3D printed hierarchical honeycombs with shape integrity under large compressive deformations

We describe the in-plane compressive performance of a new type of hierarchical cellular structure created by replacing cell walls in regular honeycombs with triangular lattice configurations. The fabrication of this relatively complex material architecture with size features spanning from micrometer to centimeter is facilitated by the availability of commercial 3D printers. We apply to these hierarchical honeycombs a thermal treatment that facilitates the shape preservation and structural integrity of the structures under large compressive loading. The proposed hierarchical honeycombs exhibit a progressive failure mode, along with improved stiffness and energy absorption under uniaxial compression. High energy dissipation and shape integrity at large imposed strains (up to 60%) have also been observed in these hierarchical honeycombs under cyclic loading. Experimental and numerical studies suggest that these anomalous mechanical behaviors are attributed to the introduction of a structural hierarchy, intrinsically controlled by the cell wall slenderness of the triangular lattice and by the shape memory effect induced by the thermal and mechanical compressive treatment

Mechanical properties of Ti-6Al-4V selectively laser melted parts with body-centred-cubic lattices of varying cell size

Significant weight savings in parts can be made through the use of additive manufacture (AM), a process which enables the construction of more complex geometries, such as functionally graded lattices, than can be achieved conventionally. The existing framework describing the mechanical properties of lattices places strong emphasis on one property, the relative density of the repeating cells, but there are other properties to consider if lattices are to be used effectively. In this work, we explore the effects of cell size and number of cells, attempting to construct more complete models for the mechanical performance of lattices. This was achieved by examining the modulus and ultimate tensile strength of latticed tensile specimens with a range of unit cell sizes and fixed relative density. Understanding how these mechanical properties depend upon the lattice design variables is crucial for the development of design tools, such as finite element methods, that deliver the best performance from AM latticed parts. We observed significant reductions in modulus and strength with increasing cell size, and these reductions cannot be explained by increasing strut porosity as has previously been suggested. We obtained power law relationships for the mechanical properties of the latticed specimens as a function of cell size, which are similar in form to the existing laws for the relative density dependence. These can be used to predict the properties of latticed column structures comprised of body-centred-cubic (BCC) cells, and may also be adapted for other part geometries. In addition, we propose a novel way to analyse the tensile modulus data, which considers a relative lattice cell size rather than an absolute size. This may lead to more general models for the mechanical properties of lattice structures, applicable to parts of varying size

The effects of defects and damage in the mechanical behavior of Ti6Al4V lattices

With recent advances in manufacturing methods for metals with defined, complex shapes, the investigation of metallic lattice materials (metals containing significant porosity with a regular arrangement of the solid, frequently in the form of thin structural members or struts) has become more common. These materials show many interesting properties, and may have the capacity to be more highly engineered and optimized for a given application than the random structures of other microcellular metals, such as metallic foams and sponges, permit. However, the novel structure brings new structure-properties correlations to bear on the mechanical behavior of the materials. This paper examines one type of lattice, made from titanium alloy (Ti6Al4V) and fabricated by Electron Beam Melting (EBM), a material which typically shows only limited plasticity on deformation. The overall mechanical response is governed by the cooperative deformation of a very large number of individual struts that make up the lattice, and thus there is great potential for significant impact from damage arising due to defects in individual struts in the assembly. We explore the effect of simulated processing defects (missing struts) on the lattice properties, and how deformation and failure is distributed across the lattice after the onset of failure. To gain knowledge of how lattices deform, samples of various geometries, designed to probe compression, indentation-compression and tension (in the form of bending) are produced and tested under Digital Image Correlation (DIC) mapping. The understanding gained here will be of great use in designing new metallic lattice structures with greater damage tolerance and resistance to failure

Open Celled Porous Titanium

Among the porous metals, those made of titanium attract particular attention due to the interesting properties of this element. This review examines the state of research understanding and technological development of these materials, in terms of processing capability, resultant structure and properties, and the most advanced applications under development. The impact of the rise of additive manufacturing techniques on these materials is discussed, along with the likely future directions required for these materials to find practical applications on a large scale

Happy Catastrophe: Recent Progress in Analysis and Exploitation of Elastic Instability

A synthesis of recent progress is presented on a topic that lies at the heart of both structural engineering and nonlinear science. The emphasis is on thin elastic structures that lose stability subcritically — without a nearby stable post-buckled state — a canonical example being a uniformly axially-loaded cylindrical shell. Such structures are hard to design and certify because imperfections or shocks trigger buckling at loads well below the threshold of linear stability. A resurgence of interest in structural instability phenomena suggests practical stability assessment require stochastic approaches and imperfection maps. This article surveys a different philosophy; the buckling process and ultimate post-buckled state are well described by the perfect problem. The significance of the Maxwell load is emphasised, where energy of the unbuckled and fully developed buckle patterns are equal, as is the energetic preference of localised states, stable and unstable versions of which connect in a snaking load-deflection path. The state of the art is presented on analytical, numerical and experimental methods. Pseudo15 arclength continuation (path-following) of a finite-element approximation computes families of complex localised states. Numerical implementation of a mountain-pass energy method then predicts the energy barrier through which the buckling process occurs. Recent developments also indicate how such procedures can be replicated experimentally; unstable states being accessed by careful control of constraints, and stability margins assessed by shock sensitivity experiments. Finally, the fact that subcritical instabilities can be robust, not being undone by reversal of the loading path, opens up potential for technological exploitation. Several examples at different length scales are discussed; a cable-stayed prestressed column, two examples of adaptive structures inspired by morphing aeroelastic surfaces, and a model for a functional auxetic material

Solid-Liquid Interface Reconstructions Using Laser Ultrasonic Fan-Beam Projection Data

Many single crystal semiconductors are grown by variants of the Bridgman technique in which a cylindrical ampoule containing a molten semiconductor is translated through a thermal gradient, resulting in directional solidification and the growth of a single crystal. During crystal growth, the shape and location of the solid-liquid interface together with the local temperature gradient control the mechanism of solidification (i.e. planar, cellular or dendritic), the likelihood of secondary grain nucleation/twin formation (i.e. loss of single crystallinity), solute (dopant) segregation, dislocation generation, etc. and thus determine the crystals’ quality [1]. For crystals grown by the vertical Bridgman (VB) technique, optimum properties are obtained with a low (∼1–5mm/hr) constant solidification velocity and a planar or near planar (slightly convex towards liquid) interface shape maintained throughout growth [2,3]. The solidification rate and the interface shape are both sensitive functions of the internal temperature gradient (both axial and radial) during solidification, which is governed by the heat flux distribution incident upon the ampoule, the latent heat release at the interface, and heat transport (by a combination of conduction, buoyancy surface tension driven convection and radiation) within the ampoule [4,5]. The solid-liquid interface’s instantaneous location, velocity and shape during crystal growth are therefore difficult to predict and to control, especially for those semiconductor materials with low thermal conductivity (i.e. CdZnTe alloys) [6]. Thus the development of ultrasonic technologies to non-invasively sense the interface location and shape throughout VB crystal growth processes has become a key step in developing a better understanding of the growth process and for enabling eventual sensor-based manufacturing.</p