International Journal of Solids and Structures 252 (2022) 111783 Available online 10 June 2022 0020-7683/© 2022 The Author(s). Published by Elsevier Ltd. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/). Damage-induced failure analysis of additively manufactured lattice materials under uniaxial and multiaxial tension Danial Molavitabrizi a , Rhodel Bengtsson a , Carlos Botero b , Lars-Erik R¨ annar b , S. Mahmoud Mousavi a, * a Division of Applied Mechanics, Department of Materials Science and Engineering, Uppsala University, 751 03 Uppsala, Sweden b Department of Quality Technology and Mechanical Engineering, Sports Tech Research Centre, Mid Sweden University, Akademigatan 1, 83125 ¨ Ostersund, Sweden A R T I C L E INFO Keywords: Multiaxial tension Elastoplastic homogenization Continuum damage Failure mechanics Electron beam melting Lattice materials Manufacturing defects ABSTRACT Mechanical behavior of additively manufactured lattice materials has been mainly investigated under uniaxial compression, while their performance under uniaxial and multiaxial tension are yet to be understood. To address this gap, a generic elastoplastic homogenization scheme with continuum damage model is developed, and three different lattice materials, namely cubic, modified face-center cubic and body-center cubic, are analyzed under uniaxial, biaxial and triaxial tension. The influence of micro-architecture on the material’s failure behavior as well as its macroscopic mechanical performance is thoroughly discussed. For validation, a set of uniaxial tensile experiments are conducted on functionally graded cubic lattice samples that are additively manufactured using Electron Beam Melting (EBM) process. Digital image correlation technique is employed to obtain the macro- scopic stress–strain curves, and manufacturing imperfections are inspected using light omitting microscopy. It turns out that the behavior of as-built samples could substantially differ from numerical predictions. Thus, a defect-informed numerical model is employed to accommodate the effect of imperfections. The outcome is in a very good agreement with experimental data, indicating that with proper input data, the developed scheme can accurately predict the mechanical and failure behavior of a given lattice material. 1. Introduction Lattice materials are a class of architectured solids made of two distinct phases, that is solid and air. These materials are lightweight and can be engineered to manifest properties that are not found in natural materials, e.g. negative Poisson’s ratio, e.g. see (Mirzaali et al., 2020; Wang, 2018). In the last decade, the advancements in additive manufacturing enabled the fabrication of complex micro-architectures and facilitated the adoption of lattice materials in wide range of in- dustries (Molavitabrizi and Laliberte, 2020). The elastic and/or elasto- plastic behavior of these materials has long been investigated, e.g. see (Gibson, 2003; Wang and McDowell, 2005; Alkhader and Vural, 2009; Dos Reis and Ganghoffer, 2014; Pal et al., 2016; Molavitabrizi and Mousavi, 2020). Yet, their mechanical testing and characterization have been mainly performed under compressive loading, e.g. see (Roos et al., 2019; Xiao et al., 2015; Liu et al., 2017; Cao et al., 2020; Wang and Li, 2018; Epasto et al., 2019; Großmann et al., 2019; Ala˜ na et al., 2021; Wang et al., 2020), while tensile behavior is less explored. This may be due to the challenges associated with the design of tensile samples and the early failure resulting from the stiffness jump. Nonetheless, understanding the tensile behavior of lattice materials is a crucial step in their design process and this has become an active field of research in the last few years. There are some studies that investigated the topic experimentally and performed tensile tests on lattice samples, e.g. (Alsalla et al., 2016; Gümrük et al., 2013; Lietaert et al., 2018; K¨ ohnen et al., 2018). However, characterization of lattice materials through experiments are time consuming and expensive, and there is a need for a suitable numerical model. In another study (Seiler et al., 2020), the tensile behavior of a set of 2D lattices were numerically and experimentally assessed, but the authors employed an elastoplastic material model with no damage mechanism. Incorporating damage models in (Geng et al., 2019; Geng et al., 2018), the fracture behavior of lattice materials under tensile loading was numerically and experi- mentally examined. In the absence of homogenization technique, to reduce the computational costs, mixed beam-solid finite element model was employed in these studies. Such numerical model is valid for low * Corresponding author. E-mail address: [email protected] (S. Mahmoud Mousavi). Contents lists available at ScienceDirect International Journal of Solids and Structures journal homepage: www.elsevier.com/locate/ijsolstr https://doi.org/10.1016/j.ijsolstr.2022.111783 Received 1 February 2022; Received in revised form 28 April 2022; Accepted 7 June 2022
Damage-induced failure analysis of additively manufactured lattice materials under uniaxial and multiaxial tension
Jun 16, 2023
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