The Use of Acoustic Emission to Determine the Safe Range of Operational Stresses of 3D-Printed ABS Polymer Components

This work proposes using acoustic emission during a static tensile test to determine the stress characteristics of the initial phase of the destruction process of elements printed using the material extrusion (MEX) additive method at various printing parameters. The changed parameters were layer height, print orientation, filling ratio, and nozzle temperature. ABS material was chosen for printing. The experiment was carried out according to the Taguchi plan. The analysis of the results showed that changes in printing parameters significantly impact the mechanical properties of the tested elements. The parameter that had the greatest impact on strength was the filling ratio. Maximum tensile strength was achieved with the following printing parameters: 0.24 mm layer, 30°, 100% infill, 275 °C, concentric pattern. The results can be the basis for optimizing the additive printing process and improving the efficiency and reliability of manufactured components. The results of recorded acoustic emissions during strength tests allow the identification of stresses characteristic of the initial phase of the destruction process of the tested material. This phase is the elastic-visco-plastic transition, and the use of the AE method enables its detection 2-5 s earlier than the static tensile test. This allows us to determine the safe range of stresses when using the mentioned materials, which is particularly helpful in designing structures or spare parts. The test results showed that the critical stress for the investigated components is approximately 6 MPa, and exceeding this value is associated with the risk of unsafe operation.