COMMUNICATION DOI: 10.1002/adem.201000145 Titanium Alloy Lattice Structures with Millimeter Scale Cell Sizes** By Pimsiree Moongkhamklang and Haydn N. G. Wadley* Titanium sandwich panels with cellular cores of a uniform 1–5 mm diameter open cell size are well suited for impact energy absorption and cross flow heat exchange applications. Periodic cellular structures (lattices) made from high specific strength, high temperature alloys are preferred for these multifunctional uses. A diffusion bonding method has been applied here to make cellular lattice structures from a Ti–6A1–4V alloy. To illustrate the approach, lattice structures with both square and diamond collinear topologies, a 2 mm open cell size, and a relative density of 15% were made from 254 mm diameter titanium alloy wires. These structures were found to have a compressive strength of 40 5 MPa that was controlled by plastic yield followed by buckling of the struts. The cellular structures have been brazed to titanium alloy face sheets to create sandwich panel structures that appear well suited for multifunctional applications up to 420 8C. Cellular metals with stochastic cell structures (foams)[1] and related materials with periodic (lattice) cell topologies[2] have attracted significant interest because of their multifunctionality.[3] When configured as the core of a sandwich panel, they provide efficient structural load support during bending[4–6] while also enabling other functions such as cross flow heat exchange,[7–9] acoustic damping,[10,11] and impact energy absorption.[12–14] The earliest foams were made from easily cast alloys based upon aluminum and copper[15,16] but recent developments are leading to the emergence of materials made from steels and other higher strength alloys.[17–19] While foam structures with either open or closed cell topologies (and occasionally with both) are relatively easily made with a small (millimeter and even submillimeter) cell size,[20] they deform by strut bending and are therefore weak.[21] Periodic structures with lattice or honeycomb cores have been shown to offer much higher specific strengths because strut stretching dominates their response to stress.[22,23] Deshpande and Fleck[24] have shown that the specific strength of a stretch dominated lattice structure usually [*] Prof. H. N. G. Wadley, P. Moongkhamklang Department of Materials Science and Engineering, University of Virginia Charlottesville, VA 22904-4745, USA E-mail: [email protected] [**] Acknowledgements, The study was supported by the Office of Navel Research (ONR) and monitored by Dr. David Shifler under grant number N00014-07-1-0114. ADVANCED ENGINEERING MATERIALS 2010, 12, No. 11 depends upon the specific strength of the material used to make it, the relative density and a geometric factor that measures the efficiency with which the lattice supports stress. Triangulated structures with the (tetrahedral) octet truss structure[25] (the pyramidal) lattice block arrangement of trusses,[26] and 3D kagome structures[27] are the most efficient topologies for load support. They can be fabricated by investment casting[28–30] and by sheet stamping/forming combined with either spot welding,[31] brazing,[32] or bonding.[33] However, it is difficult to fabricate low density versions of these structures with cell diameters below 10 mm. Small cell sizes are of interest for compact heat exchange and for impact mitigation where they then provide a more uniform deformation response. Small cell size periodic structures can be made from metal wires by laying up 2D weaves or 0/90 collinear wire arrays and brazing.[34] The mechanical response of structures made this way from stainless steels have been analyzed in compression, shear, and in bending[5] and shown to provide only slightly reduced strengths compared to optimal topologies. The best of these stainless steel structures give compressive strengths of 10–20 MPa at a density of 0.5 Mg m3. Here, we describe a diffusion bonding process that has been developed for making small cell size collinear lattices from Ti–6Al–4V wires of much higher specific strength than stainless steel. It is similar to a method recently proposed for the making of cellular materials from titanium coated SiC monofilaments.[35] We show that the compressive strength of these titanium structures is double that of equivalent steel structures making them well suited for situations where ß 2010 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim wileyonlinelibrary.com 1111 COMMUNICATION P. Moongkhamklang and H. N. G. Wadley/Titanium Alloy Lattice Structures with Millimeter Scale . . . efficient load support, impact mitigation, or heat exchange are required at temperatures up to 420 8C. Experimental Collinear lattices with square and diamond orientations were fabricated from 254 mm diameter Ti–6Al–4V wires (ATI Wah Chang, Frackville, PA). The Ti–6Al–4V wires were stacked in an orthogonal pattern within a wire alignment tool, Figure 1, which had been spray coated with boron nitride (GE Advanced Ceramics, Lakewood, OH) to prevent sticking. Alignment was achieved by a set of 1.59 mm diameter uniformly spaced stainless steel pins inserted into holes in a stainless steel base plate. Since the ‘‘as received’’ wires had significant curvature, five pairs of alignment pins were used to align each wire. The spacing between each pair of the pins defined the center-to-center truss (unit cell) spacing l ¼ 2.03 mm resulting in an assembled (but not bonded) lattice relative density, r0 ¼ 9.8%. Once assembly of the Ti–6Al–4V wire lay-up was complete, a dead weight was used to apply a force of 7.5 g force (7.4 102 N) to each truss–truss node contact. The assembly was then diffusion bonded by placing it in a vacuum furnace at a base pressure of 107 Torr and heating to 900 8C for 6 h. The lattice structures were removed from the tooling and cut to shape using wire electro-discharge machining. Square topology lattice samples were machined so that their struts were aligned at 0 and 908 to the rectangular sample surfaces. The samples were four cells high and six cells in length with a width to height ratio, W/H ¼ 1. Diamond topology lattices were rotated by 458 and cut to an aspect ratio L/H ¼ 5, with three cells in the core height direction and a W/H ¼ 1. Fig. 1. Schematic showing assembly sequence to make a Ti–6Al–4V lattice. 1112 http://www.aem-journal.com The relative density of the diffusion bonded collinear lattice structure, r, is the ratio of volumes of the solid material within a unit cell of structure to that of the unit cell. It is given by [35]: a p r¼ ; (1) 2b sinð2vÞ l where a and l are the wire radius and the inter-wire spacing (i.e., the unit cell length), b is the diffusion bonding coefficient defined as W/W0, where W and W0 are the lattice widths prior to and after the diffusion bonding process, and v is the half angle of the truss orthogonal pattern (458 for both the square and diamond lattices).[35] The measured diffusion bonding coefficient, b, of the Ti–6Al–4V lattice was 0.64 and so after diffusion bonding, the lattice had a relative density r ¼ 15.3%. Sandwich panel test structures were made by vacuum brazing the Ti–6Al–4V lattices to 2 mm thick Ti–6Al–4V face sheets using TiCuNi-601 paste braze alloy (Lucas-Milhaupt Inc., Cudahy, WI). The assemblies were first heated at 20 8C min1 to 550 8C, and held for 5 min (to volatize and remove the polymer binder), and then heated to 975 8C for 30 min at a base pressure of 107 Torr. Photographs of the sandwich test structures with both the square and diamond lattice cores are shown in Figure 2. The images reveal a small misalignment of the trusses (and the truss–truss nodes) that resulted from truss wire waviness. Fig. 2. Examples of the as-manufactured Ti–6Al–4V specimens used for compression testing (r ¼ 15.3%): front view of (a) square and (b) diamond, and side view of (c) square and (d) diamond lattice core sandwich structures. The small misalignments of the lattice resulted from curvature of the wire. ß 2010 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim ADVANCED ENGINEERING MATERIALS 2010, 12, No. 11 P. Moongkhamklang and H. N. G. Wadley/Titanium Alloy Lattice Structures with Millimeter Scale . . . Results and Discussion The through thickness, compressive stress–strain responses for square, and diamond lattice structures with r ¼ 15.3% (ro ¼ 9.8%, b 0.64) are shown in Figure 3(a) and (b), respectively. Both lattices exhibited characteristics typical of many cellular metal structures, including a region of elastic response, plastic yielding (over a small strain range), a peak in the strength (at 15–20% strain range), a large post-peak stress drop followed by a plateau region, and finally hardening associated with densification. Unload/reload tests confirmed that plastic yielding had occurred prior to attainment of the peak in compressive stress. Images of Ti–6Al–4V lattice truss structures at different level of compression are shown in Figure 4. As the square lattice was compressed, the trusses parallel to the loading direction plastically yielded and then cooperatively buckled near their midpoint. Truss buckling was only observed after attainment of the peak stress. The buckling half-wavelength corresponded with the total core height. In the diamond lattice, the trusses also yielded and then buckled, but not always in the same direction. Some trusses buckled in the 1-3 plane while some buckled in the 1–2 plane. The buckling half-wavelength varied from l to 6l throughout the sample. The Young’s modulus and compressive strength of square and diamond lattices are plotted against r in Figure 5. Both the stiffness and strength of the square lattices were higher than those of the diamond lattices. Approximate analytical expressions for the through thickness compressive stiffness and strength of a collinear and a textile lattice made from an elastic ideally plastic, monolithic solid material have been previously developed.[34,36,37] For a diamond collinear lattice made of straight struts, the out-of-plane compressive stiffness is given by:[37] 1 H 1 Es r; Ec ¼ (2) 4 L where L and H are the length and height of the lattice core, Es and r are the Young’s modulus of the Ti–6Al–4V wire and the relative density of the diamond core, respectively. Queheillalt et al.[34] have shown that the waviness in textile lattices results in a knockdown in both stiffness and strength compared to the collinear lattices. Since the trusses in the Ti–6Al–4V lattices were also wavy, it is more appropriate to model their compressive stiffness and strength with the models developed for the textile lattices. The truss waviness reduces its axial stiffness, and the effective modulus, Ew, of a wavy strut with a wave amplitude equal to the wire diameter can be written:[34] Ew ¼ 1 1:09 þ 8ð1 þ nÞða=lÞ2 (3) where n, a, and l are the Poisson’s ratio of the wire material, the wire radius and the lattice unit cell length, respectively. Substituting n ¼ 0.33, a ¼ 127 mm, and l ¼ 2.03 mm in Equation 3 gives Ew/Es ¼ 0.88. The compressive stiffness of a lattice made of wavy struts can then be estimated by replacing Es by Ew in Equation 2. Figure 5(b) shows that experimental data is well approximately by the wavy textile estimate. The relevant dimensional parameters and material properties used in the models are summarized in Table 1. The yield strength of a diamond collinear lattice with straight struts is given by:[37] 1 H sc ¼ (4) 1 syr 2 L Fig. 3. Compressive stress–strain response for Ti–6Al–4V (a) square and (b) diamond lattices with r ¼ 15.3%. The inserts show the stress–strain response at small values of strain. Plastic yielding was observed prior to the peak stress in both cases. ADVANCED ENGINEERING MATERIALS 2010, 12, No. 11 Es where sy is the yield strength of the constituent trusses (assumed straight). For a wavy truss, the load carrying capacity is again reduced and the collapse strength, sw, of a wavy strut with wave amplitude equal to ß 2010 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim http://www.aem-journal.com 1113 COMMUNICATION The lattice structures were tested in compression at ambient temperature at a nominal strain rate of 2 104 s1. The measured load cell force was used to calculate the nominal stress applied to the sandwich, and the nominal through thickness strain was obtained from a laser extensometer positioned about the sample centerline. The gage length for the strain measurement was the core height, H. To characterize the solid materials mechanical properties, Ti–6Al–4V wires were subjected to the same thermal cycles used to fabricate the Ti–6Al–4V sandwich structures and then tested in uniaxial tension at room temperature at a strain rate of 2 104 s1. These Ti–6Al–4V alloy wires could be adequately approximated as an elastic–plastic solid with Young’s modulus, Es ¼ 108 3.4 GPa and an average 0.2% offset yield strength sy ¼ 956 46.2 MPa. Two strain regions of linear hardening modulus (the tangent modulus Et ds/de) were observed after yield. In region I, 0.01 e 0.03 (where e ¼ 0.01 was the yield strain, ey), Et,I ¼ 6.32 0.2 GPa. In region II, 0.03 e 0.1 (where e ¼ 0.10 was the strain at tensile failure, " ), Et,II ¼ 1.53 0.1 GPa. The ultimate tensile strength had an average value sUTS ¼ 1179 48 MPa. COMMUNICATION P. Moongkhamklang and H. N. G. Wadley/Titanium Alloy Lattice Structures with Millimeter Scale . . . where leb and k are the length of the column and the column end constraint, respectively. The lowest strength buckling mode of the metallic lattice under uniaxial compression corresponds to struts of length l buckling as a pin joint strut. This gives leb ¼ l and k ¼ 1. The compressive strength of the lattice is then estimated by replacing sy by seb in Equation 4. The strut waviness effect has not been explored in detail. However, if the wires are assumed to buckle as pinned-end struts in the 1–3 plane, the waviness in the 1–2 plane is expected to have only a minor effect upon the elastic buckling strength of the textile lattice.[34] For the square collinear lattice with straight trusses, the out-of-plane compressive stiffness and yield strength are given by:[34,39] 1 Ec ¼ Es r 2 (7) and 1 s c ¼ s y r; 2 (8) respectively. When the lattice collapses by elastic cooperative buckling of the constituent struts, Figure 4(a), the lattice compression strength is given by:[40] 3 2 62 sc ¼ 4 2 þ n 3 p2 1 4br p 7 2 3 3 þ5b Es r (9) where n ¼ number of unit cells between the faces. The compressive modulus and plastic yield strength of the textile square lattice can be estimated by replacing Es and sy by Ew and sw, respectively, in Equations 7 and 8. Figure 5(a) shows that the experimental data Fig. 4. Sequence of photographs showing the progressive deformation of: (a) square lattice truss core; for the compressive stiffness of square lattices (b) diamond lattice truss core, made with Ti–6Al–4V wires during tests in out-of-plane compression. The strains at which photographs were taken are labeled. is in good agreement with predictions for the textile lattices. The compressive strengths of both the square and diamond lattices, a fiber diameter (2a) is given by:[34] Figure 5(c) and (d), are slightly overpredicted. The models assume that the trusses buckle in the 1–3 plane so that the strut s w ¼ 0:782s y : (5) waviness (in the 1–2 plane) effect is negligible. However, truss buckling was observed in both the 1–3 and 1–2 planes. The plastic yield strength of the wavy truss structure can Therefore, the truss waviness may also result in a reduction of then be estimated by replacing sy by sw in Equation 4. the truss buckling strength, seb, and hence a reduction in the The lattice collapses by elastic buckling of the constituent lattice compressive strength. struts if the Euler buckling strength, seb, of the constituent The compressive strength of the Ti–6Al–4V lattices in both struts is less than or equal to their plastic yield strength. the square and diamond topologies is between 35 and 45 MPa The Euler buckling strength of a cylindrical solid column is and is predicted to be controlled by plastic yield consistent given by:[38] with observations of non-recoverable strains near the peak in k2 p2 Es a2 strength. In this regime, the lattice strength is predicted to s eb ¼ ; (6) 4ðleb Þ2 scale linearly with the yield strength of the wires and the 1114 http://www.aem-journal.com ß 2010 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim ADVANCED ENGINEERING MATERIALS 2010, 12, No. 11 P. Moongkhamklang and H. N. G. Wadley/Titanium Alloy Lattice Structures with Millimeter Scale . . . Conclusions – A method for making titanium sandwich panels with millimeter-scale titanium lattice cores has been developed. The method involves laying up linear arrays of titanium alloy wires, alternating the direction of consecutive layers, and using diffusion bonding to join the wires at the nodes where they intersect. The relative density of the lattice was controlled by the diameter Fig. 5. Experimental data and analytical predictions for the Young’s modulus of (a) Ti–6Al–4V square and of the wires, the spacing between the (b) diamond lattices and the compressive strength of (c) square and (d) diamond lattices. The solid line marks the wires in each collinear layer (cell dominant failure mode as a function of the lattice relative density. length), and the degree of diffusion bonding. – The out-of-plane modulus of square Ti–6Al–4V lattice lattice relative density r. The models predict that elastic structures scaled linearly with relative density r. The buckling controls the strength when the relative densities compressive peak strength was controlled by plastic becomes less than 13%. When lattices fail by elastic truss yielding and varied also with r. buckling, the lattice compressive strength decreases rapidly – The out-of-plane modulus of diamond TMC lattice strucwith r3 . tures was about half that of the square lattice and also The compressive strength of these Ti–6Al–4V textile lattices scaled linearly with r. The compressive strength of the is superior to that of the Ti–6Al–4V lattice block structure diamond lattice was controlled by plastic yielding where (31 MPa) of approximately the same relative density[30] it is predicted to scale linearly with r. – These titanium lattices may provide interesting high Table 1. Lattice truss parameters used in the micromechanical models for predictions of temperature multifunctional opportunities. the lattice compressive stiffness and strength. Geometrical parameters/mechanical properties Symbol Value Radius of the Ti–6Al–4V wire truss [mm] Lattice unit cell length [mm] Aspect ratio of the diamond lattice Angle of the trusses to the face sheets in the diamond lattice [8] Number of unit cells between the faces of the square lattices Diffusion bonding coefficient Young’s modulus of the Ti–6Al–4V wire [GPa] Poisson’s ratio of the Ti–6Al–4V alloy[a] Yield strength of the Ti–6Al–4V wire [MPa] a l L/H v 127 2.03 5 45 n 4 b Es n sy 0.64 108 0.33 956 [a] Typical value.[41] ADVANCED ENGINEERING MATERIALS 2010, 12, No. 11 Received: April 19, 2010 Final Version: June 21, 2010 Published online: September 13, 2010 [1] H. N. G. Wadley, G. Gilmer, W. Barker, MRS Symp. Proc. 2000, 616. [2] H. N. G. Wadley, Philos. Trans. R Soc. A 2006, 364, 31. [3] A. G. Evans, J. W. Hutchinson, N. A. Fleck, M. F. Ashby, H. N. G. Wadley, Prog. Mater. Sci. 2001, 46, 309. [4] H. G. Allen, Analysis and Design of Structural Sandwich Panels, Pergamon Press, Oxford 1969. ß 2010 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim http://www.aem-journal.com 1115 COMMUNICATION and are comparable to Ti–6Al–2Sn–4Zr–2Mo lattice block structures (40 MPa).[29] At a given lattice topology and relative density, the titanium lattice is approximately two times weaker than the lattice made of titanium coated SiC fibers[40] but 15–20 times less costly. Titanium alloy lattices with a relative density that results in plastic yield controlled collapse are expected to retain good dimensional stability during loading at temperatures up to 420 8C.[41] They therefore provide interesting high temperature multifunctional opportunities. COMMUNICATION P. Moongkhamklang and H. N. G. Wadley/Titanium Alloy Lattice Structures with Millimeter Scale . . . [5] H. N. G. Wadley, N. A. Fleck, A. G. Evans, Compos. Sci. Technol. 2003, 63, 2331. [6] F. W. Zok, S. A. Waltner, Z. Wei, H. J. Rathbun, R. M. 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Deshpande, N. A. Fleck, Int. J. Solids Struct. 2001, 38, 6275. [25] W. Sanders, Metallic Materials With High Structural Efficiency, Lightweight Cellular Metals With High Structural Efficiency, Vol. 146, Springer, Netherlands 2004. [26] J. Zhou, P. Shrotriya, W. O. Soboyejo, Mech. Mater. 2004, 36, 723. [27] Y. H. Lee, B. K. Lee, I. Jeon, K. J. Kang, Acta Mater. 2007, 55, 6084. [28] S. Chiras, D. R. Mumm, A. G. Evans, N. Wicks, J. W. Hutchinson, K. Dharmasena, H. N. G. Wadley, S. Fichter, Int. J. Solids Struct. 2002, 39, 4093. [29] Q. Li, E. Y. Chen, D. R. Bice, D. C. Dunand, Adv. Eng. Mater. 2008, 10, 939. [30] Q. Li, E. Y. Chen, D. R. Bice, D. C. Dunand, Metall. Mater. Trans. A 2008, 39A, 441. [31] C. Yungwirth, H. N. G. Wadley, J. O’Connor, A. Zakraysek, V. S. Deshpande, Int. J. Impact Eng. 2008, 35, 920. [32] H. N. G. Wadley, K. P. Dharmasena, Y. Chen, P. Dudt, D. Knight, R. Charette, K. Kiddy, Int. J. Impact Eng. 2008, 35, 1102. [33] D. T. Queheillalt, H. N. G. Wadley, Mater. 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