Computational Modeling and Experimental Investigation of Additively Manufactured Fused Deposition Modeling Samples with In-Built Porosity

Additive manufacturing (AMAdditive manufacturing (AM)) is utilized in high-end industries where the reliabilityReliability of the manufactured parts is a critical factor of interest. Research efforts have been directed toward optimizing the processProcess parameters in order to mitigate porositiesPorosity in printed parts since their presence causes deterioration in the mechanical propertiesMechanical properties. Compared to experimental works, computational modeling techniques allow for efficient means to understand and mitigate defectsDefects. However, most of the simulation models assume a full dense part due to lack of appropriate models. In this work, an experimentally validated finite element analysis (FEAFinite element analysis (FEA)) model is presented that can be used to investigate the effect of porosityPorosity on the tensile response of Fused Deposition Modeling (FDMFused deposition modelling (FDM)) parts. Full dense FDMFused deposition modelling (FDM) samples as well as samples with induced macro-porosityPorosity were manufactured and tested to determine their tensile propertiesTensile properties. The experimental results were then used to validate a FEAFinite element analysis (FEA) model that simulates the samples behavior under tensile loading. The proposed framework is expected to assure the reliabilityReliability of computational modelling results that account for the effect of porosityPorosity in AMAdditive manufacturing (AM) samples.