Subdivisional modelling method for matched metal additive manufacturing and its implementation on novel negative Poisson's ratio lattice structures

Pan, Ruiqi; Yan, Chunze; He, Meng; Chen, Qiaoyu; Li, Simeng; Chen, Xiaoli; Liu, Hao; Li, Yan

doi:10.1016/j.addma.2023.103525

Cited by 7 publications

(2 citation statements)

References 67 publications

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“…Over the years, substantial research efforts have been invested into enhancing the mechanical properties of AM metallic parts, ensuring they meet or even surpass the demands of traditional manufacturing methods. These advancements aim to produce lightweight internal cellular structures for structural components marked by strides in refining processes and material compositions, resulting in remarkable improvements in the structural integrity of AM components [ 3 , 4 , 5 ]. Despite these strides, a critical challenge, notably under-addressed in current literature, is the ability to construct complex internal geometries with precision, particularly in the context of interior fine fluid channels.…”

Section: Introductionmentioning

confidence: 99%

“…The Selective Laser Melting (SLM) technique was utilized to fabricate internal lightweight cellular structures [ 3 ] and internal cooling channels in aerospace and combustion chamber components [ 8 , 9 ]. The proficiency of this technology was also extended to the creation of internal cooling channels for stainless steel injection molding tools, showcasing its versatility in diverse applications [ 10 , 11 ].…”

Section: Introductionmentioning

confidence: 99%

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Surface Roughness of Interior Fine Flow Channels in Selective Laser Melted Ti-6Al-4V Alloy Components

Islam,

Hao,

Javaid

et al. 2024

Micromachines

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A challenge remains in achieving adequate surface roughness of SLM fabricated interior channels, which is crucial for fuel delivery in the space industry. This study investigated the surface roughness of interior fine flow channels (1 mm diameter) embedded in SLM fabricated TC4 alloy space components. A machine learning approach identified layer thickness as a significant factor affecting interior channel surface roughness, with an importance score of 1.184, followed by scan speed and laser power with scores of 0.758 and 0.512, respectively. The roughness resulted from thin layer thickness of 20 µm, predominantly formed through powder adherence, while from thicker layer of 50 µm, the roughness was mainly due to the stair step effect. Slow scan speeds increased melt pools solidification time at roof overhangs, causing molten metal to sag under gravity. Higher laser power increased melt pools temperature and led to dross formation at roof overhangs. Smaller hatch spaces increased roughness due to overlapping of melt tracks, while larger hatch spaces reduced surface roughness but led to decreased part density. The surface roughness was recorded at 34 µm for roof areas and 26.15 µm for floor areas. These findings contribute to potential adoption of TC4 alloy components in the space industry.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Surface Roughness of Interior Fine Flow Channels in Selective Laser Melted Ti-6Al-4V Alloy Components

Islam,

Hao,

Javaid

et al. 2024

Micromachines

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Auxetic Liquid Crystal Vitrimers with Adjustable Poisson's Ratios Enabled by Topological Rearrangements of Polymer Network

Zheng,

Ma,

et al. 2024

Adv Funct Materials

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Metamaterials feature extraordinary physical properties that break the cognitive limitations of human beings on traditional materials. Auxetic materials and liquid crystal elastomers (LCEs) are representative of typical mechanical and thermal metamaterials. Their combination may introduce some unconventional and counterintuitive performances. Nevertheless, studies on LCEs with negative Poisson's ratio (v) are still rare. Herein, a liquid crystal vitrimer (Poly‐LCE) is developed that is a polydomain main‐chain LCE containing dynamic ester bonds. Its orientation process to monodomain (Mono‐LCE) is greatly simplified by transesterification reaction‐induced topological network rearrangement under mechanical alignment. By optimizing geometric parameters of re‐entrant (R) structures and orientation of liquid crystal units, all samples of R‐Poly‐LCE, R‐Mono‐LCE (//), and R‐Mono‐LCE (⊥) show negative Poisson's ratio (NPR) below 2% elongation (v = −0.22–0 for R‐Poly‐LCE, v = −0.12–0 for R‐Mono‐LCE (//) and v = −0.16–0 for R‐Mono‐LCE (⊥)). Interestingly, R‐Poly‐LCE presents v > 0 within 2%–10% axial elongation, while R‐Mono‐LCE (//) and R‐Mono‐LCE (⊥) exhibit v ≈ 0 under the same elongation. Materials with negative and zero Poisson's ratios are interesting in niche applications. This work develops a simple method to prepare these materials by liquid crystal vitrimers.

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An innovative approach to a UAV tails structural design for additive manufacturing

Battaglia,

Acanfora,

Garofano

et al. 2024

Polymer Composites

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The innovative approach used for the design and fabrication of a UAV tails through additive manufacturing (AM) completely changes the concept of designing and manufacturing products through conventional methods. AM based processes can reduces costs, lead times, and increases design freedom, allowing parts to be tailored to specific needs. A key benefit of AM processes is the ability to produce optimized designs with reduced mass and without compromising structural effectiveness. This is possible thanks to the combination of high‐performance AM materials and the extraordinary manufacturing capability of AM technologies combined with an appropriate design‐for‐additive manufacturing (DfAM) approach, overcoming traditional manufacturing techniques. This article presents the development process of a UAV tails, based on a Design for Additive Manufacturing (DfAM) approach in order to reduce structural mass and guarantee safe operation under service loads. Therefore, by replacing the metallic component of the UAV with a techno‐polymeric one, several configurations have been developed. The optimal additive configuration achieved a weight reduction of 60% compared to a metal configuration of equivalent volume, without loss of mechanical properties. In conclusion, a feasibility study of the proposed configuration was carried out by 3D printing the vertical tail redesigned.Highlights An innovative approach by combining DfAM processes with FFF technology. Metal replacement of UAV tails with advanced technopolymers. Efficient Weight Reduction about 60% compared to metal structure. Single‐piece design simplifies assembly and manufacturing. UAV redesigned tails with enhanced efficiency, adaptability, and feasibility.

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Subdivisional modelling method for matched metal additive manufacturing and its implementation on novel negative Poisson's ratio lattice structures

Cited by 7 publications

References 67 publications

Surface Roughness of Interior Fine Flow Channels in Selective Laser Melted Ti-6Al-4V Alloy Components

Surface Roughness of Interior Fine Flow Channels in Selective Laser Melted Ti-6Al-4V Alloy Components

Auxetic Liquid Crystal Vitrimers with Adjustable Poisson's Ratios Enabled by Topological Rearrangements of Polymer Network

An innovative approach to a UAV tails structural design for additive manufacturing

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