Integrated Fabrication of Magnesium Corrugated-Core Sandwich Structures via Wire-Arc Directed Energy Deposition

Xinglong Di; Jiayuan Cui; Xingchen Li; Qifei Han; Rui Fu; Changmeng Liu; Yueling Guo

doi:10.1016/j.amf.2025.200247

Integrated Fabrication of Magnesium Corrugated-Core Sandwich Structures via Wire-Arc Directed Energy Deposition

Xinglong Di
, Jiayuan Cui
, Xingchen Li
, Qifei Han
, Rui Fu
, Changmeng Liu
, Yueling Guo^*

^*Corresponding author for this work

Beijing Institute of Technology

Research output: Contribution to journal › Article › peer-review

2 Citations (Scopus)

Abstract

This study pioneers the integrated fabrication of magnesium corrugated-core sandwich structures using wire-arc directed energy deposition (WA-DED). Two sandwich structures—V-type and X-type—were designed with optimized deposition paths to achieve comparable grain morphology while enhancing strength. The compression properties and failure modes of the two corrugated-core sandwich structures were examined through quasi-static compression tests. Results showed that the V-type structure exhibited a higher specific compressive strength (93 MPa∙cm³/g) than the X-type structure (72 MPa∙cm³/g). Both finite element analysis and experimental compression tests indicated that failure occurred at the midsection of the corrugated core. This work offers valuable insights for the efficient fabrication of high-strength corrugated-core sandwich structures.

Original language	English
Article number	200247
Journal	Additive Manufacturing Frontiers
Volume	4
Issue number	4
DOIs	https://doi.org/10.1016/j.amf.2025.200247
Publication status	Published - Dec 2025
Externally published	Yes

Keywords

Finite element method
Integrated fabrication
Sandwich structure
Specific compressive strength
Wire-arc directed energy deposition

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10.1016/j.amf.2025.200247

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@article{2425b86922fd48788ee53b288d6de14a,

title = "Integrated Fabrication of Magnesium Corrugated-Core Sandwich Structures via Wire-Arc Directed Energy Deposition",

abstract = "This study pioneers the integrated fabrication of magnesium corrugated-core sandwich structures using wire-arc directed energy deposition (WA-DED). Two sandwich structures{\textemdash}V-type and X-type{\textemdash}were designed with optimized deposition paths to achieve comparable grain morphology while enhancing strength. The compression properties and failure modes of the two corrugated-core sandwich structures were examined through quasi-static compression tests. Results showed that the V-type structure exhibited a higher specific compressive strength (93 MPa∙cm3/g) than the X-type structure (72 MPa∙cm3/g). Both finite element analysis and experimental compression tests indicated that failure occurred at the midsection of the corrugated core. This work offers valuable insights for the efficient fabrication of high-strength corrugated-core sandwich structures.",

keywords = "Finite element method, Integrated fabrication, Sandwich structure, Specific compressive strength, Wire-arc directed energy deposition",

author = "Xinglong Di and Jiayuan Cui and Xingchen Li and Qifei Han and Rui Fu and Changmeng Liu and Yueling Guo",

note = "Publisher Copyright: {\textcopyright} 2025 The Author(s)",

year = "2025",

month = dec,

doi = "10.1016/j.amf.2025.200247",

language = "English",

volume = "4",

journal = "Additive Manufacturing Frontiers",

issn = "2950-4317",

publisher = "Elsevier B.V.",

number = "4",

}

TY - JOUR

T1 - Integrated Fabrication of Magnesium Corrugated-Core Sandwich Structures via Wire-Arc Directed Energy Deposition

AU - Di, Xinglong

AU - Cui, Jiayuan

AU - Li, Xingchen

AU - Han, Qifei

AU - Fu, Rui

AU - Liu, Changmeng

AU - Guo, Yueling

PY - 2025/12

Y1 - 2025/12

N2 - This study pioneers the integrated fabrication of magnesium corrugated-core sandwich structures using wire-arc directed energy deposition (WA-DED). Two sandwich structures—V-type and X-type—were designed with optimized deposition paths to achieve comparable grain morphology while enhancing strength. The compression properties and failure modes of the two corrugated-core sandwich structures were examined through quasi-static compression tests. Results showed that the V-type structure exhibited a higher specific compressive strength (93 MPa∙cm3/g) than the X-type structure (72 MPa∙cm3/g). Both finite element analysis and experimental compression tests indicated that failure occurred at the midsection of the corrugated core. This work offers valuable insights for the efficient fabrication of high-strength corrugated-core sandwich structures.

AB - This study pioneers the integrated fabrication of magnesium corrugated-core sandwich structures using wire-arc directed energy deposition (WA-DED). Two sandwich structures—V-type and X-type—were designed with optimized deposition paths to achieve comparable grain morphology while enhancing strength. The compression properties and failure modes of the two corrugated-core sandwich structures were examined through quasi-static compression tests. Results showed that the V-type structure exhibited a higher specific compressive strength (93 MPa∙cm3/g) than the X-type structure (72 MPa∙cm3/g). Both finite element analysis and experimental compression tests indicated that failure occurred at the midsection of the corrugated core. This work offers valuable insights for the efficient fabrication of high-strength corrugated-core sandwich structures.

KW - Finite element method

KW - Integrated fabrication

KW - Sandwich structure

KW - Specific compressive strength

KW - Wire-arc directed energy deposition

UR - https://www.scopus.com/pages/publications/105018889890

U2 - 10.1016/j.amf.2025.200247

DO - 10.1016/j.amf.2025.200247

M3 - Article

AN - SCOPUS:105018889890

SN - 2950-4317

VL - 4

JO - Additive Manufacturing Frontiers

JF - Additive Manufacturing Frontiers

IS - 4

M1 - 200247

ER -

Integrated Fabrication of Magnesium Corrugated-Core Sandwich Structures via Wire-Arc Directed Energy Deposition

Abstract

Keywords

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