Effect of Printing Parameters on the Surface Roughness of 3D-Printed Melt-Cast Explosive Substitutes Based on Melt...

Area of Science:

• Materials Science
• Additive Manufacturing
• Energetic Materials

Background:

• 3D printing offers innovative fabrication of complex energetic material structures.
• Melt extrusion is key for creating multi-component melt-cast explosives.
• Traditional methods limit complex geometries and performance optimization.

Purpose of the Study:

• To investigate the feasibility of 3D printing melt-cast explosives using a paraffin-based composite.
• To optimize printing parameters for surface roughness and structural integrity.
• To assess the influence of printing variables on the quality of 3D printed energetic materials.

Main Methods:

• A paraffin-based composite was developed as a melt-cast explosive substitute.
• A Design of Experiments approach with central composite design was employed.
• Key parameters studied: layer thickness, percent infill, extrusion temperature, and printing velocity.
• Computed tomography was used to detect internal defects.

Main Results:

• Layer thickness and printing velocity were identified as significant factors affecting surface roughness.
• No internal voids or cracks were detected via computed tomography.
• A complex-shaped composite grain was successfully fabricated using the EAM-D-1 printer.

Conclusions:

• 3D printing of melt-cast explosives with complex structures is feasible using paraffin-based composites.
• Optimizing printing parameters like layer thickness and velocity is crucial for surface quality.
• This technology holds potential for enhanced accuracy and performance in energetic materials.