CHARACTERIZING THE ANISOTROPIC TENSILE BEHAVIOR AND DUCTILITY OF FFF-PRINTED ABS BASED ON PRINT DIRECTION AND RASTER ORIENTATION | ||||
| Journal of the Egyptian Society of Tribology | ||||
| Volume 22, Issue 2, April 2025, Page 113-143 PDF (1.49 MB) | ||||
| Document Type: Original Article | ||||
| DOI: 10.21608/jest.2025.374956.1116 | ||||
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| Authors | ||||
I. S. ELDeeb   ; Ehssan Esmael ; Abdelhameed A. Zayed
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| Production Engineering and Mechanical Design Department, Faculty of Engineering, Tanta University, Tanta, 31521, EGYPT. | ||||
| Abstract | ||||
| Fused Filament Fabrication (FFF) of Acrylonitrile Butadiene Styrene (ABS) produces components with significant mechanical anisotropy, critically impacting their reliability in load-bearing applications. This study comprehensively characterizes how both printing direction (Flat, On-Edge, Up-Right) and raster orientation angle (systematically varied from 0° to 90°) govern the uniaxial tensile strength and ductility (strain at failure) of FFF-ABS. ASTM D638 Type IV specimens were fabricated with consistent parameters (50% infill), varying only these orientations, followed by tensile testing and optical fractography. Profound anisotropy was confirmed. Printing direction established distinct performance tiers: Flat yielded the highest potential strength, On-Edge was intermediate, while Up-Right consistently demonstrated the lowest strength and minimal ductility due to brittle inter-layer delamination. The raster orientation angle acted as a critical modulator, particularly for Flat and On-Edge. In the Flat direction, 0° raster alignment maximized strength, whereas 90° minimized it; notably, intermediate angles (e.g., ±45°) suggested enhanced ductility, highlighting a tunable strength-ductility trade-off. On-Edge properties also showed significant raster angle sensitivity. Conversely, Up-Right behavior remained largely insensitive to raster angle, dominated by interface weakness. Fractographic analysis correlated failure mechanisms with mechanical outcomes: delamination in Up-Right samples, mixed inter/intra-raster failure in On-Edge, and distinct raster-angle-dependent modes (inter-raster vs. intra-raster) in Flat samples. This research underscores that optimizing FFF-ABS requires careful selection of both printing direction and raster angle to achieve the targeted balance between tensile strength and ductility for specific engineering requirements. | ||||
| Keywords | ||||
| Acrylonitrile Butadiene Styrene (ABS); Fused Filament Fabrication (FFF); Additive Manufacturing (AM); Tensile Strength; Ductility; Anisotropy; Build Orientation; Raster Angle; Fractography | ||||
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