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Structural optimization of lattice cellular structures: incorporating the fatigue strength dependency on the building orientation of sub-unit struts

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Abstract

Additive manufacturing (AM) techniques are widely involved in the production of lattice-based prosthetic devices. Nevertheless, the development of implants with improved fatigue resistance is still an open debate. In lattice structures, the fatigue life of a component is a crucial issue, since it is not only strongly affected by the wide variety of manufacturing-induced defects but also by the specimen building direction. To gain a better comprehension of fatigue in AM, an investigation of sub-unit lattice elements according to their building orientation should be addressed. Additionally, this knowledge can be exploited to design a fatigue-optimized component. In this work, the authors propose a combined approach of fatigue experimental tests on sub-unit lattice elements along with optimization strategies for a wise design and fabrication of a Ti6Al4V laser powder bed fusion (L-PBF) octet truss lattice component. The specimen orientation with respect to the printing plane is chosen as the optimization variable.

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Abbreviations

AM :

Additive manufacturing

FE :

Finite element

HC :

High cycle fatigue regime

LC :

Low cycle fatigue regime

L-PBF :

Laser powder bed fusion

OT :

Octet truss

SLP :

Sequential linear programming

SEM :

Scanning electron microscopy

γ :

Rotational coordinate around the X axis

ψ :

Rotational coordinate around the Y axis

σ a :

Stress amplitude

N f :

Cycles to failure

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Acknowledgments

This project has received funding from the Italian Ministry for Education, University, and Research (MIUR) within the program “Departments of Excellence” 2018–2022 (DII-UNITN) and through the REGENERA project.

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Authors and Affiliations

  1. Department of Industrial Engineering - DII, University of Trento, Via Sommarive 9, Trento, Italy

    Raffaele De Biasi, Simone Murchio & Matteo Benedetti

  2. BIOtech Research Center, University of Trento, Via delle Regole 101, Trento, Italy

    Simone Murchio

Authors
  1. Raffaele De Biasi
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  2. Simone Murchio
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  3. Matteo Benedetti
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Corresponding author

Correspondence to Raffaele De Biasi.

Additional information

Raffaele De Biasi is currently working on lattice structures and structural optimization at the University of Trento (Italy) as part of his Ph.D. research. In 2020, at the University of Trento, he completed his master’s degree in Mechanics and Mechatronic Engineering.

Simone Murchio is a Ph.D. student in Materials, Mechatronics, and Systems Engineering at the University of Trento, Italy. His research is focused on smart hierarchical cellular materials with improved fatigue resistance and osseointegration. He received his master’s degree in Materials and Production Engineering in 2019 at the University of Trento.

Matteo Benedetti is an Associate Professor at the University of Trento, Italy. He has a 20 years of experience in the field of mechanics of metallic materials, fatigue and fracture, finite element modeling, surface treatments, and residual stresses. He was a visiting researcher at the Technical University Hamburg-Harburg, where he studied the fatigue and fracture mechanisms of titanium alloys. Since 2015 he has been investigating the fatigue-related issues of additively manufactured materials with a special focus on lattice cellular biomaterials.

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De Biasi, R., Murchio, S. & Benedetti, M. Structural optimization of lattice cellular structures: incorporating the fatigue strength dependency on the building orientation of sub-unit struts. J Mech Sci Technol 37, 1097–1102 (2023). https://doi.org/10.1007/s12206-022-2105-3

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  • DOI: https://doi.org/10.1007/s12206-022-2105-3

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