Abstract
The advances in additive manufacturing (AM) over the past decades have enabled the manufacturing of increasingly complex parts which were previously difficult or infeasible to be fabricated using traditional formative or subtractive manufacturing processes. Various configurations of periodic lattice structures are now designed and fabricated via AM in virtue of the advantages they provide such as weight reduction, high energy absorption, and superior stiffness-to-weight ratio. Such functional and mechanical properties can be tuned to meet the application requirements by varying the unit cell type, unit cell size, and volume fraction. Exploring the achievable volume fraction ranges of different lattice structure configurations and precise control of the volume fraction of AM fabricated lattice structures will significantly enlarge the scope of the application, which are the main objectives of the present study. A simple strategy is developed for periodic mesoscale lattice structures fabricated via laser-powder bed fusion (L-PBF) process to quantify the manufacturable volume fraction ranges and the relationship between designed and fabricated volume fractions. Firstly, the relationship between the lattice design parameters (unit cell type, unit cell size, and strut diameter) and designed volume fraction was formulated. Next, the theoretically achievable volume fraction ranges of lattice structures were calculated. The lattice coupons of specific designed volume fractions within the previously obtained ranges were built and the fabricated volume fractions were measured. A multiple linear regression model was set up to determine correlation factors between designed and fabricated volume fractions based on the available data and the model accuracy was validated. In the current work, AlSi12 was utilized as a model material system to demonstrate the applicability of the proposed framework. It is worth mentioning that this framework is applicable to other material systems. Based on the case study results on AlSi12, insights were developed to aid the design and manufacturing processes of periodic mesoscale lattice structures in general for fabrication by L-PBF.
Similar content being viewed by others
References
Solórzano E, Rodriguez-Perez MA (2013) Part IV cellular materials. Struct Mater Proc Transpo
Banhart J (2001) Manufacture, characterisation and application of cellular metals and metal foams. Prog Mater Sci 46(6):559
Gibson LJ, Ashby M, Harley BA (2010) Cellular materials in nature and medicine. Cambridge University Press, Cambridge
Schaedler TA, Carter WB (2016) Architected cellular materials. Annu Rev Mater Res 46:187
Li W, Wan H, Lou H, Fu Y, Qin F, He G (2017) Enhanced thermal management with microencapsulated phase change material particles infiltrated in cellular metal foam. Energy 127:671
Davies G, Zhen S (1983) Metallic foams: their production, properties and applications. J Mater Sci 18(7):1899
Wang X, Xu S, Zhou S, Xu W, Leary M, Choong P, Qian M, Brandt M, Xie YM (2016) Topological design and additive manufacturing of porous metals for bone scaffolds and orthopaedic implants: a review. Biomaterials 83:127
Yan C, Hao L, Hussein A, Young P, Raymont D (2014) Advanced lightweight 316L stainless steel cellular lattice structures fabricated via selective laser melting. Mater Des 55:533
Ashby M (2006) The properties of foams and lattices. Philos Trans R Soc A Math Phys Eng Sci 364(1838):15
Syam WP, Jianwei W, Zhao B, Maskery I, Elmadih W, Leach R (2018) Design and analysis of strut-based lattice structures for vibration isolation. Precis Eng 52:494
Nagesha B, Dhinakaran V, Shree MV, Kumar KM, Chalawadi D, Sathish T (2020) Review on characterization and impacts of the lattice structure in additive manufacturing. Mater Today Proc 21:916
Zhakeyev A, Wang P, Zhang L, Shu W, Wang H, Xuan J (2017) Additive manufacturing: unlocking the evolution of energy materials. Adv Sci 4(10):1700187
Righetti G, Savio G, Meneghello R, Doretti L, Mancin S (2020) Experimental study of phase change material (PCM) embedded in 3D periodic structures realized via additive manufacturing. Int J Therm Sci 153:106376
Takezawa A, Kobashi M, Koizumi Y, Kitamura M (2017) Porous metal produced by selective laser melting with effective isotropic thermal conductivity close to the Hashin–Shtrikman bound. Int J Heat Mass Transf 105:564
Du Y, Gu D, Xi L, Dai D, Gao T, Zhu J, Ma C (2020) Laser additive manufacturing of bio-inspired lattice structure: forming quality, microstructure and energy absorption behavior. Mater Sci Eng A 138857:773
El-Sayed MA, Essa K, Ghazy M, Hassanin H (2020) Design optimization of additively manufactured titanium lattice structures for biomedical implants. Int J Adv Manuf Technol 110(9):2257
Mahmoud D, Elbestawi MA (2017) Lattice structures and functionally graded materials applications in additive manufacturing of orthopedic implants: a review. J Manuf Mater Process 1(2):13
Plocher J, Panesar A (2019) Review on design and structural optimisation in additive manufacturing: towards next-generation lightweight structures. Mater Des 183:108164
Nazir A, Abate KM, Kumar A, Jeng JY (2019) A state-of-the-art review on types, design, optimization, and additive manufacturing of cellular structures. Int J Adv Manuf Technol 104(9-12):3489
Echeta I, Feng X, Dutton B, Leach R, Piano S (2020) Review of defects in lattice structures manufactured by powder bed fusion. Int J Adv Manuf Technol 106(5):2649
Seharing A, Azman AH, Abdullah S (2020) A review on integration of lightweight gradient lattice structures in additive manufacturing parts. Adv Mech Eng 12(6):1687814020916951
Hanks B, Berthel J, Frecker M, Simpson TW (2020) Mechanical properties of additively manufactured metal lattice structures: data review and design interface. Addit Manuf 101301:35
Ashouri D, Voshage M, Burkamp K, Kunz J, Bezold A, Schleifenbaum J, Broeckmann C (2020) Mechanical behaviour of additive manufactured 316L f2ccz lattice structure under static and cyclic loading. Int J Fatigue 134:105503
Qiu C, Yue S, Adkins NJ, Ward M, Hassanin H, Lee PD, Withers PJ, Attallah MM (2015) Influence of processing conditions on strut structure and compressive properties of cellular lattice structures fabricated by selective laser melting. Mater Sci Eng A 628:188
Van Bael S, Kerckhofs G, Moesen M, Pyka G, Schrooten J, Kruth JP (2011) Micro-CT-based improvement of geometrical and mechanical controllability of selective laser melted Ti6Al4V porous structures. Mater Sci Eng A 528(24):7423
Dallago M, Zanini F, Carmignato S, Pasini D, Benedetti M (2018) Effect of the geometrical defectiveness on the mechanical properties of SLM biomedical Ti6Al4V lattices. Procedia Struct Integr 13:161
Tsopanos S, Mines R, McKown S, Shen Y, Cantwell W, Brooks W, Sutcliffe C (2010) The influence of processing parameters on the mechanical properties of selectively laser melted stainless steel microlattice structures. J Manuf Sci Eng. 132(4)
Mazur M, Leary M, Sun S, Vcelka M, Shidid D, Brandt M (2016) Deformation and failure behaviour of Ti-6Al-4V lattice structures manufactured by selective laser melting (SLM). Int J Adv Manuf Technol 84(5-8):1391
Wauthle R, Vrancken B, Beynaerts B, Jorissen K, Schrooten J, Kruth JP, Van Humbeeck J (2015) Effects of build orientation and heat treatment on the microstructure and mechanical properties of selective laser melted Ti6Al4V lattice structures. Addit Manuf 5:77
Leary M, Mazur M, Elambasseril J, McMillan M, Chirent T, Sun Y, Qian M, Easton M, Brandt M (2016) Selective laser melting (SLM) of AlSi12Mg lattice structures. Mater Des 98:344
Cheng L, Bai J, To AC (2019) Functionally graded lattice structure topology optimization for the design of additive manufactured components with stress constraints. Comput Methods Appl Mech Eng 344:334
Xiao Z, Yang Y, Xiao R, Bai Y, Song C, Wang D (2018) Evaluation of topology-optimized lattice structures manufactured via selective laser melting. Mater Des 143:27
Brackett D, Ashcroft I, Hague R (2011) Topology optimization for additive manufacturing. In: Proceedings of the solid freeform fabrication symposium, Austin, TX, vol 1, pp 348–362
Wang Y, Zhang L, Daynes S, Zhang H, Feih S, Wang MY (2018) Design of graded lattice structure with optimized mesostructures for additive manufacturing. Mater Des 142:114
Dong G, Tang Y, Li D, Zhao YF (2020) Design and optimization of solid lattice hybrid structures fabricated by additive manufacturing. Addit Manuf 33:101116
Gibson LJ, Ashby M (1999) Cellular solids: structure and properties. Cambridge university press, Cambridge
Amani Y, Dancette S, Delroisse P, Simar A, Maire E (2018) Compression behavior of lattice structures produced by selective laser melting: X-ray tomography based experimental and finite element approaches. Acta Materialia 159:395
Crupi V, Kara E, Epasto G, Guglielmino E, Aykul H (2017) Static behavior of lattice structures produced via direct metal laser sintering technology. Mater Des 135:246
Mustapha M, Ismail F, Mamat O (2011) Empirical relationship between relative electrical conductivity and relative density of the Al-foam fabricated through pressure assisted sintering/dissolution process. In: IOP Conference series: materials science and engineering, vol 17. IOP Publishing, pp 1–19
Lu T, Stone HA, Ashby M (1998) Heat transfer in open-cell metal foams. Acta materialia 46(10):3619
Hasib H, Harrysson OL, West HA (2015) Powder removal from Ti-6Al-4V cellular structures fabricated via electron beam melting. Jom 67(3):639
Tanlak N, De Lange DF, Van Paepegem W (2017) Numerical prediction of the printable density range of lattice structures for additive manufacturing. Mater Des 133:549
Tamburrino F, Graziosi S, Bordegoni M. (2018) The design process of additively manufactured mesoscale lattice structures: a review. J Comput Inf Sci Eng 18(4)
Choy SY, Sun CN, Leong KF, Wei J (2017) Compressive properties of Ti-6Al-4V lattice structures fabricated by selective laser melting: design, orientation and density. Addit Manuf 16:213
Funding
This work was supported by the Office of Naval Research grant number N00014-17-1-2802.
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
The authors declare no competing interests.
Data availability
The authors confirm that the data supporting the findings of this study are available upon reasonable request from the corresponding author.
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Author contribution
C.Z. and A.B. conducted manufacturing and characterization experiments. A.H. and A.T. conducted numerical simulations and identified application potentials. A.E., J.F., and P.S. defined problem scope, supervised the scholarly work, conducted project management, and acquired funding support for the work. All authors contributed to manuscript writing, editing, and revisions.
Rights and permissions
About this article
Cite this article
Zhang, C., Banerjee, A., Hoe, A. et al. Design for laser powder bed additive manufacturing of AlSi12 periodic mesoscale lattice structures. Int J Adv Manuf Technol 113, 3599–3612 (2021). https://doi.org/10.1007/s00170-021-06817-w
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-021-06817-w