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Investigating the Feasibility of Processing Activated Carbon/UHMWPE Polymer Composite Using Laser Powder Bed Fusion
Yas Khalil1, Neil Hopkinson2, Adam J Kowalski3
1Department of Mechanical Engineering, University of Sheffield, Sheffield S3 7HQ, UK.
Polymers
|August 26, 2022
Summary
This study introduces additive manufacturing using Selective Laser Sintering for activated carbon (AC) and Ultra-High Molecular Weight Polyethylene (UHMWPE) composites. This novel method enhances filter pore interconnectivity and filtration efficiency compared to traditional methods.
Area of Science:
- Materials Science
- Additive Manufacturing
- Filtration Technology
Background:
- Activated Carbon (AC) is a porous, low-cost filter material but is brittle.
- Ultra-High Molecular Weight Polyethylene (UHMWPE) is a tough polymer used as a binder.
- Conventional AC/UHMWPE filter manufacturing yields low pore interconnectivity, limiting efficiency.
Purpose of the Study:
- To investigate the suitability of AC/UHMWPE composites for Selective Laser Sintering (SLS).
- To explore how varying AC and UHMWPE ratios affect composite properties for SLS.
- To compare SLS-derived filters with conventionally manufactured ones.
Main Methods:
- Preparation of AC/UHMWPE composite powders with varying ratios.
- Characterization including particle size, morphology, density, powder flow, thermal analysis, and crystallinity.
- Manufacturing of AC/UHMWPE parts using a commercial SLS machine.
Main Results:
- AC addition improved UHMWPE powder flow.
- Thermal properties of UHMWPE were largely unaffected by AC.
- AC/UHMWPE composites showed a 20 °C shift in mass loss to higher temperatures, favorable for SLS.
- SLS successfully produced AC/UHMWPE parts.
Conclusions:
- AC/UHMWPE composites are suitable for SLS.
- SLS offers potential for improved filter structures and efficiency.
- The study demonstrates a viable additive manufacturing route for advanced AC/UHMWPE filters.
