Effect of core–shell composite particles on the sintering behavior and properties of nano-Al2O3/polystyrene composite prepared by SLS

Abstract Nano-Al2O3 particles coated with polystyrene (PS) by emulsion polymerization were used as fillers to reinforce PS based composites prepared by selective laser sintering (SLS). The influences of the treated and untreated nanoparticles on the sintering behavior and mechanical properties of the laser sintered specimens were investigated. It was found that there were many uneven holes in the untreated composites. However, for the treated composites, due to the nanoparticle surfaces treated by emulsion polymerization, the absorbance of laser was improved and the nanoparticles dispersed well in the polymer matrix; a full dense structure was obtained and the properties were enhanced, such as the notched impact strength increased 50%, the maximum value was 12.1 kJ/m2; the tensile strength increased up to 300%, the maximum value was 31.2 MPa, comparing to the unfilled PS. FE-SEM studied the tensile fractured surfaces of the sintered specimens. It was noted that the fractured surfaces of composites with treated nanoparticles were rougher than those of unfilled PS and those of the untreated composite. Drawing from the results, it can be confirmed that a full dense structure can be obtained and the polystyrene matrix was strengthened and toughened when the nanoparticles were coated with PS by emulsion polymerization. This work forms a theoretical and technique basis for the production of selective laser sintered nano-Al2O3/PS functional products.