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Author: Kästner, Markus × Start date: 2020 ×

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Now showing 1 - 6 of 6
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    Experimental and numerical characterization of imperfect additively manufactured lattices based on triply periodic minimal surfaces
    (Amsterdam [u.a.] : Elsevier Science, 2023) Günther, Fabian; Pilz, Stefan; Hirsch, Franz; Wagner, Markus; Kästner, Markus; Gebert, Annett; Zimmermann, Martina
    Lattices based on triply periodic minimal surfaces (TPMS) are attracting increasing interest in seminal industries such as bone tissue engineering due to their excellent structure-property relationships. However, the potential can only be exploited if their structural integrity is ensured. This requires a fundamental understanding of the impact of imperfections that arise during additive manufacturing. Therefore, in the present study, the structure-property relationships of eight TPMS lattices, including their imperfections, are investigated experimentally and numerically. In particular, the focus is on biomimetic network TPMS lattices of the type Schoen I-WP and Gyroid, which are fabricated by laser powder bed fusion from the biocompatible alloy Ti-42Nb. The experimental studies include computed tomography measurements and compression tests. The results highlight the importance of process-related imperfections on the mechanical performance of TPMS lattices. In the numerical work, firstly the as-built morphology is artificially reconstructed before finite element analyses are performed. Here, the reconstruction procedure previously developed by the same authors is used and validated on a larger experimental matrix before more advanced calculations are conducted. Specifically, the reconstruction reduces the numerical overestimation of stiffness from up to 341% to a maximum of 26% and that of yield strength from 66% to 12%. Given a high simulation accuracy and flexibility, the presented procedure can become a key factor in the future design process of TPMS lattices.
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    Magneto-Mechanical Coupling in Magneto-Active Elastomers
    (Basel : MDPI, 2021) Metsch, Philipp; Romeis, Dirk; Kalina, Karl A.; Raßloff, Alexander; Saphiannikova, Marina; Kästner, Markus
    In the present work, the magneto-mechanical coupling in magneto-active elastomers is investigated from two different modeling perspectives: a micro-continuum and a particle–interaction approach. Since both strategies differ significantly in their basic assumptions and the resolution of the problem under investigation, they are introduced in a concise manner and their capabilities are illustrated by means of representative examples. To motivate the application of these strategies within a hybrid multiscale framework for magneto-active elastomers, their interchangeability is then examined in a systematic comparison of the model predictions with regard to the magneto-deformation of chain-like helical structures in an elastomer surrounding. The presented results show a remarkable agreement of both modeling approaches and help to provide an improved understanding of the interactions in magneto-active elastomers with chain-like microstructures.
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    Additively manufactured AlSi10Mg lattices – Potential and limits of modelling as-designed structures
    (Amsterdam [u.a.] : Elsevier Science, 2022) Gebhardt, Ulrike; Gustmann, Tobias; Giebeler, Lars; Hirsch, Franz; Hufenbach, Julia Kristin; Kästner, Markus
    Additive manufacturing overcomes the restrictions of classical manufacturing methods and enables the production of near-net-shaped, complex geometries. In that context, lattice structures are of high interest due to their superior weight reduction potential. AlSi10Mg is a well-known alloy for additive manufacturing and well suited for such applications due to its high strength to material density ratio. It has been selected in this study for producing bulk material and complex geometries of a strut-based lattice type (rhombic dodecahedron). A detailed characterisation of as-built and heat-treated specimens has been conducted including microstructural analyses, identification of imperfections and rigorous mechanical testing under different load conditions. An isotropic elastic–plastic material model is deduced on the basis of tension test results of bulk material test specimens. Performed experiments under compression, shear, torsion and tension load are compared to their virtual equivalents. With the help of numerical modelling, the overall structural behaviour was simulated using the detailed lattice geometry and was successfully predicted by the presented numerical models. The discussion of the limits of this approach aims to evaluate the potential of the numerical assessment in the modelling of the properties for novel lightweight structures.
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    Structure-property relationships of imperfect additively manufactured lattices based on triply periodic minimal surfaces
    (Amsterdam [u.a.] : Elsevier Science, 2022) Günther, Fabian; Hirsch, Franz; Pilz, Stefan; Wagner, Markus; Gebert, Annett; Kästner, Markus; Zimmermann, Martina
    Lattices based on triply periodic minimal surfaces (TPMS) have recently attracted increasing interest, but their additive manufacturing (AM) is fraught with imperfections that compromise their structural integrity. Initial research has addressed the influence of process-induced imperfections in lattices, but so far numerical work for TPMS lattices is insufficient. Therefore, in the present study, the structure–property relationships of TPMS lattices, including their imperfections, are investigated experimentally and numerically. The main focus is on a biomimetic Schoen I-WP network lattice made of laser powder bed fusion (LPBF) processed Ti-42Nb designed for bone tissue engineering (BTE). The lattice is scanned by computed tomography (CT) and its as-built morphology is examined before a modeling procedure for artificial reconstruction is developed. The structure–property relationships are analyzed by experimental and numerical compression tests. An anisotropic elastoplastic material model is parameterized for finite element analyses (FEA). The numerical results indicates that the reconstruction of the as-built morphology decisively improves the prediction accuracy compared to the ideal design. This work highlights the central importance of process-related imperfections for the structure–property relationships of TPMS lattices and proposes a modeling procedure to capture their implications.
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    Determination of the Entire Stent Surface Area by a New Analytical Method
    (Basel : MDPI, 2020) Saqib, Muhammad; Bernhardt, Ricardo; Kästner, Markus; Beshchasna, Natalia; Cuniberti, Gianaurelio; Opitz, Jörg
    Stenting is a widely used treatment procedure for coronary artery disease around the world. Stents have a complex geometry, which makes the characterization of their corrosion difficult due to the absence of a mathematical model to calculate the entire stent surface area (ESSA). Therefore, corrosion experiments with stents are mostly based on qualitative analysis. Additionally, the quantitative analysis of corrosion is conducted with simpler samples made of stent material instead of stents, in most cases. At present, several methods are available to calculate the stent outer surface area (SOSA), whereas no model exists for the calculation of the ESSA. This paper presents a novel mathematical model for the calculation of the ESSA using the SOSA as one of the main parameters. The ESSA of seven magnesium alloy stents (MeKo Laser Material Processing GmbH, Sarstedt, Germany) were calculated using the developed model. The calculated SOSA and ESSA for all stents are 33.34%(±0.26%) and 111.86 mm (±0.85 mm), respectively. The model is validated by micro-computed tomography (micro-CT), with a difference of 12.34% (±0.46%). The value of corrosion rates calculated using the ESSA computed with the developed model will be 12.34% (±0.46%) less than that of using ESSA obtained by micro-CT.
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    Virtual Testing of Geometrically Imperfect Additively Manufactured Lattice Structures
    (Hoboken, NJ : Wiley, 2021) Gebhardt, Ulrike; Kästner, Markus; Hufenbach, Julia Kristin; Kühn, Uta; Berner, Matthias; Holtzhausen, Stefan
    Additively manufactured lattice structures increase the lightweight potential of components for technical applications. When modelling the mechanical behaviour of those lattice structures, imperfections within the structures need to be considered. In this contribution we investigate the effect of process induced pores of varying size and location inside the lattice structure during pressure tests using a 2D minimal model in two configurations. It shows that the location of pores with respect to the configuration of the model has a strong influence on whether the imperfection decreases the mechanical performance.