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Geometrical parameters and mechanical properties of Ti6Al4V hollow-walled lattices
Materials Science and Engineering: A  (IF5.234),  Pub Date : 2022-01-13, DOI: 10.1016/j.msea.2022.142667
J. Noronha, M. Leary, M. Qian, E. Kyriakou, M. Brandt

Hollow-walled lattices are a recent optimization upon the conventional dense-walled lattice design. These novel microstructures can achieve extremely low densities while exhibiting robust technical properties including high ductility, strength, and stiffness. However, the current fabrication process for these structures is ineffective, requiring multiple additive and subtractive manufacturing processes to produce a single specimen. The application of a single step additive manufacturing (AM) method has not yet been evaluated for hollow-walled lattice fabrication. This study aims to assess the viability of such a method, enabling greater geometric control, and providing a single process to reduce both time and cost. The manufacturability of laser powder bed fusion (LPBF) will be explored through Ti6Al4V hollow-walled struts and lattices at varying diameters, lengths, and inclination angles while retaining a constant wall thickness. Quasi static compressional testing will also occur upon the hollow-walled body-centered cubic lattices with a reinforced strut in the Z-axis (BCCZ). These experimental BCCZ lattices have been fabricated at relative densities ranging from 5 to 40%, and strength and modulus values have been observed between 4 and 25 MPa, and 750–3640 MPa, respectively. The resultant data will assist in the generation of the Gibson-Ashby Model to systematically compare LPBF Ti6Al4V hollow-walled lattices to reported dense-walled lattices. This study presents an exploration into the single-step fabrication of metal hollow-walled struts and lattices to broaden the scope of manufacturability and facilitate future advancements.