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Within this contribution, the effect of grinding media wear on the melt crystallisation of polybutylene terephthalate (PBT) is addressed. PBT was wet ground in a stirred media mill in ethanol using different grinding media beads (silica, chrome steel, cerium-stabilised and yttrium-stabilised zirconia) at comparable stress energies with the intention to use the obtained particles as feed materials for the production of feedstocks for laser powder bed fusion additive manufacturing (PBF-AM). In PBF‑AM, the feedstock’s optical, rheological and especially thermal properties—including melt crystallisation kinetics—strongly influence the processability and properties of the manufactured parts. The influence of process parameters and used grinding media during wet comminution on the optical properties, crystal structure, molar mass distribution, inorganic content (wear) and thermal properties of the obtained powders is discussed. A grinding media-dependent acceleration of the melt crystallisation could be attributed to wear particles serving as nuclei for heterogeneous crystallisation. Yttrium-stabilised zirconia grinding beads proved to be the most suitable for the production of polymer powders for the PBF process in terms of (fast) comminution kinetics, unchanged optical properties and the least accelerated crystallisation kinetics.

Abrasion-Induced Acceleration of Melt Crystallisation of Wet Comminuted Polybutylene Terephthalate (PBT)