S. Tsopanos

The Influence of Processing Parameters on the Mechanical Properties of Selectively Laser Melted Stainless Steel Microlattice Structures

The rapid manufacturing process of selective laser melting has been used to produce a series of stainless steel 316L microlattice structures. Laser power and laser exposure time are the two processing parameters used for manufacturing the lattice structures and, therefore, control the quality and mechanical properties of microlattice parts. An evaluation of the lattice material was undertaken by manufacturing a range of struts, representative of the individual trusses of the microlattices, as well as, microlattice block structures. Low laser powers were shown to result in significantly lower strand strengths due to the presence of inclusions of unmelted powder in the strut cross-sections. Higher laser powers resulted in struts that were near to full density as the measured strengths were comparable to the bulk 316L values. Uniaxial compression tests on microlattice blocks highlighted the effect of manufacturing parameters on the mechanical properties of these structures and a linear relationship was found between the plateau stress and elastic modulus relative to the measured relative density.

The Mechanical Properties of Sandwich Structures Based on Metal Lattice Architectures

A range of metallic lattice structures were manufactured using the selective laser melting (SLM) rapid prototyping technique. The lattices were based assemblies of repeating unit-cells with their strands oriented at 0°, ±45°, and 90° to the vertical when viewed from the front. Mechanical tests on the strands and the lattice blocks showed that these systems exhibit a high level of reproducibility in terms of their basic mechanical properties. An examination of the compression failure mechanisms showed that the [±45°] and [±45°, 90°] lattices failed in bending and stretching modes of failure, whereas the [0°, ±45°] lattices failed as a result of buckling of the vertical pillars. Sandwich structures were manufactured by binding woven carbon-fiber reinforced plastic to the lattice structures. Subsequent three-point bend tests on these structures identified the principal failure mechanisms under flexural loading conditions. Here, cell crushing, hinge rotation, and gross plastic deformation in the strands were observed directly under the point of loading. Low-velocity impact tests were conducted on the sandwich beams and a simple energy-balance model was used to understand how energy is absorbed by the sandwich structures. The model suggests that the majority of the incident energy of the projectile was absorbed in indentation effects, predominantly in the core material, directly under the steel indenter.

An investigation into the compressive properties of stainless steel micro-lattice structures

This article presents a theoretical analysis for predicting the initial stiffness E*, and plastic collapse strength σ* pl of BCC micro-lattice blocks under compressive loading. This theoretical analysis is based on the observed deformation mechanisms, and can, in principle, be developed to predict the elastic properties of other micro-lattice structures. The analytical solutions are verified by comparing the predictions with FEM data using 1D beam and 3D solid elements and uniaxial compression tests on samples fabricated by selective laser melting. The FEM predictions using the 3D solid elements agree well with the experimental data for a wide range of strut aspect ratios, d/L. In addition, the range of applicability of the analytical model and the FEM predictions using beam elements are clarified.

The quasi-static and blast response of steel lattice structures

Lattice structures based on two simple architectures have been manufactured from 316L stainless steel using the selective laser melting process. The compressive properties of structures based on a body-centered cubic (BCC) and a similar structure with vertical pillars (BCC-Z) were initially investigated at quasi-static rates of strain. Blast tests were subsequently performed on the lattice structures as well as on lattice sandwich structures with CFRP skins. When subjected to quasi-static compression loading, the BCC structure exhibited a progressive mode of failure, whereas the BCC-Z lattice deformed in a buckling-dominated mode of collapse. The blast response of the lattice cubes exhibited a linear dependency on the applied impulse up to the threshold for material densification. Relationships between the blast resistance and both the yield stress and energy absorption characteristics of the lattices have been established and an examination of the failed samples indicated that the collapse modes were similar in both the quasi-static and blast-loaded samples. Finally, the failure modes observed in the blast-loaded sandwich panels were investigated and found to be similar to those observed in the lattice blocks.

Local Effects during Indentation of Fully Supported Sandwich Panels with Micro Lattice Cores

This paper discusses the penetration behavior of fully supported sandwich panels with micro-lattice and foam cores, and composite skins. This behaviour is of importance during foreign object impact and perforation of sandwich structures. Experimental results are given for quasi-static penetration of micro-lattice and foam blocks, and it is shown that these two cellular materials are comparable. Experimental results are also given for drop weight penetration of fully supported skinned panels, and it is shown that skin failure and core penetration are also similar for the two core materials. It is concluded that there is scope for improving the performance of micro-lattice structure and so making such material superior to that of aluminium foam.

Comparison of the Drop Weight Impact Performance of Sandwich Panels with Aluminium Honeycomb and Titanium Alloy Micro Lattice Cores

This paper is a study of the drop weight impact behaviour of small sandwich panels of carbon epoxy skins with aluminium honeycomb and titanium alloy micro-lattice cores. A series of experimental tests have shown that the specific impactor penetration behaviours are similar for both cores. The reasons for this are a result of the detailed deformation and rupture behaviour of the two types of core. The deformation and rupture mechanisms of honeycomb and micro-lattice structures will be discussed in general terms, and these observations will be used to inform discussion of actual deformation and rupture in the panel tests. In this way, micro energy absorbing mechanisms will be related to panel performance, and conclusions on the way forward for improved penetration performance using other core materials and geometries will be identified.

Selective laser melting of high aspect ratio 3D nickel – titanium structures for MEMS applications

Selective laser melting has been used to build high aspect ratio, three-dimensional NiTi components for the first time. The influence of laser dwell time and raster pitch on the density of NiTi shape memory alloy parts and their resolvable feature sizes are reported. The properties of shape memory springs produced by this method are reported and the application of selective laser melted NiTi components in microelectromechanical devices is discussed.