Synergistic effects of process-driven thermo-physical characteristics on fracture toughness and fatigue behaviors of additively manufactured polymers

IF 6.8 2区材料科学 Q1 ENGINEERING, MECHANICAL

International Journal of Fatigue Pub Date : 2025-07-17 DOI:10.1016/j.ijfatigue.2025.109174

Md Abu Jafor , Adam N. Swinney , Arief Yudhanto , Trevor J. Fleck

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Abstract

The thermo-physical characteristics of polymeric materials produced using fusion-based material extrusion (MEX) additive manufacturing (AM) are sensitive to variations in process parameters. These parameters affect the as-manufactured defects (void content), which are known to impact the fracture and fatigue performance. However, the synergistic effects of process-driven thermo-physical characteristics and void content on fracture toughness and fatigue crack growth in MEX polymers remains inconclusive. In this work, polylactic acid (PLA) was manufactured with varying raster orientations (0° and 90°) and infill densities (80%, 85%, 90%, 95%, and 100%, as a proxy for void content). A series of experiments evaluated how these parameters influence void content, and therefore temperature distribution and resultant fracture and fatigue properties. Fracture toughness and fatigue crack growth were evaluated using compact tension specimens (CTS) and digital image correlation (DIC) to assess crack tip plasticity. The results indicate MEX samples printed with an orientation of 90° from the intended crack propagation exhibited a degradation in fracture toughness and fatigue performance. This degradation is primarily due to interlayer fracture caused by the voids being oriented perpendicular to the applied load, rather than the extent of the void content. These findings enhance the understanding of the interaction of process-driven thermo-physical properties and damage tolerance.

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工艺驱动的热物理特性对增材制造聚合物断裂韧性和疲劳行为的协同效应

使用熔融材料挤出（MEX）增材制造（AM）生产的聚合物材料的热物理特性对工艺参数的变化很敏感。这些参数影响制造缺陷（孔隙含量），这是已知的影响断裂和疲劳性能。然而，工艺驱动的热物理特性和空隙含量对MEX聚合物断裂韧性和疲劳裂纹扩展的协同效应仍不确定。在这项工作中，制备了具有不同光栅方向（0°和90°）和填充密度（80%至100%，作为空隙含量的代表）的聚乳酸。一系列实验评估了这些参数如何影响孔隙含量，从而影响温度分布以及由此产生的断裂和疲劳性能。采用紧致拉伸试样（CTS）和数字图像相关（DIC）评估裂纹尖端塑性，对断裂韧性和疲劳裂纹扩展进行了评估。结果表明，与预期裂纹扩展方向成90°方向的MEX样品的断裂韧性和疲劳性能有所下降。这种退化主要是由于空洞垂直于施加的载荷而导致的层间断裂，而不是空洞含量的范围。这些发现增强了对过程驱动的热物理性质和损伤容限的相互作用的理解。

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来源期刊

International Journal of Fatigue 工程技术-材料科学：综合

CiteScore

10.70

自引率

21.70%

发文量

619

审稿时长

58 days

期刊介绍： Typical subjects discussed in International Journal of Fatigue address: Novel fatigue testing and characterization methods (new kinds of fatigue tests, critical evaluation of existing methods, in situ measurement of fatigue degradation, non-contact field measurements) Multiaxial fatigue and complex loading effects of materials and structures, exploring state-of-the-art concepts in degradation under cyclic loading Fatigue in the very high cycle regime, including failure mode transitions from surface to subsurface, effects of surface treatment, processing, and loading conditions Modeling (including degradation processes and related driving forces, multiscale/multi-resolution methods, computational hierarchical and concurrent methods for coupled component and material responses, novel methods for notch root analysis, fracture mechanics, damage mechanics, crack growth kinetics, life prediction and durability, and prediction of stochastic fatigue behavior reflecting microstructure and service conditions) Models for early stages of fatigue crack formation and growth that explicitly consider microstructure and relevant materials science aspects Understanding the influence or manufacturing and processing route on fatigue degradation, and embedding this understanding in more predictive schemes for mitigation and design against fatigue Prognosis and damage state awareness (including sensors, monitoring, methodology, interactive control, accelerated methods, data interpretation) Applications of technologies associated with fatigue and their implications for structural integrity and reliability. This includes issues related to design, operation and maintenance, i.e., life cycle engineering Smart materials and structures that can sense and mitigate fatigue degradation Fatigue of devices and structures at small scales, including effects of process route and surfaces/interfaces.