Experimental and Simulation Investigation on Energy Absorption of Cu Casting Lattice Structure during Compression

Abstract

This investigation aims to assess the mechanical behavior and energy absorption properties of the Cu lattice structures made by investment casting method experimentally and by finite element method (FEM) simulation. The casting pattern of lattice structures is additively manufactured with 2.0, 2.5, and 3.0 mm diameters and the lattice structures produced by investment casting of Cu. Then a uniaxial compression test is applied to measure maximum compressive strength, energy absorption density, efficiency, and specific energy absorption. The simulation and the experimental results indicate that the abovementioned properties of the lattice structures have a significant improvement and properties developments will rise by increasing the diameter of the struts. The mechanical characterization has done for Cu lattice structure with 3.0 mm strut diameter, which endures a stress of 242 MPa at the densification strain and the maximum tolerated stress of 404 MPa. The energy absorption density of this lattice structure is 67 MJ m−3 and has a specific energy absorption of 28 J g−1 followed by an energy absorption efficiency around 70%. The simulation result shows a mathematical connection between the unit cells and the final lattice structures in terms of maximum tolerated stresses, which can help the prediction of the mechanical behavior of these structures.

Mechanical Response of Open‐Cell Metal Foams with Single‐ and Multilayer Shell during Uniaxial Compression Test

“…According to ref. [47] and ISO 13 314, [ 55 ] in examining the mechanical properties of metal foams, the densification strain () is a significant factor as it ends the porous behavior and makes the material act like its bulk. Moreover, the plateau region of metal foams is the area of stress–strain graph that is responsible for the absorbed energy of these metallic foams.…”

“…Also, the increasing discrepancies between the prediction by the shock theory were due to the higher level of densification strain that can be achieved experimentally than is predicted analytically when using simple theories. Moreover, Rohani Nejad et al [ 47 ] produced a new generation of sandwich panels with open‐cell metal foam cores through additive manufacturing of polymers and electroforming of nickel and reported that the strength and energy absorption properties of these sandwich structures will increase by increasing the pores per inches (PPI) of these novel materials. Furthermore, Reda et al [ 20 ] produced a type of multilayer metal foam with unique characteristics.…”

Investigation on mechanical properties of nickel open cell metal foam after heat treatment

“…Investigating the normalized stresses are a new approach that is used to better understand the mechanical response and characteristics of porous materials 36 . Equation ( 1 ), normalized the tolerated stresses to reach a better and comparative factor.…”