Crack penetration versus deflection in extrusion-based additive manufacturing – Impact of nozzle temperature and morphology

Research output: Contribution to journalArticleResearchpeer-review

Abstract

Two different modes of fracture propagation can occur when a crack encounters a weak interface in a fused filament fabricated (FFF) part: the crack either deflects into the interface, or penetrates the subsequent layers. The objective of this work is to verify the suitability of an energy- and a strength-based criterion for predicting which failure mode will occur in FFF printed parts. Four different materials, glycol-modified poly(ethylene terephthalate), polylactide acid and two different poly(methyl methacrylate) grades were examined. Fracture mechanical tests were performed on single edge-notched bending specimens for the energy-based approach and tensile tests performed on dumbbell specimens for the strength-based approach. Additionally, porosity measurements and thermal analysis were carried out to provide structural information. The energy-based approach proved unreliable for failure mode prediction. Potential problems include failure to meet the requirements of linear elastic fracture mechanics and issues with notch design. The strength-based approach, in contrast, correctly predicted the crack path for all tested materials and seems a promising candidate for failure mode prediction in FFF materials.

Details

Original languageEnglish
Article number104032
Number of pages13
JournalTheoretical and Applied Fracture Mechanics
Volume127.2023
Issue numberOctober
Early online date5 Aug 2023
DOIs
Publication statusPublished - Oct 2023