The Effects on Thermal Efficiency of Yttria-Stabilized Zirconia and Lanthanum Zirconate-Based Thermal Barrier Coatings on Aluminum Heating Block for 3D Printer

Roadmap: Numerical-Experimental Investigation and Optimization of 3D-Printed Parts Using Response Surface Methodology

Several process variables can be taken into account to optimize the fused filament fabrication (FFF) process, a promising additive manufacturing technique. To take into account the most important variables, a numerical-experimental roadmap toward the optimization of the FFF process, by taking into account some physico-chemical and mechanical characteristics, has been proposed to implement the findings through the thermal behavior of materials. A response surface methodology (RSM) was used to consider the effect of liquefier temperature, platform temperature, and print speed. RSM gave a confidence domain with a high degree of crystallinity, Young's modulus, maximum tensile stress, and elongation at break. Applying the corresponding data from the extracted zone of optimization to the previously developed code showed that the interaction of parameters plays a vital role in the rheological characteristics, such as temperature profile of filaments during deposition. Favorable adhesion could be achieved through the deposited layers in the FFF process. The obtained findings nurture motivations for working on the challenges and bring us one step closer to the optimization objectives in the FFF process to solve the industrial challenges.

The Effect on Energy Efficiency of Yttria-Stabilized Zirconia on Brass, Copper and Hardened Steel Nozzle in Additive Manufacturing

This study aimed to investigate if a thermal barrier coating (TBC) affected the energy efficiency of 3D printers. In accordance with this purpose, the used TBC technique is clearly explained and adapted to a nozzle in a simulation environment. Brass, copper, and hardened steel were selected to be the materials for the nozzles. The reason for the usage of a thermal barrier coating method is that the materials are made with low thermal conductivity, which reduces the thermal conductivity and energy losses. Yttria-stabilized zirconia was used to coat material on brass, copper, and hardened steel. To prevent temperature fluctuations, yttria-stabilized zirconia together with a NiCRAl bond layer was used and, thus, heat loss was prevented. Additionally, the paper addressed the effects of the coating on the average heat flux density and the average temperature of the nozzles. In addition, by means of the finite element method, steady-state thermal analyses of the coated and uncoated nozzles were compared, and the results show that the thermal barrier coating method dramatically reduced energy loss through the nozzle. It was found that the average heat flux was reduced by 89.4223% in the brass nozzle, 91.6678% in the copper nozzle, and 79.1361% in the hardened steel nozzle.