Investigating particle emissions and aerosol dynamics from a consumer fused deposition modeling 3D printer with a lognormal moment aerosol model

ABSTRACT

Particle emissions from consumer-fused deposition modeling 3D printers have been reported previously; however, the complex processes leading to observed aerosols have not been investigated. We measured particle concentrations and size distributions between 7 nm and 25 μm emitted from a 3D printer under different conditions in an emission test chamber. The experimental data was combined with a moment lognormal aerosol dynamic model to better understand particle formation and subsequent evolution mechanisms. The model was based on particles being formed from nucleation of unknown semivolatile compounds emitted from the heated filament during printing, which evolve due to condensation of emitted vapors and coagulation, all within a small volume near the printer extruder nozzle. The model captured observed steady state particle number size distribution parameters (total number, geometric mean diameter and geometric standard deviation) with errors nominally within 20%. Model solutions provided a range of vapor generation rates, saturation vapor pressures and vapor condensation factors consistent with measured steady state particle concentrations and size distributions. Vapor generation rate was a crucial factor that was linked to printer extruder temperature and largely accounted for differences between filament material and brands. For the unknown condensing vapor species, saturation vapor pressures were in the range of 10^?3 to 10^?1 Pa. The model suggests particles could be removed by design of collection surfaces near the extruder tip.

Copyright © 2018 American Association for Aerosol Research     

Investigation of particle deposition on a micropatterned surface as an energy-efficient air cleaning technique in ventilation ducting systems

Abstract

Building ventilation ducting systems play a core role in controlling indoor air quality by recirculating the indoor air and mixing with ambient air. The ventilation system can serve as an air cleaning system itself either through the filtration system or integrating other means, while at the same time, attention to energy consumption is needed. The high-efficiency fibrous filters in a conventional filtration system not only cause high-pressure drops that consume fan energy but also add to the high operation cost. This article proposes an air cleaning technique, aimed at submicron particles, by means of installing patterned surfaces on the walls of ventilation ducts, which can be easily cleaned by water and reused. The effect of patterned surfaces on particle deposition was studied numerically. In the numerical simulation, the Reynolds stress turbulent model was correlated at the near-wall regions by turbulent velocity fluctuation at the normal direction. Particle trajectory was solved by using Lagrangian particle tracking. The numerical model was then validated with a particle deposition experiment. A wind tunnel experiment was carried out to quantify the particle deposition on the semicircular micropatterns for a wide range of heights. Based on our numerical results, the semicircular pattern height of 500?µm with a pitch-to-height ratio (p/e) of 10 has 8.58 times enhancement of the energy efficiency compared with a high-efficiency particulate air filter. Our results indicated that adding surface micropatterns to ventilation ducting for submicron particle deposition is a possible energy-efficient air cleaning technique for practical usage.

Copyright © 2020 American Association for Aerosol Research     

Using partial flow dilution to measure PM mass emissions from light-duty vehicles

Partial flow dilution (PFD) offers a number of benefits relative to conventional full flow dilution tunnels for motor vehicle PM emissions measurement in terms of measurement variability, footprint, and cost. Its implementation into automotive emissions test cells depends on its ability to record PM mass emissions equivalent to the current constant volume sampling (CVS) dilution tunnel approach. The present work examines factors critical to successful application of PFD sampling and compares vehicle PM emissions measured simultaneously by PFD and CVS tunnel. The combination of a current technology commercial PFD system and ultrasonic flow meter fulfill the two principal requirements of accurate exhaust flow measurement and fast time response for proportional sampling. PM mass emissions measured by PFD versus CVS systems satisfy a 1.03 ± 0.03 regression for the regulatory FTP test cycle, and comparably good agreement for the supplemental US06 drive cycle. Both dilution approaches are amenable to the single filter approach newly allowed under EPA regulations; however, the PFD sample weighted approach has the capability to provide a roughly 35% lower variability relative to the flow weighted approach used in the CVS method. Whereas partial flow dilution has seen application in heavy duty engine measurements, the present work demonstrates its feasibility for light duty chassis dynamometer testing.

Copyright © 2018 Ford Motor Company     

熔融沉积3D打印设备研究进展

阐述了3D打印技术的种类,介绍了熔融沉积成型(FDM)技术的原理、特点及其目前存在的问题;从控制方法(温度控制、运动控制、路径控制)和运动机构(送料机构、喷嘴、运动机构)两个方面系统综述了国内外FDM 3D打印设备的最新研究进展;最后,指出了目前FDM 3D打印设备所面临的挑战及需要解决的问题,展望了FDM 3D打印设...     

Characterization of nanosized silica size standards

Nanosized silica size standards produced with a sol–gel synthesis process were evaluated for particle size, effective density, and refractive index in this study. Particle size and effective density measurements were conducted following protocol from the National Institute of Advanced Industrial Science and Technology (AIST) in Japan. Particle sizes were measured via electrical mobility analysis using a differential mobility analyzer (DMA) at sheath flow rates (Q_sh) of 3.0 and 6.0 L/min and a constant aerosol flow rate (Q_a) of 0.3 L/min. The measured mean and mode diameters agreed well with the labeled sizes in the size range 40–200 nm, with differences ranging from 0.03% to 0.8%, well within the labeled expanded uncertainties (95% confidence intervals) of 1.8%–2.2%. The coefficient of variation (CV) of the size distribution was 0.012–0.027 for 40–200 nm. Particle sizes measured for 20 nm and 30 nm standards showed size differences with respect to the certified sizes of 1.7% and 8.3% at Q_sh = 6.0 L/min, but the size distributions were narrow, with CV = 0.047–0.064. The average effective density for the range 40–200 nm measured with an aerosol particle mass analyzer (APM) was 1.9 g/cm³. The real component of the refractive index measured with an optical particle counter (OPC) was 1.41 at a wavelength of 633 nm. All properties (size, effective density, and refractive index) were stable and could be measured with good repeatability. From these evaluations, it was found that the nanosized silica size standards have good characteristics for use as size standards and constitute a feasible alternative to PSL particles.

© 2017 American Association for Aerosol Research     

Evaluation of metallic filter media for sub-micrometer soot particle removal at elevated temperature

Soot particle removal performance of two types of metallic filter media, sintered metal powder and sintered metal fiber, is experimentally evaluated as potential improvements to conventional ceramic filtration media for gasoline direct injection (GDI) engine PM after-treatment application. Soot collection efficiency and flow resistance of several grades of metallic media are measured at temperatures of 25, 350, and 650°C and a range of representative filtration velocities for sub-micrometer soot particles generated from a propane flame. Theoretical collection efficiency based on single fiber efficiency theory shows good agreement with experimental data for nearly spherical KCl particles at 350°C. Improved collection efficiency is observed for soot particles in the interception-dominated size range above ～100 nm due to enhanced interception length. Soot collection is slightly enhanced at higher temperature, which is consistent with model predictions. Sintered metal fiber media are found capable of removing ～75% of soot particles by mass with an incremental flow resistance of less than 1.5 kPa under 10 cm/s and 350°C, which is promising for gasoline particulate filter (GPF) application. The media level figure of merit (FOM) is used to quantify the soot collection efficiency versus flow resistance tradeoff of all media tested. It is found that due to their more open structure (higher porosity) sintered metal fiber media have FOMs nearly one order of magnitude higher than those of sintered metal powder media, and by analogy those of conventional wall flow ceramic media. This suggests that sintered metal fiber media represents an attractive alternative to ceramic media for designing GPFs; however, further research into creating comparable surface area to the honeycomb structures used for wall flow filters is needed to extract the full potential of metal fiber media.

Copyright © 2017 American Association for Aerosol Research     

Experimental and modeling assessment of a novel automotive cabin PM2.5 removal system

Poor air quality inside vehicles and its impact on human health is an issue requiring attention, with drivers and passengers facing levels of air pollution potentially greater than street-side outdoor air. This paper assesses the potential effectiveness of a car cabin filtration system to remove fine particulate matter PM_2.5 and improve air quality for car passengers. The study was conducted as a practical evaluation coupled to a model implementation. First, the effectiveness of PM_2.5 filter material was investigated in a chamber experiment under a range of environmental and loading conditions using a realistic automotive auxiliary scrubber. Second, implementation of such a system was evaluated in a full air flow 3D computational fluid dynamical model configured for a realistic cabin and ventilation system, and related to the chamber results through a simple decay model. Additionally, performance of low-cost dust sensors was evaluated as potential cabin monitoring devices. The experiment and modeling support the feasibility of a robust system which could be integrated into automotive designs in a straightforward manner. Results suggest that an auxiliary scrubber in the rear of the cabin alone would provide suboptimal performance, but that by incorporating a PM_2.5 filter into the main air handling system, cabin PM_2.5 concentrations could be reduced from 100?µg m^?3 to less than 25?µg m^?3 in 100?s and to 5?µg m^?3 in 250?s. A health impact assessment for hypothetical occupational driver populations using such technology long term showed considerable reductions in indicative PM_2.5 attributable mortality.

Copyright © 2018 The Authors. Published with license by Taylor & Francis Group, LLC     

Experimental investigation and numerical modeling of the orientation angle of silver nanowires passing through polyester filters

In the present study, we measured the penetration of silver nanowires with the mobility diameter in the range from 200 to 400 nm through two different types of polyester filters: the screen filter with the solidity of 0.505 and fibrous filter with the solidity of 0.278. The orientation angles of silver nanowires passing through the single layer and multi-layers of polyester filter were experimentally estimated on the basis of the single fiber efficiency theory. In the case of the screen filter, the orientation angle obtained by fitting the experimental data for single layer was found to be close to 40?, indicating a random orientation of nanowires near the filter. However, the fibrous filter has the orientation angle much larger than 40?. The orientation angle can be affected by inhomogeneity of the filter. In particular, in the case of the fibrous filter, the solidity and fiber diameter may affect the orientation angle. For multi-layers of both screen and fibrous filters, it is difficult to determine the typical orientation angle and the fibrous filter tends to have a larger orientation angle than the screen filter. In addition, we carried out numerical simulations on the penetration of silver nanowires through the five layers of screen filter and the single layer of both screen and fibrous filters. Numerical prediction was carried out by using the three-dimensional numerical model determined by solidity and thickness of fibrous filter. Numerical predictions are highly congruent with experimental results and theoretical prediction.

© 2017 American Association for Aerosol Research     

Optimized preceramic polymer for 3D structured ceramics via fused deposition modeling

3D structured ceramics stemmed from preceramic polymers via additive manufacturing have attracted much attention recently. However, these polymers with high ceramic yield are so brittle that extrusion-based additive manufacturing techniques are hardly able to be utilized for assembling 3D structures. Herein, we developed a strategy to prepare feedstocks for these manufacturing techniques, i.e., utilizing a small amount of thermal-plastic polymer to optimize the preceramic polymer while good compatibility is required between the two polymers to ensure a homogeneous mixture. Polycarbosilane and polypropylene were selected as the representative materials. Polypropylene occupied a small proportion (≤5wt.%) and significantly improved the formability of the precursor. Three-dimensional SiC were obtained via fused deposition modeling combined with crosslinking and pyrolysis. The SiC ceramic filaments showed a mean tensile strength of 471 MPa. The strategy is also applicable to a large field of ceramic systems with corresponding precursor, such as sialon ceramic and multicomponent Si-based ceramics.     

Detachment of adhered particles from a cloth surface subjected to a rod strike

A mechanical impulse can cause adhered particles to detach from a surface. For various purposes, particle detachment may need to be enhanced or restricted. Unlike rigid solids, cloth material can be deformed or bent by a mechanical impulse. However, neither the cloth deformation nor the induced turbulent airflow has been well studied. This investigation experimentally measured the detachment of Arizona test dust (ATD) from cloth segments. The vertical margins of each cloth segment were fastened to a frame, and the cloth surface with the ATD adhered to the reverse side was struck with a rod. The cloth motion, induced airflow, and particle detachment were recorded by a high-speed camera. In addition, the displacement and acceleration of the cloth were monitored with a laser distance sensor. The mass percentages of detached particles from the cloth and the particle residual were weighed. Several factors that affected particle detachment were compared. The results revealed that the particle detachment was caused by a combination of the vibrating motion of the cloth surface, the hydrodynamic action of the induced turbulent airflows, and the particle agglomeration when the cloth was bent. A strike could even leave fewer residual particles when a much higher surface dust load had initially adhered to the cloth.

Copyright © 2019 American Association for Aerosol Research     

熔融沉积3D打印机机械结构的设计

3D打印技术作为一种快速成型技术,其采用数字式模型文件作为基础,采取逐层打印的办法将可粘合性的塑料或者粉末金属用以构筑所预想的实体技术.由于3D打印技术可采用的耗材种类不同,故其存在着不同的3D打印技术用于构造不同类型的部件.3D打印耗材常有尼龙玻纤、铝合金、钛合金、石膏、镀金银以及橡胶等材料.为了拓宽3D打印机所使用...     

Filtration efficiency analysis of fibrous filters: Experimental and theoretical study on the sampling of agglomerate particles emitted from a GDI engine

Fibrous filters are commonly used for aerosol purification and sampling. The filtration efficiency has been extensively studied using standard aerosol generators, yet the literature on experimental data and theoretical study concerning the filtration of agglomerates from real engines remains scarce. A filtration efficiency test system was developed to determine the filtration efficiency of two types of filters (uncoated and fluorocarbon coated) loaded by particulate matter (PM) emissions from a gasoline direct injection (GDI) engine. The experimental results showed that the filtration efficiency in terms of PM mass and number increased over time for both types of filters. The fractional efficiency (penetration efficiency) curves for the test fibrous filters rendered a U-shaped curve for particle sizes from 70 to 500 nm, and the most penetrating particulate size (MPPS) decreased over time. A small fraction of accumulation mode particles with the size between 70 nm to 500 nm penetrated the filters while almost all nucleation mode particles with the size below 50 nm were captured by the filters. The filtration efficiency derived from an empirical model based on classical single-fiber theory for laden filters generally agreed with the experimental data for the first 500 s, but suffered a significant deviation by approximately one order of magnitude at 948 s. A better estimate of the filtration efficiency trend with the maximum deviation of about 20% (except for large particles at the high end of the measurement spectra) was obtained by using a revised model which incorporates the effects of the increase in filter solidity, local velocity, dynamic shape factor and effective total length of fibers during the filtration process.

© 2017 American Association for Aerosol Research     

Mechanical properties of 3D parts fabricated by fused deposition modeling: Effect of various fillers in polylactide

Weak mechanical strength and serious mechanical anisotropy are two key limiting factors for three-dimensional (3D) parts prepared by fused deposition modeling (FDM) in industrial applications. In this work, we investigated the relationships between mechanical properties and surface quality of FDM parts with the properties of materials used. Three kinds of polylactide (PLA) filaments, composed of the same PLA matrix but different fillers (carbon fibers and talc), were used to prepare FDM specimens. Due to the nature of FDM process, FDM parts exhibited tensile properties weaker and more anisotropic than their injection-molding counterparts. The presence of fillers affected the tensile properties of FDM parts, especially the degree of mechanical anisotropy. It is found that the interlayer bond governing the mechanical performance of FDM parts was improved since the fillers added in the polymer materials facilitates the molecular diffusion across the bond interface. Also, the surface quality of FDM parts varied with fillers. Neat PLA parts exhibited surface quality superior to the 3D parts printed with composites filaments. This work is believed to provide highlights on the development of polymer composites filament and improvement of mechanical properties of FDM parts. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2019 , 136, 47824.     

熔融沉积成型用高分子材料的研究进展

介绍了熔融沉积成型(FDM)原理及所需材料要求,详细阐述了国内外FDM用丙烯腈–丁二烯–苯乙烯塑料(ABS)、聚乳酸(PLA)、聚碳酸酯(PC)的研究进展,展望了其发展前景。     

Effect of printing temperature on microstructure,thermal behavior and tensile properties of 3D printed nylon using fused deposition modeling

The present investigation aims at the thermal conditions for the printability of nylon using fused deposition modeling (FDM). Dog-bone like specimens are manufactured under two printing temperatures to measure the tensile performance of 3D printed nylon with respect to the feedstock material properties. Both Scanning Electron Microscopy (SEM) and X-ray micro-tomography analysis are conducted to shed more light on the microstructural arrangement of nylon filaments. Finite element computation based on microstructural implementation is considered to study the main deformation mechanisms associated with the nylon filament arrangement and the process-induced porosity. The results show a narrow temperature range for printability of nylon, and a significant influence of the printing temperature on the thermal cycling, porosity content and mechanical performance. With the support of both numerical and experimental results, complex deformation mechanisms are revealed involving shearing related to the filament sequencing, compression at the junction points and tension within the raster and the frame. All these mechanisms are associated with the particular and regular arrangement of nylon filaments.     

Effect of processing parameters on flexural properties of 3D-printed polyetherketoneketone using fused deposition modeling

Polyetherketoneketone (PEKK) is an engineering plastic with ultrahigh mechanical performance and has attracted considerable attention in the medical and technical fields. Printing parameters during fused deposition modeling (FDM) for PEKK have a significant impact on final part quality. In this study, a relationship between the process parameters and flexural properties of PEKK was investigated by conducting three-point bending tests, and scanning electron microscopy was employed to analyze the microstructure of fracture surfaces. Nozzle temperature, layer thickness, and infill density affected flexural properties by changing the porosity and interlayer bonding strength. Interlayer separation is the main failure mode of the upright orientation samples, while intralayer failure is likely to occur in the on-edge orientation samples. The flexural properties of FDM-printed PEKK under optimum parameters are comparable to those of mandibular bones, indicating that PEKK is a potential candidate for repairing mandibular defects. The results highlighted in this study are fundamental to the optimal design of complex ultralight, highly efficient structures.     

Study on performance characteristics of fused deposition modeling 3D-printed composites by blending and lamination

Component contacting degree in a composite material is an important reference for evaluation the performance characteristics. In this article, two composite material systems involving polylactic acid (PLA) with acrylonitrile butadiene styrene (ABS) and PLA with thermoplastic polyurethane (TPU) were prepared by blending and laminating through fused deposition modeling (FDM) 3D printing technology. The mechanical and thermal properties of the as-prepared composite materials were examined. The results indicated that PLA and TPU played a dominant role in tensile strength and breaking elongation, respectively, in individual composite material. ABS and TPU changed the glass transition peek, crystallinity, and modulus of PLA. The results also suggested that although the processing design of the blending method was more suitable for the contact between two components, but the mechanical properties of laminated composites were closer to theoretical predictions. The structural design and processing technology provide a comparative method and reference basis for studying the performance characteristics of composite materials.     

The feasibility of printing polylactic acid–nanohydroxyapatite composites using a low‐cost fused deposition modeling 3D printer

The current “gold standard” to treat bone lesions is allografts and autografts, both presenting important disadvantages such as risk of infection and morbidity. Synthetic grafts and scaffolds for bone regeneration represent a promising solution. Fused deposition modeling is a valid tool for developing synthetic bone grafts of complex shapes, which is a key issue. The possibility of building polylactic acid–nanohydroxyapatite (PLA/nanoHA) composites by 3D printing was systematically evaluated. PLA/nanoHA filaments for low‐cost 3D printers were produced by a multistep solvent‐free procedure and characterized by scanning electron microscopy, energy dispersive X‐ray spectroscopy, thermogravimetric analysis (TGA), differential scanning calorimetry, and rheometry. TGA analysis confirmed the presence of the nanoHA amounts used in the composites, equal to 5 and 15 wt %. The glass‐transition temperature and degree of crystallinity of PLA are not influenced by presence of nanoHA, which remains substantially amorphous. The morphological analysis and compression testing on printed samples showed that nanoHA was uniformly dispersed within the PLA matrix and improved the PLA mechanical properties without changing the rheological performance. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134, 44656.