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Investigation of Friction Stir Welding of Additively Manufactured Biocompatible Thermoplastics Using Stationary Shoulder and Assisted Heating
Publication . Rendas, Pedro; Figueiredo, Lígia; Melo, Pedro; Galhano, Carlos; Vidal, Catarina; Soares, Bruno A.R.; DEMI - Departamento de Engenharia Mecânica e Industrial; UNIDEMI - Unidade de Investigação e Desenvolvimento em Engenharia Mecânica e Industrial; DCT - Departamento de Ciências da Terra; GeoBioTec - Geobiociências, Geoengenharias e Geotecnologias; MDPI - Multidisciplinary Digital Publishing Institute
Additive manufacturing (AM), also known as 3D printing, offers many advantages and, particularly in the medical field, it has stood out for its potential for the manufacture of patient-specific implantable devices. Thus, the unique properties of 3D-printed biocompatible polymers such as Polylactic Acid (PLA) and Polyetheretherketone (PEEK) have made these materials the focus of recent research where new post-processing and joining techniques need to be investigated. This study investigates the weldability of PLA and PEEK 3D-printed plates through stationary shoulder friction stir welding (SS-FSW) with assisted heating. An SS-FSW apparatus was developed to address the challenges of rotating shoulder FSW of thermoplastics, with assisted heating either through the shoulder or through the backing plate, thus minimizing material removal defects in the welds. Successful welds revealed that SS-FSW improves surface quality in both PLA and PEEK welds compared to rotating shoulder tools. Process parameters for PLA welds are investigated using the Taguchi method, emphasizing the importance of lower travel speeds to achieve higher joint efficiencies. In PEEK welds, the heated backing plate proved effective in increasing process heat input and reducing cooldown rates which were associated with higher crystallinity PEEK. Despite these findings, further research is needed to improve the weld strength of SS-FSW with these materials considering aspects like tool design, process stability, and 3D printing parameters. This investigation emphasizes the potential of SS-FSW in the assembly of thermoplastic materials, offering insights into the weldability of additively manufactured biocompatible polymers like PLA and PEEK.
Investigating the effects of printing temperatures and deposition on the compressive properties and density of 3D printed polyetheretherketone
Publication . Rendas, Pedro; Figueiredo, Lígia; Cláudio, Ricardo; Vidal, Catarina; Soares, Bruno; DEMI - Departamento de Engenharia Mecânica e Industrial; UNIDEMI - Unidade de Investigação e Desenvolvimento em Engenharia Mecânica e Industrial; Springer
Polyetheretherketone (PEEK) is a biocompatible high-performance thermoplastic that can be processed through material extrusion (ME) additive manufacturing (AM) for load-bearing implant applications. In this work, density measurements and compression testing were used to investigate the relation between printing temperatures and deposition patterns of PEEK 3D printed samples. Different deposition patterns were tested with different nozzle and zone heater temperatures to observe how the heat input from the printing process influenced the deposition stability with different nozzle paths. Compression test results showed that samples with concentric-based deposition patterns resulted in higher compressive yield strength and modulus than the rectilinear samples. These results were correlated with the samples’ void contents estimated from density measurements. Both the highest 0.2% offset yield strength of 100.3 MPa and the highest modulus of 3.58 GPa were obtained with an interlayer offset deposition which resulted in reductions in estimated void contents between 48 and 72% in relation to concentric deposition. Different printing temperatures and deposition sequences were tested, where higher printing temperatures resulted in lower yield strength and stiffness. Alternating deposition between the outer and inner lines of the concentric pattern resulted in a reduction of about 43% in void contents and increased elastic modulus and yield strength from 3.12 to 3.40 GPa and 94.4 to 95.2 MPa respectively. The results from this work suggest that the relation between printing temperatures and deposition strategy for different print geometries plays a significant role in the ME-AM of PEEK for high-performance applications.
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Fundação para a Ciência e a Tecnologia
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UI/BD/151082/2021