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An investigation into the effect of gradients on the manufacturing fidelity of triply periodic minimal surface structures with graded density fabricated by selective laser melting

An investigation into the effect of gradients on the manufacturing fidelity of triply periodic minimal surface structures with graded density fabricated by selective laser melting
An investigation into the effect of gradients on the manufacturing fidelity of triply periodic minimal surface structures with graded density fabricated by selective laser melting
Triply periodic minimal surfaces (TPMSs) have attracted increasing attention for their high manufacturability, biocompatibility, and mechanical properties. In this work, graded Gyroid cellular structures (GCSs) with varying gradient directions were mathematically designed and manufactured via selective laser melting (SLM). The effect of gradients on manufacturing fidelity, i.e. degree of conformity between the manufactured part and engineering design, of these structures was investigated using X-ray computed tomography (CT). The results indicate that relative density and volume fraction of as-built GCSs are higher than those specified in the engineering design due to strut diameters being larger than specification and the presence of bonded powder particles. Manufacturing fidelity is shown to depend on the geometry of the struts in these structures, including inclination angle of struts, relative density, and density gradient direction. Bonded powder particles were particularly present at the upper inner walls of sphere-like pores, where inclination angles are low and as a result there is a lack of support and non-ideal transfer of heat from the melt pool. Decreasing density along the building direction reduces the occurrence of bonded powder particles and increases manufacturing fidelity. The empirical findings in this study provide insight into the effects of part geometry on the quality of its manufacture by SLM. Results are used to establish guidelines for optimal design of cellular structures.
Graded cellular structure, Gyroid, Selective laser melting, Triply periodic minimal surface, X-ray computed tomography
0924-0136
Yang, Lei
3374a6c7-e285-4014-a301-ad6cea7251af
Ferrucci, Massimiliano
64c091db-2b40-42d8-b44d-0d6c6b6ffaa4
Mertens, Raya
3f09123a-947a-4c09-a537-5e408a4308d4
Dewulf, Wim
d5a074b8-6b60-4d03-87b7-afc6b9d9d954
Yan, Chunze
429c7099-992f-46df-b714-b50ae2980d98
Shi, Yusheng
c5e10cdc-0c6e-4de9-877d-9b83955e0955
Yang, Shoufeng
e0018adf-8123-4a54-b8dd-306c10ca48f1
Yang, Lei
3374a6c7-e285-4014-a301-ad6cea7251af
Ferrucci, Massimiliano
64c091db-2b40-42d8-b44d-0d6c6b6ffaa4
Mertens, Raya
3f09123a-947a-4c09-a537-5e408a4308d4
Dewulf, Wim
d5a074b8-6b60-4d03-87b7-afc6b9d9d954
Yan, Chunze
429c7099-992f-46df-b714-b50ae2980d98
Shi, Yusheng
c5e10cdc-0c6e-4de9-877d-9b83955e0955
Yang, Shoufeng
e0018adf-8123-4a54-b8dd-306c10ca48f1

Yang, Lei, Ferrucci, Massimiliano, Mertens, Raya, Dewulf, Wim, Yan, Chunze, Shi, Yusheng and Yang, Shoufeng (2020) An investigation into the effect of gradients on the manufacturing fidelity of triply periodic minimal surface structures with graded density fabricated by selective laser melting. Journal of Materials Processing Technology, 275, [116367]. (doi:10.1016/j.jmatprotec.2019.116367).

Record type: Article

Abstract

Triply periodic minimal surfaces (TPMSs) have attracted increasing attention for their high manufacturability, biocompatibility, and mechanical properties. In this work, graded Gyroid cellular structures (GCSs) with varying gradient directions were mathematically designed and manufactured via selective laser melting (SLM). The effect of gradients on manufacturing fidelity, i.e. degree of conformity between the manufactured part and engineering design, of these structures was investigated using X-ray computed tomography (CT). The results indicate that relative density and volume fraction of as-built GCSs are higher than those specified in the engineering design due to strut diameters being larger than specification and the presence of bonded powder particles. Manufacturing fidelity is shown to depend on the geometry of the struts in these structures, including inclination angle of struts, relative density, and density gradient direction. Bonded powder particles were particularly present at the upper inner walls of sphere-like pores, where inclination angles are low and as a result there is a lack of support and non-ideal transfer of heat from the melt pool. Decreasing density along the building direction reduces the occurrence of bonded powder particles and increases manufacturing fidelity. The empirical findings in this study provide insight into the effects of part geometry on the quality of its manufacture by SLM. Results are used to establish guidelines for optimal design of cellular structures.

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Graded_gyroid_MANUSCRIPT_manufacturing SYang - Accepted Manuscript
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More information

Accepted/In Press date: 13 August 2019
e-pub ahead of print date: 14 August 2019
Published date: 1 January 2020
Keywords: Graded cellular structure, Gyroid, Selective laser melting, Triply periodic minimal surface, X-ray computed tomography

Identifiers

Local EPrints ID: 435918
URI: http://eprints.soton.ac.uk/id/eprint/435918
ISSN: 0924-0136
PURE UUID: 76660ad8-76ae-4f74-9ef7-c64dd9a580df
ORCID for Shoufeng Yang: ORCID iD orcid.org/0000-0002-3888-3211

Catalogue record

Date deposited: 22 Nov 2019 17:30
Last modified: 26 Nov 2021 06:31

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Contributors

Author: Lei Yang
Author: Massimiliano Ferrucci
Author: Raya Mertens
Author: Wim Dewulf
Author: Chunze Yan
Author: Yusheng Shi
Author: Shoufeng Yang ORCID iD

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