To explore a structure with a superior load-to-mass ratio applying in rockets, two types of lattice truss sandwich cylinders with corrugated-core and X-core were designed, printed, tested and analyzed. The powder bed fusion (PBF) technique of laser additive manufacturing (AM) was applied to make the structures. Uniaxial compression results reveal that these truss-core sandwich cylinders have excellent mechanical performances with long plastic deformation, and their ultimate failure modes were global or local plastic post-buckling. The finite element method (FEM) was used to explore the influences of geometrical parameters to the failure mode and the bearing capacity. A failure theory was proposed, which can consistently predict the plastic buckling loads consistent with the experimental results. The load-to-mass ratio of the X-core cylinder is slightly about five percent improved compared to the corrugated-core cylinder, but the plastic plateau stage is greatly increased. Truss-core sandwich cylindrical shell configurations with high load-to-mass ratio, long plastic stage, easy-manufacturing and controllable process were successfully proposed for aeronautical structures through this research. 

Additively manufactured truss-core sandwich cylinders: Materials, processes and performances

Uniform/gradient lattice cylindrical structures (ULCS/GLCS) and hybrid uniform/gradient lattice cylindrical structures (HULCS/HGLCS) are innovatively designed and fabricated. The axial crushing behaviors of these four-type cylindrical structures are investigated by the quasi-static axial compression experiments and numerical simulations. The influence of the density gradient and the hybrid effect (metal skin+ABS core) on the deformation mode, loading capacity, and energy absorption of the lattice cylindrical structures are elaborated systematically. The results show that the gradient design realizes the function of regulation and controllability of the structural deformation. The softer layers (with smaller relative density) in GLCS begin to deform first and then gradually extend to the harder layers (with larger relative density). And it effectively reduces the initial peak compression force (PCF), and makes the load more stable on the premise of energy absorption. However, unstably catastrophic failures are observed before the final densification in both ULCS and GLCS during the compression due to the brittleness of the ABS material and the compression–expansion​ deformation of structure. For HULCS/HGLCS, it presents progressive crushing mode and overcome the unstably catastrophic failure due to the ductility and constraint of the metal skins. The effect of “1 ＋ 1 > 2” on energy absorption from hybrid effect is achieved in HULCS/HGLCS, in which the EA of HULCS and HGLCS increases by 74.62% and 100.78% comparing the sum of all components individually compressed. Moreover, the progressive peak with increasing trend of HGLCS demonstrated that the hybrid design enhances the advantages of gradient design in sandwich structures. 

Influence of density gradient and hybrid effect on quasi-static axial crushing behavior of lattice cylindrical structures

In this paper, a new type of lattice cylindrical shell meta-structure (LCSM) with broadband vibration reduction and high load-bearing ability is designed. In particular, the proposed curved shell meta-structure is constructed by combining lattice structure and mechanical metamaterial with elastic bandgap properties. The dispersion curves of shell structure are obtained by combining Bloch's theorem with the coordinate transformation method. The vibration transmission properties and load-bearing performance of the LCSM and the sandwich LCSM are studied numerically and experimentally. The results reveal that the proposed meta-structure has excellent vibration isolation performance at broadband frequencies, and the change of structural parameters can be used to regulate the frequency range of bandgap. Especially, the existence of curvature makes the bandgap of the shell structure inevitably change when the circumferential size of the shell is changed. Moreover, the meta-structure can maintain certain broadband vibration reduction properties when increasing the load-bearing capacity. This work offers an innovative method to develop multi-functional lattice shell structures with both load-bearing and broadband vibration isolation properties. 

Design of lattice cylindrical shell meta-structures for broadband vibration reduction and high load-bearing capacity

This study aims to experimentally and numerically study the low-velocity impact (LVI) and compression after impact (CAI) behaviors of rib-stiffened CFRP panels. Experimental LVI tests have been initially performed on T- and I-shaped rib-stiffened panels. CAI tests are subsequently implemented on the impacted and intact panels. Furthermore, multiscale models are established according to the hierarchical architectures of plain woven composites. An equivalent cross-ply laminate (ECPL) cell has been constructed via local homogenization on the mesoscale modeling. The ECPL cells are topologically arranged to form macroscale models of the rib-stiffened panels. LVI and CAI simulations have been sequentially carried out to predict the LVI and CAI behaviors. The predicted results possess good agreement with the experimental ones, validating the multiscale models. Matrix damages and delamination are found to be the dominant damage modes for the rib-stiffened panels subjected to LVIs. In comparison, the I-shaped stiffener makes CFRP panel more sensitive to impact loads. During the CAI processes, fierce fiber breakage, matrix cracking and delamination appear in the skin and stiffener. Finally, the comparison of CAI strengths indicates that, the I-shaped stiffener provides CFRP panels with a better resistance to the compressive-property reduction induced by LVIs. 

Low-velocity impact and compression after impact behaviors of rib-stiffened CFRP panels: Experimental and numerical study

Mechanical properties and failure mechanisms of all-CFRP corrugated sandwich truncated cone

Recent progresses in lightweight carbon fibre reinforced lattice cylindrical shells

Free vibration theory of inhomogeneous anisogrid stiffened cylinder

A hierarchical-level failure analysis method from carbon fiber reinforced composite (CFRC), unit-cell lattice to lattice stiffened component was developed to predict the failure load of lattice stiffened panels. A nondestructive method was applied to identify the composite parameters of lattice ribs. Axial compression experiments were carried out to reveal the failure pattern and load of unit-cell lattice and lattice-stiffened panels. Compared with the standard unidirectional laminate strength, these component failure analyses suggest knock-down factors (KDFs) to include the attenuation effect of the rib node intersection. The failure loads of CFRC lattice stiffened panels were predicted by the KDFs. The research lays a good foundation to design and manufacture large-sized CFRC lattice structures. 

Hierarchical-level failure analysis for CFRC lattice stiffened panel

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Recent progresses in lightweight carbon fibre reinforced lattice cylindrical shells

Free vibration theory of inhomogeneous anisogrid stiffened cylinder

Hierarchical-level failure analysis for CFRC lattice stiffened panel