Design Optimization of Irregular Cellular Structure for Additive Manufacturing

Song, Guohua; Jing, Shikai; Zhao, Fang-Lei; Wang, Yedong; Xing, Hao; Zhou, Jingtao

doi:10.1007/s10033-017-0168-3

Cited by 24 publications

(19 citation statements)

References 27 publications

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“…It uses a moving laser beam that selectively fuses and consolidates thin layers of a loose powder based on computer-aided design (CAD) models [7][8][9][10]. It has significant advantages in saving manufacturing time, production cost and reducing personnel error rate [11,12]. Compared with steels, nickel alloys and titanium alloys [13][14][15], previous studies have shown that SLM processing of aluminum alloys is much challenging owing to their low absorptivity (only 9%) to the laser beam and the high heat conductivity (237 W/(m•K)) [16].…”

Section: Introductionmentioning

confidence: 99%

Effect of Trace Addition of Ceramic on Microstructure Development and Mechanical Properties of Selective Laser Melted AlSi10Mg Alloy

Zhang

et al. 2020

Chin. J. Mech. Eng.

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Selective laser melting (SLM) is an emerging additive manufacturing technology for fabricating aluminum alloys and aluminum matrix composites. Nevertheless, it remains unclear how to improve the properties of laser manufactured aluminum alloy by adding ceramic reinforcing particles. Here the effect of trace addition of TiB 2 ceramic (1% weight fraction) on microstructural and mechanical properties of SLM-produced AlSi10Mg composite parts was investigated. The densification level increased with increasing laser power and decreasing scan speed. A near fully dense composite part (99.37%) with smooth surface morphology and elevated inter-layer bonding was successfully obtained. A decrease of lattice plane distance was identified by X-ray diffraction with the laser scan speed decreased, which implied that the crystal lattices were distorted due to the dissolution of Si and TiB 2 particles. A homogeneous composite microstructure with the distribution of surface-smoothened TiB 2 particles was present, and a small amount of Si particles precipitated at the interface between reinforcing particles and matrix. In contrast to the AlSi10Mg alloy, the composites showed a stabilized microhardness distribution. A higher ultimate tensile strength of 380.0 MPa, yield strength of 250.4 MPa and elongation of 3.43% were obtained even with a trace amount of ceramic addition. The improvement of tensile properties can be attributed to multiple mechanisms including solid solution strengthening, load-bearing strengthening and dispersion strengthening. This research provides a theoretical basis for ceramic reinforced aluminum matrix composites by additive manufacturing.

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Section: Introductionmentioning

confidence: 99%

Effect of Trace Addition of Ceramic on Microstructure Development and Mechanical Properties of Selective Laser Melted AlSi10Mg Alloy

Zhang

et al. 2020

Chin. J. Mech. Eng.

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“…Typically, an elementary cell model is developed in CAD programs with the help of several basic objects (e.g., sphere, cylinder, cube) which are usually bounded by logical operations. Then, the elementary cell is reproduced in threedimensional space [21][22][23]. Recently, much attention has been devoted to the ability of generating cellular structures based on mathematical formulas with described triply periodic minimal surfaces (TPMS) [24][25][26][27].…”

Section: Introductionmentioning

confidence: 99%

The manufacturability and compression properties of the Schwarz Diamond type Ti6Al4V cellular lattice fabricated by selective laser melting

Maszybrocka

Gapiński

Dworak

et al. 2019

Int J Adv Manuf Technol

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Selective laser melting technology makes it possible to produce 3D cellular lattice structures with controlled porosity. The paper reflects to machining and examination of structures with predefined distribution, shape and size of the pores. In the study, the porous structures of Ti6Al4V were investigated. The tests were carried out using structures of spatial architecture of Schwarz D TPMS geometry with a total porosity of 60% and 80% and various pore sizes. Dimensional accuracy of additively manufactured structures was measured in relation to the 3D model. Geometry of the final structure differed from the CAD model in the range ± 0.3 mm. The surface morphology and porosity of the solid struts were also checked. The mechanical properties of the structures were determined in a static compression test.

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“…In this realm, Refs. [27][28][29] propose solutions using different 2D lattice structures and Ref. [30] introduces a density mapping using 3D trusses.…”

Section: Explicit Realization Of the Results Of Topology Optimizationmentioning

confidence: 99%

Density-Sensitive Implicit Functions Using Sub-Voxel Sampling in Additive Manufacturing

Montoya-Zapata

Moreno

Pareja-Corcho

et al. 2019

Metals

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In the context of lattice-based design and manufacturing, the problem of physical realization of density maps into lattices of a particular family is central. Density maps are prescribed by design optimization algorithms, which seek to fulfill structural demands on a workpiece, while saving material. These density maps cannot be directly manufactured since local graded densities cannot be achieved using the bulk solid material. Because of this reason, existing topology optimization approaches bias the local voxel relative density to either 0 (void) or 1 (filled). Additive manufacturing opens possibilities to produce graded density individuals belonging to different lattice families. However, voxel-level sampled boundary representations of the individuals produce rough and possibly disconnected shells. In response to this limitation, this article uses sub-voxel sampling (largely unexploited in the literature) to generate lattices of graded densities. This sub-voxel sampling eliminates the risk of shell disconnections and renders better surface continuity. The manuscript devises a function to produce Schwarz cells that materialize a given relative density. This article illustrates a correlation of continuity against stress concentration by simulating C 0 and C 1 inter-lattice continuity. The implemented algorithm produces implicit functions and thus lattice designs which are suitable for metal additive manufacturing and able to achieve the target material savings. The resulting workpieces, produced by outsource manufacturers, are presented. Additional work is required in the modeling of the mechanical response (stress/strain/deformation) and response of large lattice sets (with arbitrary geometry and topology) under working loads.

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Design Optimization of Irregular Cellular Structure for Additive Manufacturing

Cited by 24 publications

References 27 publications

Effect of Trace Addition of Ceramic on Microstructure Development and Mechanical Properties of Selective Laser Melted AlSi10Mg Alloy

Effect of Trace Addition of Ceramic on Microstructure Development and Mechanical Properties of Selective Laser Melted AlSi10Mg Alloy

The manufacturability and compression properties of the Schwarz Diamond type Ti6Al4V cellular lattice fabricated by selective laser melting

Density-Sensitive Implicit Functions Using Sub-Voxel Sampling in Additive Manufacturing

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