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1
Liu, Chen, Kai Xu, Yongqi Zhang, et al. "Design and Fabrication of Extremely Lightweight Truss-Structured Metal Mirrors." Materials 15, no. 13 (2022): 4562. http://dx.doi.org/10.3390/ma15134562.
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Three-dimensional printing, also called additive manufacturing (AM), offers a new vision for optical components in terms of weight reduction and strength improvement. A truss, which is a triangulated system of members that are structured and connected in such a way that they mainly bear axial force, is commonly used in steel structures to improve stiffness and reduce weight. Combining these two technologies, an extremely lightweight truss-structured mirror was proposed. First, the finite element analyses (FEA) on surface shape deviation and modal properties were carried out. Results showed that the mirrors had sufficient stiffness and a high weight reduction of up to 85%. In order to verify their performance, the truss-structured mirror blanks were fabricated with AM technology. After that, both the preprocessing and the postprocessing of the mirrors were carried out. The results show that without NiP coating, a surface shape deviation of 0.353λ (PV) and 0.028 λ (RMS) (λ = 632.8 nm) with a roughness of Ra 2.8 nm, could be achieved. Therefore, the truss-structured mirrors in this study have the characteristics of being extremely lightweight and having improved stiffness as well as strong temperature stability.
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Xinyi, Hu. "A Life-cycle Cost-benefit Analysis for Rooftop Photovoltaic Systems in Lightweight Steel-structured Industrial Buildings." Environmental Sciences and Sustainable Development (ESSD) 5, no. 2 (2020): 1–70. https://doi.org/10.21625/essd.v5i2.757.
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With the pressing need for holistic solutions that can help in overcoming the imminent environmental and resources crises, a call for the conservation of natural resources and sustainable strategies is needed. Sustainable strategies allow for the mitigation against the impact of climate change on the environment while, simultaneously, seeking the health and comfort of users. Another environmental issue that is worthy of the attention of the scientific research community is the reduction of resources consumption, through the implementation of sustainable development concepts and the use of renewable sources of energy generation. These two aforementioned paradigms are both intrinsic in nature and essential for the thriving of humanity. Hence, this issue aims at investigating sustainable strategies and approaches for the preservation of natural resources through a variety of case studies. This issue illustrates, through cases studies, how strategies such as biomimicry, shading devices, rooftop photovoltaic systems among others, can be integrated into the design of both industrial and residential buildings. The aim of such strategies is to reduce energy consumption and carbon emissions while making use of renewable solar energy in reducing our dependency on energy intensive active building services systems such as heating, ventilation, and air conditioning (HVAC). The issue also discusses the conservation of the most important of natural resources: freshwater. It highlights the issue of water scarcity and proposes a schema for the positioning of freshwater research. The need to conserve our natural resources is very crucial to the support of human life by maintaining an ecological balance and ensuring that future generations will be able to access those resources. The challenges that our natural environment is facing today, such as pollution, global warming and resource depletion need to be given their due attention.
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Hu, Xinyi, Junyu Hu, and Hong Zhang. "A Life-cycle Cost-benefit Analysis for Rooftop Photovoltaic Systems in Lightweight Steel-structured Industrial Buildings." International Journal of Environmental Science & Sustainable Development 5, no. 2 (2020): 20. http://dx.doi.org/10.21625/essd.v5i2.757.
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There is a widespread consensus that energy efficiency of buildings is an essential component of sustainable development and several kinds of renewable energy technologies have been widely used to achieve this sustainable goal. As a rapidly developing country, China’s manufacturing industry still occupies a prominent position, with a large number of industrial buildings that are also a crucial part of urban planning. Compared with multi-story and high-rise commercial buildings, large industrial sheds have a much more usable roof area, where rooftop photovoltaic (PV) systems are increasingly used. However, due to the small structural margins of the lightweight steel-structured (LSS) industrial buildings and the large initial investment of the thin-film PV system, few case studies are available for this kind of industrial buildings. In this research, three representative cities in China, with varying levels of solar radiation availability, are selected as typical external design factors. Taking a typical LSS industrial building with an added thin-film rooftop PV system as an example, a life-cycle cost-benefit analysis is conducted from environmental and economic aspects. The results of the analysis demonstrate the effectiveness of the rooftop thin-film PV system as a means to increase the energy efficiency of the LSS industrial buildings.
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Lohr, Christoph, Markus Muth, Ralf Dreher, Carolin Zinn, Peter Elsner, and Kay André Weidenmann. "Polymer-Steel-Sandwich-Structures: Influence of Process Parameters on the Composite Strength." Key Engineering Materials 809 (June 2019): 266–73. http://dx.doi.org/10.4028/www.scientific.net/kem.809.266.
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As the demand of the automotive and aerospace industries for lightweight and cost effective materials increases, it is necessary to combine different materials with respect to their lightweight and functional properties. The combination of polymer-steel-sandwich composites - which consist of a polymer core structure (transferring shear loads) and two metal face-layers (absorbing tensile and compression loads occurring at bending) - suite the need of minimizing weight per area under bending loads. The reduction of process steps can be achieved by connecting the face layers and core in-situ via an in-mold assembly process using variothermal processing. The injection mold hereby is heated near the melt temperature of the polymer with a variothermal water processing unit. Via contact heating inserted steel blanks are heated to the same temperature as the mold. This process enables the combination of the metal surface with the polymer core by infiltrating the micro or nano scale structure, which is generated by laser structuring or nano coating. Through the increased mold/blank surface temperature induced via variothermal heating the melt viscosity is lowered. This decreasing viscosity of the polymer melt hereby enables a higher degree of infiltration of the laser structured and nano coated blanks. This improved infiltration behavior is a key factor for the adhesion of the sandwich components and beneficial for the composites strength. Within this work two steel blanks are inserted into the mold to manufacture sandwich structures with steel face layers and a polymer (here: polylactidacid; PLA) core. As these sandwich composites are prone to bending failure, the 4-point-bending test is used to characterize the mechanical properties of this hybrid structure. The two surface treatments will also be compared concerning their mechanical interface properties with a shear edge test. The additional reduction on the polymer melt viscosity by means of gas inducing with chemical blowing agent is investigated on the laser structured surfaces only. To investigate the influence of the polymers melts viscosity on the bonding properties chemical blowing agent is added for some blanks.
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MARCISZ, Jarosław, Bogdan GARBARZ, Tymoteusz TOMCZAK, et al. "Development of technology for the production of a lightweight observation and protective container (LOOK) made of nanostructured ultra-strength steels." Journal of Metallic Materials 73, no. 2 (2021): 13–39. http://dx.doi.org/10.32730/imz.2657-747.21.2.2.
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The article contains results of research and analyses concerning application of nanostructured bainitic steel in the form of plates for manufacturing of armour components. The presented results of examination of microstructure and properties include a wide range of laboratory experiments and industrial tests, which resulted in the achievement of the assumed functional properties. In the period of 2017-2021, a scientific and industrial consortium consisting of Łukasiewicz – Institute of Ferrous Metallurgy (leader); WITPiS, Tarnów Mechanical Works, Alchemia and Heatmasters Poland carried out a project funded by the POIR 04.01.04 programme aimed to develop the design and to manufacture an observation and protective container with a specified resistance to penetration by armour-piercing projectiles and with a lower mass of steel armouring in relation to that currently produced. The aim of the project was achieved by using armour plates made of nanostructured bainitic steel (nanobainitic), which are characterised by high resistance to high-energy impact concentrated in a small area. The technological tests carried out in the project mainly concerned the development of a new container and industrial technology of armour plates production and their application in the armour of this container. Based on the results of investigation of the semi-industrial scale material, the optimum chemical composition for industrial scale melting and casting was determined. An industrial technology for the production of plates of nano-structured bainitic steel was developed, which includes the following processes: smelting and casting, preliminary heat treatment and ingot hot processing, as well as hot rolling, final heat treatment, and surface treatment. A test batch of the material in the form of 1500×2470 mm armoured plates was fabricated under industrial conditions. The final result of the project is a container armoured with bainitic nanostructured steel plates with implementation documentation and a technology for producing armoured plates from this steel under the technical and technological conditions of domestic steel manufacturers.
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Huang, Bin, Ke Xing, and Rameez Rameezdeen. "Exploring Embodied Carbon Comparison in Lightweight Building Structure Frames: A Case Study." Sustainability 15, no. 20 (2023): 15167. http://dx.doi.org/10.3390/su152015167.
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Structural components represent major contributors to embodied carbon emissions of buildings. While there have been numerous research efforts dedicated to modelling and assessing the embodied carbon impact of buildings, there is a conspicuous gap in research that concurrently examines various material options in building structural designs, accounting for technical, economic, and carbon implications. In this study, an integrated approach is applied to assess the embodied carbon and life cycle cost impacts of three different building structures, i.e., timber-framed (TF), steel-framed (SF), and the timber–steel composite (TSCF) framed, scaffolded with Finite Element Analysis (FEA) simulations for a strength and stability analysis of different design options. A lightweight frame-structured residential building type is examined as the data source for the modelling and simulations. The results of a comparative scenario analysis highlight that both TF structures and TSCF structures have notable advantages over their SF counterparts for embodied carbon saving and building load reduction. Assessment results indicate that the TF design offers 35.56% embodied carbon reduction, followed by the TSCF design with 8.12% decarbonization, compared to the SF design. The lifecycle cost assessments also reveal the promising cost saving potential of TF and TSCF structures for the application, with cost savings of up to 7.93% and 4%, respectively. Meanwhile, the simulations further demonstrate that TSCF materials in particular can have significant benefits for lightweight building structures in overcoming the deflection problem of long TF components and the buckling of thin-walled SF members. The results help to identify the potential of TSCF structures to minimize the material use for a “Build with Less” through design optimization, which can lead to further embodied carbon and lifecycle cost reductions.
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Hopmann, Christian, Suveni Kreimeier, Jan Keseberg, and Carsten Wenzlau. "Joining of Metal-Plastics-Hybrid Structures Using Laser Radiation by Considering the Surface Structure of the Metal." Journal of Polymers 2016 (October 12, 2016): 1–10. http://dx.doi.org/10.1155/2016/4734913.
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Lightweight construction is a central technology in today’s industrial production. One way to achieve the climate goals is the production of hybrid compounds of metal and plastic. The manufacturing process for these hybrid parts can be divided into in-mold assembly and postmold assembly. The postmold assembly includes thermal joining by laser, which is applied in the context of this paper. For the investigations, four plastics (MABS, PA6.6-GF35, PP, and PC), which differ in their properties, and three metals (unalloyed steel, stainless steel, and aluminum) are combined and analyzed. These materials have been used, since they have a huge significance in the automotive industry. Preliminary studies showed that an adhesive bond between the two materials is achieved using metal with a structured surface. According to these studies, three structuring processes for metals (selective laser melting (SLM), NRX, and a welded metallic tissue) are tested. The quality of the material/structure combinations is tested in tensile-shear-tests, microscopy images, and alternating climate tests. Compounds with SLM-Structure achieve highest strength, while compounds with aluminum are much more complex to manufacture.
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Zhan, Guo Min, Zhong Wei Li, Xing Jian Liu, and Kai Zhong. "Hand-Held Blue Light 3D Measurement Technology and its Application in Hot Stamping." Advanced Materials Research 1063 (December 2014): 362–66. http://dx.doi.org/10.4028/www.scientific.net/amr.1063.362.
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Over the last few years hot stamping for its high strength, lightweight characteristics has developed at an alarming rate, At the same time the measurement process a higher demand. Compared with the traditional three-dimensional coordinate measurement, Hand-held Blue structured Light 3D measurement technology for its fast, high precision, good flexibility, etc., has become the best choice of high-strength steel stamping in non-contact 3D measurement and accuracy detection. This paper developed a set of holding blue light 3D measurement system. The system project blue structured pattern to the surface of the object, and captured by two high-speed cameras synchronized. Then using the grabbed pictures reconstruct 3D topography of the object. Blue light projection technology can eliminate the use of influence of different surface reflectance measurement accuracy, So that a single measurement accuracy of 0.02mm, overall measurement accuracy of 0.05mm / m, Single measurement time is less than 0.12 seconds. This measuring system can be widely used in the rapid detection of various types of three-dimensional measurement and precision casting.
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Patwardhan, M. A., P. A. Nirmal, and R. S. Mahajan. "Light Weighting of Buses using Aluminium with Safety and Durability Considerations." ARAI Journal of Mobility Technology 1, no. 1 (2021): pp25–33. http://dx.doi.org/10.37285/ajmt.1.0.4.
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Automobiles, while making living easy and convenient, have also made human life more complex and vulnerable to toxic emissions. Transport sector is huge contributor in polluting air in the entire world in the tune of around 23%.Mass transport uses buses as the medium for generalized and convenient means for commutation from one place to other. Similar pattern is observed in India for mass transportation mainly in the cities. However, commuting through buses comes with penalty of environmental pollution. City buses are large contributor in GHG emission and can be considered as prime candidates for making any kind of changes which will help in reducing environmental pollution. Immense potential lies in existing bus designs for weight optimization which has direct impact in improving fuel economy and hence will have sustainable impact in reducing carbon emissions.
 This paper outlines systematic approach used for development of lightweight buses using Aluminium addressing safety, durability and necessary regulatory requirements. Effective use of aluminium in development of lightweight bus structure is demonstrated in this project. While designing lightweight structure for weight optimization due care is taken for addressing prevailing regulatory norms related to AIS:052 bus body code, AIS:153 outlining safety requirements and Urban Bus Specification issued by Ministry of Road Transport and Highways specifying strength and safety requirements of bus structure. Aluminium bus designs developed shows more than 30% weight reduction compared to steel structured buses of similar class. Fuel efficiency improvement in the tune of minimum 8% and maximum 10% are observed during field level trials.
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Ringel, Aron, Sindokht Shayan, and David Bailly. "Double-Sided Surface Structures with Undercuts on Cold-Rolled Steel Sheets for Interlocking in Hybrid Components." Machines 12, no. 8 (2024): 562. http://dx.doi.org/10.3390/machines12080562.
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Weight reduction strategies are essential for the transportation sector to reduce greenhouse gas emissions or extend the range of electric vehicles. In the field of lightweight assembly strategies, multi-material design offers great potential. Joining materials typically used in the automotive sector, such as aluminum and steel, brings challenges as conventional processes such as fusion welding are unsuitable. Therefore, new technologies can extend the design options. In previous studies, a mechanical interlocking between cold-rolled surface structures with undercuts on a steel sheet and die-cast aluminum was presented. This method has now been extended to double-sided structures for more complex applications with a joint on both sheet surfaces. Numerical simulations and validation experiments were performed to investigate the manufacturing of the double-sided structures. Furthermore, the influence of the alignment of the upper and lower structures in relation to each other on the resulting structural geometry and the rolling forces were analyzed. More advantageous geometric parameters, e.g., 24% larger undercuts, and approx. 24.1% lower forming forces at 20% height reduction were observed for a shifted alignment. However, significantly higher wear of the structured rollers occurred in the corresponding experiments.
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Li, Peng, Hong Le Sun, Yu Zhang, Xiang Yi Jiao, and Hua Ding. "The synergy of strength and ductility in a hetero-structured lightweight steel with controlled distribution, size and volume fraction of B2 precipitates." Journal of Alloys and Compounds 1010 (January 2025): 178027. https://doi.org/10.1016/j.jallcom.2024.178027.
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Senge, Stefan, and Gerhard Hirt. "Evaluation of Modular Roll-Setup to Roll Grooves into Steel Sheets." Applied Mechanics and Materials 794 (October 2015): 120–27. http://dx.doi.org/10.4028/www.scientific.net/amm.794.120.
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Hybrid structures made of aluminium and steel are used in an increasing amount to produce lightweight optimised parts, e.g. for the automotive industry. One option to produce these optimised components is a combination of a steel sheet with a reinforcing aluminium rib structure by high pressure die casting. Achieving a reliable junction between the different materials during the short casting time is a major challenge in creating these hybrid components. Improving this junction is the topic of an ongoing research study in which a form closure connection is enabled by structuring the steel surface prior to the casting process. In order to meet the demands of the later application, the surface structure has to ensure the filling during the casting as well as a stable form closure connection. Thus, deep groove structures with a perpendicular wall angel straight to the casting direction were identified, since a deeper structure increases the clamping area and a perpendicular wall angle improves the form closure connection. However, the production of this structure in a large scale and a short time becomes difficult using conventional structuring processes. In this work the capability of an adapted rolling process which consists of stacked discs with varying thickness and diameter was studied in order to manufacture these grooves. Several experiments were performed to determine the influence of the height reduction and rolling force on the resulting structure. First results obtained with the presented experiments show the good predictability of the resulting size of the structure depending on the thickness reduction and the rolling force normalised to one millimetre structured width.
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Mirnateghi, Ehsan, and Ayman S. Mosallam. "Multi-Criteria Optimization of Energy-Efficient Cementitious Sandwich Panels Building Systems Using Genetic Algorithm." Energies 14, no. 18 (2021): 6001. http://dx.doi.org/10.3390/en14186001.
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This paper presents results of a study that focuses on developing a genetic algorithm (GA) for multi-criteria optimization of orthotropic, energy-efficient cementitious composite sandwich panels (CSP). The current design concept of all commercially produced CSP systems is based on the assumption that such panels are treated as doubly reinforced sections without the consideration of the three-dimensional truss contribution of the orthotropic panel system. This leads to uneconomical design and underestimating both the strength and stiffness of such system. In this study, two of the most common types of commercially produced sandwich were evaluated both numerically and experimentally and results were used as basis for developing a genetic algorithm optimization process using numerical modeling simulations. In order to develop a sandwich panel with high structural performance, design optimization techniques are needed to achieve higher composite action, while maintaining the favorable features of such panels such as lightweight and high thermal insulation. The study involves both linear and nonlinear finite element analyses and parametric optimization. The verification and calibration of the numerical models is based on full-scale experimental results that were performed on two types of commercially produced sandwich panels under different loading scenarios. The genetic algorithm technique is used for optimization to identify an optimum design of the cementitious composite sandwich panels. The GA technique combines Darwin’s principle of survival of fittest and a structured information exchange using randomized crossover operators to evolve an optimum design for the cementitious sandwich panel. Parameters evaluated in the study include: (i) shear connectors’ geometry, its volume fraction and distribution; (ii) exterior cementitious face sheets thickness and (iii) size and geometry steel wires reinforcements. The proposed optimization method succeeded in reducing cost of materials of CSP by about 48% using genetic algorithm methodology. In addition, an optimized design for CSP is proposed that resulted in increasing the panel’s thermal resistance by 40% as compared to existing panels, while meeting ACI Code structural design criteria. Pareto-optimal front and Pareto-optimal solutions have been identified. Correlation between the design variables is also verified and design recommendation are proposed.
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Ripper, Jose Luiz Mendes, Daniel Malaguti Campos, and Joao Victor Azevedo de Menezes Correia de Melo. "Textile-Architecture Structured on Bamboo Culms." Key Engineering Materials 517 (June 2012): 189–96. http://dx.doi.org/10.4028/www.scientific.net/kem.517.189.
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This article aims to disclose the developments of a research on constructive methods of lightweight structures, developed by the Laboratory for Research on Living Design, LILD, from Pontifical Universidade Catolica do Rio de Janeiro, PUC-Rio. One of the objectives of this paper is, using principles of biomimesis, to systematize constructive processes by means of the understanding of how nature creates its forms. In the Laboratory, experiments with soap bubbles and catenaries have been serving this purpose In this case, studies resulted in the solution to the covering of the newly constructed LILDs building, located in the campus of the University, a textile-architecture where structural elements and joints, usually made of steel or wood, were replaced by bamboo culms tied together. The present article also demonstrates how these culms were benefited in order to meet specific requirements of the project.
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Zhu, Haokun, Qihan Gao, Yuming Zou, and Hua Ding. "Achieving strength ductility synergy of multiple hetero-structured Fe–24Mn–10Al–1C duplex lightweight steel." Materials Science and Engineering: A, December 2024, 147651. https://doi.org/10.1016/j.msea.2024.147651.
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Ringel, Aron, and Gerhard Hirt. "Bending behavior of structured steel sheets with undercuts for interlocking with Al die-cast metal." International Journal of Material Forming 17, no. 1 (2023). http://dx.doi.org/10.1007/s12289-023-01797-6.
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AbstractDue to the current changes in mobility, lightweight design concepts continue to be of particular interest to the automotive industry. One form is the multi-material design, in which the advantageous properties of different materials are combined in one component. In this work, a component made of a steel sheet with stiffening structures of cast aluminum is considered. The joint is created by channel structures with undercuts on the surface of the steel sheet, into which the molten aluminum can flow. After solidification, an interlocking connection is created. The aim of this work is to investigate the influence of a bending operation on the surface structure before the die casting process. Numerical simulations and experimental validations were performed with different bending angles and radii as well as orientations between the channel structure and the punch. The results show that the undercuts on the outer radius are reduced by up to 75% by the bending operation, thus weakening the resulting joint. On the inner radius, the channel opening width narrows by up to 73% and can thus impede the filling with the melt.
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Wortmann, Christoph, Maximilian Brosda, and Alexander Olowinsky. "Evaluation of measures to reduce thermal distortion caused by laser-based structuring of thin aluminum and steel sheets with continuous wave fiber laser." Journal of Laser Applications 36, no. 4 (2024). http://dx.doi.org/10.2351/7.0001564.
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Due to the increase in lightweight construction, hybrid components, such as metal and polymer, are getting more and more important. By the usage of laser radiation, a connection between these two materials can be created in a two-stage process. In the first step, the surface of the metal component is structured with a continuous wave fiber laser. The high local energy input of the laser beam leads to a thermal distortion in thin metals, which is investigated in this work. The aim of the work is to evaluate measures to reduce thermal distortion. For this, square specimens made of aluminum EN AW 5754 and stainless steel 1.4310 are structured on a large area. In addition to other factors, the influence of material properties, laser parameters, and energy deposition on thermal distortion is analyzed. The evaluation is carried out by a three-dimensional measurement of the samples with a profilometer and an optical determination of the deviation from the flat sample at defined measuring points. As a result of the investigation, the use of break times and jump speed between the laser passes to reduce thermal distortion is classified. Furthermore, external measures such as clamping the sheet metal or a heat-dissipating base are evaluated and classified with regard to the material properties.
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Warner, Justin, Dino Celli, Onome Scott-Emuakpor, Tommy George, and Trevor Tomlin. "Fused Deposition Modeling Fabrication Evaluation of a Ti-6Al-4V Centrifugal Compressor." Journal of Engineering for Gas Turbines and Power, September 12, 2022. http://dx.doi.org/10.1115/1.4055582.
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Abstract Centrifugal compressors have a critical impact on the performance of a jet engine and can be made out of aluminum, steel, or titanium alloy. However, if made out of Ti-6Al-4V it would be more lightweight than if steel were used and stronger than if aluminum were used. Compressors manufactured using traditional techniques can be relatively expensive to manufacture, therefore, fused deposition modeling (FDM) or fused filament fabrication (FFF) can help reduce the cost while maintaining structural integrity. FDM/FFF usually prints polylactic acid (PLA) or acrylonitrile butadiene styrene (ABS) layer-by-layer using an extruder with a spool of material feeding into the extruder. Recently, metal-polymer filaments have become commercially available using this same printing apparatus as common "hobby-class" FDM printers. Using FDM with a metal-polymer matrix allows for a lower cost of production because of the intricate designs it can accomplish with little to no machining involved. Even with the benefits of printing a spool of material using FDM, there has been very little research done of Ti-6Al-4V printed in a FDM format. This document records the feasibility of using Ti-6Al-4V for a centrifugal compressor using FDM by incorporating a 3D structured blue light scanner before heat treatments while also analyzing manufacturing capabilities at the tips of blades as well as the base. This analysis is a first-stage to quantify FDM metal print characteristics and properties.
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Glaser, Marcus, Kai Ehlich, Sebastian Matthes, Jörg Hildebrand, Peter Schaaf, and Jean Pierre Bergmann. "Influence of metal surface structures on composite formation during polymer‐metal‐joining based on reactive Al/Ni multilayer foil." Advanced Engineering Materials, April 11, 2024. http://dx.doi.org/10.1002/adem.202302254.
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Progressive developments in the field of lightweight construction and engineering demand continuous substitution of metals with suitable polymers. However, the combination of dissimilar materials results in a multitude of challenges based on different chemical and physical material properties. Reactive multilayer systems offer a promising joining method for flexible and low‐distortion joining of dissimilar joining partners with an energy source introduced directly into the joining zone. Within this publication, hybrid lap joints between semi‐crystalline polyamide 6 and surface‐structured austenitic steel X5CrNi18–10 (EN 1.4301) were joined using reactive Al/Ni multilayer foils of the type Indium–NanoFoil®. Main objective is to examine possibilities of influencing crack initiation in the foil plane by variation of joining pressure and different metal surface structures with regard to geometry, density and orientation. Thus, the position of foil cracks is superimposed onto the metal structure and associated filling with molten plastic is improved. Consequently, characterisation of occurring crack positions as function of joining pressure and metal structure, analysis of the composite in terms of structural filling and joint strength as well as possible causes of crack initiation are evaluated.This article is protected by copyright. All rights reserved.
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Fashanu, O., M. Rangapuram, A. Abutunis, et al. "Mechanical performance of sandwich composites with additively manufactured triply periodic minimal surface cellular structured core." Journal of Sandwich Structures & Materials, July 29, 2021, 109963622110370. http://dx.doi.org/10.1177/10996362211037012.
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Sandwich composite structures are comprised of a low-density core (commonly honeycomb) and facesheets. They are typically used in applications that require lightweight for efficient design, such as in the marine and aerospace industries. This work investigates the feasibility of adopting triply periodic minimal surface (TPMS) cellular structures as the core for sandwich composites. Sandwich structures were manufactured using a carbon fiber-reinforced polymer (CFRP) facesheet and three different 304 L stainless steel core structures (honeycomb, gyroid TPMS, and diamond TPMS). Three mechanical tests, namely edgewise compression, three-point bend, and impact test, were carried out to evaluate the performance of each sandwich configuration. The experimental results of the non-traditional sandwich configurations were compared against those of a honeycomb core sandwich composite. The edgewise compression test showed that the ultimate edgewise compressive strength increased by 7% when the honeycomb core was replaced by the gyroid core and reduced by 2% when the diamond core replaced the honeycomb core. The three-point bend test showed that the traditional honeycomb core sandwich configuration had a higher shear yield stress when compared to the non-traditional sandwich structures. The shear yield stress was reduced by 54% when non-traditional sandwich cores were used. The shear ultimate stress was reduced by 41% and 37% when the honeycomb core was replaced by the gyroid and diamond structure, respectively. Impact test results, on the other hand, showed that the peak force recorded during the impact event was reduced, while the absorbed energy was increased when non-traditional cores were used. Peak force was reduced by 28% and 39%, while the absorbed energy was increased by 9% and 16% when the honeycomb core was replaced by the gyroid and diamond cores, respectively.