Design of lightweight lattice meta-structures and approaches to manipulate their multi-functional mechanical properties
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摘要: 随着先进制造技术、多学科交叉和人工智能科技的飞速发展, 高端装备呈现出轻量化、集成化、复合化、功能化、智能化、柔性化和仿生化等发展趋势. 传统结构研究存在结构设计和制造相互分离, 复杂结构制造效率低、实际制造结构的性能指标和使用可靠性大幅低于设计理论预测、结构多功能一体化程度不足、经济成本过高等问题. 此外, 先进工业装备对材料、结构的使用性能、使用环境要求越来越高, 亟需开展结构的设计、制造、功能、应用一体化研究, 为解决我国先进制造“卡脖子”技术难题提供理论依据和技术支持. 轻量化多功能点阵超结构具有轻质高强、抗冲击吸能、减振降噪等性能优势, 在航空航天、交通运输、国防、生物医疗、能源、机械等工业领域具有巨大的应用潜力. 有鉴于此, 受多晶体微结构的多尺度力学设计启发, 以“点阵超结构力学设计”为主题, 开展点阵超结构的节点、杆件组元, 胞元类型、双相结构、梯度结构、多层级结构等典型点阵超结构的几何构筑和力学设计, 并阐明多晶体多尺度微观结构启发的点阵超结构力学设计基本原理、多功能力学性能调控方法, 以及点阵超结构在不同类型载荷下的结构变形和失效物理机理.Abstract: With the rapid development of advanced manufacturing technology, multidisciplinary integration, and artificial intelligence technology, high-end equipment demonstrates the development trends of lightweight, integrated, composited, multi-functional, intelligent, flexible, and biomimetic features. Traditional structural research has encountered many intrinsic problems that constrain devices, and instruments performances, such as structural design and manufacturing are separated from each other, relative low manufacturing efficiency of complex structures, practical structural performances, and reliability of manufactured structures are significantly lower than theoretical predictions, insufficient multi-functional integration of structures, and high costs. In addition, materials and structures for constructing advanced industrial equipments are required to maintain reliable performances and endure extremely crucial service environments. It is urgent to carry out research on the synergy effects of design, manufacture, function, and applications of structures, thus providing theoretical foundations and technical support for solving the key technical problems of advanced manufacturing strategic plans. Lightweight multi-functional lattice meta-structures exhibit extraordinary mechanical performance advantages of lightweight, specific strength, impact energy absorption, shock absorption, and noise reduction advantages, and demonstrate great industrial application potentials in aerospace, transportation, national defense, biomedical, energy, machinery, equipment, and other industrial fields. Considering the above-mentioned status-quo, inspired by the multi-scale microstructures of the polycrystalline, the mechanical design of lightweight multi-functional lattice meta-structures is reviewed in this paper, and is elaborated from the perspectives of typical design methods, such as nodes, strut components, unit cell types, dual-phase structures, gradient structures and hierarchical structures of lattice structures. Afterward, physical foundations for design innovations based on multi-scale microstructures of polycrystalline are explained, rational regulations of multi-functional mechanical properties, and the underlying deformation and failure mechanisms are demonstrated.
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图 1 点阵结构的节点和杆件组元创新设计. (a) 三维弹簧单螺旋状杆件, (b) 三维螺旋状杆件, (c) 非对称杆件, (d) 不同波长波浪状杆件, (e) 不同粗细波浪状杆件, (f) 变截面杆件, (g) 具有扭转效应的节点, (h) 节点参数化多层级设计, (i) 节点增强设计
图 3 晶体微结构启发的点阵超结构多尺度新胞元、新构型力学设计. (a) 具有镜像特征的新型孪生三斜晶系点阵超结构力学设计(Bian et al. 2021), (b) 具有异质结构特征的跨尺度随机点阵超结构设计(Quang et al. 2021), (c) FCC和BCC异质结构点阵结构胞元混杂构成的复合点阵超结构(Pham et al. 2019), (d) 具有随机取向的几种不同类型最小曲面点阵结构形成的复合结构(Oraid et al. 2021); (e) 具有共格晶界和几何镜像特征的点阵超结构设计(Liu C et al. 2021), (f) 基于结构孪生和杆件组元接触改变点阵结构变形和承载模式的相变点阵结构(Vangelatos et al. 2019, Vangelatos et al. 2020a), (g) 二维FCC和BCC混杂的多晶点阵结构(Li W et al. 2021), (h) 基于结构中心对称性和准晶拓扑构型的轻质高强准晶点阵结构(Wang & Sigmund 2020, Somera et al. 2022)
图 4 点阵结构的节点/对角线强化设计. (a) 和 (b) 将周期性点阵结构的对角线胞元更换为比强度更高的异质点阵结构胞元(Vangelatos et al. 2020a, Xiao R et al. 2021), (c) 点阵结构的节点换成直径更大的实心球(Liu Y et al. 2020), (d) 节点和中空杆件之间采用薄板平滑过渡连接 (Dever et al. 2013), (e) 和 (g) 杆件组元采用变截面设计(Qi et al. 2019b, Tancogne-Dejean & Mohr 2018a), (f) 和 (h) 节点和杆件连接过渡区域的平滑增强(Portela et al. 2018, Latture et al. 2018, Dallago et al. 2021)
图 5 多晶体多尺度微结构及典型缺陷特征. (a) 多晶体多尺度微结构特征(Roters et al. 2010), (b) 不同尺度的结构缺陷分类
图 6 多晶体微结构失效经典机制. (a) 晶格相变变形, (b) 位错滑移系开动, (c) 孪晶界面的形成, (d) 剪切滑移带的形成, (e) 高应变率载荷下的绝热剪切带, (f) 位错−夹杂物相互作用Orowan机制, (g) 位错−晶界相互作用, (h) 孔洞生长演化和贯穿, (i) 沿晶界/穿晶裂纹扩展
图 7 点阵结构中的典型结构缺陷效应. (a) 夹杂物−失效滑移带相互作用Orowan机制, (b) 硬点阵结构夹杂物增强软基体点阵结构, (c) 孔洞生长演化和贯穿, (d) 弱缺陷对应的杆件缺失和孔洞效应, (e) 随机杆件缺失效应
图 8 具有双向微结构特征的高性能双相合金材料多尺度微结构设计. (a) 双相合金异质结构界面模型, (b) 镍基单晶筏化微结构, (c) 纳米双相复合多层结构, (d) 纳米颗粒夹杂无定形基体形成的纳米双相刚, (e) 强韧一体化跨尺度异质结构, (f) 具有奥氏体/马氏体双相复合微结构特征的高强钢
图 10 孪晶微结构启发的力学结构设计 (孪晶宽度、孪晶角度、梯度孪晶角度、梯度孪晶宽度、多级次孪晶、多级次梯度孪晶) 、压缩吸能特性、孪晶力学超结构强度的尺寸效应和逆尺寸效应(Wu W et al. 2022). (a) 均匀尺寸设计, (b) 功能梯度设计, (c) 多层级设计, (d) 单轴拉伸力学实验样品, (e) 均匀尺寸设计、功能梯度设计压缩吸能曲线对比, (f) 尺寸效应(Hall-Petch effects), (g) 逆尺寸效应(inverse Hall-Petch effects)
图 11 功能梯度点阵结构设计策略. (a) 节点连续的杆件截面积梯度(Chen W et al. 2018), (b) 节点不连续分层梯度(Yue W et al. 2021), (c) 二维点阵结构单向和双向梯度(Niknam & Akbarzadeh 2020), (d) 三维点阵结构单向和双向梯度(Rafiee et al. 2020), (e) 节点半径梯度设计(Alghamdi et al. 2020), (f) 基于制造工艺和材料梯度特征的性能梯度设计(Zhang J et al. 2020b), (g) 孔隙率梯度结构设计(Dalia & Mohamed 2017), (h) 具有二阶非线性梯度效应的功能梯度结构设计(Weeger 2021), (i) 共形梯度拓扑优化点阵结构设计(Li D et al. 2019), (j) 具有手性结构特征的功能梯度结构设计(Wu W et al. 2019), (k) 杆件组元具有梯度结构特征的多层级点阵结构设计(Mueller & Shea 2018)
图 12 多层级点阵结构设计分类. (a) 胞元杆件多层级(Chen & Jin 2018, Jnha et al. 2021), (b) 节点多层级(Yu Z et al. 2021), (c) 高刚度负泊松比多层级(Khakalo et al. 2018), (d) 最小曲面无节点胞元并发多尺度多层级(Zhang L et al. 2021), (e) 胞元节点−杆件并发异质结构多层级(Wu et al. 2017), (f) 梯度多层级结构(Taylor et al. 2012), (g) 双曲型多层级(Kollar et al. 2019), (h) 胞元填充多层级(Taylor 2012), (i) 套娃多层级(Pang Y et al. 2019), (j) 分形多层级(Oftadeh et al. 2014), (k) 微纳米多层级(Chang Q et al. 2021)
图 13 具有结构相变特征的点阵结构 (a) 基于超弹性材料杆件失稳的点阵结构相变(Bertoldi et al. 2008); (b) 静水压环境下的多材料组元复合点阵结构相变(Chen & Jin 2018); (c) 伊斯兰图案启发的基于结构组元多稳态变形效应的多稳态点阵结构机械超材料(Khajehtourian et al. 2020); (d) 基于螺旋形节点实现往复折叠波浪形特征的负泊松比、负热膨胀效应相变机械超材料(Yue W et al. 2021); (e) 具有变刚度、负刚度特征的相变点阵结构(Restrepo et al. 2015); (f) 孔洞结构缺陷拓扑构型引导的结构相变(Yang D et al. 2015); (g) 基于节点接触状态的有无实现拉伸主导型和弯曲主导型点阵结构构型切换的相变点阵超结构(Wagner et al. 2019); (h) 基于变形过程中杆件组元接触引起的变形模式转换的相变孪晶点阵超结构(Vangelatos et al. 2020b); (i) 通过压缩过程中的手性点阵结构胞元构型切换 (长方形和平行四边形, 三角形和平行四边形) 实现结构相变的相变手性超结构(Hector et al. 2019)
图 14 点阵结构的缺陷不敏感性. (a) 具有马鞍状的二维网状点阵结构的孔洞结构缺陷不敏感力学设计(Liu J et al. 2021); (b) 具有螺旋形的三维微观结构的仿生点阵结构的缺陷不敏感设计, 并进一步通过磁控溅射导电纳米金属涂层实现电阻率的缺陷不敏感(Yan D et al. 2020); (c) 具有有聚合物涂层的复合陶瓷点阵结构强韧化、缺陷不敏感设计及制造(Sajadi et al. 2021); (d) 基于高熵合金纳米涂层涂覆高弹性聚合物纳米点阵结构实现强韧化和结构缺陷不敏感(Zhang X et al. 2018); (e) 基于高温热解碳技术制备纳米点阵结构的缺陷不敏感特性(Zhang X et al. 2019); (f) 基于脆性材料的点阵结构弹性模量的结构缺陷不敏感, 并通过空洞附近区域的局部增强设计来优化器缺陷不敏感特性和延展性(Jian L et al. 2019)
图 15 具有随机分布特征的无序点阵结构. (a) 九参数控制的具有随机节点特征和各向异性的杆状点阵结构、最小曲面点阵结构设计(Oraid et al. 2021); (b) 基于结构张量和等效密度协同调控的具有随机杆件组元空间取向的各向异性点阵结构设计(Munford et al. 2020); (c) 通过随机点阵结构设计实现裂纹扩展扩展路径和断裂韧性提升(Xu Y et al. 2019); (d) 具有杆件组元随机空间取向特征的拉伸主导型、玩去主导型点阵结构设计及冲击吸能性能研究(Mueller et al. 2019); (e) 通过模仿骨骼多孔微结构, 设计具有随机结构特征的点阵结构, 实现比刚度 (强度) 、相对密度、各向异性率的独立设计, 满足钛合金骨移植替代物的实际应用需求(Mcgregor et al. 2021); (f) 通过在点阵结构节点处引入随机位移量生成随机点阵结构, 发现随着随机点阵结构的几何不规则度增加, 随机点阵结构的变形模式逐渐从拉伸主导型转变为弯曲主导型变形模式(Raghavendra et al. 2021)
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