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Effect of Internal Defects on the Compression Behavior of Helical Layered Square Honeycombs Fabricated by Selective Laser Melting.

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Title: Effect of Internal Defects on the Compression Behavior of Helical Layered Square Honeycombs Fabricated by Selective Laser Melting.
Authors: Ni, Yue1,2,3 (AUTHOR), Li, Yangning1,2,3 (AUTHOR), Chen, Wei1,2,3 (AUTHOR), Hu, Pengcheng1,2,3,4 (AUTHOR) hupc@whut.edu.cn, Li, Xiaobin1,2,3 (AUTHOR), Ke, Wenchao2,4 (AUTHOR), Du, Jianye1,2,3 (AUTHOR)
Source: Materials (1996-1944). Jun2026, Vol. 19 Issue 12, p2492. 27p.
Subjects: Selective laser melting, Manufacturing defects, Finite element method, Porosity, Mechanical behavior of materials, Honeycomb structures, Computed tomography, Compression loads
Abstract: The emergence of selective laser melting (SLM) has enabled the fabrication of complex structures with exceptional mechanical performance. However, process-induced defects, including porosity and geometric deviations, pose significant challenges to structural reliability, and their dynamic evolution under loading remains poorly understood. In this study, helical layered square honeycomb structures were fabricated via SLM. The effects of process conditions on defect characteristics, as well as the influence of porosity and wall thickness defects on mechanical properties, were investigated using X-ray computed tomography (CT), in situ loading tests, and finite element simulation. The results indicate that the investigated high-quality process conditions minimize porosity, optimize pore morphology, and improve wall thickness uniformity, thereby substantially reducing the adverse effects of pores on tensile properties. Under compressive loading, defect evolution, including pore expansion and wall thickness thinning, is primarily concentrated at structural corners, with more pronounced variations observed under coarse process conditions. Increased porosity, wall thickness reduction, and uneven thickness distribution all degrade the quasi-static compressive performance and medium to high-velocity impact resistance of the structure. Furthermore, thickness distribution exerts an independent influence on mechanical properties beyond the effect of overall average thickness. [ABSTRACT FROM AUTHOR]
Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Data: Effect of Internal Defects on the Compression Behavior of Helical Layered Square Honeycombs Fabricated by Selective Laser Melting.
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  Data: <searchLink fieldCode="JN" term="%22Materials+%281996-1944%29%22">Materials (1996-1944)</searchLink>. Jun2026, Vol. 19 Issue 12, p2492. 27p.
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  Data: <searchLink fieldCode="DE" term="%22Selective+laser+melting%22">Selective laser melting</searchLink><br /><searchLink fieldCode="DE" term="%22Manufacturing+defects%22">Manufacturing defects</searchLink><br /><searchLink fieldCode="DE" term="%22Finite+element+method%22">Finite element method</searchLink><br /><searchLink fieldCode="DE" term="%22Porosity%22">Porosity</searchLink><br /><searchLink fieldCode="DE" term="%22Mechanical+behavior+of+materials%22">Mechanical behavior of materials</searchLink><br /><searchLink fieldCode="DE" term="%22Honeycomb+structures%22">Honeycomb structures</searchLink><br /><searchLink fieldCode="DE" term="%22Computed+tomography%22">Computed tomography</searchLink><br /><searchLink fieldCode="DE" term="%22Compression+loads%22">Compression loads</searchLink>
– Name: Abstract
  Label: Abstract
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  Data: The emergence of selective laser melting (SLM) has enabled the fabrication of complex structures with exceptional mechanical performance. However, process-induced defects, including porosity and geometric deviations, pose significant challenges to structural reliability, and their dynamic evolution under loading remains poorly understood. In this study, helical layered square honeycomb structures were fabricated via SLM. The effects of process conditions on defect characteristics, as well as the influence of porosity and wall thickness defects on mechanical properties, were investigated using X-ray computed tomography (CT), in situ loading tests, and finite element simulation. The results indicate that the investigated high-quality process conditions minimize porosity, optimize pore morphology, and improve wall thickness uniformity, thereby substantially reducing the adverse effects of pores on tensile properties. Under compressive loading, defect evolution, including pore expansion and wall thickness thinning, is primarily concentrated at structural corners, with more pronounced variations observed under coarse process conditions. Increased porosity, wall thickness reduction, and uneven thickness distribution all degrade the quasi-static compressive performance and medium to high-velocity impact resistance of the structure. Furthermore, thickness distribution exerts an independent influence on mechanical properties beyond the effect of overall average thickness. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
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  Data: <i>Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.3390/ma19122492
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      – SubjectFull: Manufacturing defects
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      – SubjectFull: Finite element method
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      – SubjectFull: Porosity
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      – SubjectFull: Mechanical behavior of materials
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      – SubjectFull: Honeycomb structures
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      – SubjectFull: Computed tomography
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      – SubjectFull: Compression loads
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      – TitleFull: Effect of Internal Defects on the Compression Behavior of Helical Layered Square Honeycombs Fabricated by Selective Laser Melting.
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            NameFull: Ni, Yue
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              M: 06
              Text: Jun2026
              Type: published
              Y: 2026
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