Enhancement of Mechanical and Wear Properties in 3D-printed PEEK Specimens using Eco-friendly Infill Patterns via Fused Filament Fabrication
J. Environ. Nanotechnol., Volume 13, No 4 (2024) pp. 332-340
Abstract
The increasing use of 3D-printed PEEK materials in load-bearing applications necessitates a comprehensive evaluation of their wear characteristics and hardness under dynamic loading conditions. This study investigates the wear loss, coefficient of friction, and hardness values of PEEK materials with four distinct surface patterns: Line, Grid, Cubic, and Hexagon. Controlled experiments revealed that the Line and Hexagon patterns exhibited the lowest wear loss (0.004 grams), indicating superior wear resistance, while the Cubic pattern showed the highest wear loss (0.009 grams). In terms of friction, the Grid pattern demonstrated the lowest coefficient of friction (0.21), suggesting it offers the least resistance to movement, while the Line and Hexagon patterns had moderate coefficients of friction (0.40 and 0.35, respectively). The Cubic pattern displayed the highest coefficient of friction (0.45). Hardness testing revealed that the Hexagon pattern had the highest hardness value (30), followed by the Line pattern (28), the Grid pattern (25), and the Cubic pattern (20). These findings highlight the trade-offs between wear resistance, friction, and hardness among the different surface patterns, providing valuable insights for applications where these properties are crucial. SEM images were analyzed to investigate the wear characteristics of FFF-printed PEEK samples with varying infill patterns. The results showed that the Hexagon pattern exhibited the least surface degradation, demonstrating superior wear resistance compared to the Line, Cubic, and Grid patterns. This study offers valuable guidance for selecting optimal surface patterns in engineering and industrial applications to enhance performance and durability.
Full Text
Reference
Chithambaram, K. and Senthilnathan, N., Effects of printing parameters on hardness and wear characteristics of 3D printed polyetheretherketone (PEEK) polymer, Mater. Lett., 356, 135588 (2024).
https://doi.org/10.1016/j.matlet.2023.135588
Dhakal, N., Espejo, C., Morina, A. and Emami, N., Tribological performance of 3D printed neat and carbon fiber reinforced PEEK composites, Tribol. Int., 193, 109356 (2024).
https://doi.org/10.1016/j.triboint.2024.109356
Durga, R. K. V., Ganesh, N., Yaswanth Kalyan Reddy, S., Mishra, H. and Teja Naidu, T. M. V. P., Experimental research on the mechanical characteristics of fused deposition modelled ABS, PLA and PETG specimens printed in 3D, Mater Today Proc., (2023).
https://doi.org/10.1016/j.matpr.2023.06.343
Farrugia, J., Vella, P. and Rochman, A., Combining 3D printing and injection moulding for the fabrication of polymer micro-components with internal hollow features, Prog. Addit. Manuf., 9(5), 1353–1364 (2024).
https://doi.org/10.1007/s40964-024-00616-x
Greco, A., De Luca, A., Gerbino, S., Lamanna, G., and Sepe, R., Influence of infill pattern and layer height on surface characteristics and fatigue behaviour of FFF‐printed PEEK, Fatigue Fract. Eng. Mater. Struct., 47(12), 4741–4754 (2024).
https://doi.org/10.1111/ffe.14450
Haleem, A. and Javaid, M., Polyether ether ketone (PEEK) and its manufacturing of customised 3D printed dentistry parts using additive manufacturing, Clin. Epidemiol. Glob. Heal., 7(4), 654–660 (2019).
https://doi.org/10.1016/j.cegh.2019.03.001
Hassan, M. R., Jeon, H. W., Kim, G. and Park, K., The effects of infill patterns and infill percentages on energy consumption in fused filament fabrication using CFR-PEEK, Rapid Prototyping J., 27(10), 1886–1899 (2021).
https://doi.org/10.1108/rpj-11-2020-0288
He, Y., Shen, M., Wang, Q., Wang, T. and Pei, X., Effects of FDM parameters and annealing on the mechanical and tribological properties of PEEK, Compos. Struct., 313, 116901 (2023).
https://doi.org/10.1016/j.compstruct.2023.116901
Hou, B., Ren, L., Sun, Y., Zhang, M. and Zhang, H., Structure and properties of heat-resistant ABS resins innovated via MSAMI random copolymer, J. Thermoplast. Compos. Mater., 36(3), 1004–1016 (2023).
https://doi.org/10.1177/08927057211044191
Kantaros, A., Soulis, E., Petrescu, F. I. T. and Ganetsos, T., Advanced Composite Materials Utilized in FDM/FFF 3D Printing Manufacturing Processes: The Case of Filled Filaments, Materials (Basel), 16(18), 6210 (2023).
https://doi.org/10.3390/ma16186210
Khan, F., Hossain, N., Mim, J. J., Rahman, S. M., Iqbal, M. J., Billah, M. and Chowdhury, M. A., Advances of composite materials in automobile applications – A review, J. Eng. Res., (2024).
https://doi.org/10.1016/j.jer.2024.02.017
Khan, S. and Iqbal, A., Organic polymers revolution: Applications and formation strategies, and future perspectives, J. Polym. Sci. Eng., 6(1), 3125 (2023).
https://doi.org/10.24294/jpse.v6i1.3125
Kharmanda, G., Challenges and Future Perspectives for Additively Manufactured Polylactic Acid Using Fused Filament Fabrication in Dentistry, J. Funct. Biomater., 14(7), 334 (2023).
https://doi.org/10.3390/jfb14070334
Lv, X., Pei, X., Yang, S., Zhang, Y., Wang, Q. and Wang, T., Tribological behavior of PEEK based composites with alternating layered structure fabricated via fused deposition modeling, Tribol. Int., 199, 109953 (2024).
https://doi.org/10.1016/j.triboint.2024.109953
Massocchi, D., Riboni, G., Lecis, N., Chatterton, S. and Pennacchi, P., Tribological Characterization of Polyether Ether Ketone (PEEK) Polymers Produced by Additive Manufacturing for Hydrodynamic Bearing Application, Lubricants, 9(11), 112 (2021).
https://doi.org/10.3390/lubricants9110112
Mehtedi, M. El, Buonadonna, P., Mohtadi, R. El, Aymerich, F. and Carta, M., Surface quality related to machining parameters in 3D-printed PETG components, Procedia Comput. Sci., 232, 1212–1221 (2024).
https://doi.org/10.1016/j.procs.2024.01.119
Mrówka, M., Machoczek, T., Jureczko, P., Joszko, K., Gzik, M., Wolański, W. and Wilk, K., Mechanical, Chemical, and Processing Properties of Specimens Manufactured from Poly-Ether-Ether-Ketone (PEEK) Using 3D Printing, Materials (Basel), 14(11), 2717 (2021).
https://doi.org/10.3390/ma14112717
Pulipaka, A., Gide, K. M., Beheshti, A. and Bagheri, Z. S., Effect of 3D printing process parameters on surface and mechanical properties of FFF-printed PEEK, J. Manuf. Processes, 85, 368–386 (2023).
https://doi.org/10.1016/j.jmapro.2022.11.057
Ree, B. J., Critical review and perspectives on recent progresses in 3D printing processes, materials, and applications, Polymer (Guildf), 308, 127384 (2024).
https://doi.org/10.1016/j.polymer.2024.127384
Sarker, A., Mondal, S. C., Ahmmed, R., Rana, J., Waheda Rahman Ansary, M. and Bilal, M., Prospects and challenges of polymer nanocomposites for innovative food packaging, In: Smart Polymer Nanocomposites. Elsevier, 355–377 (2023).
https://doi.org/10.1016/B978-0-323-91611-0.00021-9
Subramani, R., Mustafa, M. A., Ghadir, G. K., Al-Tmimi, H. M., Alani, Z. K., Haridas, D., Rusho, M. A., Rajeswari, N., Rajan, A. J. and Kumar, A. P., Advancements in 3D printing materials: A comparative analysis of performance and applications, Appl. Chem. Eng., 3867 (2024).
https://doi.org/10.59429/ace.v7i2.3867
Timoumi, M., Barhoumi, N., Znaidi, A., Maazouz, A. and Lamnawar, K., Mechanical behavior of 3D-printed PEEK and its application for personalized orbital implants with various infill patterns and densities, J. Mech. Behav. Biomed. Mater., 136, 105534 (2022).
https://doi.org/10.1016/j.jmbbm.2022.105534
Wang, X., Hu, J., Liu, J., Liang, Y., Wu, L., Geng, T., Liu, S. and Guo, Y., Tribological Performance and Enhancing Mechanism of 3D Printed PEEK Coated with In Situ ZIF-8 Nanomaterial, Polymers (Basel), 16(8), 1150 (2024).
https://doi.org/10.3390/polym16081150
Zhang, Y., Yang, B., Peng, S., Zhang, Z., Cai, S., Yu, J., Wang, D. and Zhang, W., Mechanistic insights into chemical conditioning on transformation of dissolved organic matter and plant biostimulants production during sludge aerobic composting, Water Res., 255, 121446 (2024).
