Modelling, additive layer manufacturing and testing of interlocking structures for joined components

Area of Science:

• Materials Science
• Mechanical Engineering
• Manufacturing Technology

Background:

• Lap joints are prone to stress concentration at edges, potentially leading to failure.
• Traditional joining methods may require adhesives or post-processing, adding complexity and cost.

Purpose of the Study:

• To investigate the use of modelling and additive layer manufacturing (ALM) for creating interlocking structures in lap joints.
• To reduce stress concentration at the edges of lap joints using novel material designs.
• To validate the effectiveness of ALM-produced interlocking structures through experimental testing.

Main Methods:

• Utilizing computational modeling to design interlocking joint geometries.
• Employing additive layer manufacturing (ALM) to fabricate components with integrated interlocking structures.
• Conducting experimental validation to assess the stress distribution and performance of the fabricated joints.

Main Results:

• ALM-produced interlocking structures effectively minimize stress mismatches in the joining region.
• The developed approach demonstrates significant reduction in stress concentration compared to conventional lap joints.
• The integrated joint design eliminates the need for separate adhesive or post-joining processes.

Conclusions:

• Additive layer manufacturing (ALM) offers a viable and innovative method for fabricating joints with enhanced structural integrity.
• Interlocking structures produced via ALM present a promising alternative or complement to traditional joining techniques.
• This technology has the potential to streamline manufacturing processes and improve the durability of joined components.