Additive Manufacturing and Cellular/Lattice Structures: Designs, Realization and Applications: Cellular/Lattice Structures III
Sponsored by: TMS Additive Manufacturing Committee, TMS Materials Characterization Committee
Program Organizers: Li Yang, University of Louisville; Allison Beese, Pennsylvania State University; John Carpenter, Los Alamos National Laboratory; Carolyn Seepersad, Georgia Tech; Miguel Aguilo, Morphorm LLC
Wednesday 8:00 AM
October 12, 2022
Room: 307
Location: David L. Lawrence Convention Center
Session Chair: Bhisham Sharma, Wichita State University
8:00 AM
Effect of Geometrical Characteristics on the Mechanical Properties of Co-Cr-Mo Triply Periodic Minimal Surface Lattices Fabricated by Laser-Powder Bed Fusion: So-Yeon Park1; Kyu-Sik Kim2; Bandar AlMangour3; Kee-Ahn Lee1; 1Inha University; 2Agency for Defense Development; 3King Fahd University of Petroleum & Minerals
Node-free minimal surfaces sheet-based lattices can have excellent mechanical properties than typical truss type lattices. Their mechanical properties can be controllable by adjusting unit cell parameters (unit cell size, wall thickness, etc.). In this study, Co-Cr-Mo alloy sheet lattices were manufactured by using laser-powder bed fusion (L-PBF). Among the minimal surface model, Neovius and I-WP were selected with different unit cell sizes (1~5mm). And their mechanical properties were investigated. In the results of tensile tests, yield strengths, stiffness values and elongations of Neovius were higher than I-WP in all unit cell sizes. Moreover, compressive energy absorption properties of Neovius were also superior. EBSD and Digital image correlation analysis was performed to analyze the micro to macro deformation behaviors by topology, and to determine the interaction of the microstructure and topology. Based on the results, the deformation behavior of the Co-Cr-Mo sheet lattice fabricated by the L-PBF were also discussed.
8:20 AM
Fabrication, Microstructure and High Temperature Mechanical Properties of Inconel 718 Lattice Structures Manufactured by Laser Powder Bed Fusion: Tae-Hoon Kang1; Yongho Sohn2; Kee-Ahn Lee1; 1Inha University; 2University of Central Florida
Unit cell topology and mechanical properties at room-temperature and 650℃ of additively manufactured IN718 lattice structures were investigated. 12-different lattice structures (BCC, FCC, BCCZ, FCCZ with 2mm, 3mm, 4mm unit-cell sizes; Z means strut designed along the build-direction) were manufactured by laser powder bed fusion process. Solution treatment and standard-aging were also conducted. The relative density of lattice structures were measured 11%~34% according to topology of unit-cell. In standard-aged strut, γ΄, γ΄΄, δ and carbide were observed and analyzed. The characteristic of compressive stress-strain curves followed the general trend of typical lattice structures. However, despite BCCZ has highest relative density, FCCZ shows higher compressive strength in all unit-cell size than BCCZ at RT (FCCZ:180.1MPa, BCCZ:155.7MPa in 2mm unit-cell) and 650℃ (FCCZ:158.5MPa, BCCZ:102.3MPa in 2mm unit-cell). In addition, standard-aged specimens show 20% higher compressive strength on average than as-built. Correlations between structural and microstructural characteristics and deformation behavior were also discussed.
8:40 AM
Synchronous Involvement of Topology and Microstructure to Design Additively Manufactured Lattice Structure: Kavan Hazeli1; 1The University of Arizona
This presentation demonstrates that simultaneously considering the effects of topology and microstructure on the mechanical behavior of AMLS has the potential to substantially improve key performance metrics, e.g., energy dissipation, and to avoid widely reported drastic strength drop of AMLS at the onset of yielding instead, an ever-hardening response is achieved. The distinguishing feature of our approach is that the topological optimization is performed while accounting for the heterogeneous distribution of strut-level microstructural features and concomitant mechanical behavior, which leads to new insights relative to peak AMLS structural performance. A new set of new topologies are designed, built, and validated against experiments. The new topologies demonstrate over 50% improvement on average in energy absorption capacity and flow stress of topologies that had been previously optimized using a homogeneous constitutive model throughout the unit cell.
9:10 AM
Effects of TiB2 in an Al-Cu-Sc Alloy in the Hybrid Investment Casting Process: Jose Marcelino Da Silva Dias Filho1; Yifan Li1; Aleeza Batool1; Ahmed Qureshi1; Hani Henein1; 1Univeristy of Alberta
Al-Cu alloys are largely used in the automotive and aerospace area, but with the advance of technology new alloys are necessary. Sc additions show an effect to improve the performance of Al-Cu alloys. This work shows the characterization of Al-4.5wt%Cu-04wt.%Sc alloy with and without TiB2 addition in the hybrid investment casting of lattices process. The experimental proceeding consists of PLA 3D printer lattice attached to the rubber base using polymer clay, pouring the plastic cast ceramic slurry into the flask with print inside, burnout cycle to eliminate wax/polymer in the mold, pouring the alloy in a preheat mold attached with an applied vacuum. Microstructure and microhardness were observed. This work aims to also explore the effect on microstructure and hardness of TiB2 as the refined grainer for Al-4.5wt%Cu-04wt.%Sc alloy.
9:30 AM
Localized Strain, Microstructure, and Property Control of Ti-5553 Lattice Materials: Caleb Andrews1; Jenny Wang2; Maria Strantza2; Manyalibo Matthews2; Mitra Taheri1; 1Johns Hopkins University; 2Lawrence Livermore National Laboratory
The laser powder bed fusion additive manufacturing (L-PBF AM) process generates complex microstructures and residual strains across length scales which can be tuned via the manufacturing controls of the L-PBF process, and allows for local and programmatic variation of microstructures across a given build volume. This localized control could be utilized to unlock an additional degree of control by varying microstructure, strain, and mechanical properties across the lattice. By enabling this ‘0th order’ microscale level of tuneability, struts and nodes within lattices are tailored microstructurally to deliver different mechanical properties locally. A combined approach of melt pool monitoring in-situ, high resolution electron backscattering diffraction ex-situ, and micromechanical measurements across the lattice will demonstrate a feedback loop of how changes in the L-PBF parameter space create effects on the local microstructure which can be tied to lattice cell properties, and enable greater tuneability in architected materials.
9:50 AM Cancelled
Miura-Ori Based Metallic Structure for Large Deformation via Additive Manufacturing: Vanshika Singh1; Eric Heikkenen1; Sudarsanam Babu1; Michael Kirka2; 1University of Tennessee, Knoxville; 2Oak Ridge National Laboratory
Nature demonstrates instances where they respond to stimuli. Inspired by this, we propose a structure that can, by virtue of its geometry, change its shape or size significantly when exposed to boundary conditions changes such as temperatures and pressures. Such designs would perform lifelike without using unique materials or external devices. Origami, a 16th century-old Japanese artwork, has shown exciting results by attaining different motions depending on the geometry via papers, polymers, or bio-material. Literature shows limited work leveraging structural metals in this domain. Here, we propose to leverage Miura-ori, a well-studied origami, to achieve significant motions of metallic structure as the boundary conditions change. We studied Miura-ori experimentally under compressive load and measured the strains in the XY plane using 3D digital image correlation. We used different materials like paper, polymer, and Aluminium sheets with different thicknesses for comparison.
10:10 AM Break
10:30 AM
Enabling Novel Porous Noise Absorbers via Additive Manufacturing: Bhisham Sharma1; 1Wichita State University
Porous materials are frequently used for acoustic insulation applications. The open cellular architecture dissipates incident acoustic energy via frequency-dependent visco-inertial and thermal loss mechanisms. While currently used noise reduction materials—such as cellular foams and glass-fibers—provide good sound absorption properties at affordable costs, their fabrication process results in batch-to-batch property variations. Further, their low mechanical stiffness and inability to sustain high-pressure, high-temperature environments limits their use for advanced engineering applications. In this presentation, I discuss our recent work on using low-cost additive manufacturing methods to design multifunctional noise absorbers. Our work shows that additive manufacturing can enable the fabrication of novel porous architectures that overcome the limitations of traditional materials while providing comparable acoustic performance. I will discuss the state-of-art and current fabrication challenges.
11:00 AM
Interlocking Metasurfaces: A Joining Technology for Additive: Ophelia Bolmin1; Benjamin Young1; Philip Noell1; Brad Boyce1; 1Sandia National Laboratories
The assembly of additively manufactured parts, including both monolithic parts and lattices, has largely been restricted to traditional joining technologies (e.g., welds, adhesives, bolts). In this talk, we present a novel AM-enabled joining technology: interlocking metasurfaces (ILM). ILMs are architected arrays of mating features that create non-permanent joints for additively manufactured parts. We define a design framework and demonstrate how AM enables rapid exploration of the ILM design space. Various designs are fabricated in a broad range of materials from polymers to metals and the performance of selected designs is experimentally evaluated. The selected designs create mechanically robust integral attachment solutions for complex structures such as lattices and vessels.Sandia National Laboratories is a multimission laboratory managed and operated by National Technology and Engineering Solutions of Sandia, LLC., a wholly owned subsidiary of Honeywell International, Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA-0003525.
11:20 AM
Multi-scale Simulations for Improving the Design of Additive Manufactured Shock Absorbers: Luiz Lima1; Nannan Song1; Kedar Malusare1; Kennedy Neves1; Flavio Souza1; 1Siemens
The design of lighter, more effective lattice structures for shock absorbers is enabled by additive manufacturing. However, the choice of the optimal lattice structure for a given application is not an easy task, given the complexity of the mechanical response in the microstructural level and the different ways it can affect the behavior of the component. The use of multi-scale finite element simulations provides an accurate and practical alternative for testing and comparing different designs. This work focuses on the modelling and execution of such multi-scale simulations for different types of shock absorbers. In each case, different lattice structures, with varying shapes, thicknesses and densities are compared. Results are validated with experimental data from the literature and confirm the predictive ability of the simulations. Moreover, in some of the cases, enhanced designs are proposed and numerically tested, supporting the use of the simulations as a means of improving design.