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Effect of additive manufactured hybrid and functionally graded novel designed cellular lattice structures on mechanical and failure properties

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Abstract

Recent advancements in additive manufacturing (AM) have opened new possibilities for fabricating highly complex lattice structures with enhanced mechanical properties, particularly hybrid and functional gradient structures. Most of the conducted research focused on linear/longitudinal designs for both hybrid and functional gradient structures. This study focuses on designing and evaluating novel functionally graded radially hybridized structures, combining different unit cells from beam-based and surface-based structures. The research introduces a cylindrical/radial hybridization approach, incorporating three distinct unit cells: body-centered cubic (BCC), face-centered cubic (FCC), and octet from beam-based structures, and diamond, gyroid, and split-p from surface-based structures. Polylactic acid (PLA) was selected as the material, and fused filament fabrication (FFF) was employed for fabrication. Quasi-static compression tests were conducted to assess the influence of hybridization and functional gradience on compressive modulus, ultimate strength, specific energy absorption, and failure properties. Both experimental and numerical results demonstrated that functionally graded lattice structures, whether surface-based or beam-based, exhibited improved mechanical performance. The surface-based functionally graded lattice structures showed the highest compressive modulus (71%), ultimate strength (36%), and specific energy absorption (19%). On the other hand, the beam-based functionally graded structures displayed a higher compressive modulus (50%), ultimate strength (11%), and specific energy absorption (19%). However, it should be noted that the beam-based functionally graded structures exhibited a decrease in these properties due to factors such as unit cell size, volume fraction, and structural buckling. Overall, the findings highlight the superior mechanical properties of functionally graded lattice structures compared to hybrid lattice structures.

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Funding

The authors from Hong Kong Polytechnic University (PolyU) acknowledge the financial support under grant number: P0040173. The authors from King Fahd University of Petroleum & Minerals (KFUPM) would also like to acknowledge the support provided by the Deanship of Research Oversight and Coordination (DROC) for funding this work through project No. EC231001.

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Authors and Affiliations

  1. Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hung Hom, Kowloon, SAR 999077, Hong Kong, China

    Sajjad Hussain

  2. Department of Mechanical Engineering, King Fahad University of Petroleum & Minerals, 31261, Dhahran, Saudi Arabia

    Aamer Nazir & Usman Ali

  3. Interdisciplinary Research Center for Advanced Materials, King Fahad University of Petroleum & Minerals, 31261, Dhahran, Saudi Arabia

    Aamer Nazir & Usman Ali

  4. State Key Laboratory of Ultra-Precision Machining Technology, Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hung Hom, Kowloon, Hong Kong, China

    Saad Waqar

  5. Division of Materials and Manufacturing Science, Graduate School of Engineering, Osaka University, 2-1, Yamadaoka, Suita, Osaka, 565-0871, Japan

    Ozkan Gokcekaya

  6. Anisotropic Design & Additive Manufacturing Research Center, Osaka University, 2-1, Yamadaoka, , Suita, Osaka, 565-0871, Japan

    Ozkan Gokcekaya

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  1. Sajjad Hussain
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  2. Aamer Nazir
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Correspondence to Aamer Nazir.

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Hussain, S., Nazir, A., Waqar, S. et al. Effect of additive manufactured hybrid and functionally graded novel designed cellular lattice structures on mechanical and failure properties. Int J Adv Manuf Technol 128, 4873–4891 (2023). https://doi.org/10.1007/s00170-023-12201-7

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