Utilization of Additive Manufacturing in Evaluating the Performance of Internally Defected Materials

The elimination of internal defects in a material present in the raw material or generated during the manufacturing or service is difficult. The inclusions of the defects have an adverse effect on the load bearing capacity. The presence of the cracks subjected to a specific orientation in materials or machinery can cause devastating unexpected failure during operation. Analysis of the failure in the components with cracks is more confined to analytical and numerical evaluation. The experimental evaluation has been tedious due to the complexity of replicating the actual defected component. The potential of additive manufacturing in developing user-defined components with cracks for the experimental evaluation is explored in this research. The present research investigated the effect of the internal elliptical cracks aligned at different orientations on the mechanical performance of polylactic acid (Green filament). The Fusion Deposition Method was utilized for the development of the standard tensile specimens with internal elliptical crack oriented at 0°, 45° and 90° using UltiMaker 2. The results proved that there is a considerable reduction in the load bearing capacity due to the presence of the cracks. The maximum load bearing capacity decreased by 15.01% for the specimen with crack inclined at 0° to the lateral axis compared to crack- free specimen. The nature of the fracture and the stress-strain graph evidently showcase the brittle nature of the material. The SEM image of the fractured region proved the phenomenal characteristics such as strong adhesion between the layers and the proper material flow. In the light of the results of this work, it can be concluded that the 3-D printing methodology is effective for evaluating the mechanical performance of the internally defected material.