Crystalline Structure and Morphology in Nylon-12: A Small- and Wide-Angle X-ray Scattering Study

New powder reuse schema in laser-based powder bed fusion of polymers

The laser-based powder bed fusion of polymers (PBF-LB/P) process often utilizes a blend of powders with varying degrees of degradation. Specifically, for polyamide 12, the traditional reuse schema involves mixing post-processed powder with virgin powder at a predetermined ratio before reintroducing it to the process. Given that only about 15% of the powder is utilized in part production, and powders are refreshed in equal proportions, there arises a challenge with the incremental accumulation of material across build cycles. To mitigate the consumption of fresh powder relative to the actual material usage, this study introduces the incorporation of recycled material into the PBF-LB/P process. This new powder reuse schema is presented for the first time, focusing on the laser sintering process. The characteristics of the recycled powder were evaluated through scanning electron microscopy, differential scanning calorimetry, X-ray diffraction, particle size distribution, and dynamic powder flowability assessments. The findings reveal that waste powders can be effectively reused in PBF-LB/P to produce components with satisfactory mechanical properties, porosity levels, dimensional accuracy, and surface quality.

A Numerical simulation method for analyzing 1H spin diffusion NMR for Multicomponent and multiphase polymer systems

A numerical simulation method, namely, SDNMR-WEBFIT, is reported for simulating proton spin diffusion NMR based on the Levenberg-Marquardt algorithm and a pseudo-2D diffusion model. This method is used for the precise quantification of dynamics heterogeneity of the interphase within multiphase polymer systems. The numerical simulation method provides measurements of spin-lattice relaxation time (T1), proton density (ρH), lamellar thickness (d), and spin diffusion coefficient (D) for each component. The pseudo-2D diffusion model is employed to simulate the proton spin diffusion build-up/decay curves, simultaneously calculating the lateral fraction of island-like structures (x-ratio). Such approach was successfully applied to various polymer systems, such as semi-crystalline polymer (Poly(ε-caprolactone), PCL), block copolymers (Styrene-butadiene-styrene triblock copolymer, SBS), and plasticized semi-polymers (Polvinyl alcohol, PVA).

Influence of Crystallization Kinetics and Flow Behavior on Structural Inhomogeneities in 3D-Printed Parts Made from Semi-Crystalline Polymers

We report the results of a study focusing on the influence of crystallization kinetics and flow behavior on structural inhomogeneities in 3D-printed parts made from polyamide 12 (PA12) and poly(lactic acid) (PLA) by dynamic mechanical analysis (DMA), differential scanning calorimetry (DSC), fast scanning calorimetry (FSC), and wide-angle X-ray diffraction (WAXD). Temperature-dependent WAXD measurements on the neat PLA filament reveal that PLA forms a single orthorhombic α phase during slow cooling and subsequent 2nd heating. The PA12 filament shows a well pronounced polymorphism with a reversible solid-solid phase transition between the (pseudo)hexagonal γ phase near room temperature and the monoclinic α' phase above the Brill transition temperature TB = 140 °C. The influence of the print bed temperature Tb on structure formation, polymorphic state, and degree of crystallinity χc of the 3D-printed parts is investigated by height and depth-dependent WAXD scans and compared with that of 3D-printed single layers, used as a reference. It is found that the heat transferred from successive layers has a strong influence on the polymorphic state of PA12 since a superimposed mixture of γ and α phases is present in the 3D-printed parts. In the case of PLA, a single α phase is formed. The print bed temperature has, in comparison to PA12, a major influence on the degree of crystallinity χc and thus the homogeneity of the 3D-printed parts, especially close to the print bed. By comparing the obtained results from WAXD, DMA, DSC, and FSC measurements with relevant printing times, guidelines for 3D-printed parts with a homogeneous structure are derived.

Effects of Laser Power and Hatch Orientation on Final Properties of PA12 Parts Produced by Selective Laser Sintering

Poly(dodecano-12-lactam) (commercially known as polyamide “PA12”) is one of the most resourceful materials used in the selective laser sintering (SLS) process due to its chemical and physical properties. The present work examined the influence of two SLS parameters, namely, laser power and hatch orientation, on the tensile, structural, thermal, and morphological properties of the fabricated PA12 parts. The main objective was to evaluate the suitable laser power and hatching orientation with respect to obtaining better final properties. PA12 powders and SLS-printed parts were assessed through their particle size distributions, X-ray diffraction (XRD), Fourier Transform Infrared spectroscopy (FTIR), differential scanning calorimetry (DSC), a scanning electron microscope (SEM), and their tensile properties. The results showed that the significant impact of the laser power while hatching is almost unnoticeable when using a high laser power. A more significant condition of the mechanical properties is the uniformity of the powder bed temperature. Optimum factor levels were achieved at 95% laser power and parallel/perpendicular hatching. Parts produced with the optimized SLS parameters were then subjected to an annealing treatment to induce a relaxation of the residual stress and to enhance the crystallinity. The results showed that annealing the SLS parts at 170 °C for 6 h significantly improved the thermal, structural, and tensile properties of 3D-printed PA12 parts.

The Effect of Physical Aging and Degradation on the Re-Use of Polyamide 12 in Powder Bed Fusion

Powder bed fusion (PBF) is an additive manufacturing (AM) technique which offers efficient part-production, light-weighting, and the ability to create complex geometries. However, during a build cycle, multiple aging and degradation processes occur which may affect the reusability of the Polyamide 12 (PA-12) powder. Limited understanding of these phenomena can result in discarding re-usable powder unnecessarily, or the production of parts with insufficient properties, both of which lead to significant amounts of waste. This paper examines the thermal, chemical, and mechanical characteristics of PA-12 via an oven storage experiment that simulates multi jet fusion (MJF) conditions. Changes in the properties of PA-12 powder during oven storage showed two separate, time-dependent trends. Initially, differential scanning calorimetry showed a 4.2 °C increase in melting temperature (T_m) and a rise in crystallinity (X_c). This suggests that secondary crystallisation is occurring instead of, or in addition to, the more commonly reported further polycondensation process. However, with extended storage time, there were substantial reductions in T_m and X_c, whilst an 11.6 °C decrease in crystallisation temperature was observed. Fourier transform infrared spectroscopy, a technique rarely used in PBF literature, shows an increased presence of imide bonds—a key marker of thermo-oxidative degradation. Discolouration of samples, an 81% reduction in strength and severe material embrittlement provided further evidence that thermo-oxidative degradation becomes the dominant process following extended storage times beyond 100 h. An additional pre-drying experiment showed how moisture present within PA-12 can also accelerate degradation via hydrolysis.

Water-Induced Crystal Transition and Accelerated Relaxation Process of Polyamide 4 Chains in Microfibers

Microplastics have recently been identified as one of the major contributors to environmental pollution. To design and control the biodegradability of polymer materials, it is crucial to obtain a better understanding of the aggregation states and thermal molecular motion of polymer chains in aqueous environments. Here, we focus on melt-spun microfibers of a promising biodegradable plastic, polyamide 4 (PA4), with a relatively greater number density of hydrolyzable amide groups, which is regarded as an alternative to polyamide 6. Aggregation states and thermal molecular motion of PA4 microfibers without/with a post-heating drawing treatment under dry and wet conditions were examined by attenuated total reflectance-Fourier transform infrared spectroscopy and wide-angle X-ray diffraction analysis in conjunction with dynamic mechanical analysis. Sorbed water molecules in the microfibers induced the crystal transition from a meta-stable γ-form to a thermodynamically stable α-form via activation of the molecular motion of PA4 chains. Also, the post-drawing treatment caused a partial structural change of PA4 chains, from an amorphous phase to a crystalline phase. These findings should be useful for designing PA4-based structural materials applicable for use in marine environments.

Comparative Characterization of Hot-Pressed Polyamide 11 and 12: Mechanical, Thermal and Durability Properties

Chemically speaking, polyamide 11 (PA11) and polyamide 12 (PA12) have a similar backbone, differing only in one carbon. From an origin point of view, PA11 is considered a bioplastic polyamide composed from renewable resources, compared to oil-based PA12. Each of them has a number of advantages over the other, which makes their selection a challenging issue. Depending on the target application, diverse assessments and comparisons are needed to fulfill this mission. The current study addresses this research gap to characterize and compare PA11 and PA12 manufactured by the hot press technique in terms of their mechanical, thermal and durability properties for the first time, demonstrating their potential for future works as matrices in composite materials. In this regard, different characterization techniques are applied to the hot-pressed polymer sheets, including X-ray diffraction (XRD), differential scanning calorimetry (DSC), Fourier transform infrared spectroscopy (FTIR) and scanning electron microscopy (SEM). The mechanical performance of the PA11 and PA12 sheets is compared based on tensile tests and shore hardness measurement. The durability behavior of these two polyamides is evaluated in water and relative humidity conditions at different aging times. The experimental results show the ductile behavior of PA12 with respect to the quasi-brittle PA11. Both have a relatively small water and moisture gain: 1.5 wt% and 0.8 wt%, respectively. The higher crystallinity of PA12 (2.1 times more than PA11) with γ-phase is one of the leading parameters to achieve better mechanical and durability properties. The FTIR spectra displayed slight acid hydrolysis. Accordingly, absorbed water or moisture does not cause plasticization; thus, neither hardness nor dimension changes.

Polyamide 12 Materials Study of Morpho-Structural Changes during Laser Sintering of 3D Printing

The polyamide (PA)-12 material used for additive manufacturing was studied in aspects of morphology and their structural properties for basic stages received during 3D laser printing. Samples were real, big-scale production powders. The structure of polymer was evaluated from the crystallinity point of view using XRD, FTIR, and DSC methods and from the surface properties using specific surface evaluation and porosity. Scanning electron microscopy was used to observe morphology of the surface and evaluate the particle size and shape via image analysis. Results were confronted with laser diffraction particles size measurement along with an evaluation of the specific surface area. Fresh PA12 powder was found as inhomogeneous in particle size of material with defective particles, relatively high specific surface, high lamellar crystallite size, and low crystallinity. The scrap PA12 crystallinity was about 2% higher than values for fresh PA12 powder. Particles had a very low, below 1 m²/g, specific surface area; particles sintered as twin particles and often in polyhedral shapes.

Crystal transition and thermal behavior of Nylon 12

The polyamide 12 (PA12) with different crystal forms is prepared with three crystallization paths. The crystal structures and corresponding thermal properties are systematically investigated. The results reveal that an α-form and a mixed (α + γ)-form of PA12 can be obtained by casting at 30°C and (40–80°C), respectively. Meanwhile, the γ-form of PA12 can be obtained by both casting at 90°C and slow melt cooling. However, the γ′-form is obtained only by melt quenching. Both the γ and γ′ forms of PA12 exhibit a single melting peak, whereas the α-form exhibits two melting peaks. The higher peak is attributed to the melting of γ-PA12, which originates from the melting–recrystallization of the α-PA12. It is found that the tensile properties of PA12 depend on the crystal forms. Both the γ and γ′-PA12 are strong and tough polymer materials, while α-PA12 is a strong but brittle polymer material.

Numerical Model and Experimental Validation for Laser Sinterable Semi-Crystalline Polymer: Shrinkage and Warping

Shrinkage and warping of additive manufacturing (AM) parts are two critical issues that adversely influence the dimensional accuracy especially in powder bed fusion processes such as selective laser sintering (SLS). Powder fusion, material solidification, and recrystallization are the key stages causing volumetric changes of polymeric materials during the abrupt heating-cooling process. In this work, the mechanisms of shrinkage and warping of semi-crystalline polyamide (PA) 12 in SLS are well investigated. Heat-transfer and thermo-mechanical models are established to predict the process-dependent shrinkage and warping. The influence of raw material- and laser-related parameters are considered in the heat-transfer and thermo-mechanical models. Such models are established considering the natural thermal gradient and dynamic recrystallization, which induce internal strain and volumetric change. Moreover, an experimental design via orthogonal approach is introduced to validate the feasibility and accuracy of the proposed models. Finally, the quantitative relationships of process parameters with product shrinkage and warping are established; the dimensional accuracy in part-scale can be well predicted and validated with printed parts in a real experiment.

Synchrotron X-ray Scattering Analysis of Nylon-12 Crystallisation Variation Depending on 3D Printing Conditions

Nylon-12 is an important structural polymer in wide use in the form of fibres and bulk structures. Fused filament fabrication (FFF) is an extrusion-based additive manufacturing (AM) method for rapid prototyping and final product manufacturing of thermoplastic polymer objects. The resultant microstructure of FFF-produced samples is strongly affected by the cooling rates and thermal gradients experienced across the part. The crystallisation behaviour during cooling and solidification influences the micro- and nano-structure, and deserves detailed investigation. A commercial Nylon-12 filament and FFF-produced Nylon-12 parts were studied by differential scanning calorimetry (DSC) and wide-angle X-ray scattering (WAXS) to examine the effect of cooling rates under non-isothermal crystallisation conditions on the microstructure and properties. Slower cooling rates caused more perfect crystallite formation, as well as alteration to the thermal properties.

A novel experimental setup for in situ optical and X-ray imaging of laser sintering of polymer particles

We present a unique laser sintering setup that allows real time studies of the structural evolution during laser sintering of polymer particles. The device incorporates the main features of classical selective laser sintering machines for 3D printing of polymers and at the same time allows in situ visualization of the sintering dynamics with optical microscopy as well as X-ray scattering. A main feature of the setup is the fact that it provides local access to one particle-particle bridge during sintering. In addition, due to the small scale of the device and the specific laser arrangement process, parameters such as the temperature, laser energy, laser pulse duration, and spot size can be precisely controlled. The sample chamber provides heating up to 360 °C, which allows for sintering of commodity as well as high performance polymers. The latter parameters are controlled by the use of a visible light laser combined with an acousto-optic modulator for pulsing, which allows small and precise spot sizes and pulse times and pulse energies as low as 500 μs and 17 μJ. The macrostructural evolution of the particle bridge during sintering is followed via optical imaging at high speed and resolution. Placing the setup in high flux synchrotron radiation with a fast detector simultaneously allows in situ time-resolved X-ray characterizations. To demonstrate the capabilities of the device, we studied the laser sintering of two spherical PA12 particles. The setup provides crucial real-time information concerning the sintering dynamics as well as crystallization kinetics, which was not accessible up to now.

In Situ WAXD and SAXS during Tensile Deformation Of Moulded and Sintered Polyamide 12

To provide knowledge to improve the mechanical performance of Polyamide 12 (PA12) sintered products, we have studied experimentally the mechanical response and structure development under constant strain rate of compression moulded and laser sintered PA12 by means of in situ small-angle X-ray scattering (SAXS) and wide-angle X-ray diffraction (WAXD) experiments. It is found that at low temperatures, i.e., below the glass transition temperature, the brittle failure of laser sintered samples is determined by the fast formation of voids that originate at the beginning of the macroscopic plastic deformation. This effect appears to be faster at temperatures below room temperature and it is less effective at higher temperatures. When tested at 120 ∘ C, sintered PA12 shows a better mechanical response in terms of yield stress and a comparable strain at break with respect to moulded PA12. This can be explained by considering that sintered samples have slightly thicker crystals that can sustain higher stress at high temperature. However, this also leads to the formation of a larger number of voids at low testing temperatures. This work does not attempt to quantify the micromechanics behind crystals deformation and disruption, but it provides a deeper insight in the difference between the mechanical response of moulded and sintered PA12.

Ultra-strong long-chain polyamide elastomers with programmable supramolecular interactions and oriented crystalline microstructures

Polyamides are one of the most important polymers. Long-chain aliphatic polyamides could bridge the gap between traditional polyamides and polyethylenes. Here we report an approach to preparing sustainable ultra-strong elastomers from biomass-derived long-chain polyamides by thiol-ene addition copolymerization with diamide diene monomers. The pendant polar hydroxyl and non-polar butyrate groups between amides allow controlled programming of supramolecular hydrogen bonding and facile tuning of crystallization of polymer chains. The presence of thioether groups on the main chain can further induce metal-ligand coordination (cuprous-thioether). Unidirectional step-cycle tensile deformation has been applied to these polyamides and significantly enhances tensile strength to over 210 MPa while maintaining elasticity. Uniaxial deformation leads to a rearrangement and alignment of crystalline microstructures, which is responsible for the mechanical enhancement. These chromophore-free polyamides are observed with strong luminescence ascribed to the effect of aggregation-induced emission (AIE), originating from the formation of amide clusters with restricted molecular motions.

AMB2018-04: Benchmark Physical Property Measurements for Powder Bed Fusion Additive Manufacturing of Polyamide 12

Laser sintering (LS) of polyamide 12 (PA12) is increasingly being adopted for industrial production of end-use parts, yet the complexity of this process coupled with the lack of organized, rigorous, publicly available process-structure-physical property datasets exposes manufacturers and customers to risks of unacceptably poor part quality and high costs. Although an extensive scientific literature has been developed to address some of these concerns, results are distributed among numerous reports based on different machines, materials, process parameters, and users. In this study, a single commercially important LS PA12 feedstock has been processed along four build dimensions of a modern production LS machine, characterized by a wide range of physical techniques, and compared to the same material formed by conventional melt processing. Results are discussed in the context of the literature, offering novel insights including distributions of particle size and shape, localization of semicrystalline phase changes due to LS processing, effect of chemical aging on melt viscosity, porosity orientation relative to LS build axes, and microstructural effects on tensile properties and failure mechanisms. The resulting datasets will be made publicly available to modelers and practitioners for the purpose of improving certifiability and repeatability of end-use parts manufactured by LS.

A path for lignin valorization via additive manufacturing of high-performance sustainable composites with enhanced 3D printability

We report the manufacture of printable, sustainable polymer systems to address global challenges associated with high-volume utilization of lignin, an industrial waste from biomass feedstock. By analyzing a common three-dimensional printing process-fused-deposition modeling-and correlating the printing-process features to properties of materials such as acrylonitrile-butadiene-styrene (ABS) and nylon, we devised a first-of-its-kind, high-performance class of printable renewable composites containing 40 to 60 weight % (wt %) lignin. An ABS analog made by integrating lignin into nitrile-butadiene rubber needs the presence of a styrenic polymer to avoid filament buckling during printing. However, lignin-modified nylon composites containing 40 to 60 wt % sinapyl alcohol-rich, melt-stable lignin exhibit enhanced stiffness and tensile strength at room temperature, while-unexpectedly-demonstrating a reduced viscosity in the melt. Further, incorporation of 4 to 16 wt % discontinuous carbon fibers enhances mechanical stiffness and printing speed, as the thermal conductivity of the carbon fibers facilitates heat transfer and thinning of the melt. We found that the presence of lignin and carbon fibers retards nylon crystallization, leading to low-melting imperfect crystals that allow good printability at lower temperatures without lignin degradation.

The Influence of Different Melt Temperatures on the Mechanical Properties of Injection Molded PA-12 and the Post Process Detection by Thermal Analysis

Polyamide 12 (PA-12) test plates were injection molded using different melt temperatures and the influence on mechanical properties was investigated using quasi-static tensile and instrumented impact behavior in two conditioned states: dried, and following accelerated moisture intake. Energy absorption in tension is strongly dependent on process temperature (variations up to 99%) and additional variation (around 18%) was evident when testing at different conditioning states. Under high-velocity loading, the total impact energy varied by up to 8.70% and 9.05%, when systematic changes were made to process melt temperature and at moisture content, respectively, with all samples failing ductile. Differential Scanning Calorimetry (DSC) was used to characterise the unique endothermic melting behavior of molded PA-12 samples, by linking different process histories to the respective mechanical properties. With focus on the first heating curve progression, significant changes within the endothermic melting region were pointed out and quantified by using MatLab (software), proving DSC as a reliable testing tool for post-production analysis with increased practical implications regarding quality control as well as failure analysis. Findings for the initial heating curve progression were explained by studying the re-crystallisation peak values during cooling phase and obtained data for the second heating.

Molecular self-assembly of nylon-12 nanorods cylindrically confined to nanoporous alumina

Molecular self-assembly of nylon-12 rods in self-organized nanoporous alumina cylinders with two different diameters (65 and 300 nm) is studied with transmission electron microscopy (TEM) and wide-angle X-ray diffraction (WAXD) in symmetrical reflection mode. In a rod with a 300 nm diameter, the tendency of the hydrogen-bonding direction of a γ-form crystal parallel to the long axis of the rod is not clear because of weak two-dimensional confinement. In a rod with a diameter of 65 nm, the tendency of the hydrogen-bonding direction of a γ-form crystal parallel to the long axis of the rod is more distinct because of strong two-dimensional confinement. For the first time, selected-area electron diffraction (SAED) is applied in a transmission electron microscope to a polymer nanorod in order to determine the hydrogen-bond sheet and lamellar orientations. Results of TEM-SAED and WAXD showed that the crystals within the rod possess the γ-form of nylon-12 and that the b axis (stem axis) of the γ-form crystals is perpendicular to the long axis of the rod. These results revealed that only lamellae with 〈h0l〉 directions are able to grow inside the nanopores and the growth of lamellae with 〈hkl〉 (k ≠ 0) directions is stopped owing to impingements against the cylinder walls. The dominant crystal growth direction of the 65 nm rod in stronger two-dimensional confinement is in between the [-201] and [001] directions due to the development of a hydrogen-bonded sheet restricted along the long axis of the rod.