AccScience Publishing / MSAM / Volume 3 / Issue 3 / DOI: 10.36922/msam.4234
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ORIGINAL RESEARCH ARTICLE

Design criteria and energy absorption prediction empirical rule for deformation-induced densification of gradient porous materials

Yi Chao1 ,  Che-Nan Kuo1
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1 Department of Materials and Optoelectronic Science, College of Engineering, National Sun Yat-Sen University, Kaohsiung, Taiwan
MSAM 2024, 3(3), 4234 https://doi.org/10.36922/msam.4234
Submitted: 12 July 2024 | Accepted: 20 August 2024 | Published: 25 September 2024
© 2024 by the Author(s). This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution 4.0 International License ( https://creativecommons.org/licenses/by/4.0/ )
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Abstract

Additive manufacturing is an excellent process for complex shapes, porous structures, and bionic structures. Recently, Ti-6Al-4V alloy has been used to fabricate these porous structures and perform well in terms of mechanical properties. In addition, compared with single porosity materials, functionally graded cellular materials have attracted increasing attention due to their good mechanical properties. Compared with single porosity materials, deformation causes the gradient porous materials to be densified layer by layer, leading to better specific energy absorption. However, not all of the gradient porosity materials present the deformation-induced densification phenomenon. Hence, the design criteria for deformation-induced densification of gradient porosity materials must be explored for further application. To explore the design criteria for deformation-induced densification and establish an empirical rule for estimating energy absorption, two types of porous/bionic structures, Schon-Gyroid sheet and Schwarz-Diamond sheet, were investigated in this study. The tendency of the deformation-induced densification phenomenon was evaluated using porous materials with two layers (two porosity changes), and the empirical rule for estimating energy absorption was developed with porous materials with three layers (three porosity changes). As a result, the energy absorption of gradient porosity materials can be estimated through the mechanical properties of single porosity materials with the same porous structure. The energy absorption of the gradient porosity materials with different designs can be predicted by the empirical rule, and the difference between calculated and experimental energy absorption is only 1 – 2%. In the empirical rule, the porosity, aspect ratio, and yield stress are designed as changeable values. Other factors, such as material’s nature, surface issues, and unit cell design, can be corrected by C value. Furthermore, the deformation-induced densification can be applied by following two design criteria: (1) the aspect ratio of the layers should be <1; and (2) the yield stress of the lower-porosity layer should be 9.8% higher than the maximum stress of the higher-porosity layer.

Keywords
Gradient porosity materials
Laser powder bed fusion
Energy absorption
Design criteria
Empirical rule
Funding
This work was financially supported by National Science and Technology Council of Taiwan, under project No. NSTC 112-2221-E-110-019.
Conflict of interest
The authors declare they have no competing interests.
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Materials Science in Additive Manufacturing, Electronic ISSN: 2810-9635 Published by AccScience Publishing
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