AlSi10Mg honeycomb lattices produced by laser powder bed fusion: Mechanical, thermal, and microstructural performances

Lightweight lattice structures are increasingly used in various fields such as aerospace, automotive and biomedical due to their superior energy absorption capacity and high strength/weight ratio. In this study, honeycomb lattice structures were designed and manufactured using AlSi10Mg alloy using Laser Powder Bed Fusion (LPBF) method. It was aimed to evaluate the mechanical, microstructural and thermal performances of these structures produced with LPBF method, which offers high precision and design flexibility. Compression and hardness tests, surface roughness measurements, density determination and microstructural analyzes such as Scanning Electron Microscopy with Energy Dispersive X-ray Spectroscopy (SEM-EDS), Fourier Transform Infrared Spectroscopy (FTIR), Simultaneous Thermal Analysis with Thermogravimetric/Differential Scanning Calorimetry (STA, TG/DSC) and X-ray Diffraction (XRD) were applied to the produced samples. The obtained results revealed that there was a significant difference in terms of compressive strength between porous and dense structures; however, the hardness values were at similar levels. Microstructure analyses confirmed surface roughness and oxidation, as well as elemental distribution by EDS and the presence of α-Al and β-Mg 2 Si phases by XRD. Thermal analyses showed that the material exhibited good thermal stability with minimal mass loss at elevated temperatures. In general, it was concluded that AlSi10Mg honeycomb lattice structures produced by the LPBF method offer promising mechanical and thermal properties for applications requiring lightness and energy absorption.