Characterization of High-Strength Aluminum Alloys Lattice Structures produced using Laser Powder Bed Fusion

The manufacturing of lattice structures using laser powder bed fusion (L-PBF) technology has not yet been explored for high-strength aluminum alloy 7075. The present study is part of a project aiming at additive manufacturing components combining high strength with reduced weight and exploring the possibility to combine with self-healing capabilities. The possibility to build lattice structures has been demonstrated for two distinct design categories: triple periodic minimal surfaces (TPMS) and strut-based lattices. The strut size is varied. These intricate geometries, manufactured in aluminum 7075, represent a significant advancement in the additive manufacturing domain, particularly for applications requiring a balance of strength and lightness. The specific process parameters and powder composition are optimized for L-PBF to produce these high strength lattice structures. The porosity level, mechanical properties of the new lattices are characterized microstructurally and mechanically. In particular, in-situ X-ray tomography compression testing with Digital Volume Correlation to track local strains is performed on the manufactured lattice structures. The initial outcomes indicate a promising potential for the use of these lattice structures in high-performance applications. The novelty of the work lies not only in the material used but also in the potential for these structures to exhibit self-healing properties, a feature that could redefine durability and longevity in critical applications.

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Farag, M., Nothomb, N., Pyka, G., Remacle, J.-F., & Simar, A. (2024). Characterization of High-Strength Aluminum Alloys Lattice Structures produced using Laser Powder Bed Fusion. European Mechanics of Materials Conference (EMMC19), Madrid, Spain. https://hdl.handle.net/2078.5/267592