CENTRE FOR TECHNOLOGY DEVELOPMENT AND TRANSFER

Student Innovative Project (2017-18) - Proposal Report

SIP ID - 1617S4042

PROPOSAL REPORT
High temperature performance of AlCrN coated Ti6Al4V micro metal lattices
synthesized by Selective laser sintering

Submitted by
MS.KRISHNAVENI (Department of Mechanical Engineering)
MR.DINESH KUMAR (Department of Mechanical
Engineering)
MR.SANDEEP (Department of Mechanical Engineering)

Guided by
DR.D.SANGEETHA
Assistant Professor (Sg), Department Of Mechanical Engineering

DEPARTMENT OF MECHANICAL ENGINEERING

COLLEGE OF ENGINEERING, GUINDY

ANNA UNIVERSITY :: CHENNAI

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 CENTRE FOR TECHNOLOGY DEVELOPMENT AND TRANSFER
Student Innovative Project (2017-18) - Proposal Report
SIP ID - 1617S4042

BONAFIDE CERTIFICATE

Certified that this proposal report " HIGH TEMPERATURE

PERFORMANCE OF ALCRN COATED TI6AL4V MICRO METAL
LATTICES SYNTHESIZED BY SELECTIVE LASER SINTERING " is
submitted by MS.KRISHNAVENI, MR.DINESH KUMAR, MR.SANDEEP.

We certify to follow the guidelines prescribed by the University during and after
implementation of the project.

SIGNATURE OF STUDENTS

1.
MS.KRISHNAVENI SIGNATURE OF MENTOR

2. 1.
MR.DINESH KUMAR DR.D.SANGEETHA

3.
MR.SANDEEP

RECOMMENDED BY HOD / DIRECTOR

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CENTRE FOR TECHNOLOGY DEVELOPMENT AND TRANSFER
Student Innovative Project (2017-18) - Proposal Report
SIP ID - 1617S4042

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 CENTRE FOR TECHNOLOGY DEVELOPMENT AND TRANSFER
Student Innovative Project (2017-18) - Proposal Report
SIP ID - 1617S4042

PROJECT DETAILS

OBJECTIVES
1. To Synthesis the micro metal lattice of Ti6Al4V through selective laser sintering

2. To Coat the synthesized micro metal lattice with heat resistant material AlCrN by PVD.

3. To characterize the coated micro metal lattice through SEM, EDS.

4. To determine the thickness of the coating above the struts using calo tester.

5. To analyze the mechanical properties of coated micro metal lattices such as energy
absorption capacity, compressive strength at high temperatures.

6. To compare the mechanical behavior of the lattice at high temperature with that of room
temperature.

INTRODUCTION
A recent breakthrough in the field of materials science has created a new material that
could possibly have a tremendous impact in the fabrication of light weight structures for
automobile and aerospace applications. Automotive and aerospace industries require light
weight structures made of cellular materials. The micro metal lattice is a material which has
ultra low density and a strength which equals its bulk counterpart while being significantly
lighter. They have good energy absorbing capacities, as like a few materials, to say for an
example foam, wood, cork, honey comb, corrugated structures. In addition, nowadays
focus is being given for the synthesizing of lattice truss structures which are in the
micrometer range.
As a result of this design, the micro lattice metals are extremely light and as strong as
bulkier metals. The material is manufactured from a periodic array of titanium alloy
(Ti6Al4V) struts. The structure of metallic micro lattices consist of hollow cylindrical
struts whose diameter and wall thickness lie in the micro meter range. These struts are
interconnected in a particular pattern to create a whole lattice. To say for an instance, the
size range of a single strut of the lattice can be compared to a dimension, which is equal to
the diameter of human hair (around 150 m). By the virtue of being hollow these struts
constitute a lattice which are almost entirely composed of air. They have advanced
mechanical properties such as high impact resistance and shock absorbing capacity which
make them an attractive and yet another viable material to be exploited in the aerospace
industry and the automotive industry.

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 CENTRE FOR TECHNOLOGY DEVELOPMENT AND TRANSFER
Student Innovative Project (2017-18) - Proposal Report
SIP ID - 1617S4042

LITERATURE SURVEY
Twin skinned, sandwich, structures are of interest for application for aerospace structures found in
fuselage, wing and other components. Such structures have advantages over monolithic shells, such
as improved specific bending stiffness and strength, and multi function potential, e.g. acoustic and
thermal properties [1].
A feature of twin skinned construction is the cellular core. Conventionally in aerospace
applications, the most widely used architecture is that of honeycomb, in either aluminum or
aramid. However, such materials have the disadvantage of closed cells, when used with
skins, which give rise to moisture and gas retention [2]. . Recently, folded textile paper
cores have been developed which have optimized mechanical properties but an open cell
architecture [2]. Another class of open cell material is the metallic lattice structure [3]. This
class of structure has been extensively studied theoretically, and although linear properties
are well understood, further research is needed on strength and toughness issues [4].
Metallic lattice structures can be manufactured a number of ways, such as textile
technology [3] and forming and brazing [5]. The focus for this paper is the study and use of
a new, innovative, micro lattice core material manufactured using selective laser melting
[SLM] [6,7]. In this process, metallic powder is selectively melted to form spatial micro
lattice structures
[8] and some testing of micro lattice blocks [9] and some theoretical parametric studies
[10] are performed.
Ushijima et al. [10] developed parametric compressive models for the body centred cubic
micro lattice geometry in the form of blocks, and showed the complexity of parametric
modelling. Labeas and Sunaric also analysed the micro lattice blocks theoretically [11].
These ideas need to be developed further to include multiple collapse mechanisms, so as to
fully exploit the manufacturing process.
The main features of Ti6Al4V are:
? Have good fatigue resistance
? Have good creep resistance
? It is non magnetic
? Low thermal expansion
? Good corrosion resistance
? Low density and high strength to weight ratio.

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 CENTRE FOR TECHNOLOGY DEVELOPMENT AND TRANSFER
Student Innovative Project (2017-18) - Proposal Report
SIP ID - 1617S4042

PROPOSED WORK WITH METHODOLOGY

Initially, the 3D design for the micro lattices has been developed and the metal micro
lattices are manufactured by additive manufacturing technique through selective laser
sintering. The resultant microstructure is characterized to analyze the micro lattice
morphology and surface finish of the struts of the lattice. For this morphological analysis
Scanning electron microscope and energy dispersive spectroscopy are made of use.
The lattices are then coated with a heat resistant coating (AlCrN) by physical vapour
deposition process. The thickness of the coating is measured by using Calo tester.
Then the compression behavior, energy absorption capacity and the impact behavior of the
lattice are determined by using compression test and impact tests at room temperature and
high temperatures. Finite element analysis of the compression and impact behavior of the
lattice is also performed. Mechanical behavior of the lattice at room temperature and high
temperatures are compared.

CHARACTERISATION TECHNIQUES:

SEM:
The strut morphology and the surface finish of the struts can be obtained from scanning
electron microscopy images. EDS analysis of the lattice is done to obtain the chemical
composition data of the produced lattice.
CALO TESTER:
The deposited coating’s thickness is measured using calo tester which works on the
principle of indenting the coated lattice with a steel ball of know diameter and then
calculating the coating the coating thickness as per the formula,
t=xy/d,
where, t is the coating thickness, d is the diameter of the spherical steel ball used to indent
the lattice, x is the difference between the radius of the crater and radius of the part of the
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 CENTRE FOR TECHNOLOGY DEVELOPMENT AND TRANSFER
Student Innovative Project (2017-18) - Proposal Report
SIP ID - 1617S4042
crater at the bottom of the coating, x+y is the diameter of the crater.
UNIVERSAL TESTING MACHINE:
The specimen is subjected to UTM machine in order to determine the compression
strength and energy absorption capacity. The lattice is cut according to the ASTM
standards and is kept in the UTM machine for compression and tested.
IMPACT TEST:
As the main feature of the micro metal lattice is energy absorption, it becomes
essential to perform impact test on the lattice produced. For this impact test, drop
weight impact test is done according to standards. The lattice is placed in the machine
and a standard amount of weight is made to fall on the lattice as per the ASTM
standards and the impact behavior of the lattice is studied.
FINITE ELEMENT ANALYSIS:
Finite elemental analysis of the compression and impact test on the lattices are performed
using software called ANSYS to obtain a digital data on the energy absorption capacity and
the compression strength of the lattice.

IMPLEMENTATION

Initially the 3D design of the lattice is made using the software CREO and micro lattice is
synthesized by selective laser sintering. The synthesized lattice is coated with AlCrN by
PVD and then it is characterized by EDS, SEM and tests for the evaluation of mechanical
properties like compression test, impact test are also done. Finally finite elemental analysis
of the compression and impact behavior of the lattice structures are performed.
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 CENTRE FOR TECHNOLOGY DEVELOPMENT AND TRANSFER
Student Innovative Project (2017-18) - Proposal Report
SIP ID - 1617S4042

WORK PLAN

EXPECTED OUTCOME / RESULTS

The surface morphology of the micro metal lattice will be made smooth and free of
asperities by sand blasting. In compression test, the stress strain curve for the material
synthesized will absorb more energy during compression test and will have better
compression strength because of the better surface finish of the struts.
The lattice will retain its mechanical properties and will have better heat resistance because
of the coating deposited by PVD.

APPLICATIONS
i.) Micro lattices made of Ti6Al4V can possibly be used a shock absorbers in automobile
bumpers.
ii.) They can be used as structural material in the construction of components for aerospace
application because of their low dense and better strength to weight ratio.
iii.) They can also be used at higher temperature without any change in their properties
because of the coating deposited on them
iv.) They can be used for marine applications as well because of their better corrosion
resistant nature.

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 CENTRE FOR TECHNOLOGY DEVELOPMENT AND TRANSFER
Student Innovative Project (2017-18) - Proposal Report
SIP ID - 1617S4042

CONCLUSION
Titanium based alloy, Ti6Al4V micro lattices are fabricated by additive manufacturing
technique through SLS and it is coated with a heat resistant coating using PVD.
It is then characterized to obtain its morphological data and then mechanical tests are
performed on it to determine its energy absorption capacity.

REFERENCES
[1] Hermann AS, Zahlen PC, Zuardy I. Sandwich structures technology in commercial
aviation. In: 7th International Conference on sandwich structures (ICSS-7), Aalborg 2005.
p. 13-26.
[2] Heimbs S, Cichosz J, Klaus M, Kilchert S, Johnson AF. Sandwich structures with
textile reinforced composite foldcores under impact loads. Comp Struct 2010;92:1484-97.
[3] Sypeck DJ. Cellular truss core sandwich structures. Appl Comp Mat 2005;12: 229-46.
[4] Fleck NA, Deshpande VS, Ashby MF. Micro-architectured materials: past, present and
future. Proc Roy Soc A 2010;466:2495-516
[5] Queheillalt DT, Wadley HNG. Titanium alloy lattice truss structures. Mat Des
2009;30:1966-75.
[6] Yadroitsev I. Selective laser melting. Saarbrucken, Germany: Lambert Academic
Publishing; 2009. [7] Rehme O. Cellular design for laser freeform fabrication. Gottingen,
Germany: Cuivillier Verlag; 2010.
[8] Tsopanos S, Mines RAW, McKown S, Shen Y, Cantwell WJ, Brookes W, et al.
The influence of processing parameters on the mechanical properties of selective laser
melted stainless steel micro lattice structures. J Manu Sc Eng 2010;132. 041011 p1-12.
[9] Shen Y, McKown S, Tsopanos S, Sutcliffe CJ, Mines RAW, W.J. The mechanical
properties of sandwich structures based on metal lattice architectures. J Sand Struct Mat
2010;12:159-80.
[10] Ushijima K, Cantwell WJ, Mines RAW, Tsopanos S, Smith M. An investigation into
the compression properties of stainless steel micro lattice structures.
J Sand Struct Mat 2010;13(3):303-29
[11] Labeas GN, Sunaric MM. Investigation on the static response and failure process of
metallic open lattice cellular structures.
Strain 2008;46:195-204.
[12] D.Erdeniz, A.J. Levinson , K.W.Sharp , D.J. Rowenhorst, R.W.Fonda, D.C. Dunand,
Metall, Mater. Trans. A 46a (2015) 426-438.
[13] M.G. Rashed, M.Ashraf, R.A.W. Mines,P.J. Hazell, Mater,Des.95920160 518-533.
[14]D.Erdeniz, K.W. Sharp, D.C. Dunand, Scr. Mater.108(2015) 60 – 63.

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 CENTRE FOR TECHNOLOGY DEVELOPMENT AND TRANSFER
Student Innovative Project (2017-18) - Proposal Report
SIP ID - 1617S4042

FINANCIAL ASSISTANCE
HEAD AMOUNT(Rs.)
Material / Fabrication / Component 10000
Travel 500
Contingency 5000
Consumables 5000
Others 4500
TOTAL 25000

Submitted to
Centre for Technology Development and Transfer
Anna University, Chennai-25.
Contact No: 044 2235 7928/7930

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