Solid State Additive Manufacturing of Acrylonitrile Butadiene Styrene with Silica Augmentative: Application of Friction Stir Processing

Abstract

The additive manufacturing processes are increasing their importance in fabrication of composite like structures. Friction stir processing is classified as a solid state additive manufacturing technique that is used for lamination or powder deposition in a matrix substrate. In the present work an attempt was made to add the silica as secondary phase into the acrylonitrile butadiene styrene (ABS) surface for enhancing the mechanical and surface properties of fabricated composite. The parameters such as amount of silica fraction, pass number, tool rotational speed and linear speed were considered to be involved in the study. The responses surface method (RSM) was used here to assess relationship between aforementioned inputs and outputs vs bending strength and deflection before fracture. Optimal setting of process parameters was determined by maximizing bending strength and deflection. The obtained optimal results showed that maximum strength and deflection can be achieved by selecting of 100% silica volume fraction, 1 pass number, 1400 rpm tool rotation and 80 mm/min travel speed. The optimum results were further verified through confirmatory experiment and the result showed that the values of prediction error for bending strength and deflection are 6.1% and 8.5%, respectively. This proves the validity of the proposed approach for empirical modeling and optimization of friction stir additive manufacturing process.