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Topological Optimization and Textile Manufacturing of 3D Lattice Materials

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Topological Optimization and Textile Manufacturing of 3D Lattice Materials

Recent advances in topological optimization methodologies for design of internal material architecture, coupled with the emergence of micro- and nanoscale fabrication processes, 3D imaging, and micron scale testing methodologies, now make it possible to design, fabricate, and characterize lattice materials with unprecedented control. This talk will describe a collaborative effort that employs scalable 3D textile manufacturing, location specific joining, and vapor phase alloying to produce metallic lattices with a wide range of internal architectures, alloy compositions, and mechanical and functional properties. The project involves three length scales. The highest level (component scale) spans centimeters to meters and encompasses gradients in unit cell architecture, porosity, and the creation of sandwich structures. The second level (architectural unit cells) spans tens of microns to millimeters and employs architectural optimization to design the geometry of the braided/woven structure. The smallest level (microstructure) spans nanometers to tens of microns focuses on vapor phase alloying of the wires after textile manufacturing. Topology optimization allows properties to be decoupled and tailored for specific applications. Dramatic enhancements in permeability have been balanced with modest reductions in stiffness and are being used to develop heat exchanger materials with high thermal transport, low impedance, low thermal gradients and high temperature strength. In a parallel effort, architectural designs to maximize both structural resonance and inter-wire friction are also being employed to develop metallic lattices capable of mechanical damping at elevated temperatures. These examples will be used to highlight the benefits to be gained by development of metallic lattice materials with a wide range of tailorable properties. [more]

 
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