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<p>Improving the wear resistance of components produced through additive manufacturing can be effectively achieved by integrating metallic fillers into polymer matrices. This study focuses on the development and evaluation of steel-reinforced polylactic acid (PLA) composites fabricated using material extrusion, which is commonly referred to as the material extrusion process. For the slurry erosion test, silica sand water mixtures with varying slurry concentrations (50 to 150&#xa0;g/L) and rotational speeds (500 to 1500 RPM) were used. Shore D hardness increased from 71 for neat PLA to 77 and 81 for 5 wt.% and 10 wt.% steel-filled composites, corresponding to hardness improvements of 8.45% and 14.08%, respectively. Slurry erosion results indicated a significant decrease in the amount of material lost when steel fillers were added: average weight loss went from 0.049&#xa0;g for neat PLA to 0.043&#xa0;g (12.2% reduction) and 0.026&#xa0;g (47% reduction) for 5 wt.% and 10 wt.% steel composites, respectively. Even at severe conditions (150&#xa0;g/L slurry concentration and 1500 RPM), the 10 wt.% steel composite always had the lowest mass loss. The transition from severe micro-cutting and brittle fracture in neat PLA to mild fatigue wear and crack-suppressed propagation in steel-filled composites was observed by SEM and confocal microscopy. The results show 10 wt.% steel-reinforced PLA has much higher hardness and slurry erosion resistance, which is applicable to erosive fluid handling applications.</p>

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Effect of Steel Fillers on Slurry Erosion Behavior of FDM-Printed PLA-Based Polymer Composites

  • 期刊论文

  • 发表日期：

    2026年6月20日

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  • R. Keshavamurthy,
  • G. S. Pradeep Kumar,
  • Dokka Abhishek Dikshith,
  • S. Dhruva Deep Verma,
  • John S. Korattiyil,
  • Ashutosh Pattanaik

摘要

Improving the wear resistance of components produced through additive manufacturing can be effectively achieved by integrating metallic fillers into polymer matrices. This study focuses on the development and evaluation of steel-reinforced polylactic acid (PLA) composites fabricated using material extrusion, which is commonly referred to as the material extrusion process. For the slurry erosion test, silica sand water mixtures with varying slurry concentrations (50 to 150 g/L) and rotational speeds (500 to 1500 RPM) were used. Shore D hardness increased from 71 for neat PLA to 77 and 81 for 5 wt.% and 10 wt.% steel-filled composites, corresponding to hardness improvements of 8.45% and 14.08%, respectively. Slurry erosion results indicated a significant decrease in the amount of material lost when steel fillers were added: average weight loss went from 0.049 g for neat PLA to 0.043 g (12.2% reduction) and 0.026 g (47% reduction) for 5 wt.% and 10 wt.% steel composites, respectively. Even at severe conditions (150 g/L slurry concentration and 1500 RPM), the 10 wt.% steel composite always had the lowest mass loss. The transition from severe micro-cutting and brittle fracture in neat PLA to mild fatigue wear and crack-suppressed propagation in steel-filled composites was observed by SEM and confocal microscopy. The results show 10 wt.% steel-reinforced PLA has much higher hardness and slurry erosion resistance, which is applicable to erosive fluid handling applications.