Mechanical, thermal, melt-flow and morphological characterizations of bentonite-filled ABS copolymer

This study aims to investigate the mechanical, thermal, melt-flow and morphological behavior of acrylonitrile-butadiene-styrene (ABS)-based composites after bentonite inclusions. Melt mixing is the most preferred production method in industrial scale and basically it has very near processing parameters compared to 3D printing applications. Rheological parameters of ABS and its composites are important for 3D applications. Melt flow behavior of ABS effects the fabrication of 3D printed product at desired levels. Shear thinning and non-Newtonian viscosity characteristics of ABS make viscosity control easier and more flexible for several processing techniques including injection molding, compression molding and 3D printing.

ABS copolymer was reinforced with bentonite mineral (BNT) at four different loading ratios of 5%, 10%, 15% and 20%. ABS/BNT composites were fabricated by lab-scale micro-compounder followed by injection molding process. Mechanical, thermo-mechanical, thermal, melt-flow and morphological properties of composites were investigated by tensile, hardness and impact tests, dynamic mechanical analysis (DMA), thermo-gravimetric analysis (TGA), melt flow index (MFI) test and scanning electron microscopy (SEM), respectively.

Mechanical tests revealed that tensile strength, elongation and hardness of ABS were enhanced as BNT content increased. Glass transition temperature and storage modulus of ABS exhibited increasing trend with the additions of BNT. However, impact strength values dropped down with BNT inclusion. According to MFI test measurements, BNT incorporation displayed no significant change for MFI value of ABS. Homogeneous dispersion of BNT particles into ABS phase was deduced from SEM micrographs of composites. Loading ratio of 15% BNT was remarked as the most suitable candidate among fabricated ABS-based composites according to findings.

The advanced mechanical properties and easy processing characteristics are the reasons for usage of ABS as an engineering plastic. Owing to the increase in its usage for 3D printing technology, the ABS became popular in recent years. The utilization of ABS in this technology is in filament form with various colors and dimensions. This is because of its proper rheological features.

Melt-mixing technique was used as preparation of composites, as this processing method is widely applied in industry. This method is also providing similar processing methodology with 3D printing technology.

According to the literature survey, to the best of the authors’ knowledge, this study is the first research work regarding the melt-flow performance of ABS-based composites to evaluate their 3D printing applications and processability. ABS and BNT containing composites were characterized by tensile, impact and shore hardness tests, DMA, TGA), MFI test and SEM techniques.