In this work, we sought to provide a deeper understanding of the energy-absorbing capabilities of cast lattice structures. These structures absorb large amounts of energy via plastic deformation, but their most attractive characteristic from a structural standpoint is the favorable energy absorption-to-weight ratio. Conventional machining techniques are not well suited for manufacturing such complex features; therefore, we combined additive manufacturing (AM) with a well-known understanding of the metalcasting process. We used AM to produce sand molds in different sizes and with additional features for various applications — these molds were then filled with molten metal. Current literature suggests that this when appropriately applied, this methodology results in complex geometries castings comparable properties to parts made with traditionally produced sand molds. We chose to study periodic lattice structures for their repeatability and subsequent ease of making predictions via computer simulations.
We first produced lightweight cast metal-ceramic composite panels of 225 x 225 x 60 mm. Our AM molds included provisions to install ceramic or hard metal tiles before pouring the molten metal. The tiles were encapsulated in the final casting to yield a composite structure. The initial material selection consisted of an aluminum A356-T6 alloy matrix with silicon carbide tiles. The composite lattice structures were tested against high-velocity projectiles — 0.30 caliber armor-piercing (AP M2) and NATO 7.62 mm ball rounds. We anticipated that the metal matrix alone would not be able to defeat these threats. However, the panels did reduce the striking velocity by approximately 20%. The thickness of the ceramic tiles varied from 4 mm to 8 mm at 2 mm increments. As expected, the hard ceramic tiles proved effective at improving the penetration resistance of the composite lattice structures — the impacts on regions with 4 mm thick tiles resulted in the reduction of striking velocity up to 49%; moreover, as the thickness was increased to 8 mm, the panels defeated the projectiles. We used these results to produce and validate a finite element (FE) model capable of replicating the experimental data within 5%. This model was later used to study how the ceramic material interacts with the lattice to absorb large amounts of kinetic energy from incident projectiles.
Following, we manufactured smaller versions of these panels—50 x 50 x 90 mm test specimens for uniaxial compression testing for this instance. Once again, we relied on the capabilities of the FE method to replicate the test results within 10% for peak load and maximum displacement. We utilized computer simulations to optimize the design of the lattice structure. Its energy-absorbing capabilities were improved significantly — in this case, a 30% increase in the specific internal energy (internal energy per unit mass) as the evaluating criteria. The FE model was also used to study the performance of several other truss topologies.
Lastly, we used computer simulations to evaluate the feasibility of making these cast lattice structures with ferrous alloys. We chose to work with Fe30Mn4Al0.9C due to its lower density and higher toughness than other steel grades. The first challenge was the lack of thermophysical property data in the literature for this alloy system. Hence, we used the CALPHAD method to calculate all the datasets needed to perform the mold filling and solidification simulation. Several of these calculations were validated experimentally. The location and severity of porosity between the model and the casting were in good agreement. / Doctor of Philosophy / The advent of additive manufacturing (AM), commonly known as 3D printing is a group of different digital-era technologies that has facilitated the production of complex designs that are not feasible to manufacture using conventional techniques. In the realm of metallic components one such technique involves the use of a laser beam to consolidate metallic powders via a layer-by-layer deposition process. Despite its advantages, this process has unique challenges, such as limited material selection and relatively small part volume.
In this work, we have employed a hybrid approach that combines the use of AM with expertise in metalcasting to produce lightweight components with complex geometries. We used 3D printed sand molds that are then filled with molten metal of different alloy systems such as aluminum and steel. At first, we incorporate hard ceramic materials to increase the performance of the final parts under ballistics testing. Our aim is to upscale the size of current designs such that these devices can be used in various applications that require high absorption of kinetic energy, and that are lightweight and easy to replace.
| Identifer | oai:union.ndltd.org:VTETD/oai:vtechworks.lib.vt.edu:10919/113835 |
| Date | 14 February 2023 |
| Creators | Umanzor, Manuel Enrique |
| Contributors | Materials Science and Engineering, Druschitz, Alan P., Williams, Christopher Bryant, Reynolds, William T., Batra, Romesh C. |
| Publisher | Virginia Tech |
| Source Sets | Virginia Tech Theses and Dissertation |
| Language | English |
| Detected Language | English |
| Type | Dissertation |
| Format | ETD, application/pdf |
| Rights | In Copyright, http://rightsstatements.org/vocab/InC/1.0/ |
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