Fakultät Maschinenbau
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Heat staking is a joining technology by which thermoplastic pins are formed by force and temperature to create a form- and force-fitting connection between components. This paper examines the characteristics of 3D printed pins in comparison to conventionally turned pins for heat staking applications. The 3D printed pins are created using fused layer modeling, with variations in horizontal and vertical building directions, as well as different layer thicknesses. The study investigates the impact of significant factors on the heat staking process, including the forming force and temperature. Tensile tests, micrographs, and micro-CT measurements were conducted to determine the properties of the heat-staked joints. Additionally, a stage plan was developed to enhance the understanding of the forming process of both printed and conventionally turned materials. The findings suggest that, under specific process parameters, 3D printed pins exhibit comparable strength to conventionally manufactured pins. The research also demonstrates that the anisotropy resulting from the layer-by-layer construction of the pins significantly influences the strength of the connection. Furthermore, the study reveals that 3D printed pins exhibit good forming accuracy during the heat staking process, and the cavities formed during printing can be substantially reduced.
Simultaneous laser beam melting (SLBM) allows the direct realization of multi-material components consisting of different polymer materials by a single Additive Manufacturing (AM) process. To achieve a high compound strength between different materials by adhesive bonding, a common boundary zone based on diffusion of the macromolecules is necessary and thus, both materials needs to be compatible regarding their specific adhesion compatibility. However, by SLBM also incompatible polymers can be processed to multi-material parts. If two incompatible polymers are processed, a positive locking between the different materials is necessary to achieve a connection between the materials. The positive locking results of a random mixture process of the different powder materials during the powder deposition process by a two chamber recoater system, which leads to the forming of undercuts of one material in the other during the melting and recrystallization. In this paper, thermoplastic elastomer (TPE) and polypropylene (PP) powders, which are incompatible, are processed to multi-material specimens. By qualifying basic material properties, their influence on the process and especially on the forming of undercuts in the boundary zone is analyzed. To also allow the analysis of the influence of both material and process parameters on the resulting part properties, tensile test specimens are built and their tensile strength is determined. Additionally, cross sections of the boundary zone are prepared and analyzed by microscope images.
Properties of Polydimethylsiloxane and Magnetoactive Polymers with Electroconductive Particles
(2018)
Magnetoactive polymers are intelligent materials whose mechanical and electrical characteristics are reversibly influenced by external magnetic stimuli. They consist of a highly elastic polymer matrix in which magnetically soft and/or hard particles are distributed by means of special fabrication processes. In addition to ferromagnetic particles such as carbonyl iron powder, electrically conductive particles may also be embedded into the polymer matrix. After characterizing a range of compounds, this work focuses on a comparison of the electrical properties and the suitability of various materials for applications, with particular emphasis on integration into 3D and 6D printing processes. 6D printing is based on the selective positioning of particles in a 3D polymer matrix with a further three degrees of freedom for a graduated dispersion of the particles at certain points and in desired directions. The aim is therefore to ensure that the polymers containing electroconductive tracks have the best possible electrical properties, that is, low resistivity but are still capable of being printed. A comparison between the traditionally used compounds containing graphite and carbon black is made for the first time. This latter is found to be greatly superior both in terms of electrical conductivity and applicability to 3D printing and 6D printing.