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Influence of post-processing on additively manufactured lattice structures

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Abstract

The rapid evolution in additive manufacturing (AM) technology advocates a periodic assessment of the recent progress in the process and product developments. One such area is lattice structure (LS) fabrication with controlled porosity, especially microscale triply periodic minimal surfaces. These nature-inspired and mechanically robust complex cellular structures are making significant progress in aerospace, automotive, and biomedical applications. However, limitations in the AM process, such as process-induced defects, microstructural heterogeneities, and post-processing challenges, may result in an inaccurate assessment of mechanical properties. This review paper presents a comprehensive overview of challenges in the fabrication of AM cellular structures, LS classification, simulation outline, and the effect of post-processing on their overall mechanical and microstructural development. It further provides a physical assessment and the underlying science of failure criteria and deformation mechanism of AM lattice structures. This review includes substantive discussions on LS topology, relative density, AM defects, and material type, critically analyzing the printability of various engineering alloys based on experimental and numerical studies. Finally, the knowledge gaps in the scientific understanding and the future research needs for the expansion of AM lattice materials are provided.

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Abbreviations

AM:

Additive manufacturing

LPBF:

Laser powder bed fusion

DED:

Direct energy deposition

PBF:

Powder bed fusion

TPMS:

Triply periodic minimal surfaces.

FGs:

Functionally graded lattice Structures

HIP:

Hot isostatic pressing.

EBAM:

Electron beam additive manufacturing.

PLB:

Pulse laser-based.

CLB:

Continuous laser-based.

CAD:

Computer aided design

GCs:

Gyroid cellular

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  1. College of Science and Engineering, James Cook University, Townsville, Australia

    Mobin Majeed, Greg Wheatley & Rong Situ

  2. Aluminum Test Training, and Research Center (ALUTEAM), Fatih Sultan Mehmet Vakif University, 34445, Beyoglu, Istanbul, Turkey

    Hamaid Mahmood Khan

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Majeed, M., Khan, H.M., Wheatley, G. et al. Influence of post-processing on additively manufactured lattice structures. J Braz. Soc. Mech. Sci. Eng. 44, 389 (2022). https://doi.org/10.1007/s40430-022-03703-8

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