Mechanical and dynamic mechanical behavior of 3D printed waste slate particles filled acrylonitrile butadiene styrene composites

Abstract

This study analyses the feasibility of utilizing waste slate particles as a strengthening component in affordable 3D-printed composite materials to address environmental issues associated with waste management. Composite filaments were created by incorporating waste slate particles (5 %, 10 %, and 15 % by weight) into an acrylonitrile butadiene styrene (ABS) matrix and subsequently evaluated for mechanical properties. A twin-screw extruder obtained the composite filaments, while test samples were produced using a 3D printer by fused deposition modelling. The developed composites have a gradual variation in evaluated properties, about an 8 % increment in hardness, and a 40 % increment in flexural and tensile modulus was noted on the inclusion of 15 wt% of waste slate particles in the ABS matrix. The composites filled with 10 wt% and 5 wt% waste slate particles exhibited the maximum flexural strength (65.24 MPa) and tensile strength (42.11 MPa), respectively. These values were 5 % and 8 % higher than those of unfilled ABS. Furthermore, it was shown that the ABS matrix saw a decrease in elongation and impact strength as the dosage of slate particles increased. The fractured surface morphology indicated that filament breaking, filler pullout, and the creation of voids between neighbouring layers were the primary causes of material failure. The dynamic mechanical analysis (DMA) results show the reinforcing effect of slate particles by an increase of storage modulus with 13 % at 35 °C for the composite with 10 wt% slate particles and 20 % for that with 15 wt% slate particles. DMA results analyzed the composite's adhesion factor, degree of entanglement, reinforcement efficiency factor, and effectiveness factor to clarify the reinforcing mechanism of slate particles. The study determines that the most effective utilization of waste slate particles in an ABS matrix is achieved by including 10 wt%. The results of this study enhance the concept of recycling waste slate powder and reveal the potential for their utilization in several industries, including the aerospace, automotive, healthcare, and architectural sectors of 3D printing.