Compressive response of selective laser-melted lattice structures with different strut sizes based on theoretical, numerical and experimental approaches

Abstract

Purpose The purpose of this paper is to investigate the effect of strut size on the compressive response for selective laser-melted lattice structure with a body-centered cubic (BCC) unit cell. Design/methodology/approach Theoretical analysis and numerical simulation were used to predict the compressive stiffness and strength of the lattice structures with different struts, and compression testing was conducted to validate the predicted results. The effect of strut size on actual porosity was determined with the dry weighting method. Scanning electron microscopy was used to observe the fracture morphologies. Findings The actual porosities in all the specimens turned out to be a little lower than the values expected from design. The maximum deviation appears at the strut size of 1.25 mm. The theoretical analysis reveals that the junctions of BCC unit cells are the most loaded points, and the maximum compression resistance load is proportional to the strut size. The stress–strain curves and collapse modes predicted by numerical simulation are in good agreement with the theoretical calculation and experimental results. The compression stress increases monotonously in strut size of 0.50–2.00 mm. The fracture morphologies reflect a transition from a mixed to ductile fracture mechanism. The lattice structure shows a stable plastic deformation without a destructive fracture for the strut size of 2.00 mm. Originality/value The findings of this study can provide theoretical and experimental support for the choice of strut size under different stress conditions. In addition, they are conductive to in-depth study of the compressive properties for lattice structures with different geometrical dimensions fabricated by selective laser melting.