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<p>This study explores the optimization of additively manufactured A286 steel micro-lattice structures using laser powder bed fusion (LPBF) for underbelly protection in armored vehicles. The objective is to develop a lightweight yet robust alternative to conventional homogeneous armor materials such as Rolled Homogeneous Armor (RHA), Modified Homogeneous Armor (MHA), and High Nitrogen Steel (HNS). Post-processing treatments, including stress relieving and heat treatment, resulted in a 14.14-57.77% reduction in surface roughness and a 39.67-57.36% increase in hardness, enhancing mechanical integrity. A multi-criteria decision-making approach (TOPSIS) was employed to determine optimal lattice dimensions for improved energy absorption and blast mitigation. Surface morphology analysis revealed fine-grain structures in honeycomb and BCC lattices, which demonstrated superior compressive residual stress retention—up to 47.30% (honeycomb) and 42.64% (BCC) compared to RHA, MHA, and HNS. Additionally, the honeycomb micro-lattice exhibited 8.14% higher residual stress than BCC, indicating superior blast wave energy dissipation. Corrosion resistance testing confirmed a 57.23% reduction in corrosion rate for honeycomb structures compared to RHA, with BCC structures showing a 53.93% improvement. The honeycomb configuration also demonstrated 7.16% lower corrosion susceptibility than BCC, reinforcing its suitability for long-term deployment in harsh environments. This study highlights the potential of LPBF-fabricated micro-lattice structures as modular solutions for enhanced armor protection, offering an optimal balance of mechanical performance, durability, and weight reduction.</p>

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Enhanced Underbelly Protection for Armored Vehicles Using Laser Powder Bed Fusion Additive Manufacturing of Micro-Lattice Structures

  • 期刊论文

  • 发表日期：

    2025年6月2日

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  • Ameer Malik Shaik,
  • B. Veera Siva Reddy,
  • C. Chandrasekhara Sastry,
  • J. Krishnaiah,
  • B. Ramakrishna

摘要

This study explores the optimization of additively manufactured A286 steel micro-lattice structures using laser powder bed fusion (LPBF) for underbelly protection in armored vehicles. The objective is to develop a lightweight yet robust alternative to conventional homogeneous armor materials such as Rolled Homogeneous Armor (RHA), Modified Homogeneous Armor (MHA), and High Nitrogen Steel (HNS). Post-processing treatments, including stress relieving and heat treatment, resulted in a 14.14-57.77% reduction in surface roughness and a 39.67-57.36% increase in hardness, enhancing mechanical integrity. A multi-criteria decision-making approach (TOPSIS) was employed to determine optimal lattice dimensions for improved energy absorption and blast mitigation. Surface morphology analysis revealed fine-grain structures in honeycomb and BCC lattices, which demonstrated superior compressive residual stress retention—up to 47.30% (honeycomb) and 42.64% (BCC) compared to RHA, MHA, and HNS. Additionally, the honeycomb micro-lattice exhibited 8.14% higher residual stress than BCC, indicating superior blast wave energy dissipation. Corrosion resistance testing confirmed a 57.23% reduction in corrosion rate for honeycomb structures compared to RHA, with BCC structures showing a 53.93% improvement. The honeycomb configuration also demonstrated 7.16% lower corrosion susceptibility than BCC, reinforcing its suitability for long-term deployment in harsh environments. This study highlights the potential of LPBF-fabricated micro-lattice structures as modular solutions for enhanced armor protection, offering an optimal balance of mechanical performance, durability, and weight reduction.