Abstract
This paper aims to design lattice structures for rapid-investment casting (RIC), and the goal of the design methodology is to minimize casting defects that are related to the lattice topology. RIC can take full advantage of the unprecedented design freedom provided by AM. Since design for RIC has multiple objectives, we limit our study to lattice structures that already have good printability, i.e., self-supported and open-celled, and improve their castability. To find the relationship between topological features and casting performance, various lattice topologies underwent mold flow simulation, finite element analysis, casting experiments, and grain structure analysis. From the results, the features established to affect casting performance in descending order of importance are relative strut size, joint number, joint valence, and strut angle distribution. The features deemed to have the most significant effect on tensile and shear mechanical performance are strut angle distribution, joint number, and joint valence. The practical application of these findings is the ability to optimize the lattice topology with the end goal of manufacturing complex lattice structures using RIC. These lattice structures can be used to create lightweight components with optimized functionality for various applications such as aerospace and medical.
Highlights
The emergence and growth of additive manufacturing (AM) has allowed for the use of more complex freeform designs
The 3D plots of only the rhombic and kelvin cell structures are presented because both the cubic and octet-truss samples solidified before filling according to the simulation, so their results were not plotted by the software
rapid-investment casting (RIC) was successfully used to create a variety of lattice structures
Summary
The emergence and growth of additive manufacturing (AM) has allowed for the use of more complex freeform designs. One promising area of study is cellular lattice structures, which use newer design methodologies. Lattice structures can reduce the amount of material and the weight of parts, while maintaining a reasonable strength. Lattice structures can be used to support complex overhangs, which improves manufacturability [1]. Lattice structures show a lot of promise in the biomedical field, e.g., lightweight orthopaedic implants can be fabricated, and the bone in-growth characteristics can be optimized for specific locations within the body [2]. The applications of metallic-AM lattices are widespread, but their manufacturability is limited to a handful or processes
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