Failure mode analysis on compression of lattice structures with internal cooling channels produced by laser powder bed fusion

Adv search

Failure mode analysis on compression of lattice structures with internal cooling channels produced by laser powder bed fusion

E. Virgillito , A. Aversa , F. Calignano , M. Lombardi , D. Manfredi , D. Ugues , P. Fino

Advances in Manufacturing ›› 2021, Vol. 9 ›› Issue (3) : 403 -413.

PDF

Advances in Manufacturing ›› 2021, Vol. 9 ›› Issue (3) : 403 -413. DOI: 10.1007/s40436-021-00348-z

Article

Failure mode analysis on compression of lattice structures with internal cooling channels produced by laser powder bed fusion

Author information +

¹ Department of Applied Science and Technology, Polytechnic University of Turin, 10129, Turin, Italy

² Center for Sustainable Future Technologies IIT, Italian Institute of Technology, 10144, Turin, Italy

³ Department of Applied Science and Technology, Polytechnic University of Turin, 10129, Turin, Italy

^a enrico.virgillito@polito.it

E. Virgillito is Ph.D. Candidate at Polytechnic University of Turin. He worked on mechanical characterization of Polymer Matrix Composites, powders analyses and structural simulation. His current research is focused on the production, characterization and development of innovative composition of aluminum alloys for powder based additive manufacturing technologies.

[graphic not available: see fulltext]

A. Aversa is Assistant Professor at Polytechnic University of Turin. Her main research interests are materials development for Additive Manufacturing processes and she focuses in particular on the characterization and the development of new Al alloys for AM processes. She participated to several Regional and European research projects focused on Additive Manufacturing processes.

[graphic not available: see fulltext]

F. Calignano is Assistant Professor at Polytechnic University of Turin. Her research is focused on the study and the definition of design rules and on the final surface optimization of the parts produced through different additive manufacturing techniques. She participated to several Regional and European research projects focused on Additive Manufacturing processes.

[graphic not available: see fulltext]

M. Lombardi is Full Professor at Polytechnic University of Turin. Her scientific activity concerned materials science and technology aspects related to the preparation and characterization of dense and porous ceramics, dense and porous polymer matrix composites, and additive manufactured metallic alloys. She participated to several Regional and European research projects focused on Additive Manufacturing processes.

[graphic not available: see fulltext]

D. Manfredi is Assistant Professor at Polytechnic University of Turin. His research is focused on the development of metallic alloys through the additive manufacturing technology and their complete microstructural characterization. He participated to several Regional and European research projects focused on Additive Manufacturing processes.

[graphic not available: see fulltext]

D. Ugues is Associate Professor at Polytechnic University of Turin. His research interests include microstructural features and mechanical properties provided to metallic components by the synergic effects of chemical composition, forming actions and thermal loads according to the specific manufacturing route. He participated to several Regional and European research projects focused on Additive Manufacturing processes and Hot Isostatic Pressing.

[graphic not available: see fulltext]

P. Fino is Full Professor at Polytechnic University of Turin. His research interests include development and characterization of ceramic powders and massive materials, metal-ceramic matrix composites, ceramic matrix composites and multi-layers, and structural materials produced through additive manufacturing technologies.

[graphic not available: see fulltext]

Show less

History +

PDF

Abstract

Conformal cooling coils have been developed during the last decades through the use of additive manufacturing (AM) technologies. The main goal of this study was to analyze how the presence of an internal channel that could act as a conformal cooling coil could affect compressive strength and quasi-elastic gradient of AlSi10Mg lattice structures produced by laser powder bed fusion (LPBF). Three different configurations of samples were tested in compression at 25 °C and 200 °C. The reference structures were body centered cubic (BBC) in the core of the samples with vertical struts along Z (BCCZ) lattices in the outer perimeter, labelled as NC samples. The main novelty consisted in inserting a straight elliptical channel and a 45° elliptical channel inside the BCCZ lattice structures, labelled as SC and 45C samples respectively. All the samples were then tested in as-built (AB) condition, and after two post process heat treatments, commonly used for AlSi10Mg LPBF industrial components, a stress relieving (SR) and a T6 treatment. NC lattice structures AB exhibited an overall fragile fracture and therefore the SC and 45C configuration samples were tested only after thermal treatments. The test at 25 °C showed that all types of samples were characterized by negligible variations in their quasi-elastic gradients and yield strength. On the contrary, the general trend of stress-strain curves was influenced by the presence of the channel and its position. The test at 200 °C showed that NC, SC and 45C samples after SR and T6 treatments exhibited a metal-foam like deformation.

Keywords

Laser powder bed fusion (LPBF) / Conformal cooling channel / Lattice structures / Failure mode analysis / Mechanical properties at 200 °C

Cite this article

Download citation ▾

E. Virgillito, A. Aversa, F. Calignano, M. Lombardi, D. Manfredi, D. Ugues, P. Fino. Failure mode analysis on compression of lattice structures with internal cooling channels produced by laser powder bed fusion. Advances in Manufacturing, 2021, 9(3): 403-413 DOI:10.1007/s40436-021-00348-z

登录浏览全文

4963

注册一个新账户忘记密码

References

Publishing order | Descend order by publishing year | Descend order by cited within

[1]	Eiamsa-Ard K, Wannissorn K. Conformal bubbler cooling for molds by metal deposition process. CAD Comput Aided Des, 2015, 69: 126-133.

[2]	Soshi M, Ring J, Young C, et al. Innovative grid molding and cooling using an additive and subtractive hybrid CNC machine tool. CIRP Ann - Manuf Technol, 2017, 66: 401-404.

[3]	Gibson LJ, Ashby MF (1988) Cellular Solids: Structure & Properties. Pergamon Press, UK

[4]	Cheng L, Liu J, Liang X, et al. Coupling lattice structure topology optimization with design-dependent feature evolution for additive manufactured heat conduction design. Comput Methods Appl Mech Eng, 2018, 332: 408-439.

[5]	Wu T, Jahan SA, Zhang Y, et al. Design Optimization of Plastic Injection Tooling for Additive Manufacturing. Procedia Manuf, 2017, 10: 923-934.

[6]	Yun S, Kwon J, Lee DC, et al. Heat transfer and stress characteristics of additive manufactured FCCZ lattice channel using thermal fluid-structure interaction model. Int J Heat Mass Transf, 2020, 149: 119187.

[7]	Mahshid R, Hansen HN, Højbjerre KL. Strength analysis and modeling of cellular lattice structures manufactured using selective laser melting for tooling applications. Mater Des, 2016, 104: 276-283.

[8]	Brooks H, Brigden K. Design of conformal cooling layers with self-supporting lattices for additively manufactured tooling. Addit Manuf, 2016, 11: 16-22.

[9]	Mazumder J, Choi J, Nagarathnam K, et al. The direct metal deposition of H13 tool steel for 3-D components. JOM, 1997, 49: 55-60.

[10]	Leary M, Mazur M, Williams H, et al. Inconel 625 lattice structures manufactured by selective laser melting (SLM): Mechanical properties, deformation and failure modes. Mater Des, 2018, 157: 179-199.

[11]	Köhnen P, Haase C, Bültmann J, et al. Mechanical properties and deformation behavior of additively manufactured lattice structures of stainless steel. Mater Des, 2018, 145: 205-217.

[12]	Yan C, Hao L, Hussein A, et al. Evaluations of cellular lattice structures manufactured using selective laser melting. Int J Mach Tools Manuf, 2012, 62: 32-38.

[13]	Yan C, Hao L, Hussein A, et al. Advanced lightweight 316L stainless steel cellular lattice structures fabricated via selective laser melting. Mater Des, 2014, 55: 533-541.

[14]	Choy SY, Sun CN, Leong KF, et al. Compressive properties of functionally graded lattice structures manufactured by selective laser melting. Mater Des, 2017, 131: 112-120.

[15]	Leary M, Mazur M, Elambasseril J, et al. Selective laser melting (SLM) of AlSi12Mg lattice structures. Mater Des, 2016, 98: 344-357.

[16]	Ozdemir Z, Hernandez-Nava E, Tyas A, et al. Energy absorption in lattice structures in dynamics: Experiments. Int J Impact Eng, 2016, 89: 49-61.

[17]	Harris JA, Winter RE, McShane GJ. Impact response of additively manufactured metallic hybrid lattice materials. Int J Impact Eng, 2017, 104: 177-191.

[18]	Chen L, Zhang J, Du B, et al. Dynamic crushing behavior and energy absorption of graded lattice cylindrical structure under axial impact load. Thin-Walled Struct, 2018, 127: 333-343.

[19]	Li C, Lei H, Liu Y, et al. Crushing behavior of multi-layer metal lattice panel fabricated by selective laser melting. Int J Mech Sci, 2018, 145: 389-399.

[20]	Yan C, Hao L, Hussein A, et al. Microstructure and mechanical properties of aluminium alloy cellular lattice structures manufactured by direct metal laser sintering. Mater Sci Eng A, 2015, 628: 238-246.

[21]	Qiu C, Yue S, Adkins NJE, et al. Influence of processing conditions on strut structure and compressive properties of cellular lattice structures fabricated by selective laser melting. Mater Sci Eng A, 2015, 628: 188-197.

[22]	Yan C, Hao L, Hussein A, et al. Evaluation of light-weight AlSi10Mg periodic cellular lattice structures fabricated via direct metal laser sintering. J Mater Process Technol, 2014, 214: 856-864.

[23]	Ferro CG, Varetti S, Maggiore P, et al. Design and characterization of trabecular structures for an anti-icing sandwich panel produced by additive manufacturing. J Sandw Struct Mater, 2018, 22: 1111-1131.

[24]	Maskery I, Aboulkhair NT, Aremu AO, et al. A mechanical property evaluation of graded density Al-Si10-Mg lattice structures manufactured by selective laser melting. Mater Sci Eng A, 2016, 670: 264-274.

[25]	Maskery I, Aboulkhair NT, Aremu AO, et al. Compressive failure modes and energy absorption in additively manufactured double gyroid lattices. Addit Manuf, 2017, 16: 24-29.

[26]	Salmi A, Atzeni E. History of residual stresses during the production phases of AlSi10Mg parts processed by powder bed additive manufacturing technology. Virtual Phys Prototyp, 2017, 12: 153-160.

[27]	Aboulkhair NT, Maskery I, Tuck C, et al. The microstructure and mechanical properties of selectively laser melted AlSi10Mg: The effect of a conventional T6-like heat treatment. Mater Sci Eng A, 2016, 667: 139-146.

[28]	Li W, Li S, Liu J, et al. Effect of heat treatment on AlSi10Mg alloy fabricated by selective laser melting: Microstructure evolution, mechanical properties and fracture mechanism. Mater Sci Eng A, 2016, 663: 116-125.

[29]	Takata N, Kodaira H, Sekizawa K, et al. Change in microstructure of selectively laser melted AlSi10Mg alloy with heat treatments. Mater Sci Eng A, 2017, 704: 218-228.

[30]	Eos O, Speed PA, Eos O et al (2014) Material data sheet EOS aluminium AlSi10Mg material data sheet technical data. Available via EOS. http://www.eos.info/de. Accessed 23 Sept 2020

[31]	Hathaway BJ, Garde K, Mantell SC, et al. Design and characterization of an additive manufactured hydraulic oil cooler. Int J Heat Mass Transf, 2018, 117: 188-200.

[32]	Manfredi D, Calignano F, Krishnan M, et al. From powders to dense metal parts: Characterization of a commercial alsimg alloy processed through direct metal laser sintering. Materials, 2013, 6: 856-869.

[33]	Diego M, Flaviana C, Manickavasagam K et al (2016) Additive manufacturing of Al alloys and aluminium matrix composites (AMCs). Intech 1:13

[34]	Marola S, Manfredi D, Fiore G, et al. A comparison of selective laser melting with bulk rapid solidification of AlSi10Mg alloy. J Alloys Compd, 2018, 742: 271-279.

[35]	Trevisan F, Calignano F, Lorusso M, et al. On the selective laser melting (SLM) of the AlSi10Mg alloy: process, microstructure, and mechanical properties. Materials, 2017, 10: 76.

[36]	Standard I (2011) ISO 13314 Mechanical testing of metals, ductility testing, compression test for porous and cellular metals. Ref number ISO 13314:1–7

[37]	Curà F, Gallinatti AE, Sesana R. Dissipative aspects in thermographic methods. Fatigue Fract Eng Mater Struct, 2012, 35: 1133-1147.

[38]	Ashby M (2011) Materials selection in mechanical design, 4ed, Butterworth-Heinemann, Cambridge

[39]	Cao Y, Lin X, Wang QZ, et al. Microstructure evolution and mechanical properties at high temperature of selective laser melted AlSi10Mg. J Mater Sci Technol, 2021, 62: 162-172.

[40]	Jiang B, Wang Z, Zhao N. Effect of pore size and relative density on the mechanical properties of open cell aluminum foams. Scr Mater, 2007, 56: 169-172.

[41]	Poonaya S, Thinvongpituk C (2007) Comparison of Energy Absorption of Various Section Steel Tubes under Axial Compression and Bending Loading. Mech Eng 590–593

Funding

Politecnico di Torino

AI Summary AI Mindmap

PDF

140

Accesses

0

Citation

Detail

Sections

Recommended

/

〈

〉