Tomography of 3D-Printed Lattice Structured Aluminum-Silicon Alloy and Its Deformation

Additive manufactured light components are desirable for airspace and automobile applications where failure resistance under contact is important. To date, understanding the nature of subsurface damage in contact is still lacking. In this research, we investigated 3D-printed aluminum-silicon (Al-Si) alloys in the lattice structure under a rolling contact condition. Using the microtomography technique, we were able to construct a 3D image of the lattice structure being plastically deformed. Finite element analysis was conducted about the strain and stress on struts of different dimensions. Results showed that morphology dominated the deformation. The significant factors affecting the deformation were the strut aspect ratio, and their relative diameter. When the aspect ratio of a strut is smaller than 0.5, the plastic deformation is distributed in the subsurface region and when it is larger than 0.5, the deformation concentrates on the top layer of struts. This research indicates that the dimensional parameters of lattice structures can be designed for optimization to achieve higher resistance to deformation.