Optimised lattice structure configuration for additive manufacturing

Lebaal, Nadhir; Zhang, Yicha; Demoly, Frédéric; Roth, Sébastien; Gomes, Samuel; Bernard, Alain

doi:10.1016/j.cirp.2019.04.054

Cited by 51 publications

(18 citation statements)

References 12 publications

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“…Research issues related to DFAM include freeform shapes, lattice structures and porous objects, topology optimization, part consolidation, non-assembly mechanism, internal channels, segmentation, embedded components, thin and small features, surface features, material choices, multiple materials, infill modifications, process dependent design parameters, etc. [2,5,[13][14][15][16][17][18][19][20][21][22]. As compared to conventional manufacturing (CM) processes, the AM technologies have several promising benefits: (a) decreased the production time and the amount of human intervention due to the reduction of the time-consuming multiple re-fixturing and calibration procedure through the completely automated AM process from design to fabrication of the product in a computer aided design and manufacturing (CAD and CAM)…”

Section: Introductionmentioning

confidence: 99%

Directed Energy Deposition (DED) Process: State of the Art

Ahn

2021

Int. J. of Precis. Eng. and Manuf.-Green Tech.

314

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Metal additive manufacturing technologies, such as powder bed fusion process, directed energy deposition (DED) process, sheet lamination process, etc., are one of promising flexible manufacturing technologies due to direct fabrication characteristics of a metallic freeform with a three-dimensional shape from computer aided design data. DED processes can create an arbitrary shape on even and uneven substrates through line-by-line deposition of a metallic material. Theses DED processes can easily fabricate a heterogeneous material with desired properties and characteristics via successive and simultaneous depositions of different materials. In addition, a hybrid process combining DED with different manufacturing processes can be conveniently developed. Hence, researches on the DED processes have been steadily increased in recent years. This paper reviewed recent research trends of DED processes and their applications. Principles, key technologies and the state-of-the art related to the development of process and system, the optimization of deposition conditions and the application of DED process were discussed. Finally, future research issues and opportunities of the DED process were identified.

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Section: Introductionmentioning

confidence: 99%

Directed Energy Deposition (DED) Process: State of the Art

Ahn

2021

Int. J. of Precis. Eng. and Manuf.-Green Tech.

314

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“…The design of freeform structures or porous structures is always a challenge, especially for cellular freeform or uniform structures (Zhang et al , 2020; Lebaal et al ,2019). In this study, to test the printability of the SLM process, a set of different porous structures with different cellular units and pore sizes was prepared.…”

Section: Experimental Methods and Setupmentioning

confidence: 99%

Manufacturability analysis of extremely fine porous structures for selective laser melting process of Ti6Al4V alloy

Ding

Tan

Chen

et al. 2021

RPJ

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Purpose The manufacturability of extremely fine porous structures in the SLM process has rarely been investigated, leading to unpredicted manufacturing results and preventing steady medical or industrial application. The research objective is to find out the process limitation and key processing parameters for printing fine porous structures so as to give reference for design and manufacturing planning. Design/methodology/approach In metallic AM processes, the difficulty of geometric modeling and manufacturing of structures with pore sizes less than 350 μm exists. The manufacturability of porous structures in selective laser melting (SLM) has rarely been investigated, leading to unpredicted manufacturing results and preventing steady medical or industrial application. To solve this problem, a comprehensive experimental study was conducted to benchmark the manufacturability of the SLM process for extremely fine porous structures (less than 350 um and near a limitation of 100 um) and propose a manufacturing result evaluation method. Numerous porous structure samples were printed to help collect critical datasets for manufacturability analysis. Findings The results show that the SLM process can achieve an extreme fine feature with a diameter of 90 μm in stable process control, and the process parameters with their control strategies as well as the printing process planning have an important impact on the printing results. A statistical analysis reveals the implicit complex relations between the porous structure geometries and the SLM process parameter settings. Originality/value It is the first time to investigate the manufacturability of extremely fine porous structures of SLM. The method for manufacturability analysis and printing parameter control of fine porous structure are discussed.

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“…Yun et al [8] carried out an experiment to study face-centered cubic LS and found that this LS showed a good thermal performance compared to non-LS channel. Due to the complex topology of LS, metal additive manufacturing technology can easily solve this limit [9,10].…”

Section: Introductionmentioning

confidence: 99%

Optimization Design of Lattice Structures in Internal Cooling Channel of Turbine Blade

Shen

Ruan

et al. 2021

Applied Sciences

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Recently, the inlet temperatures in gas turbine units have been drastically increased, which extremely affects the lifespan of gas turbine blades. Traditional cooling structures greatly improve the high temperature resistance of the blade; however, these structures scarcely concern both heat transfer and mechanical performances. Lattice structure (LS) can realize these requirements because of its characteristics of light weight, high strength, and porosity. Although the topology of LS is complex, it can be manufactured with the 3D metal printing technology. In this study, an integral optimization method of lattice cooling structure, used at the trailing edge of turbine blades, concerned with heat transfer and mechanical performance, was presented. Firstly, functions between the first-order natural frequency (freq1), elasticity modulus (E), relative density (ρ¯), and Nusselt number (Nu), and the geometric variables of pyramid type LS (PLS) and X-type LS (XLS) were established, and the reliability of these functions was verified. Then, a mathematical optimization model was developed based on these functions which contained two selected optimization problems. Finally, relations among objectives were analyzed; influence law of geometric variables to objectives were discussed, and the accuracy of the optimal LS was proved by experiment and numerical simulation. The optimization results suggest that, compared to the initial LS, Nu increases by 24.1% and ρ¯ decreases by 31% in the optimal LS of the first selected problem, and the Nu increases by 28.8% while freq1 and ρ¯ are almost unchanged in the optimal LS of the second selected problem compared to the initial LS. This study may provide a guidance for functions integration design of lattice cooling structures used at turbine blades based on 3D printing.

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Optimised lattice structure configuration for additive manufacturing

Cited by 51 publications

References 12 publications

Directed Energy Deposition (DED) Process: State of the Art

Directed Energy Deposition (DED) Process: State of the Art

Manufacturability analysis of extremely fine porous structures for selective laser melting process of Ti6Al4V alloy

Optimization Design of Lattice Structures in Internal Cooling Channel of Turbine Blade

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