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Composite Structures
journal homepage: www.elsevier.com/locate/compstruct
Advanced Manufacturing Precinct, RMIT University, GPO Box 2476, Melbourne 3001, Australia
Sir Lawrence Wackett Aerospace Research Centre, School of Aerospace, Mechanical & Manufacturing Engineering, RMIT University, GPO Box 2476, Melbourne 3001, Australia
c
Joining Technology Group, Singapore Institute of Manufacturing Technology (SIMTech), 71 Nanyang Drive, Singapore 638075, Singapore
b
a r t i c l e
i n f o
Article history:
Available online 2 August 2014
Keywords:
Selective laser melting
Sandwich materials
Bio-inspired core structures
Titanium alloys
a b s t r a c t
Additive manufacture of titanium structures allows the realisation of advanced design strategies not
achievable through traditional manufacturing methods. This work analyses the performance of Ti-6Al4V Kagome truss core structures produced by selective laser melting (SLM) for composite sandwich structures. These bio-inspired core structures can be manufactured for truss diameters larger than 0.6 mm and
internal truss angles of less than 60 without requiring additional support structures. Mechanical testing
is conducted to determine the deformation and failure of the core structure in compression and shear. A
nite element model validates the structural performance and can further optimise the unit cell design.
Design charts show that the performance of the proposed titanium core in both compression and shear is
superior (strength) or equal (stiffness) to honeycomb cores for aerospace applications.
2014 Elsevier Ltd. All rights reserved.
1. Introduction
Sandwich structures are very useful for structural applications
requiring low weight, high strength and high energy absorption.
For standard industry applications in aerospace, marine and automotive, a variety of cores including honeycomb, foam and balsa
wood cores are generally employed [13].
Advanced metallic core design has in the past been limited by
traditional manufacturing processes such as investment casting,
forming and welding [4,5]. Aerospace sandwich structures generally utilise aluminium honeycomb cores, despite of problems with
poor interface bonding between core and composite skins [6] and
possible problems with galvanic corrosion in the case of carbon
bre skin material [7].
In recent years, the advancement of additive manufacture and
in particular the selective laser melting (SLM) technology has led
to alternative design possibilities for the sandwich core. Emmelmann et al. [8] highlighted the importance of additive manufacturing for aerospace industry, to produce bionic structural
components with complex surfaces and internal features. SLM
manufacture allows the use of aerospace grade titanium alloy
Ti-6Al-4V for the core material. The excellent corrosion resistant
Corresponding author at: Joining Technology Group, Singapore Institute of
Manufacturing Technology (SIMTech), 71 Nanyang Drive, Singapore 638075,
Singapore. Tel: +65 6793 8378
E-mail address: feihs@simtech.a-star.edu.sg (S. Feih).
http://dx.doi.org/10.1016/j.compstruct.2014.07.036
0263-8223/ 2014 Elsevier Ltd. All rights reserved.
properties and exceptionally high strength to density ratio of titanium alloys make them a prominent choice for high performance
aerospace applications. Titanium alloys can also easily be bonded
to carbon bre composites.
Truss and lattice type core structures belong to the innovative
3D structural core category. Key performance parameters of a core
material are its compressive and shear strength in relation to its
weight. The structural performance of truss and lattice structures
and their potential as a metallic core in sandwich panels has been
studied by various research groups. The deformation behaviour of
a large variety of lattice structures was researched by Emmelmann
et al. [8], Mines et al. [9], Rehme and Emmelmann [10] and Cote
et al. [11]. Rehme and Emmelmann compared specic strength of
lattice structures produced from SLM. It was found that facecentred unit cell structures with vertical support (f2cc) exhibited
the highest specic yield strength. Cote et al. [11] studied properties of prismatic lattice structures for in-plane and out-of-plane
compression and shear. They compared analytical, numerical and
mechanical test results for diamond and corrugated congurations.
Furthermore they suggested that these structures are equivalent to
square honeycomb in longitudinal shear strength but lower in
transverse shear and compression. George et al. [12] used CFRP lattice structures to enhance the performance of foam cores. Compression and shear results showed increase in strength and
modulus, while a major gain was achieved for the energy absorption characteristic. Wicks and Hutchinson [13] demonstrated the
295
Fig. 2. Kagome truss cell as used for analysis with design parameters of diameter,
truss length and cell height and internal angle.
Table 1
SLM build parameters.
Parameter
Value
Laser power
Layer thickness
Area scan speed
Energy density
Hatch type
Hatch spacing
Spot size
Platform temperature
175 W
30 lm
710 mm/s
68.5 J/mm3
Checkerboard
120 lm
80 lm
200 C
Fig. 3. (a) Preprocessing of test specimen for SLM production (b) specimen panel
produced from SLM showing Kagome truss and faces.
296
Fig. 5. (a) FE mesh of Kagome cell, locating three types of elements (b) radial cross-section (c) axial cross-section, locating three types of elements (Type 1:C3D4, Type
2:C3D6, Type 3:C3D8R).
297
Fig. 6. (a) Fracture locus limit curve and (b) tensile stressstrain data.
Ti-6Al-4V Billet
Ti-6Al-4V SLM
D1
D2
D3
D4
D5
D6
D7
0.164
0.292
1.376
0.052
0.461
1.89
1.853
0.49
0.1
0.1
1.3
0.03
0.2
1.15
2.0
0.458
gT
298
Fig. 7. Deformation behaviour of single Kagome truss under compression for (a)
1.2 mm truss diameter and 55 angle and (b) 0.5 mm diameter and 60 angle.
Circles on load-displacement trace indicate the point of truss failure in the test and
numerical model.
Fig. 8. (a) Deformation behaviour of 0.5 mm diameter and 50 angle double cell
Kagome truss comparison of test and FE under shear (b) test specimen (c) FE model.
299
Fig. 9. Ti-6Al-4V Kagome trusses as compared to honeycomb and foam core family of structures for (a) compressive strength and (b) compressive modulus. Data for
benchmark honeycomb and closed-cell foam materials is obtained from CES EduPack2012.
can occur in three main modes: ductile void growth, pure shear or
a mixed mode void growth. The strain-to-failure depends on the
stress triaxiality. The distinctive regions are illustrated in
Fig. 6(a). Giglio et al. [22] used a set of three equations with seven
different coefcients (D1D7) to completely describe the failure
strain under multi-axial stress conditions:
ef
8 D1
D2
>
13g
>
>
<
2
D3 g D4 g D5
>
>
>
:
D6 D7 eD6 g
1=3 < g 6 0
Shear failure
0 < g 6 gT
Mixed mode
gT 6 g
Ductile failure
1
300
Fig. 10. Ti-6Al-4V Kagome trusses as compared to honeycomb and foam core family of structures for (a) shear strength and (b) shear modulus. Data for benchmark
honeycomb and closed-cell foam materials is obtained from CES EduPack2012.
2
3
For the given structures, the face area, Aface, was equal to the
cross-sectional area of Kagome unit cell and depended only on
the truss angle. For the linear strain conversion, the current core
height during deformation was divided by the original height of
the truss core structures, which for all congurations was
11.5 mm as outlined previously.
301
6. Conclusions
Bio-inspired Kagome truss core structures were tested to failure
in compression and shear, and the deformation characteristics and
failure could be successfully predicted with nonlinear explicit nite
element analysis incorporating a ductile failure metal criterion.
Numerical analysis was then utilised to create design charts for a
wide range of truss core parameters (diameters between 0.5 and
1.3 mm and internal angles between 45 and 60). For these parameters, core structures could be built without including additional
support structures. Minimising support structures is important to
(a) minimise manufacturing cost and (b) for the viable manufacture
of core structural panels combining a large number of unit cells.
The Kagome truss core structures were found to perform better
than conventional honeycomb aerospace core structures in terms
of their specic strength for compression and shear for all parameters analysed. The core stiffness under these loading conditions
remained similar to honeycomb structures.
It is shown that the optimisation of the Kagome truss parameters depends on the load case. The internal angle of the truss structure can be tailored to perform best for shear (close to 45) or
compressive loading (close to the 60 limit due to manufacturing
constraints). The internal angle of a larger sandwich panel with
numerous truss structures may also be changed depending on
the trusses location within the panel. The diameter of the trusses
can be maximised locally or uniformly for a given weight requirement of the panel.
These ndings make SLM manufactured titanium truss core
structures a viable replacement for honeycomb cores in future
aerospace applications. SLM manufacture of core structures
furthermore has the added advantage of better bonding to composite skins due to the integrated face sheets and the possibility of
incorporating additional through-thickness reinforcement for the
composite skins in the forms of z-pins.
Acknowledgments
The authors acknowledge the efforts of Mr. Aaron Pateras, for
manufacturing of SLM structures and Mr. Peter Tkatchyk, for providing support during mechanical testing. The CT-Scanning for this
work was done at the South Australian node of the Australian
National Fabrication Facility under the National Collaborative
Research Infrastructure Strategy to provide nano- and micro-fabrication facilities for Australias researchers. One of the authors, I.
Ullah, acknowledges the support of the Australian Government
through the Endeavour Scholarship for this research project.
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