A Strategy for 3D Printed Al‐Based Bi‐Material Lattice Optimization: Thermal‐Mechanical Coupling Performance with Load‐Bearing and Energy‐Absorption

Abstract To tackle challenges of coupled failure under high temperature/load and integrated forming of complex hypersonic aircraft structures, a bi‐material 3D‐printed lattice structure with enhanced energy absorption and high‐temperature load‐bearing capacity is developed. Using SiCp/AlSi10Mg and heat‐resistant AlSi12Fe2.5Ni3Mn4, three bi‐material lattices with 0 Vol%, 5 Vol%, and 10 Vol% SiC are fabricated via customized SLM, with printing quality verified by Micro‐CT. Quasi‐static compression tests and Johnson‐Cook models revealed effects of temperature (25 and 250 °C), SiC fraction, and loading direction (series, parallel) on thermal‐mechanical performance, clarifying failure mechanisms. Unlike 0 Vol%’s complete buckling and 10 Vol%’s complete crushing, 5 Vol%SiC's shear band network delayed failure, showing uniform densification and “buckling + crushing” response under both loadings. Compared to 0 Vol% and 10 Vol%, 5 Vol%SiC improves load‐bearing capacity by 13.0% and 15.6%, energy absorption by 11.9% and 23.0%, achieving synergistic mechanical improvement and multi‐directional stability. It has significant prospects in “thermal protection and load‐bearing” multifunctional structural design.