Meyer, Guillaume Bertrand Thibaut (2024)
Towards implementing lattice structures into load-bearing lightweight components.
doi: 10.26083/tuprints-00026946
Book, Secondary publication, Publisher's Version
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Item Type: | Book | ||||
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Type of entry: | Secondary publication | ||||
Title: | Towards implementing lattice structures into load-bearing lightweight components | ||||
Language: | English | ||||
Referees: | Mittelstedt, Prof. Dr. Christian ; Weeger, Prof. Dr. Oliver | ||||
Date: | 28 March 2024 | ||||
Place of Publication: | Darmstadt | ||||
Year of primary publication: | 20 March 2024 | ||||
Place of primary publication: | Düren | ||||
Publisher: | Shaker Verlag GmbH | ||||
Series: | Schriftenreihe Leichtbau | ||||
Series Volume: | 6 | ||||
Collation: | xvi, 258 Seiten | ||||
Date of oral examination: | 13 December 2023 | ||||
DOI: | 10.26083/tuprints-00026946 | ||||
Abstract: | The aerospace industry strives for an optimum between sustainability, cost and resource efficiency. In this frame, additive manufacturing has established itself as a disruptive technology by offering increased constructive flexibility. Recent research demonstrated that the lightweight potential of load-carrying structural components could be further enhanced using this technology. Despite the reduction of weight and resource consumption that can be achieved through topology optimised structures, the efforts involved in both manufacturing and post-processing hinder in most cases additive manufacturing at being a competitive contender against conventional manufacturing processes. As a matter of fact, additive manufacturing is often employed for rapid prototyping while its use in serial production is rather restrained due to high costs and production times. An improved competitiveness can be achieved with the realisation of innovative structures through additive manufacturing. At the meso-scale, additively manufactured cellular structures and, in particular, lattice structures offer supplementary design freedom and, thus, new engineering opportunities that cannot be realised by conventional means of manufacturing. In addition to the increased lightweight potential they offer, cellular structures can drastically reduce the printing time and therefore make additive manufacturing more viable in terms of Time-to-Market. However, lattice structures find restricted fields of application for serial production and are still not implemented into load-carrying lightweight components. This is due to lacks of standard on several levels, from the initial design to the final product certification, which hold back exploiting their potential. This work explores the challenges met by the implementation of lattice structures into bulk parts from both design and manufacturing points of view. In the first part of this work, concepts for load introduction designs avoiding local stress concentration at both lattice-to-bulk and lattice-to-lattice interfaces are developed and numerically verified. In the second part of this work, the reliable additive manufacturing of sub-millimetre lattice structures in the framework of laser powder-bed fusion and manufacturing approaches for their implementation into bulk parts are investigated. Insights into the influence of manufacturing on the structural integrity of lattice structures and their inherent mechanical properties are provided in the frame of experimental validations as well. The present work proposes a framework for both standardised design and reliable manu-facturing of test specimens for the mechanical characterisation of lattice structures under tensile loading. Furthermore, this contribution can be considered as a first milestone towards straightforward design guidelines on the implementation of lattice structures in lightweight components for daily engineering practice since the developed concepts are not specific and therefore not restricted to the employed AlSi10Mg powder material. |
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Status: | Publisher's Version | ||||
URN: | urn:nbn:de:tuda-tuprints-269469 | ||||
Classification DDC: | 600 Technology, medicine, applied sciences > 620 Engineering and machine engineering | ||||
Divisions: | 16 Department of Mechanical Engineering > Institut für Leichtbau und Strukturmechanik (LSM) | ||||
Date Deposited: | 28 Mar 2024 14:02 | ||||
Last Modified: | 27 Jun 2024 13:33 | ||||
URI: | https://tuprints.ulb.tu-darmstadt.de/id/eprint/26946 | ||||
PPN: | 516764802 | ||||
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