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. 2019 Apr 15;12(8):1225.
doi: 10.3390/ma12081225.

Static and Dynamic Loading Behavior of Ti6Al4V Honeycomb Structures Manufactured by Laser Engineered Net Shaping (LENSTM) Technology

Anna Antolak-Dudka  1 , Paweł Płatek  2 , Tomasz Durejko  3 , Paweł Baranowski  4 , Jerzy Małachowski  5 , Marcin Sarzyński  6 , Tomasz Czujko  7
Affiliations
Free PMC article

Static and Dynamic Loading Behavior of Ti6Al4V Honeycomb Structures Manufactured by Laser Engineered Net Shaping (LENSTM) Technology

Anna Antolak-Dudka et al. Materials (Basel). .
Free PMC article

Abstract

Laser Engineered Net Shaping (LENSTM) is currently a promising and developing technique. It allows for shortening the time between the design stage and the manufacturing process. LENS is an alternative to classic metal manufacturing methods, such as casting and plastic working. Moreover, it enables the production of finished spatial structures using different types of metallic powders as starting materials. Using this technology, thin-walled honeycomb structures with four different cell sizes were obtained. The technological parameters of the manufacturing process were selected experimentally, and the initial powder was a spherical Ti6Al4V powder with a particle size of 45-105 µm. The dimensions of the specimens were approximately 40 × 40 × 10 mm, and the wall thickness was approximately 0.7 mm. The geometrical quality and the surface roughness of the manufactured structures were investigated. Due to the high cooling rates occurring during the LENS process, the microstructure for this alloy consists only of the martensitic α' phase. In order to increase the mechanical parameters, it was necessary to apply post processing heat treatment leading to the creation of a two-phase α + β structure. The main aim of this investigation was to study the energy absorption of additively manufactured regular cellular structures with a honeycomb topology under static and dynamic loading conditions.

Keywords: LENS; Ti6Al4V alloy; additive manufacturing; dynamic tests; energy absorption; honeycomb structure; laser engineered net shaping.

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Conflict of interest statement

The authors declare no conflict of interest.

Figures

Figure 1
Figure 1
Scheme of the laser engineered net shaping (LENS) system [56]: 1. Powder supply; 2. pneumatic vibrating system; 3. optical system; 4. IPG fiber laser; 5. controlling computers; 6. input data; 7. working chamber; 8. optical path of the laser; 9. working head with four nozzles; 10. numerically controlled working table (movement in the X-Y plane); 11. antechamber.
Figure 2
Figure 2
Four variants with of thin-walled honeycomb structures differing in the size of the cells (No. 1–No. 4, dimensions in mm).
Figure 3
Figure 3
The morphology (a) and microstructure (b) of the Ti6Al4V powder used for manufacturing of honeycomb structures by the laser engineered net shaping (LENSTM) technique.
Figure 4
Figure 4
Four variants of Ti6Al4V thin-walled honeycomb structures with different the cell size (No. 1–No. 4) manufactured by the laser engineered net shaping (LENSTM) technique.
Figure 5
Figure 5
Geometrical evaluation of structure specimens: (a) with the application of optical microscopy, (b) based on a 3D model reconstructed from Computed Tomography (CT) data [56].
Figure 6
Figure 6
Geometrical quality control of specimen No. 1 before versus after heat treatment.
Figure 7
Figure 7
Geometrical quality control of specimen No. 2 before versus after heat treatment.
Figure 8
Figure 8
Geometrical quality control of specimen No. 3 before verses after heat treatment.
Figure 9
Figure 9
Geometrical quality control of specimen No. 4 before versus after heat treatment.
Figure 10
Figure 10
The SEM micrographs of honeycomb components microstructure before (a) and after (b) heat treatment (1050 °C/2 h).
Figure 11
Figure 11
An example of stretching curves for samples cut from the Ti6Al4V thin walls obtained using the LENS technique without (NHT) and with (HT) additional heat treatment process [56].
Figure 12
Figure 12
Deformation process of specimen No. 1 manufactured additively with LENS (1–4 stages of deformation during static compression test).
Figure 13
Figure 13
Deformation process of specimen No. 2 manufactured additively with LENS (1–4 stages of deformation during static compression test).
Figure 14
Figure 14
Deformation process of specimen No. 3 manufactured additively with LENS (1–4 stages of deformation during static compression test).
Figure 15
Figure 15
Deformation process of specimen No. 4 manufactured additively with LENS (1–4 stages of deformation during static compression test).
Figure 16
Figure 16
Comparison of deformation energy curves related to structure unit cell size (1–4—the thin-walled honeycomb structures with the different cell size).
Figure 17
Figure 17
The results of dynamic tests obtained for honeycomb specimen No. 1 (1–5 stages of deformation during dynamic compression test).
Figure 18
Figure 18
The results of dynamic tests obtained for honeycomb specimen No. 2 (1–5 stages of deformation during dynamic compression test).
Figure 19
Figure 19
The results of dynamic tests obtained for honeycomb specimen No. 3 (1–5 stages of deformation during dynamic compression test).
Figure 20
Figure 20
The results of dynamic tests obtained for honeycomb specimen No. 4 (1–5 stages of deformation during dynamic compression test).
Figure 21
Figure 21
The comparison of deformation energy plots between dynamic and quasi-static results (1–4—the thin-walled honeycomb structures with the different cell size).
Figure 22
Figure 22
The influence of relative density on structural deformation process under static and dynamic loading conditions.
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