Systematic Exploration of Cellular Lattice Structures for Aerospace Applications

Nikulin, Ivan I.; Lira, Cassandra A.; Rivelli, Julia; Lam, Chin Ngai Mike; Keklik, Neal N.; Pitti, Nicholas A.; Withington, Matthew J.

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Systematic Exploration of Cellular Lattice Structures for Aerospace Applications

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The objective of this project is to explore the utility of a novel class of lattice-structure-based materials for effective cooling in a jet engine turbine blade, thus improving the overall efficiency of the aircraft. As opposed to existing technology based on metallic foam in such applications, optimized lattice structures enabled through recent advances in additive manufacturing can provide similar cooling performance with significant improvements in structural, acoustic, and thermal performance. This multidisciplinary exploration involved the design (SolidWorks and Netfabb) based on various performance requirements for the jet turbine blades and the subsequent realization of various lattice structures using additive manufacturing. Finite element method (FEM) based thermal and structural simulations were then performed on a few lattice structures selected through preliminary analytical predictions. The FEM results for simplified boundary conditions were then validated through a series of thermal, static loading, and vibrational experiments. Structural simulations for the lattice structures for both the loading conditions experienced in jet turbine blades as well as simplified static and low amplitude vibrational loading were conducted using ABAQUS and the results are validated using static experiments (Instron tensile tester). The corresponding thermal and flow simulations were performed in COMSOL and validated through custom-built experiments to measure thermal expansion, heat transfer, and flow velocity for low-speed, laminar flows at slightly elevated temperatures.

This report represents the work of one or more WPI undergraduate students submitted to the faculty as evidence of completion of a degree requirement. WPI routinely publishes these reports on its website without editorial or peer review.

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