The forming deviation, mechanical properties and compression failure of porous structures fabricated by laser melting were analyzed
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摘要: 因多孔结构轻质高强度、力学性能可调节的特点，被广泛用于骨骼医疗、航空航天等领域. 为了探索多孔结构选区激光熔化(Selective Laser Melting, SLM)成形误差与压缩失效性能，以钻石型晶格和六孔开口球形两种多孔结构为例，采用理论预测与试验测试研究SLM制造多孔结构的压缩力学行为，使用ANSYS软件对所研究的多孔结构进行准静态压缩模拟，并对SLM成形的多孔结构进行单轴压缩试验，最后结合仿真和试验，观测和分析它们的变形过程和失效机制. 对比后发现数值设计的多孔结构尺寸与最终制造的结构存在偏差，导致力学性能理论值与试验值存在一定差异，但应力应变场变化规律一致. 试验结果表明，在孔隙率50% ~ 80%时，钻石型晶格结构屈服强度为31.85 ~ 182.13 MPa，弹性模量为1.45 ~ 2.30 GPa；六孔开口球形结构屈服强度为35.19 ~ 130.64 MPa，弹性模量为1.59 ~ 2.90 GPa，不同多孔结构随孔隙率的增大，力学性能变化趋势不一致.Abstract: Due to the characteristics of light, high strength and adjustable mechanical properties of porous structure, it is widely used in bone medicine, aerospace and other fields. In order to explore the forming error and compression failure performance of porous structure with selective laser melting (SLM), this paper takes two kinds of porous structure with diamond lattice and spherical six-hole opening as examples to study the compressive mechanical behavior of porous structure manufactured by SLM by theoretical prediction and experimental test. ANSYS software was used to simulate the quasi-static compression of the studied porous structure, and the uniaxial compression experiment of the SLM formed porous structure was carried out. Finally, the deformation process and failure mechanism of the SLM formed porous structure were observed and analyzed combined with the simulation and experiment. After comparison, it is found that the size of the numerical design porous structure deviates from that of the final manufactured structure, resulting in a certain difference between the theoretical value of mechanical properties and the experimental value, but the variation law of stress and strain field is consistent. The experimental results show that when the porosity is 50% ~ 80%, the yield strength and elastic modulus of diamond lattice structure are 31.85 ~ 182.13 MPa and 1.45 ~ 2.30 GPa respectively. The yield strength and elastic modulus of six-hole spherical structure are 35.19 ~ 130.64 MPa and 1.59 ~ 2.90 GPa respectively. The mechanical properties of different porous structures vary with the increase of porosity.
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图 1 多孔胞元模型
Figure 1. Porous cell model. (a) diamond lattice; (b) spherical six-hole opening structure
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图 5 不同孔隙率钻石型晶格多孔件表面形貌
Figure 5. Surface morphology of diamond lattice porous parts with different porosity. (a) porosity 50%; (b) porosity 60%; (c) porosity 70%; (d) porosity 80%
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图 6 50% ~ 80%孔隙率钻石型晶格结构试验及模拟的应力—应变曲线
Figure 6. Experimental and simulated stress-strain curves of diamond lattice structure with 50% ~ 80% porosity. (a) porosity 50%; (b) porosity 60%; (c) porosity 70%; (d) porosity 80%
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图 7 50% ~ 80%孔隙率六孔开口球形多孔结构试验及模拟的应力—应变曲线
Figure 7. Experimental and simulated stress-strain curves of spherical porous structures with six-hole openings with 50% ~ 80% porosity. (a) porosity 50%; (b) porosity 60%; (c) porosity 70%; (d) porosity 80%
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图 8 孔隙率对多孔结构力学性能的影响
Figure 8. Effect of porosity on mechanical properties of porous structures. (a) change trend of yield strength-porosity; (b) change trend of modulus of elasticity-porosity
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图 9 多孔结构压缩变形过程
Figure 9. Compression deformation process of porous structure. (a) diamond lattice with 80% porosity; (b) spherical six-hole opening structure with 80% porosity
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图 10 压缩仿真(左)和试验(右)各阶段变形
Figure 10. Deformation at different stages of compression simulation (left) and experiment (right). (a) diamond lattice; (b) spherical six-hole opening structure
表 1 多孔结构设计参数
Table 1 Design parameters of porous structure
孔隙率A(%) 钻石型晶格-杆直径d/mm 六孔开口球形-壁厚t/mm 50 1.2706 0.7498 60 1.0918 0.5001 70 0.9106 0.3355 80 0.7162 0.2070 
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表 2 316L粉末的化学成分(质量分数，%)
Table 2 Chemical composition of 316L powder
Si Cr Ni Mn Mo C S P Fe 0.64 16.79 11.07 0.68 2.53 0.027 0.0056 0.022 余量
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表 3 钻石型晶格多孔试样实测参数与设计参数对比
Table 3 Comparison between measured parameters and design parameters of diamond lattice porous sample
孔隙率A(%) 杆件直径d/mm 误差∆d/mm 相对误差B(%) 理论值 实际值 50 1.270 1.311 0.041 3.24 60 1.091 1.166 0.075 6.86 70 0.910 0.976 0.066 7.27 80 0.716 0.789 0.073 10.16
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