Effect of thermal history on the fracture and fatigue behaviors of semi-crystalline polymers prepared via material extrusion additive manufacturing

IF 7.6 2区材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY

Materials & Design Pub Date : 2025-04-26 DOI:10.1016/j.matdes.2025.114012

Ava M. Lea , Khaled Matalgah , Arief Yudhanto , Trevor J. Fleck

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Abstract

Material extrusion (MEX) additive manufacturing (AM) is transforming the design and production of complex structures, providing reliable on-demand components. However, the effect of thermal history on the resultant microstructure and damage tolerance of MEX-AM materials is not fully understood. This research investigates the critical role of interfacial thermal history, which is dependent on processing conditions, in determining the fracture and fatigue behaviors of semi-crystalline polymers, as exemplified by polyamide-6 (PA-6). Utilizing infrared thermography, the thermal history, and its dependence on nozzle temperature of extruded PA-6, was investigated. Quasi-static and cyclic tests of compact tension specimens were used to evaluate fracture and fatigue performance. The K_IC in samples produced at a nozzle temperature of 260 °C were 201% and 18% higher than those fabricated at 240 °C and 280 °C, respectively. X-ray computed tomography showed thermal history significantly influences interfacial diffusion and void content, directly affecting performance. Optical microscopy and digital image correlation identified damage mechanisms and examined strain evolution around crack tips, revealing that interfacial thermal history governed crack tip plasticity, impacting the energy release rate. This study establishes a crucial process-structure–property-performance relationship and highlights the damage tolerance of MEX-AM polymers, showcasing their potential for advanced structural applications.

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热历史对材料挤压增材制造制备的半晶聚合物断裂和疲劳行为的影响

材料挤压（MEX）增材制造（AM）正在改变复杂结构的设计和生产，提供可靠的按需组件。然而，热历史对MEX-AM材料的微观结构和损伤容限的影响尚不完全清楚。本研究以聚酰胺-6 （PA-6）为例，探讨了取决于加工条件的界面热历史在决定半结晶聚合物断裂和疲劳行为中的关键作用。利用红外热像仪研究了聚酰胺-6挤压成型的热历史及其与喷嘴温度的关系。采用准静态试验和循环试验对紧绷试样的断裂和疲劳性能进行了评价。在260°C喷嘴温度下制备的样品的KIC分别比在240°C和280°C喷嘴温度下制备的样品高201%和18%。x射线计算机断层扫描显示，热历史显著影响界面扩散和空隙含量，直接影响性能。光学显微镜和数字图像相关技术确定了损伤机制，并研究了裂纹尖端周围的应变演化，揭示了界面热历史决定了裂纹尖端的塑性，影响了能量释放率。这项研究建立了关键的工艺-结构-性能-性能关系，并强调了MEX-AM聚合物的损伤容限，展示了它们在先进结构应用中的潜力。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Materials & Design Engineering-Mechanical Engineering

CiteScore

14.30

自引率

7.10%

发文量

1028

审稿时长

85 days

期刊介绍： Materials and Design is a multi-disciplinary journal that publishes original research reports, review articles, and express communications. The journal focuses on studying the structure and properties of inorganic and organic materials, advancements in synthesis, processing, characterization, and testing, the design of materials and engineering systems, and their applications in technology. It aims to bring together various aspects of materials science, engineering, physics, and chemistry. The journal explores themes ranging from materials to design and aims to reveal the connections between natural and artificial materials, as well as experiment and modeling. Manuscripts submitted to Materials and Design should contain elements of discovery and surprise, as they often contribute new insights into the architecture and function of matter.