Production and Mechanical Characterization by Compression Tests of Al Alloys with Weaire–Phelan Cells Manufactured by the Lost-PLA Technique

In this study, the mechanical behavior of AA6082 foams with Weaire-Phelan (WP) cell structures under compressive loading was analyzed. The foams were produced using the lost-PLA replication method, a cost-effective and straightforward manufacturing technique. A total of six aluminum alloy samples were fabricated and subjected to compression tests to assess both their mechanical performance and the repeatability of the results. The produced foams demonstrated a well-defined morphology and high-quality surface finish, accurately replicating the geometries of the original PLA 3D-printed templates. The experimental density of the foams closely matched theoretical values, confirming the consistency of the replication process. The compressive stress-strain response of the Weaire-Phelan cell foams displayed an initial linear elastic region, followed by three distinct plateau regions with increasing stress levels. The final densification phase occurred when the structure could no longer accommodate further plastic deformation, leading to a sharp increase in the compression load. From the stress-strain data, the specific energy absorption of the foams was calculated. The average specific energy absorption was measured to be 4 J/cm³, with a standard deviation of 0.49 J/cm³ across the six tested samples. These results indicate reliable mechanical performance and reproducibility of the manufacturing process, making these foams suitable for applications requiring energy absorption and lightweight structural components.