ULTEM 9085™ Material Extrusion Polymer Based Additive Manufacturing: Process Parameter Effects on Mechanical Performance

Details

• Creators:
  Tomblin, John ; Tay, Neville ; Macormic, Kale ; Schmidt, Jacob ; Hanson, Andrew
• Corporate Creators:
  National Institute for Aviation Research (U.S.) ; Wichita State University
• Corporate Contributors:
  United States. Department of Transportation. Federal Aviation Administration
• Subject/TRT Terms:
  Additive Manufacturing ASTM D638 Composite Materials Material Extrusion Microstructure Process Control Raster Tensile Strength Three Dimensional Printing ULTEM 9085
• Publication/ Report Number:
  DOT/FAA/TC-24/28
• DOI:
  https://doi.org/10.21949/cf0z-nq68
• Resource Type:
  Tech Report
• Geographical Coverage:
  United States
• Edition:
  Final Report
• Corporate Publisher:
  United States. Department of Transportation. Federal Aviation Administration. William J. Hughes Technical Center
• Abstract:
  The project objective is to correlate the changes in microstructure caused by the adjustment of high-impact process parameters to specimen tensile mechanical performance using ASTM D638 Type 1 static tensile tests. This project evaluated the effects of high-impact process parameters on the mechanical performance of additive manufactured ULTEM 9085 CG (certified grade) in a fused filament fabrication/material extrusion process using a Stratasys Fortus 900mc. High-impact process parameters documented in the literature and previous NCAMP qualifications were selected for study based on their ability to alter microstructure and therefore mechanical performance. Analysis was performed to characterize the microstructure at ranges of parameter adjustment in order to capture baseline pristine microstructure corresponding to the ULTEM 9085 qualification and microstructure changes seen when eight selected parameters were adjusted. The air gap between adjacent rasters (AR) parameter, which adjusts the gap between parallel infill rasters, affected the tensile strength the most, where a negative value (creating overlapping beads) is more favorable than a positive value (creating gaps between beads). An increase in porosity occurs when the AR settings changes from negative to positive values, resulting in decreased tensile performance. The parameter adjustment for number of contours was the second key characteristic of microstructure for determining the strength of a printed part after air gaps.
• Format:
  PDF
• Funding:
  12-C-JAM-WISU
• Collection(s):
  FAA Technical Library
• Main Document Checksum:
  urn:sha-512:cf84c018ab42102cdb6b91b1f134a4323926227d2409dc69bbc5d8c05c6ab7dc4784120417658600920b70e24160ffe4fab8f0007fcf7c03b66bbe5f64af211b
• Download URL:
  https://rosap.ntl.bts.gov/view/dot/86775/dot_86775_DS1.pdf
• File Type:
  [PDF - 23.39 MB ]