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Effect of additive manufactured lattice defects on mechanical properties: an automated method for the enhancement of lattice geometry

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Abstract

Metal additive manufacturing (MAM) enables the fabrication of structures with complexity and resolution that cannot be achieved by traditional manufacturing techniques, including lattice structures. However, MAM processes inherently induce local manufacturing defects, resulting in variation between the idealised and as-manufactured geometry and potentially introducing stress concentrations that are detrimental to structural performance. Quantification of these effects on mechanical performance enables the manipulation of intended lattice geometry to enhance structural performance. However, due to the geometric complexity and small scale of geometric defects, experimental testing and numerical simulation of lattice structures are technically difficult and time-consuming. To overcome this limitation, a novel methodology for quantifying the effect of manufacturing defects on the mechanical properties of MAM lattice structural elements is proposed. This method involves the automated analysis of microscope images of as-manufactured lattice structures to generate numerical models that automate the identification of plastic hinge behaviour in node elements based on custom MAM material properties. This method is applied to Ti-6Al-4V lattice structures fabricated by selective laser melting (SLM) with a range of strut and node diameters and cell sizes. This novel method is shown to predict the effect of local manufacturing defects on bulk lattice mechanical response and provides an efficient tool for the optimisation of as-manufactured MAM lattice structures.

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Notes

  1. Inclination angle is the angle between the build platen and a downward-facing surface.

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Acknowledgements

This research was conducted by the Australian Research Council Industrial Transformation Training Centre in Additive Biomanufacturing (IC160100026). The authors acknowledge the facilities and the scientific and technical assistance of the RMIT Advanced Manufacturing Precinct.

Funding

This work was financially supported by the members of the ARC Training Centre for Lightweight Automotive Structures and from the Australian Research Council (Grant Reference IC160100032).

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Authors and Affiliations

  1. RMIT Centre for Additive Manufacture, School of Engineering, RMIT University, Melbourne, Australia

    Ahmad Alghamdi, Tobias Maconachie, David Downing, Milan Brandt, Ma Qian & Martin Leary

  2. College of Engineering in Al-Qunfudhah, Umm Al-Qura University, Mecca, Kingdom of Saudi Arabia

    Ahmad Alghamdi

  3. ARC Training Centre for Lightweight Automotive Structures (ATLAS), Melbourne, Australia

    Tobias Maconachie & Martin Leary

  4. ARC Training Centre in Additive Biomanufacturing, Brisbane, Australia

    David Downing, Milan Brandt & Martin Leary

Authors
  1. Ahmad Alghamdi
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  2. Tobias Maconachie
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  3. David Downing
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  4. Milan Brandt
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  5. Ma Qian
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  6. Martin Leary
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Correspondence to Martin Leary.

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Alghamdi, A., Maconachie, T., Downing, D. et al. Effect of additive manufactured lattice defects on mechanical properties: an automated method for the enhancement of lattice geometry. Int J Adv Manuf Technol 108, 957–971 (2020). https://doi.org/10.1007/s00170-020-05394-8

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  • DOI: https://doi.org/10.1007/s00170-020-05394-8

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