Dry sliding wear behavior of additively manufactured cenosphere-filled PETG syntactic foam composites

PurposeThis study aims to deal with developing composite filaments and investigating the tribological behavior of additively manufactured syntactic foam composites. The primary objective is to examine the suitability of the cenosphere (CS; 0-30 Wt.%) to develop a high-quality lightweight composite structure with improved abrasion strength. Design/methodology/approachCS/polyethylene terephthalate glycol (PETG) composite feedstock filaments under optimized extrusion conditions were developed, and a fused filament fabrication process was used to prepare CS-filled PETG composite structures under optimal printing conditions. Significant parameters such as CS (0-30 Wt.%), sliding speed (200-800 rpm) and typical load (10-40 N) were used to minimize the dry sliding wear rate and coefficient of friction for developed composites. FindingsThe friction coefficient and specific wear rate (SWR) are most affected by the CS weight percentage and applied load, respectively. However, nozzle temperature has the least effect on the friction coefficient and SWR. A mathematical model predicts the composite material's SWR and coefficient of friction with 87.5% and 95.2% accuracy, respectively. Practical implicationsBecause of their tailorable physical and mechanical properties, CS/PETG lightweight composite structures can be used in low-density and damage-tolerance applications. Social implicationsCS, an industrial waste material, is used to develop lightweight syntactic foam composites for advanced engineering applications. Originality/valueCS-reinforced PETG composite filaments were developed to fabricate ultra-light composite structures through a 3D printing routine.