journal article·2023-07Open access

A probabilistic average strain energy density approach to assess the fatigue strength of additively manufactured cellular lattice materials

S. Raghavendra, M. Dallago, F. Zanini, S. Carmignato, F. Berto, M. Benedetti

Abstract

In cellular lattice materials, fatigue failure assessment using an intricate finite element (FE) model of the entire specimen is neither feasible nor economical. To address this complex task, we propose a multi-step FE analysis methodology that can be employed for these metamaterials. FE models are created using the three-dimensional reconstructions from the mu CT scans of the specimen. Subsequently, a combination of the average strain energy density approach and extreme value statistics is used to assess the fatigue behavior of the entire specimen. The methodology was employed on two types of cubic cellular lattice materials and validated using experimental fatigue results.
Source: openaire · Quality: candidate unverified · Source record ↗

Research context

OpenAlex topics: Cellular and Composite Structures · Additive Manufacturing and 3D Printing Technologies · Automotive and Human Injury Biomechanics

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (50)

Show source-provided references
1. Properties and applications of additively manufactured metallic cellular materials: a review10.1016/j.pmatsci.2021.100918 ↗
2. Stiffness and strength of tridimensional periodic lattices10.1016/j.cma.2012.03.018 ↗
3. Mechanical performance of highly permeable laser melted Ti6Al4V bone scaffolds10.1016/j.jmbbm.2019.103517 ↗
4. Thermal conductivity of architected cellular metamaterials10.1016/j.actamat.2019.04.061 ↗
5. I. Yadroitsava, A. du Plessis, I. Yadroitsev, Bone regeneration on implants of titanium alloys produced by laser powder bed fusion: A review, in: Titan. Consum. Appl., Elsevier, 2019: pp. 197–233. 10.1016/B978-0-12-815820-3.00016-2.10.1016/B978-0-12-815820-3.00016-2 ↗
6. Strategies for creating living, additively manufactured, open-cellular metal and alloy implants by promoting osseointegration, osteoinduction and vascularization: an overview10.1016/j.jmst.2018.09.003 ↗
7. Mechanical performance of additively manufactured meta-biomaterials10.1016/j.actbio.2018.12.038 ↗
8. Dynamic compressive behaviour of cellular materials: a review of phenomenon, mechanism and modelling10.1016/j.ijimpeng.2017.10.006 ↗
9. Additive manufacturing for space: status and promises10.1007/s00170-019-03786-z ↗
10. Design complexity and performance analysis in additively manufactured heat exchangers10.1007/s00170-020-05898-3 ↗
11. L.J. Gibson, M.F. Ashby, Cellular solids: Structure and properties, second edition, 2014. 10.1017/CBO9781139878326.
12. Foam topology: bending versus stretching dominated architectures10.1016/S1359-6454(00)00379-7 ↗
13. Architected cellular materials: a review on their mechanical properties towards fatigue-tolerant design and fabrication10.1016/j.mser.2021.100606 ↗
14. Additive manufacturing of metallic components – process, structure and properties10.1016/j.pmatsci.2017.10.001 ↗
15. Realistic loads for testing hip implants
16. Fatigue performance of additively manufactured meta-biomaterials: the effects of topology and material type10.1016/j.actbio.2017.11.014 ↗
17. The role of node fillet, unit-cell size and strut orientation on the fatigue strength of Ti-6Al-4V lattice materials additively manufactured via laser powder bed fusion10.1016/j.ijfatigue.2020.105946 ↗
18. Manufacturability of lattice structures fabricated by laser powder bed fusion: a novel biomedical application of the beta Ti-21S alloy
19. Experimental and numerical investigation on compressive fatigue strength of lattice structures of AlSi7Mg manufactured by SLM10.1016/j.ijfatigue.2019.06.041 ↗
20. Relationship between unit cell type and porosity and the fatigue behavior of selective laser melted meta-biomaterials10.1016/j.jmbbm.2014.12.015 ↗
21. Fatigue and biological properties of Ti-6Al-4V ELI cellular structures with variously arranged cubic cells made by selective laser melting10.1016/j.jmbbm.2017.11.044 ↗
22. Experimental and numerical investigation on fatigue damage in micro-lattice materials by Digital Volume Correlation and μ CT-based finite element models10.1016/j.engfracmech.2022.108370 ↗
23. Effects of applied stress ratio on the fatigue behavior of additively manufactured porous biomaterials under compressive loading10.1016/j.jmbbm.2016.11.022 ↗
24. Fatigue life of additively manufactured Ti6Al4V scaffolds under tension-tension, tension-compression and compression-compression fatigue load10.1038/s41598-018-23414-2 ↗
25. Review of defects in lattice structures manufactured by powder bed fusion10.1007/s00170-019-04753-4 ↗
26. X-Ray microcomputed tomography in additive manufacturing: a review of the current technology and applications, 3D Print
27. Dimensional verification of metal additively manufactured lattice structures by X-ray computed tomography: Use of a newly developed calibrated artefact to achieve metrological traceability
28. Non-destructive simulation of node defects in additively manufactured lattice structures
29. Effect of the geometrical defectiveness on the mechanical properties of SLM biomedical Ti6Al4V lattices10.1016/j.prostr.2018.12.027 ↗
30. Analysis of strain and stress concentrations in micro-lattice structures manufactured by SLM10.1108/RPJ-10-2018-0270 ↗
31. Reiss · 2019
32. On the effect of geometrical imperfections and defects on the fatigue strength of cellular lattice structures additively manufactured via Selective Laser Melting10.1016/j.ijfatigue.2019.03.019 ↗
33. Notch sensitivity
34. Taylor · 2007
35. Recent developments in brittle and quasi-brittle failure assessment of engineering materials by means of local approaches10.1016/j.mser.2013.11.001 ↗
36. A comparative study of multiaxial high-cycle fatigue criteria for metals10.1016/S0142-1123(96)00064-3 ↗
37. Statistical significance of notch fatigue prognoses based on the strain-energy–density method: application to conventionally and additively manufactured materials10.1016/j.tafmec.2020.102720 ↗
38. Notch fatigue and crack growth resistance of Ti-6Al-4V ELI additively manufactured via selective laser melting: a critical distance approach to defect sensitivity10.1016/j.ijfatigue.2018.12.020 ↗
39. Compensation strategy to reduce geometry and mechanics mismatches in porous biomaterials built with Selective Laser Melting10.1016/j.jmbbm.2016.04.041 ↗
40. Micro-CT-based improvement of geometrical and mechanical controllability of selective laser melted Ti6Al4V porous structures10.1016/j.msea.2011.06.045 ↗
41. Acta Biomaterialia Mechanical characterization of structurally porous biomaterials built via additive manufacturing : experiments, predictive models, and design maps for load-bearing bone replacement implants10.1016/j.actbio.2017.09.013 ↗
42. Analysis of mechanical properties of lattice structures with stochastic geometric defects in additive manufacturing10.1016/j.msea.2021.141666 ↗
43. Geometric assessment of lattice materials built via Selective Laser Melting10.1016/j.matpr.2018.11.096 ↗
44. M. Dallago, F. Zanini, S. Carmignato, G. Zappini, V. Luchin, M. Benedetti, Comparative metrological characterization of Ti6Al4V lattice structures produced by laser powder bed fusion, STP Sel. Tech. Pap. (In press) (2021).10.1520/STP163720200128 ↗
45. Effect of heat treatment temperature and turning residual stresses on the plain and notch fatigue strength of Ti-6Al-4V additively manufactured via laser powder bed fusion10.1016/j.ijfatigue.2022.107009 ↗
46. M. Dallago, F. Zanini, S. Carmignato, G. Zappini, V. Luchin, M. Benedetti, Comparative Metrological Characterization of Ti-6Al-4V Lattice Structures Produced by Laser-Powder Bed Fusion, in: Prog. Addit. Manuf. 2020, ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, 2022: pp. 235–250. 10.1520/STP163720200128.10.1520/STP163720200128 ↗
47. An introduction to statistical modeling of extreme values, springer, London
48. Advanced lightweight 316L stainless steel cellular lattice structures fabricated via selective laser melting10.1016/j.matdes.2013.10.027 ↗
49. Surface roughness and morphology customization of additive manufactured open porous Ti6Al4V Structures10.3390/ma6104737 ↗
50. Basic design rules of unit cells for additive manufactured lattice structures10.1051/matecconf/201713702005 ↗