Synthesis and characterization of flyash reinforced polymer composites developed by Fused Filament Fabrication

Fused filament fabrication (FFF) has seen an upsurge in its utilization towards development of tailored made materials of polymer base. The advancement and diversity in fabricating the polymer composite parts by using FFF has seen the embracement of this technology in wider aspects, ranging from automotive, aerospace, construction and has marched towards day to day requirements. This research article focuses on development of polymer composite; by using flyash (FA), an industrial waste produced during coal combustion, as reinforcement in Acrylonitrile butadiene styrene (ABS) matrix, to study the physical and mechanical properties. FA, which is primarily made up of metal oxides, plays an imperative role as reinforcement. Easily and abundantly available, FA is being used in several applications to reduce the landfills utilization and also helps the environment. In this study FA was added as reinforcement in 5 and 10 wt. % respectively to ABS matrix and was developed into filament of 1.75 mm diameter. The developed ABS + FA polymer composite using FFF, were analyzed for physical and mechanical properties as per American Society for Testing and Materials (ASTM) standards. Microstructure studies were carried out for the developed composite to understand their behavior in enhancing the dimensional accuracy and tensile strength with incremental addition of FA up to 10 wt%. Tensile strength was enhanced by 28.19% and 36.13% for ABS + 5wt. % FA and ABS + 10wt. % FA respectively. Dimensional stability was also enhanced. Similarly, surface roughness analysis was carried out and it was observed to reduce with addition of FA. The surface roughness measurements provided suitable results of decrement by 9.64% and 14.6% for ABS + 5wt. % FA and ABS + 10wt. % FA respectively. Overall, the usage of FA along with FFF, has paved a path in sustainable and green technology in manufacturing.