Additive Manufacturing of Three-Phase Syntactic Foams Containing Glass Microballoons and Air Pores

Ashish Kumar Singh; Alexander J. Deptula; Rajesh Anawal; Mrityunjay Doddamani; Nikhil Gupta

doi:10.1007/s11837-019-03355-5

Additive Manufacturing of Three-Phase Syntactic Foams Containing Glass Microballoons and Air Pores

Ashish Kumar Singh^*
, Alexander J. Deptula
, Rajesh Anawal
, Mrityunjay Doddamani
, Nikhil Gupta

^*Corresponding author for this work

New York University
Rose Hulman Institute Technology
National Institute of Technology Karnataka

Research output: Contribution to journal › Article › peer-review

48 Citations (Scopus)

Abstract

High-density polyethylene and its syntactic foams reinforced with 20 vol.% and 40 vol.% glass microballoons were 3D printed using the fused filament fabrication method and studied for their compressive response. The three-phase microstructure of syntactic foams fabricated in this work also contained about 10 vol.% matrix porosity for obtaining light weight for buoyancy applications. Filaments for 3D printing were developed using a single screw filament extruder and printed on a commercial 3D printer using settings optimized in this work. Three-dimensional printed blanks were machined to obtain specimens that were tested at 10 ⁻⁴ s ⁻¹ , 10 ⁻³ s ⁻¹ , 10 ⁻² s ⁻¹ and 1 s ⁻¹ strain rates. The compression results were compared with those of compression-molded (CM) specimens of the same materials. It was observed that the syntactic foam had a three-phase microstructure: matrix, microballoons and air voids. The air voids made the resulting foam lighter than the CM specimen. The moduli of the 3D-printed specimen were higher than those of the CM specimens at all strain rates. Yield strength was observed to be higher for CM samples than 3D-printed ones.

Original language	English
Pages (from-to)	1520-1527
Number of pages	8
Journal	JOM
Volume	71
Issue number	4
DOIs	https://doi.org/10.1007/s11837-019-03355-5
Publication status	Published - 15 Apr 2019
Externally published	Yes

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SDG 9 Industry, Innovation, and Infrastructure

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10.1007/s11837-019-03355-5

Cite this

@article{dcd2775e8dbb4fdd899ab59cd59abe02,

title = "Additive Manufacturing of Three-Phase Syntactic Foams Containing Glass Microballoons and Air Pores",

abstract = " High-density polyethylene and its syntactic foams reinforced with 20 vol.\% and 40 vol.\% glass microballoons were 3D printed using the fused filament fabrication method and studied for their compressive response. The three-phase microstructure of syntactic foams fabricated in this work also contained about 10 vol.\% matrix porosity for obtaining light weight for buoyancy applications. Filaments for 3D printing were developed using a single screw filament extruder and printed on a commercial 3D printer using settings optimized in this work. Three-dimensional printed blanks were machined to obtain specimens that were tested at 10 −4 s −1 , 10 −3 s −1 , 10 −2 s −1 and 1 s −1 strain rates. The compression results were compared with those of compression-molded (CM) specimens of the same materials. It was observed that the syntactic foam had a three-phase microstructure: matrix, microballoons and air voids. The air voids made the resulting foam lighter than the CM specimen. The moduli of the 3D-printed specimen were higher than those of the CM specimens at all strain rates. Yield strength was observed to be higher for CM samples than 3D-printed ones.",

author = "Singh, \{Ashish Kumar\} and Deptula, \{Alexander J.\} and Rajesh Anawal and Mrityunjay Doddamani and Nikhil Gupta",

note = "Publisher Copyright: {\textcopyright} 2019, The Minerals, Metals \& Materials Society.",

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doi = "10.1007/s11837-019-03355-5",

language = "English",

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T1 - Additive Manufacturing of Three-Phase Syntactic Foams Containing Glass Microballoons and Air Pores

AU - Singh, Ashish Kumar

AU - Deptula, Alexander J.

AU - Anawal, Rajesh

AU - Doddamani, Mrityunjay

AU - Gupta, Nikhil

PY - 2019/4/15

Y1 - 2019/4/15

N2 - High-density polyethylene and its syntactic foams reinforced with 20 vol.% and 40 vol.% glass microballoons were 3D printed using the fused filament fabrication method and studied for their compressive response. The three-phase microstructure of syntactic foams fabricated in this work also contained about 10 vol.% matrix porosity for obtaining light weight for buoyancy applications. Filaments for 3D printing were developed using a single screw filament extruder and printed on a commercial 3D printer using settings optimized in this work. Three-dimensional printed blanks were machined to obtain specimens that were tested at 10 −4 s −1 , 10 −3 s −1 , 10 −2 s −1 and 1 s −1 strain rates. The compression results were compared with those of compression-molded (CM) specimens of the same materials. It was observed that the syntactic foam had a three-phase microstructure: matrix, microballoons and air voids. The air voids made the resulting foam lighter than the CM specimen. The moduli of the 3D-printed specimen were higher than those of the CM specimens at all strain rates. Yield strength was observed to be higher for CM samples than 3D-printed ones.

AB - High-density polyethylene and its syntactic foams reinforced with 20 vol.% and 40 vol.% glass microballoons were 3D printed using the fused filament fabrication method and studied for their compressive response. The three-phase microstructure of syntactic foams fabricated in this work also contained about 10 vol.% matrix porosity for obtaining light weight for buoyancy applications. Filaments for 3D printing were developed using a single screw filament extruder and printed on a commercial 3D printer using settings optimized in this work. Three-dimensional printed blanks were machined to obtain specimens that were tested at 10 −4 s −1 , 10 −3 s −1 , 10 −2 s −1 and 1 s −1 strain rates. The compression results were compared with those of compression-molded (CM) specimens of the same materials. It was observed that the syntactic foam had a three-phase microstructure: matrix, microballoons and air voids. The air voids made the resulting foam lighter than the CM specimen. The moduli of the 3D-printed specimen were higher than those of the CM specimens at all strain rates. Yield strength was observed to be higher for CM samples than 3D-printed ones.

UR - https://www.scopus.com/pages/publications/85061215719

U2 - 10.1007/s11837-019-03355-5

DO - 10.1007/s11837-019-03355-5

M3 - Article

AN - SCOPUS:85061215719

SN - 1047-4838

VL - 71

SP - 1520

EP - 1527

JO - JOM

JF - JOM

IS - 4

ER -

Additive Manufacturing of Three-Phase Syntactic Foams Containing Glass Microballoons and Air Pores

Abstract

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