Macro-, meso- and microstructural characterization of metallic lattice structures manufactured by additive manufacturing assisted investment casting

Abstract Cellular materials are recognized for their high specific mechanical properties, making them desirable in ultra-lightweight applications. Periodic lattices have tunable properties and may be manufactured by metallic additive manufacturing (AM) techniques. However, AM can lead to issues with...

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Autores principales:	V. H. Carneiro, S. D. Rawson, H . Puga, P. J. Withers
Formato:	article
Lenguaje:	EN
Publicado:	Nature Portfolio 2021
Materias:	Medicine R Science Q
Acceso en línea:	https://doaj.org/article/7fd7935efad6499caca7a32a07a2d601
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spelling	oai:doaj.org-article:7fd7935efad6499caca7a32a07a2d6012021-12-02T13:34:32ZMacro-, meso- and microstructural characterization of metallic lattice structures manufactured by additive manufacturing assisted investment casting10.1038/s41598-021-84524-y2045-2322https://doaj.org/article/7fd7935efad6499caca7a32a07a2d6012021-03-01T00:00:00Zhttps://doi.org/10.1038/s41598-021-84524-yhttps://doaj.org/toc/2045-2322Abstract Cellular materials are recognized for their high specific mechanical properties, making them desirable in ultra-lightweight applications. Periodic lattices have tunable properties and may be manufactured by metallic additive manufacturing (AM) techniques. However, AM can lead to issues with un-melted powder, macro/micro porosity, dimensional control and heterogeneous microstructures. This study overcomes these problems through a novel technique, combining additive manufacturing and investment casting to produce detailed investment cast lattice structures. Fused filament fabrication is used to fabricate a pattern used as the mold for the investment casting of aluminium A356 alloy into high-conformity thin-ribbed (~ 0.6 mm thickness) scaffolds. X-ray micro-computed tomography (CT) is used to characterize macro- and meso-scale defects. Optical and scanning electron (SEM) microscopies are used to characterize the microstructure of the cast structures. Slight dimensional (macroscale) variations originate from the 3D printing of the pattern. At the mesoscale, the casting process introduces very fine (~ 3 µm) porosity, along with small numbers of (~ 25 µm) gas entrapment defects in the horizontal struts. At a microstructural level, both the (~ 70 μm) globular/dendritic grains and secondary phases show no significant variations across the lattices. This method is a promising alternative means for producing highly detailed non-stochastic metallic cellular lattices and offers scope for further improvement through refinement of filament fabrication.V. H. CarneiroS. D. RawsonH . PugaP. J. WithersNature PortfolioarticleMedicineRScienceQENScientific Reports, Vol 11, Iss 1, Pp 1-12 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	Medicine R Science Q
spellingShingle	Medicine R Science Q V. H. Carneiro S. D. Rawson H . Puga P. J. Withers Macro-, meso- and microstructural characterization of metallic lattice structures manufactured by additive manufacturing assisted investment casting
description	Abstract Cellular materials are recognized for their high specific mechanical properties, making them desirable in ultra-lightweight applications. Periodic lattices have tunable properties and may be manufactured by metallic additive manufacturing (AM) techniques. However, AM can lead to issues with un-melted powder, macro/micro porosity, dimensional control and heterogeneous microstructures. This study overcomes these problems through a novel technique, combining additive manufacturing and investment casting to produce detailed investment cast lattice structures. Fused filament fabrication is used to fabricate a pattern used as the mold for the investment casting of aluminium A356 alloy into high-conformity thin-ribbed (~ 0.6 mm thickness) scaffolds. X-ray micro-computed tomography (CT) is used to characterize macro- and meso-scale defects. Optical and scanning electron (SEM) microscopies are used to characterize the microstructure of the cast structures. Slight dimensional (macroscale) variations originate from the 3D printing of the pattern. At the mesoscale, the casting process introduces very fine (~ 3 µm) porosity, along with small numbers of (~ 25 µm) gas entrapment defects in the horizontal struts. At a microstructural level, both the (~ 70 μm) globular/dendritic grains and secondary phases show no significant variations across the lattices. This method is a promising alternative means for producing highly detailed non-stochastic metallic cellular lattices and offers scope for further improvement through refinement of filament fabrication.
format	article
author	V. H. Carneiro S. D. Rawson H . Puga P. J. Withers
author_facet	V. H. Carneiro S. D. Rawson H . Puga P. J. Withers
author_sort	V. H. Carneiro
title	Macro-, meso- and microstructural characterization of metallic lattice structures manufactured by additive manufacturing assisted investment casting
title_short	Macro-, meso- and microstructural characterization of metallic lattice structures manufactured by additive manufacturing assisted investment casting
title_full	Macro-, meso- and microstructural characterization of metallic lattice structures manufactured by additive manufacturing assisted investment casting
title_fullStr	Macro-, meso- and microstructural characterization of metallic lattice structures manufactured by additive manufacturing assisted investment casting
title_full_unstemmed	Macro-, meso- and microstructural characterization of metallic lattice structures manufactured by additive manufacturing assisted investment casting
title_sort	macro-, meso- and microstructural characterization of metallic lattice structures manufactured by additive manufacturing assisted investment casting
publisher	Nature Portfolio
publishDate	2021
url	https://doaj.org/article/7fd7935efad6499caca7a32a07a2d601
work_keys_str_mv	AT vhcarneiro macromesoandmicrostructuralcharacterizationofmetalliclatticestructuresmanufacturedbyadditivemanufacturingassistedinvestmentcasting AT sdrawson macromesoandmicrostructuralcharacterizationofmetalliclatticestructuresmanufacturedbyadditivemanufacturingassistedinvestmentcasting AT hpuga macromesoandmicrostructuralcharacterizationofmetalliclatticestructuresmanufacturedbyadditivemanufacturingassistedinvestmentcasting AT pjwithers macromesoandmicrostructuralcharacterizationofmetalliclatticestructuresmanufacturedbyadditivemanufacturingassistedinvestmentcasting
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Macro-, meso- and microstructural characterization of metallic lattice structures manufactured by additive manufacturing assisted investment casting

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