Statistical-based optimization of fused filament fabrication parameters for short-carbon-fiber-reinforced poly-ether-ether-ketone considering multiple loading conditions
Fused filament fabrication (FFF) is one of the most widely used additive manufacturing processes and allows the production of complex parts. FFF can manufacture lightweight and strong structural components when processing high-performance carbon-fiber-reinforced thermoplastics. Although the process...
| Main Authors: | , , , , , |
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| Format: | Article |
| Language: | English |
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Elsevier
2023-11-01
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| Series: | Polymer Testing |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S0142941823002878 |
| _version_ | 1797682897303371776 |
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| author | Willian S. de Carvalho Francesco Marzemin Carlos Belei Sandra Petersmann Florian Arbeiter Sergio T. Amancio-Filho |
| author_facet | Willian S. de Carvalho Francesco Marzemin Carlos Belei Sandra Petersmann Florian Arbeiter Sergio T. Amancio-Filho |
| author_sort | Willian S. de Carvalho |
| collection | DOAJ |
| description | Fused filament fabrication (FFF) is one of the most widely used additive manufacturing processes and allows the production of complex parts. FFF can manufacture lightweight and strong structural components when processing high-performance carbon-fiber-reinforced thermoplastics. Although the process feasibility for printing 20% short-carbon-fiber reinforced PEEK was already demonstrated in the literature, a systematic study addressing the influence of printing parameters on different loading conditions is still lacking. Therefore, the present study investigates the influence of selected FFF parameters – i.e., layer height (LH), printing temperature (PT) and printing speed (PS) – on three mechanical properties: tensile (UTS), bending (UBS), and impact (UIS) ultimate strengths. The analyzed samples were printed and tested according to a central composite design of experiments, and each parameter's individual and combined effects were assessed by analysis of variance (ANOVA). Different regression models were obtained for each test, allowing the optimization of the parameters for each condition and resulting in three distinct optimized parameter sets. The relationship between parameters and microstructure was also assessed via fractography analyses, showing that lower LH and PS reduce the number and size of volumetric defects observed within the printed parts, as lower values improve interlayer cohesion. Contrarily, PT showed that average values (around 385 °C) benefit the microstructure the most, as higher temperatures result in larger defects and low temperatures reduce interlayer cohesion. Finally, the contour plots of the three produced models were overlaid to identify a universal parameter set capable of simultaneously correlating and maximizing all three performances. This procedure allowed the identification of the following optimized values: LH of 0.1 mm, PT of 385 °C and PS of 17.5 mm/s, resulting in the experimental UTS, UBS and UIS values of 116.7 ± 5 MPa, 167.2 ± 11 MPa and 28.2 ± 3 kJ/m2. |
| first_indexed | 2024-03-12T00:06:34Z |
| format | Article |
| id | doaj.art-d4149fb298954dd1b2186252b0870cc3 |
| institution | Directory Open Access Journal |
| issn | 0142-9418 |
| language | English |
| last_indexed | 2024-03-12T00:06:34Z |
| publishDate | 2023-11-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Polymer Testing |
| spelling | doaj.art-d4149fb298954dd1b2186252b0870cc32023-09-17T04:55:46ZengElsevierPolymer Testing0142-94182023-11-01128108207Statistical-based optimization of fused filament fabrication parameters for short-carbon-fiber-reinforced poly-ether-ether-ketone considering multiple loading conditionsWillian S. de Carvalho0Francesco Marzemin1Carlos Belei2Sandra Petersmann3Florian Arbeiter4Sergio T. Amancio-Filho5Graz University of Technology – TU Graz, Institute of Materials Science, Joining and Forming, BMK Endowed Professorship for Aviation, Kopernikusgasse 24/1, 8010, Graz, Austria; Corresponding author.Graz University of Technology – TU Graz, Institute of Materials Science, Joining and Forming, BMK Endowed Professorship for Aviation, Kopernikusgasse 24/1, 8010, Graz, AustriaGraz University of Technology – TU Graz, Institute of Materials Science, Joining and Forming, BMK Endowed Professorship for Aviation, Kopernikusgasse 24/1, 8010, Graz, AustriaMontanuniversitaet Leoben – MUL, Institute of Materials Science and Testing of Polymers, Otto Glöckel-Straße 2/II, 8700, Leoben, AustriaMontanuniversitaet Leoben – MUL, Institute of Materials Science and Testing of Polymers, Otto Glöckel-Straße 2/II, 8700, Leoben, AustriaGraz University of Technology – TU Graz, Institute of Materials Science, Joining and Forming, BMK Endowed Professorship for Aviation, Kopernikusgasse 24/1, 8010, Graz, Austria; Corresponding author.Fused filament fabrication (FFF) is one of the most widely used additive manufacturing processes and allows the production of complex parts. FFF can manufacture lightweight and strong structural components when processing high-performance carbon-fiber-reinforced thermoplastics. Although the process feasibility for printing 20% short-carbon-fiber reinforced PEEK was already demonstrated in the literature, a systematic study addressing the influence of printing parameters on different loading conditions is still lacking. Therefore, the present study investigates the influence of selected FFF parameters – i.e., layer height (LH), printing temperature (PT) and printing speed (PS) – on three mechanical properties: tensile (UTS), bending (UBS), and impact (UIS) ultimate strengths. The analyzed samples were printed and tested according to a central composite design of experiments, and each parameter's individual and combined effects were assessed by analysis of variance (ANOVA). Different regression models were obtained for each test, allowing the optimization of the parameters for each condition and resulting in three distinct optimized parameter sets. The relationship between parameters and microstructure was also assessed via fractography analyses, showing that lower LH and PS reduce the number and size of volumetric defects observed within the printed parts, as lower values improve interlayer cohesion. Contrarily, PT showed that average values (around 385 °C) benefit the microstructure the most, as higher temperatures result in larger defects and low temperatures reduce interlayer cohesion. Finally, the contour plots of the three produced models were overlaid to identify a universal parameter set capable of simultaneously correlating and maximizing all three performances. This procedure allowed the identification of the following optimized values: LH of 0.1 mm, PT of 385 °C and PS of 17.5 mm/s, resulting in the experimental UTS, UBS and UIS values of 116.7 ± 5 MPa, 167.2 ± 11 MPa and 28.2 ± 3 kJ/m2.http://www.sciencedirect.com/science/article/pii/S0142941823002878Fused filament fabricationExperimental designParameter optimizationCentral composite designMechanical propertiesPolymer characterization |
| spellingShingle | Willian S. de Carvalho Francesco Marzemin Carlos Belei Sandra Petersmann Florian Arbeiter Sergio T. Amancio-Filho Statistical-based optimization of fused filament fabrication parameters for short-carbon-fiber-reinforced poly-ether-ether-ketone considering multiple loading conditions Polymer Testing Fused filament fabrication Experimental design Parameter optimization Central composite design Mechanical properties Polymer characterization |
| title | Statistical-based optimization of fused filament fabrication parameters for short-carbon-fiber-reinforced poly-ether-ether-ketone considering multiple loading conditions |
| title_full | Statistical-based optimization of fused filament fabrication parameters for short-carbon-fiber-reinforced poly-ether-ether-ketone considering multiple loading conditions |
| title_fullStr | Statistical-based optimization of fused filament fabrication parameters for short-carbon-fiber-reinforced poly-ether-ether-ketone considering multiple loading conditions |
| title_full_unstemmed | Statistical-based optimization of fused filament fabrication parameters for short-carbon-fiber-reinforced poly-ether-ether-ketone considering multiple loading conditions |
| title_short | Statistical-based optimization of fused filament fabrication parameters for short-carbon-fiber-reinforced poly-ether-ether-ketone considering multiple loading conditions |
| title_sort | statistical based optimization of fused filament fabrication parameters for short carbon fiber reinforced poly ether ether ketone considering multiple loading conditions |
| topic | Fused filament fabrication Experimental design Parameter optimization Central composite design Mechanical properties Polymer characterization |
| url | http://www.sciencedirect.com/science/article/pii/S0142941823002878 |
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