Investigation for dimensional accuracy of AMC prepared by FDM assisted investment casting using nylon-6 waste based reinforced filament

In the recent years, the whole world is facing a serious problem in handling nylon-6 wastes of various societies like: fibres/textile, household, carpets, tires, military supplies, etc. Ordinary recycling process of such wastes is costlier process and also omits its major mechanical properties. In the present research work, nylon-6 waste (collected from local plastic based industry) has been recycled, through extrusion process, in the form of fused deposition modelling (FDM) feedstock filament. This alternatively developed FDM filament has been successfully used to fabricate sacrificial patterns for investment casting process (ICP). The process was started with investigating the melt flow index (MFI) of collected nylon-6 waste which was matched with the commercial FDM filament through reinforcement. Finally, single screw extruder of has been used for the development of FDM filament proportion with a mixture of 60% nylon-6, 30% Al and 30% Al2O3 (by wt.). The resulting FDM patterns have been used in ICP for development of aluminum matrix composite (AMC). Taguchi L9 was used to investigate the affect of process parameters (volume of pattern, density of pattern and number of IC coatings) on dimensional accuracy of AMC developed. Apart from suggesting an alternative method for management and recycling of nylon-6 waste, the present research work also described a new approach for the development of AMC with tailor made properties.