Process-Structure-Property Relationships of Laser Powder Bed Fusion Lattice Structures

IF 2.4 3区 工程技术 Q3 ENGINEERING, MANUFACTURING Journal of Manufacturing Science and Engineering-transactions of The Asme Pub Date : 2023-05-22 DOI:10.1115/1.4062580
E. Jost, J. Pegues, D. Moore, C. Saldana
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Abstract

Lattice structure metamaterials offer a variety of unique and tailorable properties, yet industrial adoption is slowed by manufacturability and inspection-related difficulties. Despite recent advances in laser powder bed fusion (LPBF) additive manufacturing (AM), the sub-millimeter features of lattices are at the edge of process capabilities and suffer from low geometric quality. To better understand their complex process-structure-property (PSP) relationships, octahedron structures were manufactured across a power spectrum, inspected, and mechanically tested. X-ray computed tomography (CT) was used to characterize lattice geometry, and demonstrated that lattice strut geometry measures, increased significantly as a function of laser power. Furthermore, lattices are shown to exhibit a direct correlation between laser power and mechanical performance metrics. Performance variations up to 60% are shown as a function of process parameters despite nominally identical geometry. Significant geometry variations are found to be the cause of performance variation, while material properties as measured by microindentation hardness are constant across the studied parameter range. PSP relationships are modeled, and the limitations of these models are explored. It was found that resulting models can predict mechanical performance based on geometric characteristics with R2 values of up to 0.86. Finally, mechanistic causes of observed performance changes are discussed.
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激光粉末床聚变晶格结构的工艺结构与性能关系
晶格结构超材料提供了各种独特和可定制的特性,但由于可制造性和检测相关的困难,工业应用缓慢。尽管近年来在激光粉末床融合(LPBF)增材制造(AM)方面取得了进展,但晶格的亚毫米特征处于工艺能力的边缘,并且几何质量较低。为了更好地理解它们复杂的工艺-结构-性能(PSP)关系,在功率谱上制造了八面体结构,进行了检查和机械测试。x射线计算机断层扫描(CT)用于表征晶格几何形状,并证明了晶格支柱几何尺寸随激光功率的增加而显著增加。此外,晶格显示出激光功率和机械性能指标之间的直接相关性。性能变化高达60%显示为工艺参数的函数,尽管名义上相同的几何形状。发现显著的几何变化是性能变化的原因,而通过微压痕硬度测量的材料性能在所研究的参数范围内是恒定的。建立了PSP关系模型,并探讨了这些模型的局限性。结果表明,所建立的模型可以基于几何特征预测力学性能,R2值高达0.86。最后,讨论了观察到的性能变化的机理原因。
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来源期刊
CiteScore
6.80
自引率
20.00%
发文量
126
审稿时长
12 months
期刊介绍: Areas of interest including, but not limited to: Additive manufacturing; Advanced materials and processing; Assembly; Biomedical manufacturing; Bulk deformation processes (e.g., extrusion, forging, wire drawing, etc.); CAD/CAM/CAE; Computer-integrated manufacturing; Control and automation; Cyber-physical systems in manufacturing; Data science-enhanced manufacturing; Design for manufacturing; Electrical and electrochemical machining; Grinding and abrasive processes; Injection molding and other polymer fabrication processes; Inspection and quality control; Laser processes; Machine tool dynamics; Machining processes; Materials handling; Metrology; Micro- and nano-machining and processing; Modeling and simulation; Nontraditional manufacturing processes; Plant engineering and maintenance; Powder processing; Precision and ultra-precision machining; Process engineering; Process planning; Production systems optimization; Rapid prototyping and solid freeform fabrication; Robotics and flexible tooling; Sensing, monitoring, and diagnostics; Sheet and tube metal forming; Sustainable manufacturing; Tribology in manufacturing; Welding and joining
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