Lightweight lattice structures are increasingly used in various fields such as aerospace, automotive and biomedical due to their superior energy absorption capacity and high strength/weight ratio. In this study, honeycomb lattice structures were designed and manufactured using AlSi10Mg alloy using Laser Powder Bed Fusion (LPBF) method. It was aimed to evaluate the mechanical, microstructural and thermal performances of these structures produced with LPBF method, which offers high precision and design flexibility. Compression and hardness tests, surface roughness measurements, density determination and microstructural analyzes such as Scanning Electron Microscopy with Energy Dispersive X-ray Spectroscopy (SEM-EDS), Fourier Transform Infrared Spectroscopy (FTIR), Simultaneous Thermal Analysis with Thermogravimetric/Differential Scanning Calorimetry (STA, TG/DSC) and X-ray Diffraction (XRD) were applied to the produced samples. The obtained results revealed that there was a significant difference in terms of compressive strength between porous and dense structures; however, the hardness values were at similar levels. Microstructure analyses confirmed surface roughness and oxidation, as well as elemental distribution by EDS and the presence of α-Al and β-Mg2Si phases by XRD. Thermal analyses showed that the material exhibited good thermal stability with minimal mass loss at elevated temperatures. In general, it was concluded that AlSi10Mg honeycomb lattice structures produced by the LPBF method offer promising mechanical and thermal properties for applications requiring lightness and energy absorption.
EndoRD. The effect of manufacturing defects on compressive strength of polymeric lattices fabricated via fused deposition modeling. Irvine: University of California, 2017. Available online: https://escholarship.org/uc/item/0b98b9p7 (accessed on 22 December 2024).
DeckardC. Method and apparatus for producing parts by selective sintering. US Patent, 1986.
5.
WenSFYanCZWeiQS, et al.Investigation and development of large-scale equipment and high performance materials for powder bed laser fusion additive manufacturing. Virtual Phys Prototyp2014; 9(4): 213–223. DOI: 10.1080/17452759.2014.949406.
6.
OlakanmiEOCochraneRFDalgarnoKW. A review on selective laser sintering/melting (SLS/SLM) of aluminium alloy powders: processing, microstructure, and properties. Prog Mater Sci2015; 74: 401–477. DOI: 10.1016/j.pmatsci.2015.03.002.
7.
SoniHLimbasiyaNJainA, et al.Investigation of mechanical and surface properties of additively manufactured AlSi10Mg part produced through direct metal laser sintering. Mater Today Proc2022; 62: 7204–7209. DOI: 10.1016/j.matpr.2022.03.506.
8.
ZhangPWangYXieY, et al.A study on the dynamic shock performance of 7055-T6I4 aluminum alloy based on experimental and simulation. Vacuum2018; 157: 306–311. DOI: 10.1016/j.vacuum.2018.08.042.
9.
MezaLRZelhoferAJClarkeN, et al.Resilient 3D hierarchical architected metamaterials. Proc Natl Acad Sci U S A2015; 112(37): 11502–11507. DOI: 10.1073/pnas.150912011.
10.
ChallisVJXuXZhangLC, et al.High specific strength and stiffness structures produced using selective laser melting. Mater Des2014; 63: 783–788. DOI: 10.1016/j.matdes.2014.05.064.
11.
ButlerCBabuSLundyR, et al.Effects of processing parameters and heat treatment on thermal conductivity of additively manufactured AlSi10Mg by selective laser melting. Mater Char2021; 173: 110945. DOI: 10.1016/j.matchar.2021.110945.
12.
Ghasri-KhouzaniMPengHAttardoR, et al.Comparing microstructure and hardness of direct metal laser sintered AlSi10Mg alloy between different planes. J Manuf Process2019; 37: 274–280. DOI: 10.1016/j.jmapro.2018.12.005.
KothaSLaxminarayanaPBuchaiahK. Selective laser melting process optimization and mechanical properties evolution of AlSi10Mg. Educational Administration: Theory and Practice2024; 30(1): 1035–1044. DOI: 10.53555/kuey.v30i1.5924.
15.
TakataNKodairaHSekizawaK, et al.Change in microstructure of selectively laser melted AlSi10Mg alloy with heat treatments. Mater Sci Eng2017; 704: 218–228. DOI: 10.1016/j.msea.2017.08.029.
16.
ArabnejadSBurnett JohnstonRPuraJA, et al.High strength porous biomaterials for bone replacement: a strategy to assess the interplay between cell morphology, mechanical properties, bone ingrowth and manufacturing constraints. Acta Biomater2016; 30: 345–356. DOI: 10.1016/j.actbio.2015.10.048.
17.
ZhangXZLearyMTangHP, et al.Selective electron beam manufactured Ti-6Al-4V lattice structures for orthopedic implant applications: current status and outstanding challenges. Curr Opin Solid State Mater Sci2018; 22(3): 75–99. DOI: 10.1016/j.cossms.2018.05.002.
18.
AlessandraPTeresaPAntoniDP, et al.Mechanical behaviour of AlSi10Mg lattice structures manufactured by the selective laser melting (SLM). Int J Adv Des Manuf Technol2023; 124: 1651–1680. DOI: 10.1007/s00170-022-10390-1.
19.
Sallica-LevaEJardiniALFogagnoloJB. Microstructure and mechanical behavior of porous Ti-6Al-4V parts obtained by selective laser melting. J Mech Behav Biomed Mater2013; 26: 98–108. DOI: 10.1016/j.jmbbm.2013.05.011.
20.
YanCHaoLHusseinA, et al.Ti-6Al-4V triply periodic minimal surface structures for bone implants fabricated via selective laser melting. J Mech Behav Biomed Mater2015; 51: 61–73. DOI: 10.1016/j.jmbbm.2015.06.024.
21.
ZhangSWeiQChengL, et al.Effects of scan line spacing on pore characteristics and mechanical properties of porous Ti6Al4V implants fabricated by selective laser melting. Mater Des2014; 63: 185–193. DOI: 10.1016/j.matdes.2014.05.021.
22.
GarofanoAAcanforaVRiccioA. On the use of hybrid shock absorbers to increase safety of commercial aircraft passengers during a crash event. Prog Aero Sci2024; 148: 101004. DOI: 10.1016/j.paerosci.2024.101004.
23.
KhanNRiccioA. A systematic review of design for additive manufacturing of aerospace lattice structures: current trends and future directions. Prog Aero Sci2024; 149: 101021. DOI: 10.1016/j.paerosci.2024.101021.
24.
ASTM International. Standard practices for sampling metal powders. ASTM, 2004, vol B215.
25.
SingSLYeongWYWiriaFE, et al.Characterization of titanium lattice structures fabricated by selective laser melting using an adapted compressive test method. Exp Mech2016; 56(5): 735–748. DOI: 10.1007/s11340-015-0117-y.
26.
Van BaelSKerckhofsGMoesenM, et al.Micro-CT-based improvement of geometrical and mechanical controllability of selective laser melted Ti6Al4V porous structures. Mater Sci Eng2011; 528(24): 7423–7431. DOI: 10.1016/j.msea.2011.06.045.
27.
ASTM International. Standard test method for flatwise compressive properties of sandwich cores. ASTM, 2011. C365/C365M.
28.
Turkish Standard. Standard Vickers hardness test methods for the three different ranges of test force for metallic materials. TS EN ISO 6507-1.
29.
ASTM International. Standard test methods for density of compacted or sintered powder metallurgy (PM) products using Archimedes’ principle. ASTM, 2008, vol B962.
30.
HitzlerLSchochNHeineB, et al.Compressive behaviour of additively manufactured AlSi10Mg. Mater Werkst2018; 49: 683–688. DOI: 10.1002/mawe.201700239.
31.
KhanHMDirikoluMHKoçE. Weibull distribution of selective laser melted AlSi10Mg parts for compression testing. J Adv Manuf Eng2021; 2(1): 14–19. DOI: 10.14744/ytu.jame.2021.00003.
32.
SertEHitzlerLHafensteinS, et al.Tensile and compressive behaviour of additively manufactured AlSi10Mg samples. Prog Addit Manuf2020; 5: 305–313. DOI: 10.1007/s40964-020-00131-9.
33.
XuYYangZHuangG, et al.Size shrinkage and compressive behaviour of Al2O3 honeycomb structures fabricated via Digital Light Processing technology. Ceram Int2024; 50(22): 45713–45722. DOI: 10.1016/j.ceramint.2024.08.412.
34.
HarrisJAWinterREMcShaneGJ. Impact response of additively manufactured metallic hybrid lattice materials. Int J Impact Eng2017; 104: 177–191. DOI: 10.1016/j.ijimpeng.2017.02.007.
YuWSingSLChuaCK, et al.Influence of re-melting on surface roughness and porosity of AlSi10Mg parts fabricated by selective laser melting. J Alloys Compd2019; 792: 574–581. DOI: 10.1016/j.jallcom.2019.04.017.
37.
LeonAAghionE. Effect of surface roughness on corrosion fatigue performance of AlSi10Mg alloy produced by selective laser melting (SLM). Mater Char2017; 131: 188–194. DOI: 10.1016/j.matchar.2017.06.029.
38.
FashanuOBuchelyMFSprattM, et al.Effect of SLM build parameters on the compressive properties of 304L stainless steel. Journal of Manufacturing and Materials Processing2019; 3: 43. DOI: 10.3390/jmmp3020043.
39.
WangXXuSZhouS, et al.Topological design and additive manufacturing of porous metals for bone scaffolds and orthopaedic implants: a review. Biomaterials2016; 83: 127–141. DOI: 10.1016/j.biomaterials.2016.01.012.
40.
HuiWQingyongZYiqingY. Influence of Ni contents on microstructure and mechanical performance of AlSi10Mg alloy by selective laser melting. Materials2023; 16(13): 4679–4697. DOI: 10.3390/ma16134679.
