Delamination Testing of AlSi10Mg Sandwich Structures with Pyramidal Lattice Truss Core made by Laser Powder Bed Fusion
Abstract Sandwich structures possess a high bending stiffness compared to monolithic structures with a similar weight. This makes them very suitable for lightweight applications, where high stiffness to weight ratios are needed. Most common manufacturing methods of sandwich structures involve adhesi...
| Main Authors: | , , , |
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| Format: | Article |
| Language: | English |
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SpringerOpen
2021-12-01
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| Series: | Chinese Journal of Mechanical Engineering |
| Subjects: | |
| Online Access: | https://doi.org/10.1186/s10033-021-00643-7 |
| _version_ | 1819202924824231936 |
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| author | M. Nuño J. Bühring M. N. Rao K. -U. Schröder |
| author_facet | M. Nuño J. Bühring M. N. Rao K. -U. Schröder |
| author_sort | M. Nuño |
| collection | DOAJ |
| description | Abstract Sandwich structures possess a high bending stiffness compared to monolithic structures with a similar weight. This makes them very suitable for lightweight applications, where high stiffness to weight ratios are needed. Most common manufacturing methods of sandwich structures involve adhesive bonding of the core material with the sheets. However, adhesive bonding is prone to delamination, a failure mode that is often difficult to detect. This paper presents the results of delamination testing of fully additive manufactured (AM) AlSi10Mg sandwich structures with pyramidal lattice truss core using Laser Powder Bed Fusion (LPBF). The faces and struts are 0.5 mm thick, while the core is 2 mm thick. The inclination of the struts is 45°. To characterise the bonding strength, climbing drum peel tests and out-of-plane tensile tests are performed. Analytical formulas are derived to predict the expected failure loads and modes. The analytics and tests are supported by finite element (FE) calculations. From the analytic approach, design guidelines to avoid delamination in AM sandwich structures are derived. The study presents a critical face sheet thickness to strut diameter ratio for which the structure can delaminate. This ratio is mainly influenced by the inclination of the struts. The peel tests resulted in face yielding, which can also be inferred from the analytics and numerics. The out-of-plane tensile tests didn’t damage the structure. |
| first_indexed | 2024-12-23T04:11:45Z |
| format | Article |
| id | doaj.art-adfb1c572712422b9dd4815fb25ad095 |
| institution | Directory Open Access Journal |
| issn | 1000-9345 2192-8258 |
| language | English |
| last_indexed | 2024-12-23T04:11:45Z |
| publishDate | 2021-12-01 |
| publisher | SpringerOpen |
| record_format | Article |
| series | Chinese Journal of Mechanical Engineering |
| spelling | doaj.art-adfb1c572712422b9dd4815fb25ad0952022-12-21T18:00:29ZengSpringerOpenChinese Journal of Mechanical Engineering1000-93452192-82582021-12-0134111210.1186/s10033-021-00643-7Delamination Testing of AlSi10Mg Sandwich Structures with Pyramidal Lattice Truss Core made by Laser Powder Bed FusionM. Nuño0J. Bühring1M. N. Rao2K. -U. Schröder3Institute of Structural Mechanics and Lightweight Design, RWTH Aachen UniversityInstitute of Structural Mechanics and Lightweight Design, RWTH Aachen UniversityInstitute of Structural Mechanics and Lightweight Design, RWTH Aachen UniversityInstitute of Structural Mechanics and Lightweight Design, RWTH Aachen UniversityAbstract Sandwich structures possess a high bending stiffness compared to monolithic structures with a similar weight. This makes them very suitable for lightweight applications, where high stiffness to weight ratios are needed. Most common manufacturing methods of sandwich structures involve adhesive bonding of the core material with the sheets. However, adhesive bonding is prone to delamination, a failure mode that is often difficult to detect. This paper presents the results of delamination testing of fully additive manufactured (AM) AlSi10Mg sandwich structures with pyramidal lattice truss core using Laser Powder Bed Fusion (LPBF). The faces and struts are 0.5 mm thick, while the core is 2 mm thick. The inclination of the struts is 45°. To characterise the bonding strength, climbing drum peel tests and out-of-plane tensile tests are performed. Analytical formulas are derived to predict the expected failure loads and modes. The analytics and tests are supported by finite element (FE) calculations. From the analytic approach, design guidelines to avoid delamination in AM sandwich structures are derived. The study presents a critical face sheet thickness to strut diameter ratio for which the structure can delaminate. This ratio is mainly influenced by the inclination of the struts. The peel tests resulted in face yielding, which can also be inferred from the analytics and numerics. The out-of-plane tensile tests didn’t damage the structure.https://doi.org/10.1186/s10033-021-00643-7Additive ManufacturingSandwich StructuresPyramidal Lattice Core |
| spellingShingle | M. Nuño J. Bühring M. N. Rao K. -U. Schröder Delamination Testing of AlSi10Mg Sandwich Structures with Pyramidal Lattice Truss Core made by Laser Powder Bed Fusion Chinese Journal of Mechanical Engineering Additive Manufacturing Sandwich Structures Pyramidal Lattice Core |
| title | Delamination Testing of AlSi10Mg Sandwich Structures with Pyramidal Lattice Truss Core made by Laser Powder Bed Fusion |
| title_full | Delamination Testing of AlSi10Mg Sandwich Structures with Pyramidal Lattice Truss Core made by Laser Powder Bed Fusion |
| title_fullStr | Delamination Testing of AlSi10Mg Sandwich Structures with Pyramidal Lattice Truss Core made by Laser Powder Bed Fusion |
| title_full_unstemmed | Delamination Testing of AlSi10Mg Sandwich Structures with Pyramidal Lattice Truss Core made by Laser Powder Bed Fusion |
| title_short | Delamination Testing of AlSi10Mg Sandwich Structures with Pyramidal Lattice Truss Core made by Laser Powder Bed Fusion |
| title_sort | delamination testing of alsi10mg sandwich structures with pyramidal lattice truss core made by laser powder bed fusion |
| topic | Additive Manufacturing Sandwich Structures Pyramidal Lattice Core |
| url | https://doi.org/10.1186/s10033-021-00643-7 |
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