Hostname: page-component-cd9895bd7-dk4vv Total loading time: 0 Render date: 2025-01-01T19:53:55.576Z Has data issue: false hasContentIssue false
  • English
  • Français

Polyetherimide powders as material alternatives for selective laser-sintering components for aerospace applications

Published online by Cambridge University Press:  16 November 2020

Yifan Lv ,
Wayne Thomas ,
Rodger Chalk ,
Andrew Hewitt  and
Sarat Singamneni
Yifan Lv
Affiliation:
Additive Manufacturing Research Centre, Auckland University of Technology, Auckland1010, New Zealand
Wayne Thomas
Affiliation:
Air New Zealand, Mangere, Auckland2022, New Zealand
Rodger Chalk
Affiliation:
Air New Zealand, Mangere, Auckland2022, New Zealand
Andrew Hewitt
Affiliation:
Air New Zealand, Mangere, Auckland2022, New Zealand
Sarat Singamneni*
Affiliation:
Additive Manufacturing Research Centre, Auckland University of Technology, Auckland1010, New Zealand
*
a)Address all correspondence to this author. e-mail: [email protected]
Get access

Abstract

Additive manufacturing (AM) has made long strides in the recent past and rapidly evolved into a promising alternative in specific applications. The aircraft industry is not an exception to this. The true just-intime production possibility is critical for the aircraft maintenance industries, though the lack of material freedom is a major hurdle. Several fire-retardant materials were investigated for AM in the aerospace context, but mainly for fused deposition modeling (FDM). The material consolidation constraints in FDM led to the expansion to the use of selective laser sintering (SLS) to some extent. Nevertheless, the material options are still limited, proprietary, and lack scientific insights into the material consolidation mechanics. Attempts are made in this paper to fill this gap, evaluating a new fire-retardant material for processing by SLS. Experiments conducted to ascertain the material, process, structure, and consolidation relationships indicated energy density levels 0.062–0.070 J/mm2 with laser power 13 W and scan speed varied slightly around 390 mm/s to give the best laser sintering and mechanical property results in polyetherimide powders.

Keywords

3D printingadditive manufacturingaerospacelaserlayeredfiringmesoscalepolymerscanning electron microscopysintering
Type
Article
Information
Journal of Materials Research , Volume 35 , Issue 23-24 , 14 December 2020 , pp. 3222 - 3234
Check for updates
Copyright
Copyright © The Author(s), 2020, published on behalf of Materials Research Society by Cambridge University Press

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

Irving, P.E. and Soutis, C.: Polymer Composites in the Aerospace Industry (Elsevier Science, London, U.K., 2019), pp. 19, 561.Google Scholar
Njuguna, J. and Pielichowski, K.: Polymer nanocomposites for aerospace applications: properties. Adv. Eng. Mater. 5, 769 (2003).10.1002/adem.200310101CrossRefGoogle Scholar
Horrocks, A.R., Price, D., and Price, D.: Fire Retardant Materials (Elsevier Science, London, U.K., 2001), pp. 31.Google Scholar
Wilkie, C.A. and Morgan, A.B.: Fire Retardancy of Polymeric Materials, 2nd ed. (CRC Press, Florida, USA, 2010), pp. 1–13.Google Scholar
Hu, Y. and Wang, X.: Flame Retardant Polymeric Materials: A Handbook (CRC Press, Florida, USA, 2019), pp. 13.10.1201/b22345-2CrossRefGoogle Scholar
Yin, H., Sypaseuth, F. D., Schubert, M., Schoch, R., Bastian, M. and Schartel, B.: Routes to halogen-free flame-retardant polypropylene wood plastic composites. Polym. Adv. Technol. 30(1), 187–202 (2019).10.1002/pat.4458CrossRefGoogle Scholar
Lu, S. and Hamerton, I.: Recent developments in the chemistry of halogen-free flame retardant polymers. Prog. Polym. Sci. 27(8), 1661–1712 (2002).CrossRefGoogle Scholar
Matsuyama, Y.: Toxic Gas and Particulates Characterization in a Smoke Density Chamber (Case West. Reserve Univ., Ohio, USA, 2019), pp. 12.Google Scholar
Li, M. and Zhang, T.: Flame-retardant properties of peek fabric. J. Text. Res. 1, 019 (2010).Google Scholar
Santos, C.V.d., Leiva, D.R., Costa, F.R., and Gregolin, J.A.R.: Materials selection for sustainable executive aircraft interiors. Mater. Res. 19, 339 (2016).10.1590/1980-5373-MR-2015-0290CrossRefGoogle Scholar
National Research Council: Improved Fire-and Smoke-Resistant Materials for Commercial Aircraft Interiors: A Proceedings (National Academy Press, Washington, D.C., USA, 1995).Google Scholar
Lyon, R.E.: Fire-Resistant Materials: Research Overview (Federal Aviation Administration, Washington, D.C., USA, 1997).Google Scholar
Lyon, R.E.: Fire-Safe Aircraft Cabin Materials (ACS Publications, Washington, D.C., USA, 1995).CrossRefGoogle Scholar
Fetisov, K. and Maksimov, P.: Topology optimization and laser additive manufacturing in design process of efficiency lightweight aerospace parts. J. Phys.: Conf. Ser. 1015, 1–5 (2018).Google Scholar
Kausar, A., Rafique, I., and Muhammad, B.: Aerospace application of polymer nanocomposite with carbon nanotube, graphite, graphene oxide, and nanoclay. Polym.-Plast. Technol. Eng. 56, 1438 (2017).10.1080/03602559.2016.1276594CrossRefGoogle Scholar
Horner April: Aircraft materials fire test handbook (Fed. Aviat. Adm., Virginia, USA, 2000).Google Scholar
Tai, C and Li, R K: Studies on the impact fracture behaviour of flame retardant polymeric material. Mater. Des 22 (2001)CrossRefGoogle Scholar
Grand, A.F. and Wilkie, C.A.: Fire Retardancy of Polymeric Materials (CRC Press, Florida, USA, 2000).Google Scholar
Froes, F.H., and Boyer, R.: Additive Manufacturing for the Aerospace Industry (Elsevier, Amsterdam, Netherlands, 2019).Google Scholar
Gebisa, A.W. and Lemu, H.G.: Influence of 3D printing FDM process parameters on tensile property of ULTEM 9085. Proc. Manuf. 30, 331 (2019).Google Scholar
Zaldivar, R., Witkin, D., McLouth, T., Patel, D., Schmitt, K., and Nokes, J.: Influence of processing and orientation print effects on the mechanical and thermal behavior of 3D-printed ULTEM® 9085 material. Addit. Manuf. 13, 71 (2017).Google Scholar
Byberg, K.I., Gebisa, A.W., and Lemu, H.G.: Mechanical properties of ULTEM 9085 material processed by fused deposition modeling. Polym. Test. 72, 335 (2018).10.1016/j.polymertesting.2018.10.040CrossRefGoogle Scholar
GE Plastics: GE Engineering Thermoplastics ULTEM PEI Resin (General Electric Company, Massachusetts, USA, 1997).Google Scholar
Chuang, K.C., Grady, J.E., Draper, R.D., Shin, E.-S.E., Patterson, C., and Santelle, T.D.: Additive manufacturing and characterization of Ultem polymers and composites. in CAMX Conf. Proc. (The CAMX Expo, Dallas, TX, USA, October, 2015).Google Scholar
Cicala, G, Ognibene, G., Portuesi, S., Blanco, I., Rapisarda, M, Pergolizzi, E and Recca, G.: Comparison of Ultem 9085 Used in Fused Deposition Modelling (FDM) with Polytherimide Blends. Mater. 11, 285 (2018)10.3390/ma11020285CrossRefGoogle ScholarPubMed
Fischer, M. and Schöppner, V.: Fatigue Behavior of FDM Parts Manufactured with Ultem 9085. JOM 69(3), 563–568 (2017).CrossRefGoogle Scholar
Bagsik, A., Josupeit, S, Schoeppner, V and Klemp, E.: AIP Conference Proceedings (American Institute of Physics, 1593, 2014), pp. 696–701Google Scholar
Blanco, I., Cicala, G, Ognibene, G., Rapisarda, M. and Recca, A: Thermal properties of polyetherimide/polycarbonate blends for advanced applications. Polym. Degrad. Stab. 154, 234–238 (2018) 10.1016/j.polymdegradstab.2018.06.011CrossRefGoogle Scholar
Ng, M. and Brennan, S. N: ASME International Mechanical Engineering Congress and Exposition (American Society of Mechanical Engineers, 52149, 2018), pp. 9–12Google Scholar
Wu, H., Sulkis, M., Driver, J., Saade-Castillo, A., Thompson, A. and Koo, J. H.: Multi-functional ULTEM1010 composite filaments for additive manufacturing using Fused Filament Fabrication (FFF). Addit. Manuf. 24, 298–306 (2018)Google Scholar
Gibson, I, Rosen, D W and Stucker, B: Additive Manufacturing Technologies (Springer, New York, USA, 2014), Vol. 17, pp. 147–173.Google Scholar
Kruth, J.-P., Wang, X., Laoui, T. and Froyen, L.: Lasers and materials in selective laser sintering. Assem. Autom. 23(4), 357–371 (2003).CrossRefGoogle Scholar
Goodridge, R., Tuck, C., and Hague, R.: Laser sintering of polyamides and other polymers. Prog. Mater. Sci. 57, 229 (2012).CrossRefGoogle Scholar
Schmid, M. and Wegener, K.: Additive manufacturing: polymers applicable for laser sintering (LS). Proc. Eng. 149, 457 (2016).CrossRefGoogle Scholar
Kodre, K., Attarde, S., Yendhe, P., Patil, R., and Barge, V.: Differential scanning calorimetry: A review research and reviews. J. Pharm. Anal. 3, 11 (2014).Google Scholar
Halawani, N., Augé, J.-L., Morel, H., Gain, O., and Pruvost, S.: Electrical, thermal and mechanical properties of poly-etherimide epoxy-diamine blend. Compos. B: Eng. 110, 530 (2017).CrossRefGoogle Scholar
Belana, J., Canadas, J., Diego, J., Mudarra, M., Diaz, R., Friederichs, S., Jaimes, C., and Sanchis, M.: Physical ageing studies in polyetherimide ULTEM 1000. Polym. Int. 46, 29 (1998).3.0.CO;2-C>CrossRefGoogle Scholar
Velu, R. and Singamneni, S.: Evaluation of the influences of process parameters while selective laser sintering PMMA powders. Proc. Inst. Mech. Eng. C 229, 603 (2015).CrossRefGoogle Scholar
Berretta, S., Evans, K., and Ghita, O.: Predicting processing parameters in high temperature laser sintering (HT-LS) from powder properties. Mater. Des. 105, 301 (2016).10.1016/j.matdes.2016.04.097CrossRefGoogle Scholar
Luchinsky, D.G., Hafiychuk, H., Hafiychuk, V., and Wheeler, K.R.: Molecular Dynamics of ULTEM 9085 for 3D Manufacturing: Spectra, Thermodynamic Properties, and Shear Viscosity (NASA, Washington, D.C., USA, 2018), pp. 54.Google Scholar
Sun, M.-s., Nelson, C., Beaman, J.J., and Barlow, J.J.: A model for partial viscous sintering. In Solid Freeform Fabr. Symp. Proc. (Austin, USA, 1991).Google Scholar
Yadroitsev, I., Gusarov, A., Yadroitsava, I., and Smurov, I.: Single track formation in selective laser melting of metal powders. J. Mater. Process. Technol. 210, 1624 (2010).CrossRefGoogle Scholar
Schmidt, M., Pohle, D., and Rechtenwald, T.: Selective laser sintering of PEEK. CIRP Ann. 56, 205 (2007).CrossRefGoogle Scholar
Ho, H., Gibson, I., and Cheung, W.: Effects of energy density on morphology and properties of selective laser sintered polycarbonate. J. Mater. Process. Technol. 89, 204 (1999).CrossRefGoogle Scholar
Lomellini, P.: Viscosity-temperature relationships of a polycarbonate melt: Williams-Landel-Ferry versus Arrhenius behaviour. Die Makromol. Chem. 193, 69 (1992).CrossRefGoogle Scholar
Franco, A., Lanzetta, M., and Romoli, L.: Experimental analysis of selective laser sintering of polyamide powders: An energy perspective. J. Cleaner Prod. 18, 1722 (2010).CrossRefGoogle Scholar
Grellmann, W., Seidler, S., and Anderson, P.I.: Polymer Testing (Hanser, Munich, Germany, 2007).CrossRefGoogle Scholar
Gibson, I. and Shi, D.: Material properties and fabrication parameters in selective laser sintering process. Rapid Prototyp. J. 4(4), 129–136 (1997).CrossRefGoogle Scholar
Supplementary material: File

Lv et al. supplementary material

Figures S1-S2 and Tables S1-S2

Download Lv et al. supplementary material(File)
File 861.6 KB