i FEASIBILITY OF FUSED DEPOSITION OF CERAMICS WITH ZIRCONIA AND ACRYLIC BINDER ...

97 Pages·2016·9.14 MB·English

FEASIBILITY OF FUSED DEPOSITION OF CERAMICS WITH ZIRCONIA AND
ACRYLIC BINDER

A Thesis
presented to
the Faculty of California Polytechnic State University,
San Luis Obispo

In Partial Fulfillment
of the Requirements for the Degree
Master of Science in Industrial Engineering

by
Lindsay V. Page
June 2016

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© 2016
Lindsay V. Page
ALL RIGHTS RESERVED

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COMMITTEE MEMBERSHIP

TITLE: Feasibility of Fused Deposition of Ceramics with
Zirconia and Acrylic Binder

AUTHOR: Lindsay V. Page

DATE SUBMITTED: June 2016

COMMITTEE CHAIR: Dr. Xuan Wang, Ph.D.
Assistant Professor of Industrial and Manufacturing
Engineering

COMMITTEE MEMBER: Dr. Daniel Waldorf, Ph.D.
Professor of Industrial and Manufacturing
Engineering

COMMITTEE MEMBER: Ethan Escowitz
AREVO Labs
Director of Sales & Additive Manufacturing
Services

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ABSTRACT
Feasibility of Fused Deposition of Ceramics with Zirconia and Acrylic Binder
Lindsay V. Page

Processing of ceramics has always been difficult due to how hard and brittle the
material is. Fused Deposition of Ceramics (FDC) is a method of additive
manufacturing which allows ceramic parts to be built layer by layer, abetting
more complex geometries and avoiding the potential to fracture seen with
processes such as grinding and milling. In the process of FDC, a polymeric
binder system is mixed with ceramic powder for the printing of the part and then
burned out to leave a fully ceramic part. This experiment investigates a new
combination of materials, zirconia and acrylic binder, optimizing the process of
making the material into a filament conducive to the printer system and then
performing trials with the filament in the printer to assess its feasibility. Statistical
analysis was used to determine optimal parameter levels using response surface
methodology to pinpoint the material composition and temperature yielding the
highest quality filament. It was discovered that although the mixture had
adequate melting characteristics to be liquefied and printed into a part, the binder
system did not provide the stiffness required to act as a piston to be fed through
the printer head. Further studies should be completed continuing the
investigation of zirconia and acrylic binder, but with added components to
increase strength and rigidity of the filament.

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ACKNOWLEDGMENTS

I would like to thank my thesis advisor Dr. Xuan Wang for all of his guidance
through this process. Additionally, thanks to my other committee members Dr.
Daniel Waldorf and Ethan Escowitz for contributing their time to help me reach
this milestone. I would also like to express appreciation for the faculty of the IME
Department for making my five years at Cal Poly so rewarding, and thank you to
my friends and family who helped me throughout my entire education.

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TABLE OF CONTENTS

Page
LIST OF TABLES ................................................................................................ viii
LIST OF FIGURES ............................................................................................... ix
CHAPTER
CHAPTER 1 – INTRODUCTION ........................................................................... 1
1.1 Purpose of Research ................................................................................... 2
1.2 Introduction to Additive Manufacturing ........................................................ 2
1.3 Fused Deposition of Ceramics ..................................................................... 3
1.4 Approach ..................................................................................................... 6
1.5 Issues, Assumptions, Limitations ................................................................. 6
CHAPTER 2 – LITERATURE REVIEW ................................................................. 8
2.1 Material Composition ................................................................................... 9
2.2 Filament Processing .................................................................................. 12
2.3 3D Printing ................................................................................................. 14
2.3.1 Best Printing Practices ........................................................................ 14
2.3.2 Printing with Ceramic Filament ........................................................... 17
2.4 Post Processing ......................................................................................... 18
2.5 Results ....................................................................................................... 19
2.5.1 Measurement Methods ....................................................................... 19
2.5.2 Part Defects ........................................................................................ 21
CHAPTER 3 – DESIGN & METHODOLOGY ...................................................... 23
3.1 Material Selection ...................................................................................... 23
3.1.1 Binder .................................................................................................. 23
3.1.2 Ceramic Powder .................................................................................. 24
3.1.3 Preliminary Material Selection ............................................................. 25
3.2 Equipment .................................................................................................. 26
3.2.1 Material Mixing Set-Up ........................................................................ 26
3.2.2 Extruder ............................................................................................... 28
3.2.3 FDM Simulator System ....................................................................... 28
3.2.4 Equipment Trials ................................................................................. 30
3.3 Feasibility Trials ......................................................................................... 31
3.3.1 Final Material Selection ....................................................................... 34
3.4 DOE ........................................................................................................... 36
3.4.1 ANOVA ................................................................................................ 37
3.4.2 Factorial Analysis ................................................................................ 39
3.4.3 Response Surface ............................................................................... 41
3.4.4 Analysis of Optimized Filament ........................................................... 41
CHAPTER 4 –RESULTS ..................................................................................... 43
4.1 Factorial Experiment Results ..................................................................... 43
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4.2 Response Surface Optimization ................................................................ 49
4.3 Analysis of Optimized Filament ................................................................. 52
4.4 FDM Printing Trial Findings ....................................................................... 53
4.5 Steps for Further Development .................................................................. 55
CHAPTER 5 – SUMMARY AND CONCLUSIONS .............................................. 57
5.1 Contributions .............................................................................................. 58
5.2 Future Work ............................................................................................... 59
REFERENCES .................................................................................................... 61
APPENDICES
Appendix A: Summary of Previous FDC Experiments ..................................... 67
Appendix B: ANOVA Extrusion Temp vs. Diameter Assumptions ................... 68
Appendix C: Factorial Analysis Residual Plots for Diameter ........................... 69
Appendix D: Factorial Analysis Residual Plots for Diameter Standard
Deviation .......................................................................................................... 70
Appendix E: Factorial Analysis Residual Plots for Length ............................... 71
Appendix F: Factorial Analysis Residual Plots for Length ............................... 72
Appendix G: Results for First Factorial Analysis (Listed by Response) ........... 73
Appendix H: Results for Second Factorial Analysis (Listed by Response) ...... 78
Appendix I: Assumptions for Response Surface Analysis ............................... 81
Appendix J: Response Surface Optimization Results ..................................... 83
Appendix K: Raw Data Used in Factorial and Response Surface Analyses ... 87

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LIST OF TABLES

Table Page
Table 3-1: Preliminary Material Selection…………………………………...... 26
Table 3-2: Material Composition……………………………………………….. 31
Table 3-3: Final Material Selection…………………………………………….. 35
Table 3-4: 2^4 Factorial Design Factor Levels……………………………….. 41
Table 4-1: Summary of Significant Terms Identified in Factorial Analysis… 47
Table 4-2: Response Surface Optimization Goal Values…………………… 50
Table 4-3: Summary of Optimized Filament Measurements……………..… 52

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LIST OF FIGURES

Figure Page
Figure 1-1: Fused Deposition Modeling (Source: FDM (Fused Deposition
Modeling) [Diagram]. Retrieved from http://swiatdruku3d.pl/fdm
-fused-deposition-modeling/)…….……….................................... 4
Figure 1-2: Flowchart of FDC Process…………………………………………. 5
Figure 2-1: Filament Extrusion Process……………………………………...… 13
Figure 2-2: Strains Associated with Printing Patterns (Source: Kantaros &
Karalekas, 2013)…………………….…........................................ 15
Figure 2-3: Build Orientations Upright (left), Side Up (middle), Face Up
(right) (Source: Smith & Dean, 2013) ……………………...…….. 17
Figure 2-4: Stress-Strain Curves by Print Orientation (Source: Smith &
Dean, 2013)……………………………………………………..…… 17
Figure 2-5: Staircase Effect with Different Layer Thicknesses (Source:
Sabourin, Houser & Bohn, 1997)………………………………….. 21
Figure 2-6: Chordal Effect on Rounded Surface………………………………. 22
Figure 3-1: Material Compounding Set-Up…………………………………….. 27
Figure 3-2: Air Filtration Chamber………………………………………………. 27
Figure 3-3: Filastruder Used to Create Filament……………………………… 28
Figure 3-4: FDM Simulator System…………………………………………….. 29
Figure 3-5: Hot End………………………………………………………………. 30
Figure 3-6: FDM Simulator System Set-Up…………………………...……….. 30
Figure 3-7: HA-12 with Zirconia…………………………………………………. 32
Figure 3-8: B-1022 with Zirconia………………………………………………... 33
Figure 3-9: B-1000 with Zirconia (left) and Alumina (right)…………………… 33
Figure 3-10: Down-Selected B-1000 Binder and Zirconia Mixture……….…. 35
Figure 3-11: B-1000 and Zirconia Filament……………………………………. 35
Figure 3-12: DOE Process Flow………………………………………………… 36
Figure 3-13: ANOVA Table for Diameter vs. Extrusion Temperature………. 37
Figure 3-14: Results of Tukey Comparison Study…………………..………… 38
Figure 3-15: 2^4 Factorial Design……………………………..………………... 39
Figure 4-1: Initial Half Normal Plot for Diameter …………………..………..... 43
Figure 4-2: Initial Half Normal Plot for Diameter Standard Deviation……...... 44
Figure 4-3: Initial Half Normal Plot for Length ………………..…………......... 44
Figure 4-4: Initial Half Normal Plot for Breaking Weight …………..……........ 45
Figure 4-5: Second Analysis Half Normal Plot for Diameter …………..…..... 46
Figure 4-6: Second Analysis Half Normal Plot for Breaking Weight ….......... 46
Figure 4-7: Interaction Effect Between Powder, Water and Dispersant.……. 48
Figure 4-8: Main Effects for Extrusion Temperature ………………….……… 48
Figure 4-9: Visual Depiction of Response Surface Optimization …………… 51
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Figure 4-10: Filament Buckling…………..….................................................. 53
Figure 4-11: Ceramic Filament with ABS Plastic Filament as Piston ……..... 54
Figure 4-12: Printed Ceramic Filament …………………..….......................... 54
Figure 5-1: Future Steps for FDC Development ……………………………… 60
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