On secondary recycling of ZrO2-reinforced HDPE filament prepared from domestic waste for possible 3-D printing of bearings

Abstract

In this study, an innovative route for secondary recycling (with zirconium oxide (ZrO2) reinforcement) has been proposed based on melt processing of high-density polyethylene (HDPE) in low-temperature bearing applications. Initially, secondary recycled HDPE, acrylonitrile butadiene styrene, and nylon 6 thermoplastic composites were investigated for melt flow index (MFI) according to ASTM D1238 standard. Based on the acceptable MFI, secondary recycled HDPE matrix was selected for second-stage processing on twin screw extrusion (TSE). The final process involves reinforcement of ZrO2 into HDPE matrix by TSE in 60:40 ratio (by weight %) for preparation of feedstock filament (for possible 3-D printing of bearings). The results of the study suggest that for processing of HDPE, 40% ZrO2 composite matrix, 50 r min−1 screw speed, 190°C barrel temperature, and 15 kg applied load are the best setting of TSE (for maximizing the tensile strength of feedstock filament). The results are also supported by wear properties, thermal stability, and morphological analysis (based on scanning electron microscopy and electron-dispersive X-ray analysis).