Failure modes in high strength and stiffness to weight scaffolds produced by Selective Laser Melting

Sercombe, TB; Xu, X; Challis, VJ; Green, R; Yue, S; Zhang, Z; Lee, PD

Failure modes in high strength and stiffness to weight scaffolds produced by Selective Laser Melting

Sercombe, TB Xu, X

Challis, VJ Green, R Yue, S Zhang, Z Lee, PD

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Publisher:: ELSEVIER SCI LTD
Publication Type:: Journal Article
Citation:: Materials and Design, 2015, 67, pp. 501-508
Issue Date:: 2015

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Field	Value	Language
dc.contributor.author	Sercombe, TB
dc.contributor.author	Xu, X https://orcid.org/0000-0002-2598-3766
dc.contributor.author	Challis, VJ
dc.contributor.author	Green, R
dc.contributor.author	Yue, S
dc.contributor.author	Zhang, Z
dc.contributor.author	Lee, PD
dc.date.accessioned	2023-02-28T03:27:56Z
dc.date.available	2023-02-28T03:27:56Z
dc.date.issued	2015
dc.identifier.citation	Materials and Design, 2015, 67, pp. 501-508
dc.identifier.issn	0261-3069
dc.identifier.issn	1873-4197
dc.identifier.uri	http://hdl.handle.net/10453/166516
dc.description.abstract	The production of porous scaffold structures using additive manufacturing is becoming widespread, however a detailed understanding of the scaffold failure mechanisms is lacking. In this research, Selective Laser Melting (SLM) is used to produce Ti-6Al-4V scaffold structures consisting of a regular array of unit cells previously designed using topology optimisation. Interrupted compression testing and subsequent X-Ray Micro Tomography (XMT) characterisation is used to study the deformation and failure of the scaffolds for a range of solid fractions. Further, the XMT data of the unloaded scaffolds is used to generate meshes for finite element analysis which allowed direct comparison of desired and as built behaviour. Likely failure sites predicted from the finite element analysis compare favourably with the experimentally observed ones. Failure is initiated in areas that exhibit the greatest tensile stress, while the onset of the commonly observed layered failure occurs afterwards. The XMT of the unloaded scaffolds also highlights the inaccuracies in the SLM build process, which contributes to stress concentrations in the horizontal arms within the scaffolds. The results indicate that although the strength of the topology optimised structures is very high, further refinement in both the unit cell design and build quality would further increase the strength.
dc.language	English
dc.publisher	ELSEVIER SCI LTD
dc.relation.ispartof	Materials and Design
dc.relation.isbasedon	10.1016/j.matdes.2014.10.063
dc.rights	info:eu-repo/semantics/openAccess
dc.subject	0910 Manufacturing Engineering, 0912 Materials Engineering, 0913 Mechanical Engineering
dc.subject.classification	Materials
dc.title	Failure modes in high strength and stiffness to weight scaffolds produced by Selective Laser Melting
dc.type	Journal Article
utslib.citation.volume	67
utslib.for	0912 Materials Engineering
utslib.for	0913 Mechanical Engineering
utslib.for	0910 Manufacturing Engineering
utslib.for	0912 Materials Engineering
utslib.for	0913 Mechanical Engineering
pubs.organisational-group	/University of Technology Sydney
pubs.organisational-group	/University of Technology Sydney/Faculty of Engineering and Information Technology
pubs.organisational-group	/University of Technology Sydney/Faculty of Engineering and Information Technology/School of Biomedical Engineering
pubs.organisational-group	/University of Technology Sydney/Strength - IBMD - Initiative for Biomedical Devices
utslib.copyright.status	open_access	*
dc.date.updated	2023-02-28T03:27:55Z
pubs.publication-status	Published
pubs.volume	67

Abstract:

The production of porous scaffold structures using additive manufacturing is becoming widespread, however a detailed understanding of the scaffold failure mechanisms is lacking. In this research, Selective Laser Melting (SLM) is used to produce Ti-6Al-4V scaffold structures consisting of a regular array of unit cells previously designed using topology optimisation. Interrupted compression testing and subsequent X-Ray Micro Tomography (XMT) characterisation is used to study the deformation and failure of the scaffolds for a range of solid fractions. Further, the XMT data of the unloaded scaffolds is used to generate meshes for finite element analysis which allowed direct comparison of desired and as built behaviour. Likely failure sites predicted from the finite element analysis compare favourably with the experimentally observed ones. Failure is initiated in areas that exhibit the greatest tensile stress, while the onset of the commonly observed layered failure occurs afterwards. The XMT of the unloaded scaffolds also highlights the inaccuracies in the SLM build process, which contributes to stress concentrations in the horizontal arms within the scaffolds. The results indicate that although the strength of the topology optimised structures is very high, further refinement in both the unit cell design and build quality would further increase the strength.

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http://hdl.handle.net/10453/166516