Thermal‐Mechanical Coupling Performance of Heat‐Resistant, High‐Strength and Printable Al‐Si Alloy Antisymmetric Lattice Structure

Abstract The unsatisfactory mechanical performance at high temperatures limits the broad application of 3D‐printed aluminum alloy structures in extreme environments. This study investigates the mechanical behavior of 4 different lattice cell structures in high‐temperature environments using AlSi12Fe2.5Ni3Mn4, a newly developed, heat‐resistant, high‐strength, and printable alloy. A novel Antisymmetric anti‐Buckling Lattice Cell (ASLC‐B) based on a unique rotation reflection multistage design is developed. Micro‐CT (Computed Tomography) and SEM (Scanning Electron Microscope) analyses revealed a smooth surface and dense interior with an average porosity of less than 0.454%. Quasi‐static compression tests at 25, 100, and 200 °C showed that ASLC‐B outperformed the other 3 lattice types in load‐bearing capacity, energy absorption, and heat transfer efficiency. Specifically, the ASLC‐B demonstrated a 51.56% and 44.14% increase in compression load‐bearing capacity at 100 and 200 °C compared to ASLC‐B(AlSi10Mg), highlighting its excellent high‐temperature mechanical properties. A numerical model based on the Johnson‐Cook constitutive relationship revealed the damage failure mechanisms, showing ASLC‐B's effectiveness in preventing buckling, enhancing load‐transfer efficiency, and reducing stress concentrations. This study emphasizes the importance of improving energy absorption and mechanical performance for structural optimization in extreme conditions. The ASLC‐B design offers significant advancements in maintaining structural integrity and performance under high temperatures.