Meter-Scale Thin-Walled Structure with Lattice Infill for Fuel Tank Supporting Component of Satellite:Multiscale Design and Experimental Verification

Lightweight thin-walled structures with lattice infill are widely desired in satellite for their high stiffness-to-weight ratio and superior buckling strength resulting fromthe sandwich effect.Such structures can be fabricated bymetallic additive manufacturing technique,such as selective laser melting(SLM).However,the maximum dimensions of actual structures are usually in a sub-meter scale,which results in restrictions on their appliance in aerospace and other fields.In this work,a meter-scale thin-walled structure with lattice infill is designed for the fuel tank supporting component of the satellite by integrating a self-supporting lattice into the thickness optimization of the thin-wall.The designed structure is fabricated by SLM of AlSi10Mg and cold metal transfer welding technique.Quasi-static mechanical tests and vibration tests are both conducted to verify the mechanical strength of the designed large-scale lattice thin-walled structure.The experimental results indicate that themeter-scale thin-walled structure with lattice infill could meet the dimension and lightweight requirements of most spacecrafts.

Honeycomb-spiderweb-inspired self-similar hybrid cellular structures for impact applications

Inspired by nature's self-similar designs,novel honeycomb-spiderweb based self-similar hybrid cellular structures are proposed here for efficient energy absorption in impact applications.The energy absorption is enhanced by optimizing the geometry and topology for a given mass.The proposed hybrid cellular structure is arrived after a thorough analysis of topologically enhanced self-similar structures.The optimized cell designs are rigorously tested considering dynamic loads involving crush and high-velocity bullet impact.Furthermore,the influence of thickness,radial connectivity,and order of patterning at the unit cell level are also investigated.The maximum crushing efficiency attained is found to be more than 95%,which is significantly higher than most existing traditional designs.Later on,the first and second-order hierarchical self-similar unit cell designs developed during crush analysis are used to prepare the cores for sandwich structures.Impact tests are performed on the developed sandwich structures using the standard 9-mm parabellum.The influence of multistaging on impact resistance is also investigated by maintaining a constant total thickness and mass of the sandwich structure.Moreover,in order to avoid layer-wise weak zones and hence,attain a uniform out-of-plane impact strength,off-setting the designs in each stage is proposed.The sandwich structures with first and second-order self-similar hybrid cores are observed to withstand impact velocities as high as 170 m/s and 270 m/s,respectively.

Sandwich structures with tapered tubes as core:A quasi-static investigation

In this article,the experimental and finite element analysis is utilized to investigate the quasi-static compression features of sandwich constructions built with tapered tubes.3D printing technology was utilized to create the hollow centers of the tapering tubes,with and without corrugations.The results demonstrate that the energy absorption(EA)and specific energy absorption(SEA)of the single corrugated tapered tube sandwich are 51.6% and 19.8% higher,respectively,than those of the conical tube sandwich.Furthermore,the results demonstrate that energy absorbers can benefit from corrugation in order to increase their efficiency.Additionally,the tapered corrugated tubes'resistance to oblique impacts was studied.Compared to a straight tube,the tapered tube is more resistant to oblique loads and has a lower initial peak crushing force(PCF),according to numerical simulations.After conducting a parametric study,it was discovered that the energy absorption performance of the sandwich construction is significantly affected by the amplitude,number of corrugations,and wall thickness.EA and SEA of DTS with corrugation number of 8 increased by 17.4%and 29.6%,respectively,while PCF decreased by 9.2% compared to DTS with corrugation number of 10.

Ballistic performances of the hourglass lattice sandwich structures under high-velocity fragments

In this paper,the numerical simulation method is used to study the ballistic performances of hourglass lattice sandwich structures with the same mass under the vertical incidence of fragments.Attention is paid to elucidating the influences of rod cross-section dimensions,structure height,structure layer,and rod inclination angle on the deformation mode,ballistic performances,and ability to change the ballistic direction of fragments.The results show that the ballistic performances of hourglass lattice sandwich structures are mainly affected by their structural parameters.In this respect,structural parameters optimization of the hourglass lattice sandwich structures enable one to effectively improve their ballistic limit velocity and,consequently,ballistic performances.

Laser Powder Bed Fusion of Multifunctional Bio-inspired Vertical Honeycomb Sandwich Structures:For the Application of Lightweight Bipolar Plates of Proton Exchange Membrane Fuel Cells

The bipolar plate(BPP)is a crucial component of proton exchange membrane fuel cells(PEMFC).However,the weight of BPPs can account for around 80%of a PEMFC stack,posing a hindrance to the commercialization of PEMFCs.Therefore,the lightweight design of BPPs should be considered as a priority.Honeycomb sandwich structures meet some requirements for bipolar plates,such as high mechanical strength and lightweight.Animals and plants in nature provide many excellent structures with characteristics such as low density and high energy absorption capacity.In this work,inspired by the microstructures of the Cybister elytra,a novel bio-inspired vertical honeycomb sandwich(BVHS)structure was designed and manufactured by laser powder bed fusion(LPBF)for the application of lightweight BPPs.Compared with the conventional vertical honeycomb sandwich(CVHS)structure formed by LPBF under the same process parameters setting,the introduction of fractal thin walls enabled self-supporting and thus improved LPBF formability.In addition,the BVHS structure exhibited superior energy absorption(EA)capability and bending properties.It is worth noting that,compared with the CVHS structure,the specific energy absorption(SEA)and specific bending strength of the BVHS structure increased by 56.99%and 46.91%,respectively.Finite element analysis(FEA)was employed to study stress distributions in structures during bending and analyze the influence mechanism of the fractal feature on the mechanical properties of BVHS structures.The electrical conductivity of structures were also studied in this work,the BVHS structures were slightly lower than the CVHS structure.FEA was also conducted to analyze the current flow direction and current density distribution of BVHS structures under a constant voltage,illustrating the influence mechanism of fractal angles on electrical conductivity properties.Finally,in order to solve the problem of trapped powder inside the enclosed unit cells,a droplet-shaped powder outlet was designed for LPBF-processed components.The number of powder outlets was optimized based on bending properties.Results of this work could provide guidelines for the design of lightweight BPPs with high mechanical strength and high electrical conductivity.

Lignin‐derived carbon with pyridine N‐B doping and a nanosandwich structure for high and stable lithium storage

Biomass‐derived carbon is a promising electrode material in energy storage devices.However,how to improve its low capacity and stability,and slow diffusion kinetics during lithium storage remains a challenge.In this research,we propose a“self‐assembly‐template”method to prepare B,N codoped porous carbon(BN‐C)with a nanosandwich structure and abundant pyridinic N‐B species.The nanosandwich structure can increase powder density and cycle stability by constructing a stable solid electrolyte interphase film,shortening the Li^(+) diffusion pathway,and accommodating volume expansion during repeated charging/discharging.The abundant pyridinic N‐B species can simultaneously promote the adsorption/desorption of Li^(+)/PF_(6)^(−) and reduce the diffusion barrier.The BN‐C electrode showed a high lithium‐ion storage capacity of above 1140 mAh g^(−1) at 0.05 A g^(−1) and superior stability(96.5% retained after 2000 cycles).Moreover,owing to the synergistic effect of the nanosandwich structure and pyridinic N‐B species,the assembled symmetrical BN‐C//BN‐C full cell shows a high energy density of 234.7Wh kg^(−1),high power density of 39.38 kW kg−1,and excellent cycling stability,superior to most of the other cells reported in the literature.As the density functional theory simulation demonstrated,pyridinic N‐B shows enhanced adsorption activity for Li^(+) and PF_(6)^(−),which promotes an increase in the capacity of the anode and cathode,respectively.Meanwhile,the relatively lower diffusion barrier of pyridinic N‐B promotes Li^(+) migration,resulting in good rate performance.Therefore,this study provides a new approach for the synergistic modulation of a nanostructure and an active site simultaneously to fabricate the carbon electrode material in energy storage devices.

Energy-absorption forecast of thin-walled structure by GA-BP hybrid algorithm

In order to analyze the influence rule of experimental parameters on the energy-absorption characteristics and effectively forecast energy-absorption characteristic of thin-walled structure, the forecast model of GA-BP hybrid algorithm was presented by uniting respective applicability of back-propagation artificial neural network （BP-ANN） and genetic algorithm （GA）. The detailed process was as follows. Firstly, the GA trained the best weights and thresholds as the initial values of BP-ANN to initialize the neural network. Then, the BP-ANN after initialization was trained until the errors converged to the required precision. Finally, the network model, which met the requirements after being examined by the test samples, was applied to energy-absorption forecast of thin-walled cylindrical structure impacting. After example analysis, the GA-BP network model was trained until getting the desired network error only by 46 steps, while the single BP-ANN model achieved the same network error by 992 steps, which obviously shows that the GA-BP hybrid algorithm has faster convergence rate. The average relative forecast error （ARE） of the SEA predictive results obtained by GA-BP hybrid algorithm is 1.543%, while the ARE of the SEA predictive results obtained by BP-ANN is 2.950%, which clearly indicates that the forecast precision of the GA-BP hybrid algorithm is higher than that of the BP-ANN.

Solidified structure of thin-walled titanium parts by vertical centrifugal casting

The solidified structure of the thin-walled and complicated Ti-6AI-4V castings produced by the vertical centrifugal casting process was studied in the present work. The results show that the wall thickness of the section is featured with homogeneously distributed fine equiaxial grains, compared with the microstructure of the thick-walled section. The grain size of the castings has a tendency to decrease gradually with the increasing of the centrifugal radius. The inter-lamellar space in thick-walled casting parts is bigger than that of the thin-walled parts, and the profile of inter-lamellar space is not susceptible to the centrifugal radius.

Boundary Element Analysis forModeⅢCrack Problems of Thin-Walled Structures from Micro-to Nano-Scales

This paper develops a new numerical framework for modeⅢcrack problems of thin-walled structures by integrating multiple advanced techniques in the boundary element literature.The details of special crack-tip elements for displacement and stress are derived.An exponential transformation technique is introduced to accurately calculate the nearly singular integral,which is the key task of the boundary element simulation of thin-walled structures.Three numerical experiments with different types of cracks are provided to verify the performance of the present numerical framework.Numerical results demonstrate that the present scheme is valid for modeⅢcrack problems of thin-walled structures with the thickness-to-length ratio in the microscale,even nanoscale,regime.

Elastoplastic analysis of thin-walled structures in reservoir area

In the structural design of the high pier,in order to analyze the strength and structure stability,the pier was often considered a thin-walled structure.Elastoplastic incremental theory was used to establish the model of elastoplastic stability of high pier.By considering the combined action of pile,soil and pier together,the destabilization bearing capacity was calculated by using 3-D finite element method(3-D FEM) for piers with different pile and section height.Meanwhile,the equivalent stress in different sections of pier was computed and the processor of destabilization was discussed.When the pier is lower,the bearing capacity under mutual effect of pile,soil and pier is less than the situation when mutual effect is not considered;when the pier is higher,their differences are not conspicuous.Along with the increase of the cross-sectional height,the direction of destabilization bearing capacity is varied and the ultimate capacity is buildup.The results of a stability analysis example are almost identical with the practice.

Dynamic stiffness for thin-walled structures by power series

The dynamic stiffness method is introduced to analyze thin-walled structures including thin-walled straight beams and spatial twisted helix beam. A dynamic stiffness matrix is formed by using frequency dependent shape functions which are exact solutions of the governing differential equations. With the obtained thin-walled beam dynamic stiffness matrices, the thin-walled frame dynamic stiffness matrix can also be formulated by satisfying the required displacements compatibility and forces equilib-rium, a method which is similar to the finite element method (FEM). Then the thin-walled structure natural frequencies can be found by equating the determinant of the system dynamic stiffness matrix to zero. By this way, just one element and several elements can exactly predict many modes of a thin-walled beam and a spatial thin-walled frame, respectively. Several cases are studied and the results are compared with the existing solutions of other methods. The natural frequencies and buckling loads of these thin-walled structures are computed.

Geometric Accuracy and Energy Absorption Characteristics of 3D Printed Continuous Ramie Fiber Reinforced Thin-Walled Composite Structures

The application of continuous natural fibers as reinforcement in composite thin-walled structures offers a feasible approach to achieve light weight and high strength while remaining environmentally friendly.In addition,additive manufacturing technology provides a favorable process foundation for its realization.In this study,the printability and energy absorption properties of 3D printed continuous fiber reinforced thin-walled structures with different configurations were investigated.The results suggested that a low printing speed and a proper layer thickness would mitigate the printing defects within the structures.The printing geometry accuracy of the structures could be further improved by rounding the sharp corners with appropriate radii.This study successfully fabricated structures with vari-ous configurations characterized by high geometric accuracy through printing parameters optimization and path smoothing.Moreover,the compressive property and energy absorption characteristics of the structures under quasi-static axial compression were evaluated and compared.It was found that all studied thin-walled structures exhibited progressive folding deformation patterns during compression.In particular,energy absorption process was achieved through the combined damage modes of plastic deformation,fiber pullout and delamination.Furthermore,the com-parison results showed that the hexagonal structure exhibited the best energy absorption performance.The study revealed the structure-mechanical property relationship of 3D printed continuous fiber reinforced composite thin-walled structures through the analysis of multiscale failure characteristics and load response,which is valuable for broadening their applications.

Emerging Challenges for Numerical Simulations of Quasi-Static Collision Experiments on Laser-Welded Thin-Walled Steel Structures

This paper re-evaluates recently published quasi-static tests on laser-welded thin-walled steel structures in order to discuss the fundamental challenges in collision simulations based on finite element analysis.Clamped square panels were considered,with spherical indenter positioned at the mid-span of the stiffeners and moved along this centerline in order to change the load-carrying mechanism of the panels.Furthermore,the use of panels with single-sided flat bar stiffening and web-core sandwich panels enabled the investigation of the effect of structural topology on structural behavior and strength.The changes in loading position and panel topology resulted in different loading,structural and material gradients.In web-core panels,these three gradients occur at the same locations making the panel global responses sensitive for statistical variations and the failure process time-dependent.In stiffened panel with reduced structural gradient,this sensitivity and time-dependency in failure process is not observed.These observations set challenges to numerical simulations due to spatial and temporal discretization as well as the observed microrotation,which is beyond the currently used assumptions of classical continuum mechanics.Therefore,finally,we discuss the potential of non-classical continuum mechanics as remedy to deal with these phenomena and provide a base for necessary development for future.

LOCALIZED ANALYSIS OF THIN-WALLED STRUCTURE’S BUCKLING/INITIAL POST-BUCKLING AND ITS ACCURACY

A method of localization is proposed to lower the high order of equations in FEM calcula- tion for the stability of a complex thin-walled structure.The localized analysis enables us to obtain both the upper and lower limits for the bifurcating point in a whole linear elastic structural system,as well as an ap- proximate solution to asymptotic post-buckling problem.Some numerical examples are included.

Optimization Design of an Embedded Multi-Cell Thin-Walled Energy Absorption Structures with Local Surface Nanocrystallization

Bymeans of the local surface nanocrystallization that enables to change the material on local positions,an innovative embedded multi-cell(EMC)thin-walled energy absorption structures with local surface nanocrystallization is proposed in this paper.The local surface nanacrystallization stripes are regarded as the moving morphable components in the domain for optimal design.Results reveal that after optimizing the local surface nanocrystallization layout,the specific energy absorption(SEA)is increased by 50.78%compared with the untreated counterpart.Besides,in contrast with the optimized 4-cell structure,the SEA of the nanocrystallized embedded 9-cell structure is further enhanced by 27.68%,in contrast with the 9-cell structure,the SEA of the nanocrystallized embedded clapboard type 9-cell structure is enhanced by 3.61%.Thismethod provides a guidance for the design of newenergy absorption devices.

Transformation Matrix for Combined Loads Applied to Thin-Walled Structures

This paper transforms combined loads, applied at an arbitrary point of a thin-walled open section beam, to the shear centre of the cross-section of the beam. Therein, a generalized transformation matrix for loads with respect to the shear centre is derived, this accounting for the bimoments that develop due to the way the combined loads are applied. This and the authors’ earlier paper (World Journal of Mechanics 2021, 11, 205-236) provide a full solution to the theory of thin-walled, open-section structures bearing combined loading. The earlier work identified arbitrary loading with the section’s area properties that are necessary to axial and shear stress calculations within the structure’s thin walls. In the previous paper attention is paid to the relevant axes of loading and to the transformations of loading required between axes for stress calculations arising from tension/compression, bending, torsion and shear. The derivation of the general transformation matrix applies to all types of loadings including, axial tensile and compression forces, transverse shear, longitudinal bending. One application, representing all these load cases, is given of a simple channel cantilever with an eccentrically located end load.

Sandwich Structure-like Meshes Fabricated via Electrospinning for Controllable Release of Zoledronic Acid

Novel sandwich structure-like nanofiber multilayered meshes were fabricated via electrospinning. The purpose of the present work was to control zoledronic acid release via the novel structure of sandwich structure-like meshes. The in vitro release experiments reveal that the drug release speed and initial burst release were controllable by adjusting the thicknesses of electrospun barrier mesh and drug-loaded mesh. Compared with those of other drug delivery systems, the main advantages of the sandwich structure-like fiber meshes are facile preparation conditions and the generality for hydrophobic and hydrophilic pharmaceuticals.

Effects of electric/magnetic impact on the transient fracture of interface crack in piezoelectric-piezomagnetic sandwich structure: anti-plane case

Due to the incompatibility of the interlaminar deformations,the interface debonding or cracking usually happens in a layered magnetoelectric(ME)structure under an applied load.In this paper,the transient responses of the anti-plane interface cracks in piezoelectric(PE)-piezomagnetic(PM)sandwich structures are studied by the standard methods of the integral transform and singular integral equation.Discussion on the numerical examples indicates that the PE-PM-PE structure under electric impact is more likely to fracture than the PM-PE-PM structure under a magnetic impact.The dynamic stress intensity factors(DSIFs)are more sensitive to the variation of the active layer thickness.The effects of the material constants on the DSIFs are dependent on the roles played by PE and PM media during the deformation process.

High Velocity Impact Experiment on Ti/CFRP/Ti Sandwich Structure

Aircraft laminated composite components often suffer a variety of high velocity impacts with large quantity of energy,which usually affects aircraft behavior and would incur component damages,even disastrous consequences.Therefore,one investigates the impact resistance of a new type of composite material,Ti/CFRP/Ti sandwich structure,and launches impact tests by using an air gun test system.Then one acquires the critical breakthrough rate of the structure and analyzes the damages.The results show that the main failure mode of the front titanium sheet is shear plugging and brittle fracture of adhesive layer with fiber breakage,while the back titanium sheet is severely ripped.The rear damage is worse than the front one.Compared with traditional CFRP laminates,the critical breakthrough rate of Ti/CFRP/Ti sandwich structure is improved by 69.9% when suffered the impact of a bearing ball with 2mm radius.

Design and Simulation of Single Hull Side Structure Based on Filling Sandwich

Ship collision accidents are catastrophic accidents, and as the main energy-absorbing structure, the anti-collision capacity of the side structure has an important influence on the crashworthiness of the ship. It is necessary to improve the crashworthiness of the ship by increasing energy absorption of the side structure, in such ways as adding a filling sandwich in a single hull. The aim of the present study is to discuss the crashworthiness of the side structure stressed under lateral dynamic loads through simulation with the finite element code MSC/Dytran. The collision force, the damage deformation, the critical collision speed as well as the energy absorption of a side structure improved with a filling sandwich are compared to the standard structure through numerical simulations. The results indicate that a sandwich panel structure is an advanced ship protection structure that can remarkably improve the ability of the side structure to withstand collisions; the effect of the tube-style sandwich panel structure has the best results. The outcome of this study provides a reference for the crashworthiness assessment of side structures and the crashworthiness optimization design of new side structures.