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Laser powder bed fusion of multilayer corrugated sandwich structures: Mechanical properties and failure mechanisms under bending loadings

Xinqiang Lan, Siqi Yang, Liang Meng, Jingxiang Lu, Shuwen Mei and Zemin Wang

Vol. 18 (2023), No. 5, 711–726
Abstract

The single and multilayer corrugated sandwich structures (number of layers is 1–4) are designed and manufactured by laser powder bed fusion (LPBF). The mechanical properties and failure mechanisms of the as-fabricated structures subjected to quasistatic three-point bending were investigated theoretically, experimentally and numerically. Results demonstrate that structures fabricated by LPBF with the optimal processing parameters show good printability and high quality. The failure mode transitions from overall structural failure to local damage as the number of layers increases. As the number of layers increased from 2 to 4, the bending load of specimens increased by 70.2%, 17.4%, and 10.9%, and the effective deflection increased by 54.3%, 9.7%, and 2.4%, respectively. The multilayer corrugated sandwich structures (MCSS) show favorable bending performance with lower structural density, and the appropriate increase in the number of layers is beneficial to improve the structural performance. These findings could facilitate the applications of MCSS in design of parts for bending beams or plates.

Keywords
multilayer corrugated sandwich structure, laser powder bed fusion, bending behavior, failure mechanisms, numerical simulation
Milestones
Received: 2 April 2023
Revised: 20 June 2023
Accepted: 26 June 2023
Published: 25 October 2023
Authors
Xinqiang Lan
Wuhan National Laboratory for Optoelectronics
Huazhong University of Science and Technology
Wuhan
China
Siqi Yang
Wuhan National Laboratory for Optoelectronics
Huazhong University of Science and Technology
Wuhan
China
Liang Meng
Wuhan National Laboratory for Optoelectronics
Huazhong University of Science and Technology
Wuhan
China
Jingxiang Lu
Wuhan National Laboratory for Optoelectronics
Huazhong University of Science and Technology
Wuhan
China
Shuwen Mei
Nantong Jinyuan Intelligence Manufacturing Technology Co., Ltd.
Nantong
China
Zemin Wang
Wuhan National Laboratory for Optoelectronics
Huazhong University of Science and Technology
Wuhan
China