Computational and Experimental Studies of Cellular Samples Manufactured Using Additive Methods for Use in Advanced Lightweight Designs of Engine Parts

Abstract

Abstract The use of cellular structures is one way to reduce the weight of engine parts. Cellular structures are used to provide rigidity and strength for parts subject to compression, bending, and shock loads. Failure of the individual elements of a lattice/cell structure does not result in the destruction of the entire part; this stands in contrast to the structure of a conventional homogeneous metal object, in which cracks will continue to increase with increasing load, causing the destruction of the entire part. Lattice/cell structures have relatively high characteristics of rigidity and strength, excellent thermal insulation properties, energy absorption characteristics, and high fatigue resistance. The use of this type of structure in engine part construction opens up new opportunities for advanced aviation applications. However, the deformation behavior of porous and metallic structures differs significantly from that of conventional homogeneous materials. Samples with cellular and porous structures are themselves designs. Therefore, procedures for strength testing and interpretation of experimental results for cellular and porous structures differ from those for samples derived from homogeneous materials. The criteria for determining the properties of cellular structures include density, stiffness, ability to accumulate energy, etc. These parameters depend on the configuration of the cells, the size of each cell, and the thickness of the connecting elements. Mechanical properties of cellular structures can be established experimentally and confirmed numerically. Special cellular specimens have been designed for uniaxial tensile, bending, compression, shear, and low-cycle fatigue testing. Several variants of cell structures with relative densities ranging from 13 to 45% were considered. Specifically, the present study examined the stress-strain states of cell structures from brands “CobaltChrome MP1” powder compositions obtained by laser synthesis on an industrial 3D printer Concept Laser M2 Cusing Single Laser 400W. Numerical simulations of the tests were carried out by the finite element method. Then, the most rational cellular structures in terms of mass and strength were established on the basis of both real and numerical experiments.