Investigating the Microstructural Behavior and Energy Absorption of Pure Copper Lattice Structures Fabricated by Selective Electron Beam Melting

Pure copper’s exceptional thermal and electrical properties, along with its processability, make it indispensable in aerospace, automotive, and electrical industries, particularly in heat exchangers and radiators. Lattice structures, with high specific surface areas, low weight, and high strength, are ideal for lightweight yet strong components. While traditional methods struggle with complex lattice geometries, selective electron beam melting (SEBM) enables the fabrication of intricate pure copper lattices with high energy efficiency in a vacuum environment. This study used SEBM to fabricate OCTET pure copper lattices with relative densities of 21.16%–73.77%. The macrostructure matched the design, achieving a maximum energy absorption capacity of 15.00 MJ/m3. At 40.04% relative density, compressive response shifted from shock to compression hardening, with densification strains ranging from 23.96% to 51.68%. Microdefects such as corrugation, size differences, and internal holes influenced mechanical properties and energy absorption. Post-polishing reduced surface roughness from 14.12 μm to 2.70 μm without affecting specific energy absorption. Increasing strut diameter reduced the microdefects’ impact on lattice strength, enhancing performance and reliability.