Reduction of particle embedding in solid particle erosion of polymers

Particle embedding can be an unwanted consequence of abrasive jet micromachining (AJM) of polymeric materials. The embedding of aluminum oxide particles into acrylonitrile butadiene styrene (ABS), polytetrafluoroethylene (PTFE), polydimethylsiloxane (PMDS) and polymethylmethacrylate (PMMA) was studied under cryogenic and room temperature conditions. Scanning electron microscopy (SEM) with energy dispersive X-ray spectroscopy (EDX) showed the fractional area coverage by embedded Al2O3 particles after room temperature AJM to be: 16% (ABS), 19% (PTFE), 25% (PDMS) and 3.2% (PMMA). Under cryogenic conditions, however, the fractional area coverage of embedded Al2O3 was found to be significantly reduced: 10% (ABS), 0.8% (PTFE), and 1.6% (PDMS). For PMMA, it was demonstrated that the surface was shielded by the embedded particles, resulting in an erosion rate that decreased with increasing embedded particle coverage.