Additive manufactured high-performance topology-optimized lattice structure: Compressive behavior and flow heat transfer characteristics

In this study, topological optimization techniques were employed to construct innovative TopS lattice structures, to achieve a lightweight design while simultaneously optimizing their mechanical properties and enhancing flow and heat transfer performance. Through model reconstruction and proportional scaling techniques, lightweight configurations with increased surface areas were achieved, leading to the successful fabrication of Ti-6Al-4V lattice structures via Laser Powder Bed Fusion (LPBF) technology. A comprehensive investigation combining numerical simulations and experimental testing revealed that the TopS-L 16 lattice structure outperforms TopS-L 1 and TopS-L 4 in terms of compressive strength, demonstrating values of 386.00 MPa for compressive strength, 352.00 MPa for upper compressive yield strength, and 6938.00 MPa for elastic modulus. Furthermore, multilayer-filled lattice structures were found to effectively improve streamline distribution and vorticity, reducing boundary layers, which indicates a significant enhancement in fluid flow and heat transfer performance, with TopS-L 16 exhibiting the best performance. The novelty of this work lies in its exploration of the interplay between lattice structures and their interactions with compressive deformation, energy absorption capabilities, and flow heat transfer.