Numerical Investigation of Impact Behavior of Strut-Based Cellular Structures Designed by Spatial Voronoi Tessellation

Numerical design of open-porous titanium scaffolds for Powder Bed Fusion using Laser Beam (PBF-LB)

The paper concerns the numerical design of novel three-dimensional titanium scaffolds with complex open-porous structures and desired mechanical properties for the Powder Bed Fusion using Laser Beam (PBF-LB). The 60 structures with a broad range of porosity (38-78%), strut diameters (0.70-1.15 mm), and coefficients of pore volume variation, CV(Vp), 0.35-5.35, were designed using the Laguerre-Voronoi tessellations (LVT). Their Young's moduli and Poisson's ratios were calculated using Finite Element Model (FEM) simulations. The experimental verification was performed on the representative designs additively manufactured (AM) from commercially pure titanium (CP Ti) which, after chemical polishing, were subjected to uniaxial compression tests. Scanning Electron Microscopy (SEM) observations and microtomography (μ-CT) confirmed the removal of the support structures and unmelted powder particles. PBF-LB structures after chemical polishing were in close agreement with the CAD models' dimensions having 4-12% more volume. The computational and experimental results show that elastic properties were predicted in very close agreement for the low CV(Vp), and with even 30-40% discrepancies for CV(Vp) higher than 4.0, mainly due to PBF-LB scaffold architecture drawbacks rather than CAD inaccuracy. Our research demonstrates the possibility of designing the open-porous scaffolds with pore volume diversity and tuning their elastic properties for biomedical applications.

Elastic Properties of Open Cell Metallic Foams-Modeling of Pore Size Variation Effect

Elastic properties of open-cell metallic foams are investigated in correlation with relative density and pore size variation. A variety of foam architectures, with open porosity above 70% (relative density below 0.30) and various pore size distributions, were modeled using Laguerre-Voronoi tessellations (LVT). The coefficient of pore volume variation, CV(V), was introduced to quantify the uniformity of designed structures and ranged between 0.5 to 2.1. Elastic behavior of the modeled foams to uniaxial compression along three orthogonal directions was analyzed using the finite element (FE) method. It is shown that Young's modulus and Poisson's ratio of open-cell metals is not solely a function of relative density (porosity) but the pore size variation as well. For similar porosity (approx. 74-98%), Young's modulus and Poisson's ratio may be reduced by approx. 25-30% and 10-25%, respectively, when CV(V) increases from 0.5 to 2.1. Furthermore, the incorporation of a relationship between Young's modulus and the coefficient of pore volume variation to the Gibson-Ashby model is proposed.