Statistical-based optimization of fused filament fabrication parameters for short-carbon-fiber-reinforced poly-ether-ether-ketone considering multiple loading conditions
Research output: Contribution to journal › Article › Research › peer-review
Standard
In: Polymer Testing, Vol. 128.2023, No. November, 108207, 15.09.2023.
Research output: Contribution to journal › Article › Research › peer-review
Harvard
APA
Vancouver
Author
Bibtex - Download
}
RIS (suitable for import to EndNote) - Download
TY - JOUR
T1 - Statistical-based optimization of fused filament fabrication parameters for short-carbon-fiber-reinforced poly-ether-ether-ketone considering multiple loading conditions
AU - de Carvalho, Willian S.
AU - Marzemin, Francesco
AU - Belei, Carlos
AU - Petersmann, Sandra
AU - Arbeiter, Florian
AU - de Traglia Amancio-Filho, Sergio
N1 - Funding Information: The authors gratefully acknowledge financial support from the Austrian aviation program ‘‘TAKEOFF” (PILOT, grant number 852796, 2018) and the BMK – The Austrian Ministry for Climate Action, Environment, Energy, Mobility, Innovation and Technology.The authors would like to acknowledge the Open Access Funding by the Graz University of Technology. Publisher Copyright: © 2023 The Authors
PY - 2023/9/15
Y1 - 2023/9/15
N2 - 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.
AB - 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.
KW - Central composite design
KW - Experimental design
KW - Fused filament fabrication
KW - Mechanical properties
KW - Parameter optimization
KW - Polymer characterization
UR - http://www.scopus.com/inward/record.url?scp=85171440750&partnerID=8YFLogxK
U2 - 10.1016/j.polymertesting.2023.108207
DO - 10.1016/j.polymertesting.2023.108207
M3 - Article
AN - SCOPUS:85171440750
VL - 128.2023
JO - Polymer Testing
JF - Polymer Testing
SN - 0142-9418
IS - November
M1 - 108207
ER -