Multi-Material Structural Systems

Glad to share our latest research on the design and fabrication of a cable-supported, unreinforced and re-assemblable 3D-printed concrete structure using multi-material topology optimization. The full paper has been published in the Additive Manufacturing journal and is available here: https://lnkd.in/grAViSCe Project team: Yu Li, Hao Wu, Xinjie Xie, Liming Zhang, Philip F. Yuan of Tongji University and Yi Min 'Mike' Xie of RMIT University Centre for Innovative Structures and Materials. #topologyoptimization #digitaldesign #generativedesign #computationaldesign #additivemanufacturing #3dprinting #3dcp #digitalfabrication #architecturedesign #structuraldesign #concrete #steel #cable #assembly Spatial Structures IASS 2023 IASS 2024

Our recent publication in the Materials Science in Additive Manufacturing (https://lnkd.in/eWBtK3FH) journal is focused on multi-material structures of Ti6Al4V and Ti6Al4V-B4C via directed energy deposition (DED)-based additive manufacturing (AM). DED-based metal AM was used to manufacture radial multi-material structures, keeping Ti6Al4V (Ti64) in the core and Ti6Al4V-5 wt% B4C composite as the outer layer. X-ray diffraction (XRD) analysis and microstructural observation show distinct B4C particles strongly attached to the Ti6Al4V matrix. The addition of B4C increased the average hardness from 313 HV for Ti6Al4V to 538 HV for the composites. The addition of 5 wt% B4C in Ti6Al4V increased the average compressive Yield strength (YS) to 1440 MPa from 972 MPa for the control Ti6Al4V, >48% increase without any significant change in the elastic modulus. The radial multi-material structures showed no change in the compressive modulus compared to Ti6Al4V but increased the average compressive YS to 1422 MPa, >45% increase over Ti6Al4V. Microstructural characterization revealed a smooth transition from the pure Ti6Al4V at the core to the Ti64-B4C composite outer layer. No interfacial failure observed during compressive deformation indicates a strong metallurgical bonding during multi-materials radial composite processing. Our results show that a significant improvement in mechanical properties can be accomplished in one AM build operation through designing innovative multi-material structures using DED-based AM. The full-text article can be accessed at https://lnkd.in/eiKdmD3q Full citation – Nathaniel W. Zuckschwerdt, Amit Bandyopadhyay. Multi-material structures of Ti6Al4V and Ti6Al4V-B4C through directed energy deposition-based additive manufacturing. MSAM 2024, 3(3), 3571. https://lnkd.in/eYB8GRNe #additivemanufacturing #3dprinting #wsu #metallurgy #msecoug #implants #Titanium  

Directed Energy Deposition (DED) enables the combination of dissimilar materials in a single component, enhancing performance and functionality. A prime example is the integration of copper and Inconel. Copper, known for its excellent thermal and electrical conductivity, is ideal for heat dissipation, while Inconel, a high-temperature-resistant superalloy, provides strength and oxidation resistance. By leveraging #DED, manufacturers can create optimized hybrid components, such as high-performance heat exchangers or rocket engine nozzles, where copper efficiently conducts heat away, and Inconel ensures structural integrity under extreme conditions. This approach reduces material waste, improves performance, and extends component lifespan, making it a game-changer in aerospace, energy, and advanced manufacturing industries. At our Laser Center of Competence we have gained interesting experiences by working with multi-materials in the frame of Disco2030 #disco2030 https://lnkd.in/ejcGNCh4

NASA - National Aeronautics and Space Administration #scientists and #engineers presented a revolutionary #robotic structural system that embodies the concept of programmable matter, offering mechanical performance and scalability comparable to traditional high-performance materials and truss systems. The system utilizes fiber-reinforced composite truss-like building blocks to create robust lattice structures with exceptional strength, stiffness, and lightweight characteristics, functioning as mechanical metamaterials. This innovative approach is geared towards applications in adaptive #infrastructure, #space exploration, disaster response & beyond. The system's self-reconfiguring #autonomous design is underlined by experimental results, including a demonstration involving a 256-unit cell assembly and lattice mechanical testing. The assembled lattice material exhibits remarkable properties, boasting an ultralight mass density (0.0103 grams per cubic centimeter) coupled with high strength (11.38 kilopascals) and stiffness (1.1129 megapascals) for its weight. These characteristics position it as an ideal material for space structures. In structural testing, a 3x3x3 voxel assemblies could support more than 9000N. #robots #research: https://lnkd.in/dcS3XRC5 Future long-duration and deep-space exploration missions to the #Moon, #Mars, and #beyond will require a way to build large-scale infrastructure, such as solar power stations, communications towers, and habitats for crew. To sustain a long-term presence in deep space, NASA needs the capability to construct and maintain these systems in place, rather than sending large pre-assembled hardware from #Earth.