Title: Natural Carbon-Enhanced Composite Material for Sustainable Additive Manufacturing Applications

Authors: Grace S. Baranack, Yahya T. Al-Majali

DOI: 10.33599/nasampe/s.24.0120

Abstract: This study delves into the development of sustainable and 3D printable natural carbon-enhanced polymer composite (NCPC) materials for utilization in high-volume applications including additive housing construction and composite tooling applications. Readily available and inexpensive high-density polyethylene (HDPE) was compounded with natural carbons including freshly mined coal, reclaimed coal waste, and coal-derived carbon at various loadings (15-60 wt. %) to create 3D printable filament that can integrate with commercially available fused deposition modeling printers. The effect of the type and content of natural carbon on the tensile, flexural, and impact resistance properties of the resulting composites was investigated. Owing to limited polymer chain mobility and stiffer particles, flexural and tensile moduli increased with natural carbon content. However, flexural and tensile strengths as well as impact resistance showed a negative correlation with filler content. Furthermore, the performance of the 3D-printed NCPC materials was comparable and, in some cases, better than traditional wood plastic composites. Compared to state-of-the-art technologies, additive manufacturing using NCPC materials is projected to substantially reduce manufacturing and material costs, and lower embodied energy and CO2 emissions, while meeting the ASTM and building code requirements.

References: 1.Abdulhameed, O., Al-Ahmari, A., Ameen, W., & Mian, S. H., ""Additive Manufacturing: Challenges, Trends, and Applications."" Advances in Mechanical Engineering 11(2) (2019) [https://doi.org/10.1177/1687814018822880] 2.Bhatia, A., & Seghal, A. K., ""Additive Manufacturing Materials, Methods and Applications: A Review."" Materialstoday: Proceedings 81(2) (2023): 1060-1067 [https://doi.org/10.1016/j.matpr.2021.04.379] 3.Post, B. K., Richardson, B., Lind, R., Love, L. J., Lloyd, P., Kune, V., Rhyne, B. J., Roschli, A., Hannan, J., Nolet, S., Veloso, K., Kurup, P., Remo, T., & Jenne, D., “Big Area Additive Manufacturing Application in Wind Turbine Molds.” Solid Freeform Fabrication Symposium. 2017. University of Texas at Austin [https://doi.org/10.26153/tsw/16964] 4.Angelopoulos, P. M., Samouhos, M., Taxiarchou, M., “Functional Fillers in Composite Filaments for Fused Filament Fabrication; a Review.” Materials Today Proceedings 37(4) (2021): 4031–4043 [https://doi.org/10.1016/j.matpr.2020.07.069] 5.Wang, X., Jiang, M., Zhou, Z., Gou, J., & Hui, D., “3D Printing of Polymer Matrix Composites: A Review and Prospective.” Composites Part B: Engineering 110(2017): 442–458 [https://doi.org/10.1016/j.compositesb.2016.11.034] 6.Eterigho-Ikelegbe, O., Yoro, K. O., Bada, S., “Coal as a Filler in Polymer Composites: A Review.” Resources, Conservation and Recycling 174(2021) [https://doi.org/10.1016/j.resconrec.2021.105756] 7.Phillips, L. N., Kappagantula, K. S., & Trembly, J. P., “Mechanical Performance of Thermoplastic Composites Using Bituminous Coal as Filler: Study of a Potentially Sustainable End-Use Application for Appalachian Coal.” Polymer Composites 40(2) (2019): 591–599 [https://doi.org/10.1002/pc.24696] 8.Veley, L. E., Ugwumadu, C., Trembly, J. P., Drabold, D. A., & Al-Majali, Y., “3D Printing of Sustainable Coal Polymer Composites: Study of Processing, Mechanical Performance, and Atomistic Matrix-Filler Interaction.” ACS Appl. Polym. Mater. 5(11) (2023): 9286–9296 [https://doi.org/10.1021/acsapm.3c01784] 9.Fu, S.-Y., Feng, X. Q., Lauke, B., & Mai, Y.-W., “Effects of Particle Size, Particle/Matrix Interface Adhesion and Particle Loading on Mechanical Properties of Particulate-Polymer Composites.” Composites Part B: Engineering 39(2008): 933-961 [https://doi:10.1016/j.compositesb.2008.01.002] 10.Dobrosielska, M., Dobrucka, R., Brząkalski, D., Frydrych, M., Kozera, P., Wieczorek, M., Jałbrzykowski, M., Kurzydłowski, K. J., & Przekop, R. E., “Influence of Diatomaceous Earth Particle Size on Mechanical Properties of PLA/Diatomaceous Earth Composites.” Materials 15(10) (2022) [https://doi.org/10.3390/ma15103607://doi.org/10.3390/ma15103607] 11.Al-Majali, Y. T., Alamiri, E. S., Wisner, B., & Trembly, J. P., “Mechanical Performance Assessment of Sustainable Coal Plastic Composite Building Materials.” Journal of Building Engineering 80(2023) [https://doi.org/10.1016/j.jobe.2023.108089] 12.Rivera, A. D. P. F., Magalhães, F. C., & Rubio, J. C. C., “Experimental Characterization of PLA Composites Printed by Fused Deposition Modeling.” Journal of Composite Materials 57(5) (2022): 941-953 [https://doi.org/10.1177/00219983221146619] 13.Al-Majali, Y., Daramola, D., Veley, L., Statnick, R., Dhanapal, V., Connell, D., Shereda, E., & Trembly, J., “Direct Utilization of U.S. Coal as Feedstock for the Manufacturing of High-Volume Coal Plastic Composites.” United States, 2023 [https://doi.org/10.2172/1907170] 14.Al-Majali, Y., Veley, L., Daramola, D., Dhanapal, V., Statnick, R., Shereda, E., Trembly, J., “Coal Plastic Composite Piping Infrastructure Components.” United States, 2022 [https://doi.org/10.2172/1970232] 15.Veley, L., Trembly, J., Al-Majali, Y., “3D Printing of Sustainable Coal Polymer Compsoites: Thermophysical Characteristics.” Materials Today Communications 37(2023) [https://doi.org/10.1016/j.mtcomm.2023.106989] 16.Al-Majali, Y. A., Chirume, C. T., Marcum, E. P., Daramola, D. A., Kappagantula, K. S., Trembly, J. P., “Coal-Filler-Based Thermoplastic Composites as Construction Materials: A New Sustainable End-Use Application.” ACS Sustainable Chemistry & Engineering 7(2019): 16870 – 16878 [https://doi.org/10.1021/acssuschemeng.9b04453] 17.Al-Majali, Y. T., Trembly, J. P., “Flammability and Thermal Stability of Thermoplastic-based Composites Filler with Natural Carbon.” Journal of Fire Sciences 40(3) (2022):175-193 [https://doi.org/10.1177/07349041221082928] 18.Al-Majali, Y. T., Forshey, S., Trembly, J. P., “Effect of Natural Carbon Filler on Thermo-oxidative Degradation of Thermoplastic-based Composites.” Thermochimica Acta 713(2022) [https://doi.org/10.1016/j.tca.2022.179226]

Conference: SAMPE 2024

Publication Date: 2024/05/20

SKU: TP24-0000000120

Pages: 13

Price: $26.00