Deformation Behavior and Energy Absorption Capacity of Additively Manufactured Dual‐Phase Hybrid Ti–6Al–4V Lattice Structures

Hybrid lattice structures have emerged as promising candidates for lightweight, energy‐absorbing applications due to their superior mechanical properties compared to uniform lattice designs. However, the influence of unit cell arrangement on their performance remains further explored. This study investigates the mechanical and energy absorption (EA) behaviors of dual‐phase hybrid lattices (DPHLs) with varying angular configurations (0°, 45°, and 90°), fabricated via laser powder bed fusion using Ti – 6Al – 4V powder. By combining body‐centered cubic with z‐struts and modified face‐ and body‐centered cubic with z‐struts unit cells, it is demonstrated how structural anisotropy governs deformation modes and failure mechanisms. Quasistatic compression tests and numerical simulations reveal that DPHL‐90 achieves an exceptional ultimate strength of ≈201 MPa and an EA capacity of 8.82 MJ m − 3 , outperforming DPHL‐0 (5.64 MJ m − 3 ) and DPHL‐45 (5.55 MJ m − 3 ). Fractography analysis via scanning electron microscopy indicates that DPHL‐0 fails via layer‐by‐layer collapse, while DPHL‐45 and DPHL‐90 exhibit shear‐dominated fracture with 45°‐oriented bands. The junction regions between unit cells display mixed brittle–plastic failure, highlighting stress concentration effects. These findings provide critical insights for designing and optimizing hybrid lattice structures, particularly for impact‐resistant aerospace applications.