additive fabrication of structural elements, but also structural electronics and sensors.

scholarly journals On the Post-Processing of 3D-Printed ABS Parts

Polymers ◽  
2021 ◽  
Vol 13 (10) ◽  
pp. 1559
Author(s):  
Mohammad Reza Khosravani ◽  
Jonas Schüürmann ◽  
Filippo Berto ◽  
Tamara Reinicke
Keyword(s):  
Surface Treatment ◽  
Fused Deposition Modeling ◽  
Three Dimensional ◽  
Acrylonitrile Butadiene Styrene ◽  
Experimental Tests ◽  
Fracture Load ◽  
Post Processing ◽  
Fused Deposition ◽  
Dog Bone ◽  
3D Printed

Application of Additive Manufacturing (AM) has significantly increased in the past few years. AM also known as three-dimensional (3D) printing has been currently used in fabrication of prototypes and end-use products. Considering the new applications of additively manufactured components, it is necessary to study structural details of these parts. In the current study, influence of a post-processing on the mechanical properties of 3D-printed parts has been investigated. To this aim, Acrylonitrile Butadiene Styrene (ABS) material was used to produce test coupons based on the Fused Deposition Modeling (FDM) process. More in deep, a device was designed and fabricated to fix imperfection and provide smooth surfaces on the 3D-printed ABS specimens. Later, original and treated specimens were subjected to a series of tensile loads, three-point bending tests, and water absorption tests. The experimental tests indicated fracture load in untreated dog-bone shaped specimen was 2026.1 N which was decreased to 1951.7 N after surface treatment. Moreover, the performed surface treatment was lead and decrease in tensile strength from 29.37 MPa to 26.25 MPa. Comparison of the results confirmed effects of the surface modification on the fracture toughness of the examined semi-circular bending components. Moreover, a 3D laser microscope was used for visual investigation of the specimens. The documented results are beneficial for next designs and optimization of finishing processes.

Influence of Part Orientation on the Surface Roughness in the Process of Fused Deposition Modeling

2021 ◽  
Vol 896 ◽  
pp. 29-37
Author(s):  
Ján Milde ◽  
František Jurina ◽  
Jozef Peterka ◽  
Patrik Dobrovszký ◽  
Jakub Hrbál ◽  
...  
Keyword(s):  
Surface Roughness ◽  
3D Printing ◽  
Fused Deposition Modeling ◽  
Orientation Angle ◽  
Acrylonitrile Butadiene Styrene ◽  
Lower Surface ◽  
Geometrical Model ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Part Orientation

The article focused on the influence of part orientation on the surface roughness of cuboid parts during the process of fabricating by FDM technology. The components, in this case, is simple cuboid part with the dimensions 15 mm x 15mm x 30 mm. A geometrical model is defined that considers the shape of the material filaments after deposition, to define a theoretical roughness profile, for a certain print orientation angle. Five different print orientations in the X-axis of the cuboid part were set: 0°, 30°, 45°, 60°, and 90°. According to previous research in the field of FDM technology by the author, the internal structure (infill) was set at the value of 70%. The method of 3D printing was the Fused Deposition Modeling (FDM) and the material used in this research was thermoplastic ABS (Acrylonitrile butadiene styrene). For each setting, there were five specimens (twenty five prints in total). Prints were fabricated on a Zortrax M200 3D printer. After the 3D printing, the surface “A” was investigated by portable surface roughness tester Mitutoyo SJ-210. Surface roughness in the article is shown in the form of graphs (Fig.7). Results show increase in part roughness with increasing degree of part orientation. When the direction of applied layers on the measured surface was horizontal, significant improvement in surface roughness was observed. Findings in this paper can be taken into consideration when designing parts, as they can contribute in achieving lower surface roughness values.

Electrical Properties of Additively Manufactured Acrylonitrile Butadiene Styrene/Carbon Nanotube Nanocomposite

2018 ◽  
Author(s):  
Dominic Thaler ◽  
Nahal Aliheidari ◽  
Amir Ameli
Keyword(s):  
Electrical Conductivity ◽  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Functional Materials ◽  
Acrylonitrile Butadiene Styrene ◽  
Extrusion Process ◽  
Print Quality ◽  
Fused Deposition ◽  
Order Of Magnitude ◽  
Butadiene Styrene

Additive manufacturing is an emerging method to produce customized parts with functional materials without big investments. As one of the common additive manufacturing methods, fused deposition modeling (FDM) uses thermoplastic-based feedstock. It has been recently adapted to fabricate composite materials too. Acrylonitrile butadiene styrene (ABS) is the most widely used material as FDM feedstock. However, it is an electrically insulating polymer. Carbon Nanotubes (CNTs) on the other hand are highly conductive. They are attractive fillers because of their high aspect ratio, and excellent mechanical and physical properties. Therefore, a nanocomposite of these two materials can give an electrically conductive material that is potentially compatible with FDM printing. This work focuses on the investigation of the relationships between the FDM process parameters and the electrical conductivity of the printed ABS/CNT nanocomposites. Nanocomposite filaments with CNT contents up to 10wt% were produced using a twin-screw extruder followed by 3D printing using FDM method. The starting material was pellets from a masterbatch containing 15 wt% CNT. Compression-molded samples of ABS/CNT were also prepared as the bulk baselines. The effects of CNT content and nozzle size on the through-layer and in-layer electrical conductivity of the printed nanocomposites were analyzed. Overall, a higher percolation threshold was observed in the printed samples, compared to that of the compression-molded counterparts. This resulted in the conductivity of the printed samples that is at least one order of magnitude lower. Moreover, at CNT contents up to 5 wt%, the in-layer conductivity of the printed samples was almost two orders of magnitudes higher than that in the through-layer direction. In ABS/3 wt% CNT samples, the through-layer conductivity continuously decreased as the nozzle diameter was decreased from 0.8 mm to 0.35 mm. These variations in the electrical conductivity were explained in terms of the CNT alignment, caused by the extrusion process during the print, quality of interlayer bonding during deposition, and the voids created due to the discrete nature of the printing process.

scholarly journals USE OF FUSED DEPOSITION MODELING PROCESS IN INVESTMENT PRECISION CASTING AND RISK OF USING SELECTIVE LASER SINTERING PROCESS

2012 ◽  
pp. 226-230
Author(s):  
SIVADASAN M ◽  
N.K SINGH ◽  
ANOOP KUMAR SOOD
Keyword(s):  
Fused Deposition Modeling ◽  
Selective Laser Sintering ◽  
Thermal Response ◽  
Acrylonitrile Butadiene Styrene ◽  
Laser Sintering ◽  
Precision Casting ◽  
Fused Deposition ◽  
Rp Process ◽  
Deposition Modeling ◽  
Metallic Parts

Investment Castings (IC) is one of the most economical ways to produce intricate metallic parts when forging, forming and other casting processes tend to fail. However, high tooling cost and long lead time associated with the fabrication of metal moulds for producing IC wax (sacrificial) patterns result in cost justification problems for customized single casting or small-lot production. Generating pattern using rapid prototyping (RP) process may be one of the feasible alternatives. For this purpose present study assessed the suitability of the fused deposition modeling (FDM) process for creating sacrificial IC patterns by studying FDM fabricated part thermal response at various temperatures. A series of experiments with RP patterns are conducted and a set of test castings are also made in steel for establishing feasibility. The build material used is acrylonitrile butadiene styrene (ABS). As an annexe to this work a concurrent attempt is also made to quantify the risk in using Selective Laser Sintering patterns for Investment Castings. Authors hope this work might establish applicability of ABS in IC and also lead the investigations to theoretically tone down the shell cracking tendency with Selective Laser Sintering patterns when Proprietary Duraform is used as the build material.

90% Hydrogen Peroxide/Polyethylene Solid Fuel Hybrid Rocket Engine

2005 ◽  
Author(s):  
Nobuo Tsujikado ◽  
Masatoshi Koshimae ◽  
Rikiya Ishikawa ◽  
Kazuki Kitahara ◽  
Atsushi Ishihara
Keyword(s):  
Hydrogen Peroxide ◽  
Solid Fuel ◽  
Rocket Engine ◽  
Hybrid Rocket ◽  
Hybrid Rocket Engine

Dimensional accuracy of FDM-printed polymer parts

2019 ◽  
Vol 26 (2) ◽  
pp. 288-298 ◽  
Author(s):  
Oğuzhan Emre Akbaş ◽  
Onur Hıra ◽  
Sahar Zhiani Hervan ◽  
Shahrad Samankan ◽  
Atakan Altınkaynak
Keyword(s):  
Experimental Data ◽  
Numerical Model ◽  
Feed Rate ◽  
Fused Deposition Modeling ◽  
Dimensional Accuracy ◽  
Acrylonitrile Butadiene Styrene ◽  
Strip Width ◽  
Content Type ◽  
Fused Deposition ◽  
Nozzle Temperature

Purpose This paper aims to analyze experimentally and numerically the effect of the nozzle temperature and feed rates on the dimensions of the fused deposition modeling (FDM) polymer parts. Design/methodology/approach In total, 30 strips per sample were printed with the same width as the nozzle diameter. The strips were printed with one vertical movement of the nozzle head. The width of the strips was measured with a caliper at five locations. A linear regression model was created based on the experimental data to understand the correlation between the strip width deviation and the parameters of interest. Numerical simulations were performed to predict the swell of the polymer exiting the nozzle using finite element method combined with level set method. The experimental results were then used to validate the models. Findings The average accuracy of polylactic acid (PLA) samples was better than that of acrylonitrile butadiene styrene (ABS) samples. The average strip width had a tendency to increase with increasing temperature for PLA samples, whereas ABS samples showed mixed behavior. The strip width decreased with increasing feed rate for most cases. The measurement positions had a major effect on strip width when compared to nozzle temperature and feed rate. The numerical model predictions were in good agreement with the experimental data. A few discrepancies were observed at high feed rates and nozzle temperatures. Originality/value This study will contribute to gaps in knowledge regarding the effect of processing conditions on dimensional accuracy of FDM-printed parts. The developed numerical model can be efficiently used to predict the dimensional accuracy of FDM-printed parts.

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