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Full text release has been delayed at the author's request until September 01, 2025

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Fused Deposition Modeling of Natural Carbon-Enhanced Composite Filaments for Structural Applications

Veley, Logan Edward
http://orcid.org/0000-0002-4555-1637
http://rave.ohiolink.edu/etdc/view?acc_num=ohiou16872722068166

Abstract Details

2023, Master of Science (MS), Ohio University, Mechanical Engineering (Engineering and Technology).
Bituminous coal was utilized as a particulate filler in polymer-based composites to fabricate standard 1.75 mm coal-plastic composite filaments for use in commercially available fused deposition modeling 3D printers. The composites were formulated by incorporating Pittsburgh No. 8 coal into polylactic acid, polyethylene terephthalate glycol, high-density polyethylene, and polyamide-12 resins with loadings ranging from 20 wt.% to 70 wt.%. CPC filaments were extruded and printed using the same processing parameters as the respective neat plastics. All coal-plastic composite filaments exhibited uniform particle dispersion throughout the microstructure. The mechanical properties of the 3D printed composites were characterized and compared to composites fabricated using traditional compression molding. Tensile and flexural moduli as well as hardness had direct proportionality with increasing coal content while flexural strength, tensile strength, and impact resistance decreased for most composite formulations. Interestingly, polyamide-based composites demonstrated greater maximum tensile and flexural strengths than unfilled plastic. Microscopy of as-fractured samples revealed that particle pull-out and particle fracture were the predominant modes of composite failure. The introduction of coal reduced the coefficient of thermal expansion of the composites, ameliorating the warping problem of 3D printed high-density polyethylene and allowing for additive manufacturing of an inexpensive and widely available thermoplastic. The high-density polyethylene composites demonstrated increased heat deflection temperatures, but all composites maintained comparable glass and metal transition temperatures, allowing them to be processed with commercial 3D printer extruders. The composites exhibited decreased specific heat capacities suggesting lower energy requirements for processing the material. Coal reduced the composite thermal conductivities compared to the neat plastics but improved the thermal stability of the polymers. This work establishes the foundation for the additive manufacturing of novel, sustainable coal-plastic composites for future technology scaling and industrial adoption.
Jason Trembly (Advisor)
Yahya Al-Majali (Committee Member)
Brian Wisner (Committee Member)
David Drabold (Committee Member)
116 p.
Engineering; Materials Science; Mechanical Engineering; Sustainability
Coal Plastic Composite; Additive Manufacturing; Fused Deposition Modeling; 3D Printing; Material Extrusion; Sustainability; Thermoplastic Composite; High-density Polyethylene; Mechanical Characterization; Thermal Properties

Recommended Citations

Citations

  • Veley, L. E. (2023). Fused Deposition Modeling of Natural Carbon-Enhanced Composite Filaments for Structural Applications [Master's thesis, Ohio University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=ohiou16872722068166

    APA Style (7th edition)

  • Veley, Logan. Fused Deposition Modeling of Natural Carbon-Enhanced Composite Filaments for Structural Applications. 2023. Ohio University, Master's thesis. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=ohiou16872722068166.

    MLA Style (8th edition)

  • Veley, Logan. "Fused Deposition Modeling of Natural Carbon-Enhanced Composite Filaments for Structural Applications." Master's thesis, Ohio University, 2023. http://rave.ohiolink.edu/etdc/view?acc_num=ohiou16872722068166

    Chicago Manual of Style (17th edition)

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© 2023, all rights reserved.
This open access ETD is published by Ohio University and OhioLINK.