<p>The manufacture of thin wall honeycomb structures by additive manufacturing, though challenging, offers a unique opportunity for light weighting by topological optimization for energy absorbing components. In the current investigation, the structural performance of a honeycomb-structured cylindrical sample of Ti6Al4V alloy manufactured by direct metal laser sintering process was investigated under compressive loading in the quasistatic and dynamic regime. The microstructural characterization was performed using secondary electron imaging and electron backscatter diffraction in a scanning electron microscope. The as-printed sample was characterized by closed porosity, partially sintered particles, and surface microcracks as major defects. The quasistatic compression behavior of the sample was characterized by a fluctuating load-displacement curve due to the layer-by-layer progressive collapse of the structure from top to bottom. The microcracks on the walls of the structure propagate in the transverse direction upon load application, causing local instability in the structure. A similar behavior was also observed for dynamic deformed sample although the amount of collapse was limited. Detailed microstructural characterization indicates the absence of plastic deformation under quasistatic and dynamic regimes highlighting the role of surface microcracks in the final failure of the structure. Lastly, the specific energy absorption capacity of the experimental sample was found to be higher than the specific energy absorption capacity reported for some cellular structures of Ti alloys in literature.</p>

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Structural Performance and Failure Behavior of Direct Metal Laser Sintered Honeycomb-Structured Sample of Ti6Al4V

  • Amit Kumar Yadav,
  • N. P. Gurao

摘要

The manufacture of thin wall honeycomb structures by additive manufacturing, though challenging, offers a unique opportunity for light weighting by topological optimization for energy absorbing components. In the current investigation, the structural performance of a honeycomb-structured cylindrical sample of Ti6Al4V alloy manufactured by direct metal laser sintering process was investigated under compressive loading in the quasistatic and dynamic regime. The microstructural characterization was performed using secondary electron imaging and electron backscatter diffraction in a scanning electron microscope. The as-printed sample was characterized by closed porosity, partially sintered particles, and surface microcracks as major defects. The quasistatic compression behavior of the sample was characterized by a fluctuating load-displacement curve due to the layer-by-layer progressive collapse of the structure from top to bottom. The microcracks on the walls of the structure propagate in the transverse direction upon load application, causing local instability in the structure. A similar behavior was also observed for dynamic deformed sample although the amount of collapse was limited. Detailed microstructural characterization indicates the absence of plastic deformation under quasistatic and dynamic regimes highlighting the role of surface microcracks in the final failure of the structure. Lastly, the specific energy absorption capacity of the experimental sample was found to be higher than the specific energy absorption capacity reported for some cellular structures of Ti alloys in literature.