Fatigue response of multiscale extrusion-based additively manufactured acrylonitrile butadiene styrene-graphene nanoplatelets composites

Abstract

This study investigates the effect of varying concentrations of graphene nanoplatelets (GNPs) on the mechanical and fatigue characteristics of acrylonitrile butadiene styrene (ABS)/GNPs nanocomposites, both in filament form and as 3D-printed parts with different raster orientations. Quasi-static and cyclic loading tests were performed on specimens containing 0.1 wt%, 0.5 wt%, 1.0 wt%, and 2.0 wt% GNPs. The results indicated that the addition of 0.1 wt% GNPs to the ABS polymer matrix increased the ultimate tensile strength (UTS) of the filament by 18 %. Addition of 1.0 wt% and 2.0 wt% GNPs to the matrix improved the Young's modulus of the filament by up to about 35 % but did not enhance the UTS. The filament containing 0.5 wt% GNPs demonstrated the highest fatigue life, even higher than that of the standard samples fabricated through injection molding technique. This was due to its high static strength, Young's modulus, and ductility. However, when the ABS/GNPs nanocomposites were 3D-printed, the addition of GNPs had no major impact on their fatigue life, especially in the higher load levels. Inadequate adhesion and reduced interlayer bonding strength resulted in a detrimental impact on fatigue life of 3D-printed objects. The extrudate-swell phenomenon seems to significantly affect this reduction in fatigue life. To address this, larger nozzle diameter (0.6 mm) was used in fabricating 3D-printed samples. Results indicated that samples with less distortion and smaller extrudate-swell had higher fatigue life. It highlights the importance of considering GNP concentration and printing parameters for optimal fatigue properties in ABS/GNPs composites.