Extrusion Temperature Research Articles

Electro-mechanical analysis of nanostructured polymer matrix composite materials for 3D printing using machine learning

Recently, additive manufacturing (AM) techniques like 3D printing have emerged as a potentially game-changing example of digital manufacturing. However, high entry barriers of a tiny material library, different processing defects, and unpredictable product quality are still holding back its widespread use in the industry. Due to its remarkable success in data tasks like classification, regression, and clustering, machine learning (ML) has recently gained a great deal of interest in the subject of the material library. This paper examines the current state of ML applications in several key areas of AM, including polymer matrix composite materials and machine parameter optimization. Composite filaments have been extruded using Polylactic Acid (PLA) as it is a biodegradable material and shows how High-Density Poly Ethylene (HDPE) enhances physical strength. All the parameters for the filament extruder have been designed by machine learning. Thermal stability is a significant concern for polymers that have been overcome by introducing Titanium Dioxide nanoparticles. The microstructure, surface texture, electro-mechanical behavior, and other general features of extruded filaments made from recycled plastics have been investigated. The extrusion temperature, approximated using ML, is in excellent agreement with the surface texture and microstructure of the polymers, as confirmed by FESEM, EDX, and Particle analysis. Extruded filaments experienced 2500 Vs and confirmed their non-conductivity up to 77.7GΩ. Tensile strength and elongation at break, two measures of mechanical properties, have been examined. Incorporation of Titanium Dioxide Nanoparticles improved mechanical properties significantly. When it comes to 3D printing, the physical properties and potential uses of each composite material are different.

Effect of extrusion conditions on microstructural characteristics and mechanical properties of SEN6 magnesium alloy

This study investigates the influence of extrusion conditions on the microstructure and tensile properties of Mg–6Al–0.3Mn–0.3Ca–0.2Y (SEN6) alloy, which is processed at various extrusion temperatures and ratios. An increase in both the extrusion temperature and ratio facilitates dynamic recrystallization during hot extrusion by enhancing thermal and strain energies, increasing the area fraction of recrystallized grains within the extruded material. As either the extrusion temperature or ratio increases, lattice rotation within the recrystallized grains intensifies, resulting in a stronger basal texture in the extruded material. During extrusion, the undissolved Al2Y, Al8Mn4Y, and Al2Ca particles within the billets are partially fragmented and realigned along the extrusion direction. However, the quantity, size, and dispersion of these particles are largely unaffected by variations in extrusion temperature and ratio. The tensile yield strength of the extruded material shows a positive correlation with increasing extrusion temperature and ratio, predominantly due to enhanced texture hardening. Specifically, the tensile yield strength of the material extruded at 400 °C with an extrusion ratio of 25 is 23.2 MPa higher than that of the material extruded at 300 °C with an extrusion ratio of 10. Despite the presence of non-recrystallized grains in materials extruded at the lower extrusion ratio of 10, compression and double twins form uniformly throughout the material during tension, as the widths of non-recrystallized grains are similar to those of recrystallized grains. Consequently, all extruded materials exhibit high tensile elongations, exceeding 20%.

A pilot-study on the influence of fused filament fabrication (FFF) parameters on multiple performance metrics.

Abstract This study examines the key process parameters in the 3D printing of PLA and their influence on different responses. The examined parameters include layer thickness, infill percentage, raster width, build orientation, raster angle, and extrusion temperature. Their impact was evaluated using a fractional factorial design on key essential characteristics such as tensile strength, dimensional capability, surface roughness, and cost-effectiveness. Pareto plots were utilized to identify and prioritize the most influential parameters for each response. The study’s findings showed that layer thickness, infill percentage, and orientation around the x and y axes have a notable impact on all of the observed responses. In contrast, it was found that the angle between two successive layers did not have a significant impact on any of the responses.

Eco-friendly material extrusion 3D printing for fabricating W-Ni-Fe lattices with improved compressive resistance

Tungsten (W) and its alloys are prevalently utilized in many special fields, such as the military and nuclear industry, owing to their exceptional attributes, including superior hardness, high density, and remarkable resistance to high temperatures. However, there are still challenges to achieve easy preparation of porous W alloys and uncover the secrets of their mechanical behavior. In this work, a porous lattice made from W93Ni4.9Fe2.1 with uniform microstructure was designed using enhanced material extrusion (MEX) 3D printing technology, offering exceptional formability while ensuring safety and environmental friendliness. The W93Ni4.9Fe2.1 lattice, fabricated at an extrusion temperature of 150 °C and infill percentage of 60 % exhibits the optimal geometry and homogeneous sintering shrinkage. The W93Ni4.9Fe2.1 lattice, fabricated at an extrusion temperature of 170 °C and infill percentage of 60 % shows the best compressive properties with the ultimate compressive strength of 1442 MPa and plastic strain of 19.8 %. The study of rheological properties of designed slurry determines the viscous flow activation energy of 1.64 kJ·mol−1 for the smooth extrusion of slurry, which is crucial for the formability of W93Ni4.9Fe2.1 lattice 3D printing. The ball milling treatment significantly improves the sinterability of W93Ni4.9Fe2.1 powder, confirming the effectiveness of mechanical alloying. This work presents a novel approach for fabricating complex structured porous W alloy with high-performance in a low-cost and environmentally friendly manner.

Effects of Nozzle Temperature on Mechanical Properties of Polylactic Acid Specimens Fabricated by Fused Deposition Modeling.

This paper investigates the effect of nozzle temperature, from 180 to 260 °C, on properties of polylactic acid (PLA) samples manufactured by fused deposition modeling (FDM) technology. The main objective of this research is to determinate an optimum nozzle temperature relative to tensile, flexural and compressive properties of printed specimens. After manufacturing, the samples exhibit an amorphous structure, without crystallization effects, independently of the fabrication temperature. In order to determine the influence of printing temperature on mechanical properties, uniaxial tensile, three-point flexural and compression strength tests were carried out. The obtained results suggest that a relative low printing temperature could reduce the material flow and decrease the density of the final prototype, with a negative effect on both the quality and the mechanical properties of the pieces. If temperature increases up to 260 °C, an excess of material can be deposited, but with no significant negative effect on mechanical parameters. There is an optimum nozzle temperature interval, depending on the considered piece and test, for which mechanical values can be optimized. Taking into account all tests, a recommended extruder temperature interval may be identified as 220-240 °C. This range encompasses all mechanical parameters, avoiding the highest temperature where an excess of material was observed. For this printing temperature interval, no significant mechanical variations were appreciated, which corresponds to a stable behavior of the manufactured specimens.

Effect of Extrusion Temperature Variations for Manufacturing 3D Printer Filament Based on Used Bottle Waste on Impact Strength

Effect of Extrusion Temperature Variations for Manufacturing 3D Printer Filament Based on Used Bottle Waste on Impact Strength

Evaluation of operational process parameters of polylactic acid filament extruder by quality and dynamic‐mechanical analysis measurements: A comparative study and classification

AbstractIn this study, the operational conditions of a low‐cost in‐house‐built single screw filament extruder including operational parameters of extruder temperature (170–190°C) and screw speed (20–40 rpm) were evaluated in terms of the quality and dynamic‐mechanical properties of extruded PLA filaments. The designed experimental parameters were used to investigate the impact of operational parameters on filament diameter by Taguchi model where the predicted responses were evaluated. Results showed superior performance with R2 value of 0.9898. The measured filament diameters validated the predicted responses, and the error percentage was in the range of 0%–2.1%. Furthermore, in order to classify and distinguish filaments, we adept the artificial neural network (ANN) model classifier, and the measured dynamic mechanical analysis (DMA) values at certain temperatures were taken into consideration where the classes they belonged to be determined. Results reveal successful classification accuracy of filaments in the range of 94.82%–99.98% depends on different cases of classification process.

The Effects of Extrusion Temperature and Sodium Bicarbonate Foaming Agent on Density and Tensile Properties of Kenaf Fibre-Reinforced Biocomposites

The Effects of Extrusion Temperature and Sodium Bicarbonate Foaming Agent on Density and Tensile Properties of Kenaf Fibre-Reinforced Biocomposites

Atomic strain concentration induced by interfaces in extruded carbon nanotube reinforced 2024Al matrix composite

Inhomogeneous deformation occurs in aluminum matrix composite, resulting in strain concentration near reinforcement/matrix interfaces. In this work, for the CNT/2024Al composite extruded by porthole die extrusion, the effects of reinforcements (CNTs and Al4C3) and intermetallic (Al2Cu) on atomic strain concentration and grain boundary migration were systematically studied. The results indicate that obvious atomic strain concentration appears near the CNT/Al and Al4C3/Al interfaces, and then, the strain is transferred from the interfaces to Al matrix. Mirco-Al2Cu phases are mainly distributed at grain boundaries, increasing Zener force, and thus inhibit grain growth of the composite. In addition, the Al4C3/Al and Al2Cu/Al interfaces are observed, and the (111)Al atom plane is parallel to 1̄107Al4C3, while large number of misfit dislocations are observed near the Al2Cu/Al interface. Transmission Kikuchi diffraction and transmission electron microscope observations indicate that the grains, which contains more second phases, exhibit higher dislocation density than neighboring grains, providing driving force for grain boundary migration. High extrusion temperature brings about Al2Cu dissolution, leading to grain growth, and interfacial bonding strength decreases with increasing extrusion speed. Consequently, the composite extruded at low-temperature and low-ram speed has ultrafine grains, high dislocation density, and strong interfacial bonding, exhibiting high hardness, tensile strength and elongation.

Effects of homogenization temperature on microstructure, mechanical properties and corrosion behavior of binary Zn-Mn alloys extruded at different temperatures

In order to optimize the mechanical properties (MPs) of biodegradable Zn-based alloys, many researches have been conducted. However, the effect of homogenization treatment before the plastic deformation process on the MPs of biodegradable Zn-based alloys has not received sufficient attention, although it has been demonstrated to play an important role in improving the MPs of Al- and Mg-based alloys. In this work, as-cast Zn-0.8 wt% Mn alloys were firstly homogenized at two different temperatures (330 and 390 °C) followed by quenching and then extruded at three different temperatures (170, 230 and 300 °C). This work revealed the effects of homogenization temperature (HT) on microstructure, MPs and corrosion behavior of Zn-0.8 wt% Mn alloys extruded at different temperatures. The results showed that compared to the alloy homogenized at 330 °C (HT330), the alloy homogenized at 390 °C (HT390) has less precipitation of micron-sized MnZn13 particles in the homogenization process. During the subsequent extrusion processes at 170 and 230 °C, more submicron-sized MnZn13 particles are precipitated and finer Zn grains are formed in the HT390 alloys than in the HT330 alloys. Correspondingly, the two extruded HT390 alloys exhibit elongations of up to 133 % and 86 %, respectively, which are much higher than the 71 % and 65 % of the two extruded HT330 alloys. However, when the extruding temperature is elevated to 300 °C, high HT causes decrease in the fraction of both the micron- and submicron-sized MnZn13 particles as well as coarsening of Zn grains, followed by an increase in the strength of the as-extruded alloy. In addition, high HT is conductive to improving the corrosion resistance of the as-extruded alloys regardless of the extrusion temperature.

Impact of extrusion temperature and moisture incorporation on nutrient digestibility in barramundi (Lates calcarifer) diet

This study aimed to evaluate the influence of extrusion temperature and moisture incorporation procedure on nutrient digestibility of diets fed to barramundi (Lates calcarifer). A single premix was processed under six contrasted extrusion processing conditions, with extruder barrel temperatures set at 100 °C and 110 °C, and liquid water either incorporated in the preconditioner, in the barrel, or in both. In a subsequent 33-day feeding trial, grow-out fish (758.3 ± 24.5 g) were fed the 6 diets and apparent digestibility coefficients (ADC) were assessed for 42 fatty acids, 17 amino acids, protein, lipids and energy. Digestibility of protein (92.3–93.7%), lipid (84.1–89.4%), and energy (69.4–75.2%) also remained unaffected by extrusion settings (P > 0.05). However, lower extrusion temperature and moisture incorporation in both preconditioner and barrel resulted in higher digestibility of poly-unsaturated fatty acids (PUFA), long-chain poly-unsaturated fatty acids (LC-PUFA), omega-3, omega-6 and 22:6 docosahexaenoic n-3 (DHA). Moreover, lower extrusion temperature significantly improved ADCs of essential amino acids, except lysine, histidine, and threonine (P < 0.05). The results showed no significant impact (P > 0.05) of the tested extrusion parameters on fish growth (TGC: 2.11 ± 0.17), feed intake, or feed conversion performance (FCR: 1.67 ± 0.13). The study unveils diverse responses to extrusion temperature and moisture levels regarding amino acid and fatty acid digestibility. These findings highlight the advantages of preconditioning during the extrusion process to enhance fatty acid digestibility.

Scalable Microwires through Thermal Drawing of Co-Extruded Liquid Metal and Thermoplastic Elastomer.

This article demonstrates scalable production of liquid metal (LM)-based microwires through the thermal drawing of extrudates. These extrudates were first co-extruded using a eutectic alloy of gallium and indium (EGaIn) as a core element and a thermoplastic elastomer, styrene-ethylene/butylene-styrene (SEBS), as a shell material. By varying the feed speed of the co-extruded materials and the drawing speed of the extrudate, it was possible to control the dimensions of the microwires, such as core diameter and shell thickness. How the extrusion temperature affects the dimensions of the microwire was also analyzed. The smallest microwire (core diameter: 52 ± 14 μm and shell thickness: 46 ± 10 μm) was produced from a drawing speed of 300.1 mm s-1 (the maximum attainable speed of the apparatus used), SEBS extrusion speed of 1.50 mm3 s-1, and LM injection rate of 5 × 105 μL s-1 at 190 °C extrusion temperature. The same extrusion condition without thermal drawing generated significantly large extrudates with a core diameter of 278 ± 26 μm and shell thickness of 430 ± 51 μm. The electrical properties of the microwires were also characterized under different degrees of stretching and wire kinking deformation which proved that these LM-based microwires change electrical resistance as they are deformed and fully self-heal once the load is removed. Finally, the sewability of these microwires was qualitatively tested by using a manual sewing machine to pattern microwires on a traditional cotton fabric.

Structure Formation by 3D-Printing of Cellulose from Cellulose-NMMO-Water Solutions: Analysis of Extrusion, Regeneration, and Drying Stages.

Processing cellulose from 4-methyl morpholine n-oxide (NMMO)-water solutions is a completely circular route that produces biodegradable cellulose fibers or films while recovering reusable NMMO [Guo, Y.; Cai, J.; Sun, T.; Xing, L.; Cheng, C.; Chi, K.; Xu, J.; Li, T. The purification process and side reactions in the N-methylmorpholine-N-oxide (NMMO) recovery system. Cellulose 2021, 28(12), 7609-7617]. Despite proven success in two-dimensional applications, challenges in transitioning to three-dimensional objects arise from the critical changes that cellulose undergoes during deposition, regeneration, and postregeneration stages. While emphasizing the critical diffusion-driven precipitation during regeneration, this investigation explores the influence of extrusion temperature, printing alignment, regeneration, and drying processes on interfilament fusion, bonding, shape integrity, and mechanical properties. Three distinct drying processes: ambient, vacuum, and freeze-drying were investigated. Tensile and flexural bending tests provided insight into the delamination of dried specimens. Ambient and vacuum drying enhanced the properties of specimens, while freeze-drying resulted in a more stable shape. The findings contribute to advancing the understanding of 3D-printing cellulose from NMMO solutions, addressing crucial aspects of the extrusion, regeneration, and drying stages for enhanced applications in sustainable manufacturing.

Precision control and parameter optimization in screw extrusion 3D printing of polypropylene materials

Fused Deposition Modeling (FDM), a widely-utilized additive manufacturing (AM) technology, has found significant favor among automotive manufacturers. Polypropylene (PP) compound is extensively employed in the production of automotive parts due to its superior mechanical properties and formability. However, aiming at the problem of poor dimensional accuracy of pure PP parts, the quality of products can be enhanced by optimizing the combination of processing parameters. In this paper, the dimensional accuracy of 3D-printed components made from pure PP material is investigated. Key influencing factors such as infill percentage, infill pattern, layer thickness, and extrusion temperature are considered. To gain a deeper understanding, fluid simulation is conducted, and mathematical models are established to correlate processing parameters with dimensional accuracy. Furthermore, the Taguchi's experiments are designed and the experimental data are subjected to rigorous Signal-to-Noise ratio and ANOVA analyses. Within the experimental range, the lower extrusion temperature, infill percentage and layer thickness yield the best dimensional accuracy. Considering the influence factors of X, Y and Z directions, the optimal processing parameters for PP prints using screw extrusion 3D printers are determined as follows: an extrusion temperature of 210 °C, an infill percentage of 40 %, a layer thickness of 0.3 mm, and a concentric circle infill pattern. This study provides reference value for the subsequent improvement of the dimensional accuracy of the printed parts.

Orthogonal experimental study of ultrasound-assisted fused deposition molding

To improve the quality of fused deposition molding (FDM), we introduced ultrasonic vibration into the molding process to enhance the strength of the tensile samples. We used the response surface method to optimize the FDM molding process. We carried out orthogonal experiments to investigate the effects of ultrasonic power and process parameters (extrusion temperature, hotbed temperature, and delamination thickness) on the mechanical properties of fused deposition acrylonitrile butadiene styrene products. We obtained the quadratic regression equations and response surfaces of the data through analysis of variance and significance analysis by software. Last, we received the optimum combination of process parameters for tensile strength as extrusion temperature 233.85 °C, hotbed temperature 93.38 °C, delamination thickness 0.1 mm, and ultrasonic power 43.09 W.

Optimal Process Parameters for FDM‐Based 3D Printing of Metal‐Polymer Mixtures with Low‐Temperature Powder Feeding

In this study, a proprietary powder‐fed 3D printer is employed to fabricate impellers from metal‐polymer mixtures via low‐temperature extrusion, simplifying the traditional complex metal molding process. By adjusting the extrusion speed and temperature, various quality impeller blanks are produced, identifying optimal printing conditions. The best results are achieved with a feed temperature of 170 °C, extrusion speed of 6 r min−1, printing platform temperature of 50 °C, and nozzle temperature of 175 °C, achieving a surface roughness of Ra = 9.973 μm. Post‐processing densification of the stainless steel wheels reach 97.23%, with a tensile strength of 255 MPa, elongation at break of 49%, and hardness of 60 HRB. These parameters meet the physical and mechanical standards required for general metal parts, demonstrating potential for precision metal processing in sectors such as aircraft engines, gas turbines, and high‐performance pumps.

The effects of 3D printing designs on PLA polymer flexural and fatigue strength

This study assessed the comprehensive assessment of flexural and fatigue strength of the three-dimensional (3D)-printed polylactic acid (PLA) samples across diverse printing designs and parameters. The experiment framework included a diverse array of printing parameters: layer heights, first layer thicknesses, infill densities, top/bottom infill patterns, extruder temperatures, perimeters, and types of solid layer top and bottom. Our findings suggest that there is an interplay between these parameters and the mechanical properties of PLA specimens. Notably, the fatigue strength of PLA printing specimens is more significantly influenced (0.44%) by an increase in the thickness of the first layer compared to flexural strength (87%). The rate of increase in bending strength is lower in cases of layer height (3.55%) and initial layer height (0.44%) in contrast with other factors. Specimens with an initial layer thickness of 0.4 mm reached the highest number of cycles until failure, recording 21 022 cycles. Furthermore, the study identifies the infill pattern’s impact on strength, highlighting that the line infill pattern type case has the highest bending strength of 75.97 MPa and surpasses the honeycomb pattern in bending strength. Compared to the Honeycomb pattern, the rectilinear design has 2.1% higher bending strength. The number of cycles to failure of the rectilinear pattern is greater than those of the honeycomb pattern. In comparison to other patterns, the Rectilinear Top/Bottom infill pattern has a higher interest rate of 27.5% for bending strength and 200.83% for fatigue strength. Additionally, greater bending and flexural strength are obtained by raising the solid layer top, bottom, and perimeter values, respectively. In comparison to the other temperatures, the bending strength and fatigue strength are highest at 200 °C. Therefore, the first layer height of 0.4 mm, the top/bottom rectilinear infill pattern, the extruder temperature of 200 °C, the perimeter value of 3, the solid layer/top value of 3, and the solid layer/bottom value of 3 are the optimal values for the part subjected to at the same time bending strength combined with fatigue strength. This comprehensive study may provide a broader and deeper understanding of individual and combined effects on an overview of the bending and fatigue strength in connection to printing design and printing parameters, as well as the ideal optimal parameters for 3D printing with the PLA material. Manufacturers and designers can use the recommended parameters to optimize the strength of their printed parts, considering both bending and fatigue performance.

Microstructure, aging behavior, and friction and wear properties of ultrafine-grained 7050 aluminum alloy produced by cryogenic temperature extrusion machining

Cryogenic temperature extrusion machining (CT-EM), as a novel cryogenic temperature severe plastic deformation (CT-SPD) process, is an effective method to produce ultrafine-grained (UFG) materials. In this paper, the microstructure, microhardness, friction and wear properties of the UFG chips prepared by CT-EM and room temperature extrusion machining (RT-EM) were analyzed. The results show that CT-EM has a better grain refinement effect. The grain size of the CT-EM samples is smaller, the dislocation density is larger, and the microhardness is higher. After aging treatment, a large number of small secondary precipitates (η '/η) appear in the microstructure of the samples, which further improves the microhardness. This is the result of a synergistic effect of fine grain, dislocation, and precipitation strengthening. Cryogenic treatment can increase the precipitation kinetics of the secondary phase and shorten the time for the samples to reach peak hardness. The CT-EM samples have a lower friction coefficient and wear mass. With the increase of the machining velocity, the wear mechanism of the samples changes from abrasion wear to oxidation, adhesion, and fatigue wear.

Optimization of the FDM Processing Parameters on the Compressive Properties of ABS Objects for the Production of High-Heeled Shoes

The influence of 3D printing parameters on compressive properties is an important factor in the application of additive manufacturing processes for products subjected to compressive loads in use. In this study, the compressive strength and compressive modulus of acrylonitrile/butadiene/styrene (ABS) test specimens fabricated using the fused deposition modeling (FDM) process were investigated with the aim of producing products of high-heeled shoes for women. The experimental part of the study includes a central composite experimental design to optimize the main 3D printing parameters (layer thickness, infill density, and extrusion temperature) and the infill geometry (honeycomb and linear at a 45° angle—L45) to achieve maximum printing properties of the 3D-printed products. The results show that the infill density has the greatest influence on the printing properties, followed by the layer thickness and, finally, the extrusion temperature as the least influential factor. The linear infill at a 45° angle resulted in higher compressive strength and lower compressive modulus values compared to the honeycomb infill. By optimizing the results, the maximum compressive strength (that of L45 is 41 N/mm2 and that of honeycomb 35 N/mm2) and modulus (that of L45 is 918 N/mm2 and that of honeycomb is 868 N/mm2) for both types of infill is obtained at a layer thickness of 0.1 mm and infill density of 40%, while the temperature for L45 can be in the range of 209 °C to 254 °C, but for the honeycomb infill, the processing temperature is 255 °C. Additionally, the study highlights the potential for sustainable manufacturing practices and the integration of advanced 3D printing technologies to enhance the efficiency and eco-friendliness of the production process.

Selection and Optimization of Carbon-Reinforced Polyether Ether Ketone Process Parameters in 3D Printing-A Rotating Component Application.

The selection of process parameters is crucial in 3D printing for product manufacturing. These parameters govern the operation of production machinery and influence the mechanical properties, production time, and other aspects of the final product. The optimal process parameter settings vary depending on the product and printing application. This study identifies the most suitable cluster of process parameters for producing rotating components, specifically impellers, using carbon-reinforced Polyether Ether Ketone (CF-PEEK) thermoplastic filament. A mathematical programming technique using a rating method was employed to select the appropriate process parameters. The research concludes that an infill density of 70%, a layer height of 0.15 mm, a printing speed of 60 mm/s, a platform temperature of 195 °C, an extruder temperature of 445 °C, and an extruder travel speed of 95 mm/s are optimal process parameters for manufacturing rotating components using carbon-reinforced PEEK material.