Thickness‐Dependent Formability and Thermal Management of Ti6Al4V/AlSi10Mg Multimaterial Structures with Thin‐Walled AlSi10Mg Features Fabricated by Laser Powder Bed Fusion

Laser powder bed fusion (LPBF) enables the fabrication of multimaterial components with tailored properties, yet the influence of multimaterial thin‐wall geometry on formability, thermal behavior, and residual stress remains insufficiently understood. In this work, a combined experimental–numerical approach is used to investigate the effect of wall thickness on formability, residual stress, and heat dissipation performance in LPBF‐fabricated Ti6Al4V/AlSi10Mg multimaterial structures with thin‐walled AlSi10Mg features. Surface roughness increased with thickness, reaching minimum (22.834 μm) at 0.5 mm and maximum (28.886 μm) at 1.5 mm. Porosity exhibits a thickness‐dependent trend, measuring 0.045% at 0.5 mm, decreasing to its minimum value of 0.039% at 0.8 mm, and then increasing with further wall thickening, reaching 0.109% at 1.5 mm. Increased wall thickness enhances thermal management capacity. 1.5‐mm specimen achieves reduced peak surface temperature (333.29 K) with more uniform thermal distribution, accompanied by expanded moderate‐temperature zones in downstream airflow and improved convective efficiency. However, thickening walls demonstrate diminishing returns in substrate cooling and potential thermal performance degradation due to residual stress accumulation and interfacial defects. This research elucidates the thickness‐dependent mechanisms governing formability, interfacial reactions, and thermal behavior in LPBF‐processed Ti6Al4V/AlSi10Mg multimaterial structures, providing theoretical foundations and engineering guidelines for structural optimization and performance control.