SEM Fractography Research Articles

Influence of in situ heating and laser remelting on martensitic precipitation-hardening stainless steel fabricated by laser powder bed fusion

AbstractThe introduction of in situ heat-assisted fabrication and laser remelting as novel techniques within laser-based additive manufacturing aims to mitigate porosity and reduce surface roughness. However, a comprehensive understanding of the impact of in situ heating and laser remelting on mechanical properties and microstructure is still lacking, particularly for precipitate-hardenable metals like 15-5PH and 17-4 PH stainless steel, which can yield mechanical properties comparable to conventionally fabricated materials. This study presents experimental findings that demonstrate the efficacy of in situ heating during laser powder bed fusion (LPBF) in significantly reducing porosity and enhancing the material’s ductility. The performed XRD analyses indicate that the retained austenite phase increased in samples fabricated with heat-assisted LPBF. There is a reduction in the experimentally measured ultimate tensile strength, yield strength, and hardness in the precipitate-hardenable stainless steel samples that were fabricated by the introduced method using a heated plate. The experimental results reveal a 25% increase in ductility for heat-assisted LPBF fabrication compared to without heated substrate. In addition, SEM fractography analysis indicates a significant reduction in crack size and porosity in samples produced by heat-assisted LPBF.

Disclosing Connection Links between Microstructure and Mechanical Performance in Pulsating Current Gas Tungsten Arc Welding of Hastelloy B-2 Superalloy

In this study, welding a Ni-Mo-based superalloy (Hastelloy B-2) was examined in order to characterize the microstructure and mechanical performance of joints along with assessing the effects of current intensity on the microstructure and mechanical responses of different weld zones. The gas tungsten arc welding (GTAW) process was used to weld the samples using ERNiCrMo-2 filler metal. The pulsed current GTAW process was used to weld the superalloy sheets of thickness of 1 mm with background current (Ib) of 20 A and 40 A and peak current (Ip) of 80 A and 60 A. Tensile and Vickers microhardness tests were conducted to evaluate the effect of pulsed current on mechanical properties of the welds along with chemistry and microstructure characterizations. Finally, the fracture surfaces after the tensile test were studied using SEM fractography analysis. The results indicated that increasing Ib and decreasing Ip led to low heat input and high cooling rate resulting in a high thermal gradient. This caused microstructure transition from the columnar dendrites to the coaxial ones in the weld zone; molten metal convection in the fusion zone led to fine grains in the weld zone during welding time. Moreover, a significant decrease in the amount of molybdenum carbides at the interdendritic regions of the weld metal was observed under these conditions. The tensile strength of the weld metal was higher than that of the base metal resulting in the fracture of all welds from the base metal. Additionally, the microhardness results indicated a significant increase for the weld metal compared to both heat-affected zone (HAZ) and base metal. The higher mechanical properties of the weld metal is attributed to the increase in background current and decrease in peak current leading to a fine grain microstructure. Fractography following the tensile test showed a completely ductile fracture.

Fatigue crack initiation and failure analysis of IN718 alloy after push–pull loading at room temperature and at 700 °C

The paper deals with the effect of applied fatigue loading with cycle asymmetry parameter R = −1(a symmetric push–pull, σm = 0 MPa), test temperature and loading frequency on the initiation of fatigue cracks in superalloy IN718. Two sets of experimental specimens were fabricated, for fatigue tests at ambient temperature and fatigue tests at 700 ± 5 °C. The loading frequency was f ≈ 20 150 Hz at ambient temperature and f ≈ 58 Hz at 700 ± 5 °C. The number of cycles to fracture, Nf = 2.107, was determined as the so-called “run-out”. SEM fractography analysis was performed on all specimens to define the fatigue crack initiation mechanism. Fatigue crack initiation was always performed on the surface of the samples, most often by the slip mechanism (PSB′s − Persistent Slip Bands) − tests at ambient temperature, in the case of tests at 700 ± 5 °C, initiation was observed on the oxide phases on the surface or just below the surface. The initiation of oxide phases (mostly of NiO or FeO type) on the surface at 700 ± 5 °C is related to the creep-fatigue load interaction. After fatigue tests, S-N fatigue life curves were plotted with emphasis on determining the Ni − critical number of cycles required to initiate a fatigue crack with approximate length “a” ≈ 25 μm. Based on the tests performed, it can be concluded that the number of cycles required to initiate a crack of critical dimensions increases with decreasing load amplitude σa. In general, the fatigue crack initiation (depending on the microstructure and the δ-phase fraction) in the case of superalloy IN718 represents approximately 80–90 % of the total fatigue life.

Influence of sub-zero coolant circulation and additive nanoparticles on performance characteristics of FSPed Al6061 alloy

ABSTRACT Al6061 alloy has become prevalent in the industrial sector because of its low density, excellent machinability, and corrosion resistance but it lacks properties like hardness and wear. Therefore, surface modifications by friction stir processing (FSP) are done with additive nanosized particles like multi-walled carbon nanotubes (MWCNT), Titanium oxide (TiO2), and Graphene nanoparticles (GNP) To perform 2-pass FSP, a uniquely engineered fixture with coolant circulated underneath the plate at sub-zero temperatures is used. Grain refinement has been observed in micrographs as a consequence of 2-pass FSP. The coolant circulated beneath carries the heat generated and enhances the heat dispersion rate, culminating in finer grains. The calculated mean grain size of the Al6061 alloy was considerably decreased in all the surface composites. There is a substantial improvement in the microhardness profile, which has increased by nearly 70–90%, as well as a significant enhancement in tensile strength of almost 20–30% in all the composites. The ductile type of failure during tensile load is revealed by SEM fractography. The process of dynamic recrystallisation is responsible for the development of equiaxed grains. The wear resistance of all the composites is also enhanced, and the COF of Al6061/GNP composite is found to be lowest at 0.23.

Conditioning Influence of Kaolinite Matrices on Flexural Strength of Raw Pressed Slurry Collected from Ceramic Tile Production Wastewater

Kaolinite is able to assure the high binding affinity of the filler particles of raw ceramic bodies. It acts as a matrix that strongly holds the other constituents’ particles in a compact structure. The slurry samples were characterized by XRD, mineralogical microscopy and SEM coupled with an EDX elemental analysis. The slurry collected from the ceramic tile production wastewaters had a significant amount of kaolinite (36%), mostly fine particles of 3 µm, less surrounding quartz (37%) and mullite (19%) particles of 5–100 µm in diameter and traces of lepidocrocite (8%). It is a dense paste with a relative moisture of 25%. The square bar of the slurry as received, pressed at a load of 350 N, had a flexural strength of 0.61 MPa. Increasing the moisture to 33% using regular water, followed by mechanical attrition at 2000 rpm for 5 min, resulted in a porous bar with a flexural strength of 0.09 MPa; by increasing the attrition speed to 6000 rpm, the microstructural homogenization was improved and the flexural strength was about 0.68 MPa. It seems that regular water does not assure an optimal moisture for the kaolinite matrix conditioning. Therefore, we used technological water at pH = 10, a moisture of 33% and attrition at 6000 rpm for 5 min, and the bar pressed at a load of 350 N had a flexural strength of 1.17 MPa. The results demonstrate that the bar moistened with technological water and an attrition regime assured a proper conditioning for the kaolinite matrix, achieving the optimal binding of the quartz and mullite particles under the pressing load. Bars with the optimal mixture were pressed at several loads, including 70, 140, 210 and 350 N, and the flexural strength was progressively increased from 0.56 MPa to 1.17 MPa. SEM fractography coupled with atomic force microscopy (AFM) revealed that the optimal moisture facilitated a proper kaolinite particle disposal regarding the quartz and mullite filler particles, and the progressive load assured the strong binding of the finest kaolinite platelets onto their surface.

Study on the behavior of small cracks in PA38-T6 (6060-T6) aluminum alloy under multiaxial fatigue loadings

This study investigated the effects of multiaxial cyclic loading on the initiation and propagation of fatigue cracks in an industrial-grade aluminum alloy. Four different loading cases, including 90° out-of-phase and asynchronous loading, were used under the control of strain. The study used cellulose acetate film replication and SEM fractography techniques to increase the understanding of the evolution of fatigue damage on specimen surfaces. The material exhibited a shear damage mechanism with a significant amount of small cracks coalescence. It was explained why, despite a high agreement with the assumptions of the critical plane approach, the predicted fatigue life was overestimated at high loading levels. A correlation between the crack initiation period and overall fatigue life, regardless of loading case, was presented, which has a potential for practical applications.

Fractographic analysis of fiber‐reinforced polymer laminate composites for marine applications: A comprehensive review

AbstractIn the past decade, polymer‐based glass fiber‐reinforced laminate composites have gained significant popularity in various mass transit applications, including marine, aircraft, and automotive industries. However, it is crucial to consider the degradation and potential failure of these materials, especially in mass transit networks. To address this concern, fractographic analysis has emerged as a valuable approach for investigating fracture surfaces, extracting vital information, and facilitating the development of new materials. Furthermore, it sheds light on the underlying physical mechanisms that contribute to composite failure. This paper primarily focuses on examining flaws, failure modes, and performing fractography analysis on fiber‐reinforced polymer (FRP) laminate composites subjected to various loading conditions such as tension, compression, flexure, impact, shear, and fracture. Fractography, as an indispensable method, plays a pivotal role in the comprehensive development of composite structures and has become a reliable tool for composite engineers. The outcomes of this study are expected to serve as a foundation for identifying areas that require further investigation in terms of fracture analysis and failure modes specific to FRP composite materials, particularly those used in marine applications.Highlights Introduction to FRP laminate composites in marine structures. Concise analysis of failure modes in FRP laminate composites. SEM fractography review of FRP laminate composites under varied loading conditions. Comprehensive study on tensile, flexural, impact, compression, shear, and fracture toughness failure modes. Summarization of identified defects in FRP composites.

Increased Hardness Value of Medium Manganese Steel Through Double Tempering, Hot Rolling, and Variation of Cooling Media

Research has been conducted to enhance the hardness value of medium manganese steel through a heat treatment. Initially, this process begins with austenization at a temperature of 900°C, followed by tempering at 650°C and double tempering at 600°C, with each stage lasting 30 minutes. Subsequently, each stage concludes with a hot rolling process, after which air or water cools the material. As a result of these processes, the hardness tests revealed an increase in the hardness of medium manganese steel, reaching up to 389.70 BHN with a tensile strength of 827 MPa, which was notably achieved through air cooling. This significant increase in hardness is attributed to the emergence of the martensite phase and the presence of a large number of carbides, which are more evenly distributed after the double-tempering process. Additionally, small amounts of carbides were observed in the austenite matrix. Upon examination of the SEM fractography results, it was revealed that the fracture was mixed, with a cleavage area slightly larger than the dimple area. This observation suggests that despite its high hardness value, the sample retains good toughness.

“Evaluation of microstructure and mechanical properties of Al6005 MMCs reinforced with B4C via stir casting route and optimisation through ANOVA DOE technique”

ABSTRACT MMCs are used in variety of applications due to their distinctive characteristics, including superior stiffness, wear resistance and service temperatures, brake rotor, cylinder liners, automobile drive shaft, and connecting rod. In the present studies, Al6005-B4C composites were developed using the gravity die-casting technique to investigate mechanical properties (hardness and tensile strength). Later, microstructural characterisation is conducted using an optical microscope. Also, fracture surface analysis was carried out using SEM. The optical micrographs revealed that Al6005 alloy has a fine-grained, uniform microstructure and Al6005-B4C MMCs. Also, SEM fractographs of Al6005 displayed ductile fracture due to more dimples, and Al6005-B4C MMCs exhibited brittle fracture. From the hardness and tensile test results, it is noticed that the addition of B4C enhances the mechanical properties of Al6005-B4C MMCs. Overall, it is observed that the hardness and strength value steadily increase up to 4% B4C as the reinforcement percentage grows and then somewhat decrease when the B4C addition is improved to 6%. The accumulation of particles in the matrix may be the cause. The regression analysis results confirm that the coefficient of determination was achieved with an 86% of confidence interval, and the P-values is less than 0.05 for all the combination considered.

Thermo-mechanical fatigue deformation and fracture mechanisms of nickel-based powder metallurgy superalloy

Thermo-mechanical fatigue (TMF) failure is one of the major concerns for aero-engine turbine discs under complex service loading conditions. By conducting both in-phase (IP) and out-of-phase (OP) TMF tests, the stress-strain hysteresis loops and the cyclic stress responses were analyzed for the third-generation nickel-based powder metallurgy (P/M) superalloy FGH4098. To reveal the failure mechanism, advanced microscopy analysis was carried out to characterize the fracture surface and microstructure of the alloy after failure. The phase angle between alternating mechanical and thermal loads plays an important role for the magnitude and evolution of mean stress. According to SEM fractography, the crack growth exhibits intergranular fracture under IP TMF and transgranular fracture under OP TMF. From the electron backscatter diffraction (EBSD) and transmission electron microscope (TEM) characterization results, the geometrically necessary dislocation (GND) density is higher for IP TMF, indicating more severe plastic deformation. The material shows cyclic softening in the high-temperature half-cycle, but cyclic hardening in the low-temperature half-cycle. The cyclic deformation is mainly related to dislocation activities under IP loading conditions, for which fatigue damage dominates the failure process. Under OP loading conditions, the deformation behavior is mainly associated with the generation of stacking faults (SF), and its failure mechanism includes both fatigue and oxidation damage.

Root cause analysis of flywheel gear failure in a marine diesel engine

Engine gear failures are of significant concern across a wide range of industries. It is important to investigate each gear failure in light of its unique loading and operating conditions for root cause analysis (RCA) and further corrective actions to avoid such failures in the future. The aim of this study was to investigate the premature failure of a flywheel gear of a marine diesel engine and establish the root cause and damage mechanisms using experimental and numerical analysis techniques. A bottom-up creative approach was adopted to assess the loading conditions on the failed gear by first estimating the bending deformation of the failed securing bolt, assuming overload torque on the flywheel caused an equivalent bending moment permanently bending the bolt. Von Mises equivalent stress acting on the gear was numerically estimated as σVM = 737 MPa, which was found significantly more than the specified yield strength of gear governing material AISI 1055 (σY = 550 MPa). SEM fractography revealed a quasi-cleavage failure mechanism in the ‘case’ region near the gear root and a ductile failure mechanism inside the ‘core’ region of the flywheel gear. A crack was found to initiate from the gear root consisting of high-stress concentration under overload stresses. RCA established that the flywheel gears had failed by overload stresses, caused due to overload torque generated from sudden inertial thrust in the internal combustion (IC) engine due to excess fuel throttle opening.

Multi-source data driven fatigue failure analysis and life prediction of pre-corroded aluminum–lithium alloy 2050-T8

In this paper, the fatigue failure behavior of pre-corroded Al-Li alloy 2050-T8 was investigated through measured multi-source experimental information involving 3D corrosion morphology, 3D-DIC strain fields, SEM fractography, and EBSD material microstructure. A data-driven fatigue life prediction model for pre-corroded aluminum alloy was developed based on machine learning, in which the characteristic parameters of corrosion macro-morphology, local corrosion micro-morphology, and loading condition were trained by XGBoost algorithm to be associated with the residual fatigue life. Experimental results show that corrosion pits induce fatigue macro-crack initiation with varied time, amount, and specific location, due to the diverse corrosion morphologies. Four typical forms of fatigue micro-crack initiation were summarized, i.e., corrosion micro-pit, corrosion jut-in, corrosion tunnel, and pit sub-surface, mainly attributed to the mechanisms of local stress/strain concentration or local material embrittlement. It was demonstrated that the proposed data-driven model can effectively predict the fatigue life of pre-corroded aluminum alloy with high accuracy.

Elasto-plastic bending behavior of Ti–6Al–4V alloy under coupling conditions of elevated temperature and combined tension-bending

Overload failure under coupling conditions of elevated temperature and combined tension-bending (CTB) is one of the typical failure modes of aero-engine low-pressure compressor blade materials, which is commonly occurring in fighter engines performing low-altitude high-speed penetration missions. In this study, the elasto-plastic deformation behavior and fracture mechanism of Ti–6Al–4V titanium alloy under coupling conditions of elevated temperature and CTB were investigated by experiments and finite element analysis (FEA). CTB tests were conducted on Ti–6Al–4V alloy in the pre-tension ratio range of 0.60–0.90 and in the temperature range of 298 K–573 K. The results show that the maximum bending load, effective bending modulus, and total energy dissipated for the Ti–6Al–4V alloy at room temperature increase with the increase of the pre-tension ratio. The maximum bending load and the energy dissipated are significantly higher at elevated temperatures compared to that of room temperature, due to the elevated temperature induced deformation mode change from bending-dominated to tensile-dominated. The FEA results are in good agreement with the experimental results. SEM fractography indicated that the Ti–6Al–4V alloy fracture at elevated temperature showed only equiaxed dimples, which exhibited a tensile fracture mode. This study is valuable for the in-depth understanding of the deformation behavior and fracture mechanism of blade materials under elevated temperature and complex loads.

Low cycle fatigue behaviour of additive manufactured maraging steel: Influence of build orientation and heat treatment

The effect of build orientation and heat treatment (solution treatment and aging) on low cycle fatigue (LCF) behaviour of additive manufactured (AM) maraging steel, processed via powder bed fusion, using laser beam (PBF-LB) was investigated in the present work. The build orientation has significant influence on LCF behaviour of AM maraging steel. Un-melted defects were found to be the most detrimental to fatigue life. Defects in 90° oriented samples were more damaging than those in 45° and 0° oriented samples. Heat treatment (HT) of the AM maraging steel was found to be very effective in enhancing the fatigue life by 8–10 times due to marked strengthening by precipitation of intermetallic precipitates and reduction in size and number of AM defects. SEM fractography showedthat surface and interior flaws increased susceptibility to crack propagation through the cross-section.

Mechanical and microstructural characterization of Nimonic 263 superalloy after constrained groove pressing at elevated temperatures

Nimonic 263 superalloy is primarily being used in gas turbines, high-pressure pipelines, steam heaters, etc. due to its capability to withstand high temperatures and pressure for a longer duration. In this work, an experimental investigation on Nimonic 263 alloy has been carried out to improve its mechanical and microstructural properties using constrained groove pressing (CGP) at various temperatures. CGPed specimens have been characterized through mechanical tests (tensile test and hardness test) and microstructural studies (XRD, SEM fractography, and optical microscope). The results demonstrated that the CGP process had a significant impact on the alloy's properties. Compared to the as-received material, the CGPed specimens exhibited substantial improvements in yield strength (YS), ultimate tensile strength (UTS), and micro hardness, with average values of 234.58%, 43.79%, and 110.31%, respectively. The average grain size gets reduced due to CGP from 220.70 μm for the as-received material to 106.02 μm, 117.09 μm and 94.01 μm for CGP at room temperature, 250o C, and 450o C, respectively. An increase in the peak intensity is observed in the XRD after the CGP process due to a decrease in crystal size and an improvement in dislocation density with an average value of 31.68%. Fractography studies have revealed a mixed-mode (ductile and brittle) failure for the CGPed specimens compared to the ductile failure mode in the as-received material. Using Abaqus 6.14 software, the finite element analysis of the CGP process has been performed and the results have been found in good agreement with the analytical results. Thus, the CGP process can effectively improve the mechanical and microstructural properties of Nimonic 263 alloy for high-temperature applications.

Hydrogen embrittlement in high strength fasteners: Comparison between bainitic and tempered martensitic steels

The scope of this work is to explore innovative microstructure typologies, as well as heat treatments, for the manufacturing of high-strength steel fasteners aimed at obtaining a reduced susceptibility to hydrogen embrittlement. The research evaluates the role of microstructure and the notch tensile strength (RNTS) in relation to the geometry tested on hydrogen embrittlement of steels used in fasteners production. High-strength steel fasteners are increasingly used especially in Automotive industry to mechanically join parts together, increase vehicle performance and promote car weight reduction. High-strength steel fasteners, included in property class 12.9 and higher, are characterized by an ultimate tensile strength above 1200 MPa, despite the remarkable mechanical performance they are historically prone to hydrogen embrittlement phenomena. The phenomenon of hydrogen embrittlement is widely investigated, characterized by its unpredictability and its ability to result in brittle fractures. In this study, slow strain rate tensile tests were conducted to investigate and compare the effect of internal hydrogen concentration on the mechanical properties of fasteners with martensitic microstructure in property classes 10.9and 12.9, as well as innovative high strength fasteners with bainitic microstructure in property class 12.9U.The commonly utilized methodologies for assessing hydrogen embrittlement in fasteners are standardized procedures primarily focused on mechanical tests conducted on finished fasteners. They do not effectively differentiate the influence of surface treatment from material selection and fastener design. For this reason, during the present research, a simpler, faster and very promising methodology has been used. This procedure could be the basis for developing a new Standard guideline for prevention of hydrogen delayed fracture. Additionally, SEM fractography has been interpreted according to the well-known HELP and HEDE models.

Dependence on fibre type of interlaminar fracture toughness enhancement in interleaved polymer composites

A systematic investigation into the influence on the Interlaminar Fracture Toughness (IFT) of carbon/epoxy composites interleaved with nonwoven veils formed with a range of fibre types is presented. For veils with a range of areal densities and coverage, both mode I and mode II IFT were found to increase to a plateau above a mean coverage of about 3. The dependence of IFT on the fibre type of microfibre veils was found to differ depending on the mode of loading. For mode I, the increase in IFT with coverage was dependent on veil fibre type, with polymer fibres showing higher increases than inorganic fibres; for mode II, the increase in IFT was broadly insensitive to fibre type. For the polymer veil interleaves that significantly increased IFT, SEM fractography revealed highly curled veil fibres that were absent from the original veil, revealing a significant energy absorbing mechanism.

Physical and mechanical behavior of aluminum-magnesium alloy matrix hybrid composite fabricated through friction stir consolidation process

Nowadays metal matrix composite materials are preferable in automotive and aerospace industries due to their mechanical properties and essentially attractive strength to weight ratios. However, their availability in use is limited because of their manufacturing method difficulty and process extravagancy. The aim of this research was to fabricate metal matrix hybrid composite through a novel approach thermo-mechanical method called friction stir consolidation (FSC) process. XRD result witnessed the presence of SiC, ZrO2, and AZ61 alloy phases. Different compositions of AZ61, SiC, and ZrO2 powder were taken into consideration and the progression of the FSC process were examined through properties of compressive strength, hardness, density, and porosity. For instance, the compressive yield strength of composition 85%Vol. of AZ61, 10%Vol. of ZrO2, and 5%Vol. of SiC accounts 164.2 MPa with an acceptable 2.2451 g/cm3 and 0.593% density and porosity respectively. However, when the strength to weight ratio was taken into consideration, 95%Vol. of AZ61, 2.5%Vol. of ZrO2, and 2.5%Vol. of SiC composition attained highest strength to weight ratio value. Additionally, the compressive yield strength value increased directly proportional with the ZrO2 volumetric composition. Likewise, the fractured surface of sample acquired highest strength to weight ratio was examined through SEM Fractography analysis.

Mechanical Behavior and Low-Cycle Fatigue Performance of a Carburized Steel for GTF Engines

Using nanoindentation technology to analyze the hardness and elastic modulus distributions of the local microzones within materials, it can be determined that the case-carburized specimen is a composite of the carburized case and the pseudo-carburized material in the core. The overall mechanical behavior of the case-carburized material is much closer to that of the completely carburized material, indicating that the carburized case dominates the case-carburized material. Stress fatigue tests conducted on carburized tubular specimens, pseudo-carburized solid specimens, and case-carburized solid specimens showed that the fatigue performance of the completely carburized material is slightly lower than that of the pseudo-carburized specimens due to lower plasticity. However, the fatigue performance of the case-carburized specimens is significantly better than that of the two homogeneous materials. This could be attributed to the graded material behavior and the larger compressive residual stress in the carburized case, which are the primary positive factors for improving the fatigue life of case-carburized materials. SEM fractographs revealed that the fatigue nucleation in the case-carburized specimen initiates from the transition zone rather than from the surface of the specimens as observed in the homogeneous materials. Low-cycle fatigue evaluation of ultra-high-power gear transmission systems should focus on the influences of the carburized case.

EXPERIMENTAL INVESTIGATION ON MECHANICAL PROPERTIES OF FDM-BASED NYLON CARBON PARTS USING ANN APPROACH

The implementation of the fused deposition modeling (FDM) technique in the production system is mainly due to its flexibility and ability to fabricate complex 3D prototypes and geometries. However, the mechanical strength of the printed parts needs to be investigated which was influenced by the process parameters such as layer thickness (LT), raster angle (RA), and Infill Density (ID). Therefore, these process parameters need to be optimized to attain better mechanical strength from the FDM printed parts. In this research, ePA-CF filament material was used to fabricate the specimens based on the selected process parameters such as LT (0.07, 0.14, and 0.20[Formula: see text]mm), RA (0∘, 45∘, and 90∘) and ID (50%, 75%, and 100%). The artificial neural network (ANN) method was implemented to determine the influential printing process parameters. Tensile, flexural, and impact tests were considered as the response parameters based on the various combination of the input parameters. It was concluded that the printing of nylon carbon parts using [Formula: see text][Formula: see text]mm, [Formula: see text], [Formula: see text] retains improved tensile strength of 66 MPa, flexural strength of 87[Formula: see text]MPa and impact strength of 12.5[Formula: see text]KJ/m2. Further, the propagation of cracks and the mode of failure were examined using SEM fractography. These observations substantiate that the selection of an optimal combination of FDM parameters assists in enhancing the mechanical strength of the printed nylon carbon parts.