Failure analysis of additively manufactured PLA with different morphological arrangements in erosive flow

Bilal Khan; Rehan Khan; Abdel-Hamid I. Mourad; Michał Wieczorowski; Asiful H. Seikh; Ibrahim A. Alnaser

Journal of Materials Research and Technology (Nov 2024)

Failure analysis of additively manufactured PLA with different morphological arrangements in erosive flow

Bilal Khan,
Rehan Khan,
Abdel-Hamid I. Mourad,
Michał Wieczorowski,
Asiful H. Seikh,
Ibrahim A. Alnaser

Affiliations

Bilal Khan: Department of Mechanical Engineering, College of Electrical and Mechanical Engineering, National University of Sciences and Technology, Islamabad, 44000, Pakistan
Rehan Khan: Department of Mechanical Engineering, College of Electrical and Mechanical Engineering, National University of Sciences and Technology, Islamabad, 44000, Pakistan
Abdel-Hamid I. Mourad: Mechanical and Aerospace Engineering Department, College of Engineering, United Arab Emirates University, Al-Ain, P.O. Box. 15551, United Arab Emirates; National Water and Energy Center, United Arab Emirates University, Al-Ain, P.O. Box. 15551, United Arab Emirates; Corresponding author. Mechanical and Aerospace Engineering Department, College of Engineering, United Arab Emirates University, Al-Ain, P.O. Box. 15551, United Arab Emirates.
Michał Wieczorowski: Faculty of Mechanical Engineering, Institute of Applied Mechanics, Poznan University of Technology, 3 Piotrowo St., 60-965, Poznan, Poland
Asiful H. Seikh: Center of Excellence for Research in Engineering Materials (CEREM), Deanship of Scientific Research, King Saud University, Riyadh, 11421, Saudi Arabia
Ibrahim A. Alnaser: Center of Excellence for Research in Engineering Materials (CEREM), Deanship of Scientific Research, King Saud University, Riyadh, 11421, Saudi Arabia

Journal volume & issue: Vol. 33
pp. 5838 – 5849

Abstract

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This study investigated the impact of water-sand slurry on Polylactic Acid (PLA) in Fused Deposition Modeling (FDM), exploring different morphologies and variables using Taguchi design. Variables included three designs (D1: Flat, D2: Groove, D3: Square groove), slurry concentrations (1%, 3%, 5% by weight), and impact angles (60°, 75°, 90°). Surface damage observed on PLA included cracks, micro-cutting, flakes, and craters due to erosion. The Groove design (D2) showed superior erosion resistance compared to Flat (D1) and square groove (D3). Analysis identified slurry concentration (64.68%) as the primary influencer of erosion, followed by design (23.80%) and impact angle (10.56%). These findings highlight the importance of optimizing FDM parameters to enhance PLA durability against abrasive conditions.

Published in Journal of Materials Research and Technology

ISSN: 2238-7854 (Print); 2214-0697 (Online)
Publisher: Elsevier
Country of publisher: Netherlands
LCC subjects: Technology: Mining engineering. Metallurgy
Website: https://www.journals.elsevier.com/journal-of-materials-research-and-technology/

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