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Processing-Structure-Performance Relationships in Fused Filament Fabricated Fiber Reinforced ABS for Material Qualification

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Processing-Structure-Performance Relationships in Fused Filament Fabricated Fiber Reinforced ABS for Material Qualification University of Tennessee, Knoxville TRACE: Tennessee Research and Creative Exchange Doctoral Dissertations Graduate School 12-2020 Processing-Structure-Performance Relationships in Fused Filament Fabricated Fiber Reinforced ABS for Material Qualification William Howard Ferrell University of Tennessee, Knoxville, [email protected] Follow this and additional works at: https://trace.tennessee.edu/utk_graddiss Part of the Applied Mechanics Commons, and the Polymer and Organic Materials Commons Recommended Citation Ferrell, William Howard, "Processing-Structure-Performance Relationships in Fused Filament Fabricated Fiber Reinforced ABS for Material Qualification. " PhD diss., University of Tennessee, 2020. https://trace.tennessee.edu/utk_graddiss/6070 This Dissertation is brought to you for free and open access by the Graduate School at TRACE: Tennessee Research and Creative Exchange. It has been accepted for inclusion in Doctoral Dissertations by an authorized administrator of TRACE: Tennessee Research and Creative Exchange. For more information, please contact [email protected]. To the Graduate Council: I am submitting herewith a dissertation written by William Howard Ferrell entitled "Processing- Structure-Performance Relationships in Fused Filament Fabricated Fiber Reinforced ABS for Material Qualification." I have examined the final electronic copy of this dissertation for form and content and recommend that it be accepted in partial fulfillment of the equirr ements for the degree of Doctor of Philosophy, with a major in Materials Science and Engineering. Stephanie C. TerMaath, Major Professor We have read this dissertation and recommend its acceptance: David Keffer, Yanfei Gao, Sudarsanam Babu Accepted for the Council: Dixie L. Thompson Vice Provost and Dean of the Graduate School (Original signatures are on file with official studentecor r ds.) Processing-Structure-Performance Relationships in Fused Filament Fabricated Fiber Reinforced ABS for Material Qualification A Dissertation Presented for the Doctor of Philosophy Degree The University of Tennessee, Knoxville William Howard Ferrell December 2020 Copyright © 2020 by William Howard Ferrell All rights reserved. ii DEDICATION I dedicate this work to 10-year-old me. You had to tell people you were going to get a PhD and now here I am cleaning up that mess. iii ACKNOWLEDGEMENTS Thank you to everyone I have met along the way. I know this is as generic and boring of a starting thank you as it can get, but truly I am grateful for so many people. From Robyn Collette getting me to join RunKnox when we started graduate school to now, my life has taken a lot of turns that I never could have predicted. So, here is my attempt to acknowledge some people and groups. To all of the awesome runners, triathletes, swimmers, gym go-ers, crossfitters, trail runners, cyclists, wilderness men and women, and so many more, thank you for reminding me that having a screw loose isn’t a bad thing. Thank you for reminding me that just getting up and doing “the thing” is courageous and impressive and it doesn’t matter if you are fast or slow. Thank you for making it normal to have shaved legs part of the year and hairy the rest. Thank you for making short shorts fashionable and slip on sandals customary brunch footwear. These little lessons carried over into grad school and helped provide the confidence needed to make my voice heard. To all of the graduate students I have worked with, lived with, partied with, laughed with, and bemoaned grad life with, you are all awesome. Some of the smartest people I have met in my life and some of the hardest working individuals out there. Knowing you are not alone is sometimes all that is needed to make really bizarre situations not feel suffocating. Whether you are graduating soon, graduating eventually, or moving on to better times, you are all worth it and sharing intellectual space with you all has been a pleasure. To all the people who have been a part of my life but maybe aren’t as active in it now, thank you for all of the fun times, the hard times, and the lessons along the way. Whether it was just a function of a global pandemic, my tunnel vision towards certain goals, or a decided parting of ways, everything that has happened has helped push me or pull me towards this moment. So, thank you all for being who you are and for helping me on my journey through grad school. iv Finally, I want to thank my research group, my advisor, and my parents specifically. I would not be who I am today with the support and the environment provided by my parents that got me to and through graduate school. I would not have the success I have without the continued support and guidance from my colleagues in the lab and from my advisor Dr. TerMaath. Thank you all so much for all of the good times, the bad times, the hard times, and just the plain old times. The process is what makes you, and I appreciate everyone who has been a part of my process. Thank you. v ABSTRACT This dissertation uses the processing-structure-performance relationships to elucidate future needs in qualification of materials manufactured by fused filament fabrication and also introduces a previously unused testing method for the determination of fracture toughness in these materials. Fused filament fabrication (FFF) is an additive manufacturing technique that utilizes the layering of deposited molten plastic in two dimensional shapes to create three dimensional objects. This technique has gained traction over the past two decades as a disruptive manufacturing technology that promises many benefits. In order for FFF to truly be a staple in manufacturing spaces across the world for the production of end-user parts, standardization of testing procedures for the qualification of FFF specific materials must take place. Adjusting standards for qualification must occur with analysis in ultimate tensile strength, response to environmental conditions, and the fracture behavior of these parts. In Chapter 1, a comprehensive analysis of the current state of the art in fracture of FFF parts is presented and discussed. Discussed in this section are the rheological specific phenomena that govern the polymer chain physics at interfaces and within deposited beads. This is tied to the fracture strength and the current questions in part behavior. In chapter 2, a commonly used tensile testing standard is explored and tested on fiber reinforced acrylonitrile-butadiene-styrene (ABS). Due to the complex manufacturing process, new naming standards and testing recommendations are made and the influence of part production methodologies and processing parameters on ultimate tensile strength are explored. The response of fiber reinforced and non-reinforced ABS in environmental conditioning is tested and discussed in chapter 3, where specimens were exposed to heat and moisture then tested in tension. Chapter 4 introduces a unique testing specimen to the FFF literature to obtain multiple fracture modes. Through this test specimen, the nature of the material as a laminate or as a porous homogeneous material is also explored and documented. vi TABLE OF CONTENTS CHAPTER I Fracture behavior of fused filament fabricated polymers: A Review . 1 Abstract ............................................................................................................. 2 Introduction ....................................................................................................... 2 Phenomenological Complexity .......................................................................... 6 Tube Theory .................................................................................................. 8 Polymer Melts in FFF conditions .................................................................. 14 Polymer Diffusion for Bead Contacts ........................................................... 18 Rheological Phenomena: Slip Springs and Beyond ..................................... 21 Fracture Mechanics and FFF .......................................................................... 23 Fracture Mechanics Concepts and Terminology .......................................... 23 Linear Elastic Fracture Mechanics for FFF .................................................. 26 Elastic-Plastic Fracture Mechanics in FFF ................................................... 30 Interlaminar Fracture in FFF ........................................................................ 32 Complexity of fracture in FFF....................................................................... 37 Scale up of FFF ............................................................................................... 41 BAAM Fracture ................................................................................................ 46 CONCLUSIONS .............................................................................................. 48 REFERENCES ................................................................................................ 50 CHAPTER II Uniaxial Tensile Testing Standardization for the Qualification of Fiber Reinforced Plastics for Fused Filament Fabrication ................................... 65 Abstract ........................................................................................................... 66 Introduction ..................................................................................................... 67 Materials and Methods .................................................................................... 70 Results ...........................................................................................................
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